AN AIR TREATMENT SYSTEM

Abstract

There is provided an air handling assembly that comprises a support structure; at least one air handling chamber arranged on the support structure, the, or each, air handling chamber including an inlet subchamber and an outlet subchamber, the inlet subchamber being in fluid communication with the outlet subchamber; a coil assembly arranged on the support structure and interposed between the inlet subchamber and the outlet subchamber so that air passing from the inlet subchamber to the outlet subchamber passes through the coil assembly; an air inlet in fluid communication with the inlet subchamber; and an air outlet in fluid communication with the outlet subchamber.

Description

SUMMARY

International patent application number PCT/AU2015/050799, published on 23 Jun. 2016, is incorporated herein by reference.

FIELD

Various embodiments of an air treatment system and an air handling assembly are described herein.

In one aspect, there is provided an air handling assembly that comprises:

a support structure;

at least one air handling chamber arranged on the support structure, the, or each, air handling chamber including an inlet subchamber and an outlet subchamber, the inlet subchamber being in fluid communication with the outlet subchamber;

a coil assembly arranged on the support structure and interposed between the inlet subchamber and the outlet subchamber so that air passing from the inlet subchamber to the outlet subchamber passes through the coil assembly;

an air inlet in fluid communication with the inlet subchamber; and

an air outlet in fluid communication with the outlet subchamber.

The coil assembly may be an evaporator coil assembly.

The air handling assembly may include an air treatment apparatus that is arranged in the, or each, outlet subchamber.

The air treatment apparatus may include an air heating apparatus.

The air treatment apparatus may include an infrared emitter that is positioned to direct infrared rays on to the evaporator coil assembly to heat the coil assembly so that air passing through the coil assembly is heated.

The air treatment apparatus may include a disinfecting apparatus to disinfect air in the outlet subchamber.

The air treatment apparatus may include a UV emitter that is positioned to direct UV rays on to the evaporator coil assembly to disinfect air passing through the coil assembly.

The air handling assembly may include an air extractor arranged in the outlet subchamber and operable to draw air into the inlet subchamber, via the air inlet, into the outlet subchamber and to expel treated air from the outlet subchamber and out of the air outlet.

The support structure may include a floor, a roof and four sidewalls.

The air handling assembly may include an intermediate transverse wall interposed between the floor and the roof, and at least one dividing wall extending from the transverse wall to the roof so that the intermediate transverse wall, the roof, the sidewalls, and the at least one dividing wall define at least two air handling chambers.

At least one compressor may be arranged on the support structure and operatively connected to the, or each respective, evaporator coil assembly.

In another aspect, there is provided an air treatment system that comprises:

an air handling assembly including

• • a support structure;
  • at least one air handling chamber arranged on the support structure, the, or each, air handling chamber including an inlet subchamber and an outlet subchamber, the inlet subchamber being in fluid communication with the outlet subchamber;
  • an evaporator coil assembly arranged on the support structure and interposed between the inlet subchamber and the outlet subchamber so that air passing from the inlet subchamber to the outlet subchamber passes through the coil assembly;
  • an air inlet in fluid communication with the inlet subchamber; and
  • an air outlet in fluid communication with the outlet subchamber;

an air supply duct connected to the air outlet to supply air to a zone in which air is to be conditioned and/or treated;

an air return duct connected to the air inlet to return air to the air handling assembly from the zone; and

a condenser having a housing, the housing having at least one inlet and at least one outlet, a fan for directing air from the, or each, inlet and out through the, or each, outlet, and a condenser coil assembly positioned within the housing and interposed between the inlet and the outlet and operatively connected to the coil assembly.

The air conditioning system may include a compressor and an expansion valve assembly operatively connected to the evaporator coil assembly and the condenser coil assembly to define a refrigeration circuit.

The air conditioning system may include a system controller operatively connected to the expansion valve assembly to control operation of the expansion valve assembly.

An air heating apparatus may be arranged in the outlet subchamber and may be operatively connected to the system controller so that the system controller can control a temperature of the air being discharged from the air outlet.

An air disinfecting apparatus may be arranged in the outlet subchamber and may be operatively connected to the system controller so that the system controller can control a disinfection process carried out on the air in the outlet subchamber.

An air extractor may be arranged in the outlet subchamber and may be operable to draw air into the inlet subchamber, via the air inlet, into the outlet subchamber and to expel conditioned and/or treated air from the outlet subchamber and out of the air outlet, the air extractor being operatively connected to the system controller so that the system controller can control a volumetric rate of air being discharged from the outlet subchamber.

In another aspect, there is provided a method of conditioning air, the method comprising the steps of:

displacing air into an inlet subchamber of an air handling chamber having the inlet subchamber and an outlet subchamber with an evaporator coil assembly interposed between the inlet and outlet subchambers so that the air passes from the inlet subchamber through the evaporator coil assembly and into the outlet subchamber; and

treating the air in the outlet subchamber before the air is discharged from the outlet subchamber.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a three-dimensional view of an air handling assembly for an air treatment system.

FIG. 2 shows the air handling assembly with panels removed to show components of the assembly.

FIG. 3A shows a close-up view of part of the air handling assembly.

FIG. 3B shows an internal view of inlet subchambers of the air handling assembly.

FIG. 4 shows a schematic view of an air conditioning circuit including the air handling assembly.

FIG. 5 shows a three-dimensional view of a condenser assembly for the air-conditioning system.

FIG. 6 shows a side sectional view of the condenser assembly of FIG. 5.

FIG. 7 shows an air treatment system including two air handling assemblies of FIG. 1.

FIG. 8 shows a dwelling that incorporates four of the air handling assemblies of FIG. 1.

FIG. 9 shows a schematic view of a dwelling including four of the air handling assemblies.

FIG. 10 shows a three-dimensional, exploded view of a duct assembly for the air-conditioning system.

FIG. 11 shows a three-dimensional view of the duct assembly of FIG. 10.

FIG. 12 shows a sectioned view of a duct section of the duct assembly of FIG. 10.

FIG. 13 shows an electronic management system for the air-conditioning system.

FIG. 14 shows an air treatment assembly.

FIG. 15 shows a physical architecture of the air handling assembly of FIG. 1.

FIG. 16 shows a logical architecture of the air handling assembly of FIG. 1.

DETAILED DESCRIPTION

FIGS. 1 and 2 show an air handling assembly 10 for two air treatment systems 13 suitable for treating and conditioning air supplied to two respective zones.

The air handling assembly 10 includes a support structure 12. The two air treatment systems 13 are arranged on the support structure 12. Each air treatment system 13 includes an air handling chamber 29 having an inlet subchamber 14 and an outlet subchamber 16. The inventor(s) envisages that more than two air handling chambers 29 can be arranged on the support structure 12 depending upon the number of zones that are to be supplied with air from the air handling assembly 10.

The inlet subchamber 14 is in fluid communication with the outlet subchamber 16. An evaporator coil assembly 18 is arranged on the support structure 12 and is interposed between the inlet subchamber 14 and the outlet subchamber 16 so that air passing from the inlet subchamber 14 to the outlet subchamber 16 passes through the evaporator coil assembly 18.

It is envisaged that the evaporator coil assembly 18 can also be used for carrying a chilled liquid, such as water, used for cooling. In that case, the coil assembly 18 can be connected to a chiller plant or the like that feeds the chilled water through the coil assembly 18.

An air inlet 20 is in fluid communication with the inlet subchamber 14 so that air to be treated can be supplied to the inlet subchamber 14. An air outlet 21 is in fluid communication with the outlet subchamber 16 so that treated air can be expelled from the outlet subchamber 16.

The support structure 12 includes an enclosure 19 having a floor 24, a roof 26, and four sidewalls 28, which define a volume 27 in which the components of the air handling assembly 10 are arranged. The enclosure 19 includes a support frame 30 in which panels 32 defining the floor 24, roof 26 and sidewalls 28 are mounted.

Each air inlet 20 is provided by an inlet vent 22 mounted in the roof 26. Similarly, each air outlet 21 is provided by an outlet vent 23 that is mounted in the roof 26. Each of the vents has an ovoid cross-sectional profile to suit ovoid ducting of a ducting assembly described herein.

The enclosure 19 includes an intermediate transverse wall 34 interposed between the floor 24 and the roof 26. A dividing wall 36 extends from the transverse wall 34 to the roof 26 so that the intermediate transverse wall 34, the roof 26, the sidewalls 28, the dividing wall 36 and the coil assembly 18 define the inlet subchamber 14 and the outlet subchamber 16. In this example, the air handling assembly 10 includes two outlet subchambers 16 and two inlet subchambers 14, one on each side of the dividing wall 36, suitable for the two air conditioning or air treatment systems 13. It is envisaged that different numbers of outlet and inlet subchambers can be provided, suitable for different numbers of air treatment systems.

An air extractor 38 is arranged in the outlet subchamber 16 and is configured so that operation of the air extractor 38 generates a flow of air from the inlet vent 22, through the inlet subchamber 14, the evaporator coil assembly 18, the outlet subchamber 16 and out through the outlet vent 23. The extractor 38 can include an extractor fan operable to extract air from the outlet subchamber 16. The extractor fan thus plays the role of an evaporator fan. The existence of the outlet subchamber 16 allows the fan to be positioned away from the evaporator coil assembly 18, unlike conventional air conditioners.

The enclosure 19 includes a support tray 40 positioned beneath the transverse wall 34. Two refrigerant compressors 42 are mounted on the support tray 40, one connected to each respective evaporator coil assembly 18 in a conventional manner.

A control box 33 containing controls for the assembly 10 is also included beneath the transverse wall 34.

The enclosure 19 is sound attenuated so that any disturbance resulting from the operation of the compressors 42 and the various components within the enclosure 19 is minimised.

It will thus be appreciated that an air treatment or air conditioning system including the air handling assembly 10 has the evaporator coil assembly 18 and the compressor 42 at a single physical location. This is unlike conventional air conditioning systems in which the compressor is located remotely from the evaporator coil assembly 18 and usually outside of a dwelling or building.

This arrangement is indicated schematically in FIG. 4, which shows a refrigeration circuit where the dotted lines demarcate the air handling assembly 10 and a condenser unit or assembly 58 with a condenser coil 44 and a condenser fan 46. As can be seen, the arrangement in FIG. 4 also shows an expansion valve 48 and an optional dryer 50. These can both be in the enclosure 19 and can form part of the air handling assembly 10.

As shown in FIGS. 1 and 2, the air handling assembly 10 is elongate. It is also configured to be positioned vertically. In various embodiments, the air handling assembly 10 has a cross-sectional area and height that makes it suited for positioning in a closet, cupboard or similar structure or enclosure within a dwelling or building. The inventor(s) envisages that the air handling assembly 10 can have other shapes depending on the required location. For example, the enclosure 19 can be positioned horizontally, with the wall 34 in a vertical orientation and functioning as a dividing wall between the subchambers 14, 16 and the compressors 42. Thus, an air conditioning arrangement of two or more air-conditioning systems to supply respective zones with treated and/or conditioned air can incorporate air handling assemblies of different shapes depending on the required locations.

It is relevant to note that air can mostly only enter the outlet subchamber 16 via the evaporator coil assembly 18 and can mostly only leave the outlet subchamber 16 via the outlet 21 during operation of the assembly 10. It will thus be appreciated that the outlet subchamber 16 provides a zone or volume in which air can be treated and which is physically separated from ambient air. This physical separation is distinctive from other air conditioning systems.

When operation of the assembly 10 ceases, any backflow of air into the inlet subchamber 14 is limited to that air that has already been treated in the outlet subchamber 16. This air can be retained in the inlet subchamber 14, relatively undisturbed. Thus, an environment in the inlet subchamber 14 can be kept optimal to inhibit the build-up of mould and to inhibit fluctuations in humidity while the assembly is not operating. Furthermore, on start-up, an initial volume of air is pre-treated, to some extent, before being displaced into the outlet subchamber 16.

The enclosure 19 is configured so that the outlet subchamber 16 and the inlet subchamber 14 are substantially sealed apart from the inlet 20 and outlet 21. Thus, the outlet subchamber 16 is substantially hermetically sealed particularly during flow of air through the subchambers 14, 16. It follows that the outlet subchamber 16 forms a zone or volume in which it is convenient to treat air.

Contact time of the air with the coils of the evaporator coil assembly 18 can be optimised by an air flow disruptor or diffuser, such as a foraminous or perforated plate 11, shown in FIG. 3A and FIG. 3B, interposed between the inlet subchamber 14 and the evaporator coil assembly 18. The plate 11 can inhibit laminar flow of air through the evaporator coil assembly 18 by creating turbulence in the air flowing through the coil assembly 18. This can increase dwell time of air in the assembly 18 to facilitate maximum exposure of the air to the coils. The foraminous plate 11 can also serve to inhibit or limit the drift of air from the outlet subchamber 16 to the inlet subchamber 14 when the evaporator fan is inoperative. Other forms of air flow disruptor or diffuser can be used instead of the plate 11. For example, the plate 11 could be replaced by a series of spaced, narrow plates or some other structure that can disrupt the flow of air before it impinges on the coils.

FIG. 3B more clearly shows the foraminous plates 11, viewed from a rear face of two adjacent inlet subchambers 14, separated by division 15, which can be defined by the dividing wall 36. In this representation, the coil assemblies 18 are not visible as they are situated behind or downstream of the foraminous plates 11. Each foraminous plate 11 substantially overlies the coil assembly 18 such that the air flows through the plate 11 before impinging on the coil assembly 18.

The treatment of the air can take many forms. The air handling assembly 10 can include air treatment apparatus 25 arranged in or operatively with respect to the outlet subchamber 16. The apparatus 25 includes a disinfecting apparatus to disinfect the air in the outlet subchamber 16. The disinfecting apparatus is a UV emitter 52, which is mounted in the outlet subchamber 16 to disinfect the air and the evaporator coil assembly 18.

The evaporator coil assembly 18 extends from a condensate tray 54. The condensate tray 54 collects condensate, in the form of water, from the evaporator coil assembly 18. The condensate tray 54 is also exposed to the UV emitter 52 so that the water in the tray 54 can be disinfected. The disinfected water can be fed to a storage arrangement, such as a water tank, for use in the dwelling, or other structure in which the air handling assembly is located, via a condensate conduit 17.

The air can also be heated with an air heating apparatus in the form of a radiant heater. For example, the radiant heater is an infrared emitter 56 that is mounted in the outlet subchamber 16. The infrared emitter 56 is configured to emit infrared rays that bathe the evaporator coil assembly 18, so heating the coils and thus the air that passes through the coils.

Further devices can be mounted within the outlet subchamber 16 to treat the air in the outlet subchamber 16. These might include humidification devices to adjust a level of humidity within the air expelled from the outlet vent 23. These might also include humidity sensors or hygrometers to measure the humidity in the air expelled from the outlet vent 23. A sensor for a hygrometer may also be mounted in the inlet subchamber 14 to measure the humidity in the air being fed into to the inlet subchamber 14 so that measurements generated by the hygrometers can be used to control operation of the air handling assembly to control the humidity of the air in the outlet subchamber 16.

Various sensors can also be mounted in the outlet subchamber 16 to provide information concerning an environment within the outlet subchamber 16. The role of the sensors is described below with reference to the electronic management system.

In FIGS. 5 and 6, there is shown the condenser assembly or unit 58 for an air-conditioning or air treatment system incorporating the air handling assembly 10.

The condenser assembly 58 includes a housing 60. The housing 60 has mounting brackets 61 so that the condenser assembly 58 can be mounted in a desired location. The housing 60 defines an inlet 62 and two, opposed exhaust outlets 64. The housing 60 can define two or more inlets 62, if necessary. A condenser fan 66 is mounted in the housing 60 to draw air into the housing 60 via the inlets 20 and to expel air from the exhaust outlets 64. The condenser fan 66 can be the condenser fan 46 described in FIG. 4. A condenser coil assembly 68 is arranged within the housing 60 so that air can pass through the condenser coil assembly 68 and out through the exhaust outlets 64. The condenser coil assembly 68 can include the condenser coil 44. The condenser coil assembly 68 is connected to the evaporator coil assembly 18 and to the compressor 42 via suitable refrigerant conduits 70. This can be done according to the arrangement shown in FIG. 4. The condenser coil assembly 18 can incorporate the coil 44 that is configured to form part of a micro-channel heat exchanger. This facilitates a low-profile shape of the condenser assembly 58.

As can be seen in the drawings, the condenser assembly 58 has the relatively low profile. It can also be sound-attenuated.

In FIG. 7 there is shown two air treatment assemblies 80.1, 80.2 for use in a dwelling. The air treatment assemblies 80 can be used to regulate the temperature of two respective zones 82.1, 82.2. Each air treatment assembly 80 has a supply air vent 84 and a return air vent 86. The supply air vent 84 is connected to the outlet vent 23 of the air handling assembly 10 with an outlet duct 88. The return air vent 86 is connected to the inlet vent 22 with an inlet duct 90. The supply air vents 84, the return air vents 86 and the condenser unit 58 are all mounted in a ceiling space 92.

In this case, the condenser unit 58 is configured to receive refrigerant from both the evaporator coil assemblies 18 and compressors 42 via refrigerant conduits 94. Alternatively, there could be provided two condenser units 58 in a condenser assembly 96, with each condenser unit 58 associated with a respective air handling assembly 10.

Operation of the condenser fan 66 results in air being drawn into the condenser housing 60, via the inlets 62, from the ceiling space 92. The exhaust outlets 64 of the condenser unit 58 are connected to respective exhaust manifolds 98. In turn, the manifolds 98 are connected to respective exhaust conduits 100 that can extend through a roof (not shown) of the dwelling or building to expel the exhaust to atmosphere.

Temperature sensors 104 are arranged on the condenser unit 58 to monitor and provide information relating to a temperature of the air within the ceiling space 92.

The role of the temperature sensors 104 and the advantages of having the condenser unit 58 positioned in the ceiling space 92 are described below.

In FIG. 8, there is shown four air treatment assemblies 110 for use in a dwelling 112. The air treatment assemblies 110 can be used to regulate the temperature of four respective zones 114 and to regulate the air quality in the zones 114. In this drawing, a ceiling 116 is shown and the positions of the respective components within the ceiling space 92 can be seen. Furthermore, each zone 114 is a room.

In FIG. 9, there is shown an air treatment system for regulating the temperature and air quality in four zones 118. In this case, there are two condenser units 58 connected to respective air handling assemblies 10.

The condenser units 58 are arranged in a dedicated area such as a patio or balcony 120, that is physically remote from the zones 118, as far as the air treatment process is concerned. The condenser units 58 could also be in an area that is specifically configured for location of the condenser units 58. For example, in a building containing many residential dwellings or office spaces, it may be more convenient to have a single area containing condenser units that can connect to the various air handling assemblies throughout the building.

In small enclosed indoor areas, such as hotel rooms, refrigerant management can be a significant issue. The assembly of the invention can cater for relatively small zones, each zone being associated with a separate air treatment system 13 having a refrigerant circuit which includes a small inverter compressor being the compressor 42, evaporator, including the evaporator coil assembly 18 and condenser assembly 58, in which the average volumetric refrigerant charge is less than 1 kg. The condenser coil 44 described herein uses micro-channel heat exchanger technology which reduces refrigerant requirements by 30-40% compared to conventional air conditioning systems, which typically hold up to 40-60 kg of refrigerant and can pose an asphyxiation risk to inhabitants.

In FIGS. 10 and 11, there is shown an air duct assembly 122 that is suitable for use with the air treatment assemblies. The air duct assembly 122 includes straight conduit sections 124 and curved conduit sections 126. The air duct assembly also includes collars 128 that are configured to permit the straight and curved conduit sections 126 to be clipped together in a substantially hermetically sealed manner.

Each of the conduit sections 124, 126 and associated collars 128 have an ovoid cross-section. This allows them to have a reduced profile to facilitate location in areas in which space is at a premium, such as in a ceiling or in a wall space.

The conduit sections 124, 126 are of a material having high thermal insulation properties. For example, as can be seen in FIG. 12, the conduit sections 124, 126 can have an outer liner 130 and an inner liner 132 of a relatively rigid material. An insulating material 134 can be interposed between the outer and inner liners 130, 132. The outer and inner liners 130, 132 can be of PVC. The insulating material 134 can be urethane. The inventor(s) envisages that any number of other materials can be used. The inventor(s) has found that this arrangement provides a next to zero thermal loss.

As can be seen in FIG. 12, ends of the sections 124, 126 have portions of the liners 130, 132 removed. The collars 128 can then also define opposed annular recesses 136 so that adjacent ends 138 of consecutive sections 124, 126 can be received in the recesses 136 to connect the sections 124, 126. Thus, the conduit sections 124, 126 can be readily clipped together and configured to suit a region or zone in which the duct assemblies 122 are to be mounted or arranged. Instead of being clipped together, the duct sections could also be glued together or fastened together in any other suitable manner.

The conduit sections 124, 126 are configured so that, when connected, a resultant bore of the duct is substantially smooth and continuous.

The air treatment system includes an electronic control management system 140, schematically shown in FIG. 13.

The control system 140 includes a system controller 142. The system controller 142 can be a PLC (programmable logic controller) or a DDC (direct digital controller) that can control the various components of the air treatment system.

The system controller 142 can be connected to a modem 144. The air treatment system can include a server 146 that is capable of wireless communication with the system controller 142, via the modem 144. Thus, the server 146 can be used to program the system controller 142 and to monitor and control, automatically, via suitable feedback controls, various operational characteristics of the air treatment system. For example, the server 146 can be used to set up a controllable dehumidification/temperature program.

The server 146 can take various forms. For example, the server 146 can be a single data processing apparatus. In other embodiments, the server 146 can be a number of data processing apparatus connected together. The server 146 could also be a virtual server and could be made up of a number of networked mobile devices.

The system controller 142 can be operatively connected to a UV controller 148 for the UV emitter 52, an infrared controller 150 for the infrared emitter 56, an evaporator controller 152 for the air extractor 38, a condenser controller 154 for the condenser fan 66, a compressor controller 156 for the compressor 42 and a valve controller 158 for the expansion valve 48.

In various embodiments, the expansion valve 48 can be an electronic expansion valve. The valve controller 158 is then a suitable expansion valve driver that can be controlled by the system controller 142. It will be appreciated that use of the electronic expansion valve 48 and associated driver allows the system controller 142 to respond to feedback signals relating to a refrigeration cycle of the treatment system received from the various sensors. For example, the electronic expansion valve 48 can be actuated to adjust a temperature of a zone in response to temperature measurements received by the system controller 142. The inventor(s) envisages that the control system can be used in a wide variety of ways.

For example, the system controller 142 can be configured to control the operation of the UV emitter 52 periodically or upon receipt of measurements, via the UV controller 148. For periodic operation, the UV emitter 52 can be operated based on a predetermined cycle to maintain the evaporator coil assembly 18 and the contents of the condensate tray 54 in a disinfected condition. Furthermore, the system controller 142 could be configured to control operation of the UV emitter 52 for a predetermined period to disinfect the air being supplied to a particular zone, for example, a zone in a healthcare facility. In such a case, the system controller 142 can be configured to actuate just the UV emitter 52 and the extractor 38 solely for the purposes of disinfecting the air. As a step up from that, the system controller 142 can be configured to actuate either the infrared emitter 56 or the compressor(s) 42 to heat or cool the air, respectively.

The system controller 142 can be configured so that, when a zone requires heating, the system controller 142 can operate to switch off the compressor 42, via the compressor controller 156, and actuate the infrared emitter 56, via the infrared controller 150. Optionally, the UV emitter 52 can also be actuated via the UV controller 148.

The signals can be communicated to the server so that the air treatment system can be remotely monitored, controlled, interrogated and calibrated using the server, via the system controller 142.

The temperature sensors 104 of the condenser unit 58 are used to monitor a temperature within the ceiling space 92, as mentioned above. Ceiling spaces can become extremely warm relative to living areas below the ceiling 116. It will be understood that it is undesirable that warm air impinges on the condenser coil since that would retard the required condensation process within the coil. The ceiling temperature sensors 104 provide the system controller 142 with a measurement of the temperature within the ceiling 116. The system controller 142 is configured to operate the condenser fan 66 to maintain a temperature within the ceiling space 92 at a predetermined level suitable for proper operation of the air treatment system. Thus, the system controller 142 is configured to operate the condenser fan 66 even without operation of the compressor(s) 42 to maintain the ceiling space 92 at that predetermined temperature so that, when air-conditioning is required, the air impinging on the condenser coil is at an appropriate temperature. This is achieved because of the operation of the condenser fan 66 that serves to draw air into the ceiling space 92, through the condenser coil assembly 18 and out through the exhaust conduits 100.

It follows that the condenser fan 66, the condenser controller 156 and the system controller 142 can be used to maintain the ceiling space 92 at a desired temperature to enhance cooling of the zone(s).

The need to maintain an airflow within the ceiling space 92 to inhibit heat build-up in the living area is known. Attempts have been made to address this by positioning venting assemblies on the roof of a building and in communication with the ceiling space. Such venting assemblies can include fans that rotate as air passes through the venting assembly. The build-up of momentum in the fan serves further to displace air from the ceiling space. Such venting assemblies have limited efficacy since the air within the ceiling space is not positively directed out of the ceiling space. In the present embodiments, the condenser fan 66 carries out this function and so is an improvement on such venting assemblies for the purposes of maintaining airflow within the ceiling space 92 and reducing a temperature of the air within the ceiling space 92.

The air treatment system includes one or more zone temperature sensors 160 that are connected to the system controller 142 so that the various components of the air treatment system can be operated to maintain a desired temperature within the zone.

As will be appreciated from the drawings, each zone has a dedicated inlet duct 90 and outlet duct 88, the nature of which are described above. Thus, the air in each zone is limited to a closed loop. This is unlike a conventional ducted system in which air is distributed from a central point throughout a building to provide air to several zones. The conventional ducted systems can require extended lengths of ducting that is subject to build-up of mould and deposits. This can be unhealthy, particularly for those who are prone to allergies. Other undesirable health risks can also be posed by such mould and deposits.

As mentioned above, the ducts and the outlet subchambers are hermetically sealed. It follows that the build-up of such mould and deposits can be avoided. The use of the UV emitter and, optionally, other air purification apparatus within the outlet subchamber 16 can inhibit the build-up of mould and deposits. While this is beneficial in a conventional dwelling, it will readily be appreciated that it is particularly beneficial in healthcare environments where the quality of the air in the zones is paramount. The foraminous plate 11 also serves to reduce the build up of mould by increasing the dwell time of treated air in the evaporator coil assembly 18.

The smoothness and continuity of the bore of the duct assembly 122 also serves to inhibit the build-up of such mould and deposits.

A problem with conventional ducting is air leakage which results in energy loss. It is not unusual for conventional ducting to result in an energy loss of up to 40%. On the other hand, the air duct assembly 122 of the air treatment system has a relatively short run compared to conventional ducting. Also, the configuration and structure of the conduit sections 124, 126 provides a high level of insulation, so minimising energy loss.

Each outlet vent 23 can contain a filtration device or apparatus 25 to filter air passing out of the outlet subchamber 16. The filtration device can take different forms. For example, the filtration device can be an activated carbon air purification device. The filtration device can be positioned elsewhere in the duct assembly 122, depending on requirements, such as available space and convenient access for cleaning and replacing.

It will be appreciated that air quality and temperature in each zone is associated with a single outlet subchamber 16 and evaporator coil assembly 18. Thus, each zone can be controlled independently of other zones in a single building or dwelling. Furthermore, each zone can be customised to suit the occupant(s) of that zone. Such control is not possible with a ducted system that feeds conditioned air from a central point to a number of different zones.

Conventional air conditioning systems can include an external unit that includes a compressor, a condenser coil and a condenser fan. Such external units can be unsightly. For example, external units on balconies or patios can be both unsightly and noisy. They can also take up valuable real estate. For example, in a high-rise building it is often necessary to place the condenser units on an upper floor of the building. Such a floor could have significant real estate value, particularly if it provides views. In contrast, by locating the air handling assemblies 10, incorporating the compressors 42, within the respective zones, it is possible to locate the associated condenser units 58 in areas in which conventional condenser units would not normally fit.

The relatively low profile of the condenser unit 58 allows it to be in a large variety of positions. Furthermore, the low profile allows the condenser unit 58 to be architecturally concealed or camouflaged. For example, in certain dwellings, it is necessary to mount a condenser unit in a bulkhead. This can significantly reduce ceiling height within the dwelling. The low profile of the condenser unit 58 allows it to be positioned in a similar location without sacrificing ceiling height.

External condenser units can be prone to damage by the weather or by creatures such as insects, lizards and geckos that can make their way into the condenser units and damage the internal componentry. The condenser unit 58 of the air treatment assembly described herein can be located indoors or within a ceiling space where it can be protected from the elements and from ingress by insects, lizards and geckos.

In various embodiments, the condenser unit 58 can be used to heat the ceiling space 92 or sub roof and/or wall cavities.

The UV emitter 52 provides ultraviolet germicidal irradiation that can destroy biofilm in the form of mould, bacteria and viruses that may be growing in the evaporator coil assembly 18. Not only does this improve the health and comfort of the occupants, but it also saves coil maintenance labour and coil cleaning material costs. In addition, it can increase the life of the filtration or air purification device. For example, it can increase the life of a HEPA air filter that could be positioned in the outlet vent 23 or the duct assembly 122.

Conventionally, a reverse cycle is used with air-conditioning systems to heat a zone. However, a problem with such reverse cycle systems is that the heated air can be musty and unclean. One of the reasons for this is that a reverse cycle system does not generate enough heat to sterilise. By using the infrared emitter 56, the air treatment system can generate heated air that is both clean and relatively dry. In some cases, the infrared emitter 56 can be configured to generate sufficient heat to sterilise. However, sterilisation can also be further enhanced by using the UV emitter 52 at the same time to disinfect the heated air.

A further issue with reverse cycle systems is that they can have problems when operating in low temperature ambient conditions. It will be appreciated that these issues do not arise with the use of an infrared emitter.

It is envisaged that any form of radiant heater can be used in place of the infrared emitter. The required functionality is achieved provided the evaporator coil assembly 18 can be substantially bathed with radiant heat or infrared.

The assembly of the invention can address conventional issues of thermal comfort by monitoring and controlling temperature and humidity of the air leaving the assembly. For example, in FIG. 7, the temperature in zone 82.1 is sensed via a thermocouple in the return air vent 86. The assembly 10 can include carbon dioxide, volatile organic compounds, and relative humidity sensors operatively arranged with respect to the inlet and outlet subchambers 14, 16 so that these characteristics can be controlled with the server 146, via the controller 142 and the modem 144. The supply air vent 84 can include 2 thermocouples, measuring coil actual temperatures and air-off temperatures.

The assembly of the invention can also address the issue of draft, where wind chill can cause discomfort in a conditioned space. The assembly of the invention can operate at an evaporator coil assembly temperature up to about 10° C. colder than conventional air conditioners and circulate conditioned air at lower CFM (cubic feet/minute) to maintain a comfortable conditioned space. As set out below, this is achieved using a particular evaporator in which the evaporator coil assembly 18 has certain characteristics, such as having about 14 fins per inch. The use of such an evaporator coil assembly 18 is made possible through the humidification control described herein and the low thermal losses achieved with the air duct assembly 122.

It will be appreciated by those of ordinary skill in the field that a relative humidity (RH) of air in the outlet subchamber 16 can be relatively low during operation of the evaporator coil assembly 18. This is a known result of cooling air to its dewpoint as it passes through the coil assembly 18. The relatively dry and cool air creates an environment that is hostile to the growth of mould. However, conventional air conditioning systems are configured so that the compressor switches off once a certain temperature is reached. As soon as this occurs, the relative humidity can spike upwardly, even though the air-conditioned area is still at the required temperature. Once the compressor switches on again, it can take some time before the relative humidity reaches a desired level.

In the various embodiments described herein, the infrared emitter can be used to bathe the evaporator coil assembly 18, while the compressor is still operational. The resultant heat prevents the compressor from being turned off and maintains the temperature at the desired level. It follows that operation of the infrared emitter 56 can be controlled in such a way as to maintain a relative humidity of the air in the outlet subchamber 16 within a certain range in which the growth of mould is inhibited.

Thus, a hygrometer sensor or humidity sensor 182 can be mounted in the outlet subchamber 16 to measure the humidity of the air in the outlet subchamber 16. It is envisaged that the sensor 182 can be mounted anywhere else in the system where it would be appropriate to measure the relative humidity. However, for the purposes of maintenance and convenience, it may be more appropriate to mount the sensor 182 in the outlet subchamber 16.

The sensor 182 can be coupled to the controller 142. The controller 142 can be programmed to control operation of the infrared emitter to achieve a desired relative humidity measurement within the outlet subchamber 16. For example, the controller can be programmed to achieve a relative humidity measurement of between about 40% and 60%, which has been found to be most beneficial for inhibiting the growth of mould.

The relative humidity can also be effectively controlled by particular configurations of the evaporator coil assembly 18. Coil temperature, direction of air flow over the coil, and air flow velocity all contribute to extraction of moisture from the air. The evaporator coil assembly 18 can be a twin-circuited evaporator with about 14 fins per inch. This enables the evaporator coil assembly 18 to run efficiently at colder temperatures, resulting in a greater temperature difference across the evaporator coil assembly 18, and therefore an increased extraction of moisture from the air passing over the evaporator coil assembly 18.

De-humidification can also be maximised by the vertical configuration of the assembly 10. A configuration of the evaporator coil assembly 18 in a vertical orientation, preferably about 800 mm high, and the extractor 38 configured as illustrated in at least in FIG. 2, causes the air to pass over the evaporator coil assembly 18 at an approximately 60° angle. This results in an optimised contact time between the air and the evaporator coil assembly 18, with corresponding increase in dehumidification. This contact time in the assembly of the invention can be in the order of twenty times greater than conventional systems.

Humidity control can also be achieved in the assembly of the invention when the infrared emitter 56 is used to heat the coil assembly 18, and thereby the air passing through the coils. Pulsing of the infrared emitter 56, which can be controlled by a PID (proportional, derivative, integral) loop enables increased de-humidification.

In addition, humidity control can be further effected by precise control by the system of the invention of the amount of refrigerant fed into the system for optimal stable evaporator and temperature control. The system of the invention can also control the saturated suction temperature and compressor speed to 1 HZ accuracy, which can contribute to humidity control.

The provision of the outlet subchamber 16 should be particularly noted. The outlet subchamber 16 permits treated air to be supplied to the zones in a number of ways, as set out above. The air can also be monitored in the outlet subchamber 16 to assess variables such as humidity, CO₂ content, temperature, et cetera.

In FIG. 15, there is shown an example of the physical architecture of the air handling assembly 10 with the two air treatment systems 13. With reference to the preceding drawings, like reference numerals refer to like parts, unless otherwise specified.

The assembly 10 includes a radio module 202 that is used by both air treatment systems 13. Both air treatment systems 13 are powered by a single power supply 204.

Each air treatment system 13 includes a sensor module 206 that is connected to the radio module 202 with a suitable interface, for example, an RS485 interface, or similar. The sensor module 206 is connected to the various sensors described herein, for example the hygrometer sensor 182 and a thermistor 210, to communicate signals generated by those sensors to the radio module 202 for transmission to the remotely located control server 146.

Each air treatment system 13 includes an interface module 212 that is connected to the radio module 202 with a suitable interface, for example, an RS485 interface, or similar. Each interface module 212 is connected to a controller 214 for controlling operation of the compressor 42, an evaporator fan 218 of the extractor 38, and the condenser fan 66. The connection of the interface module 212 with the controller 214 can be via a suitable communications protocol, such as a MODBUS protocol.

The controller 214 can be a suitable air conditioning controller, such as a Frecon controller. The controller 214 can also be the controller 142.

In FIG. 16, there is shown an example of the logical architecture of the air handling assembly 10 with reference to one air treatment system 13. With reference to the preceding drawings, like reference numerals refer to like parts, unless otherwise specified.

There is shown a carbon dioxide sensor 222 that is operatively positioned with respect to the air inlet 224. A temperature/humidity sensor 226 is also operatively positioned with respect to the air inlet 224. Both the carbon dioxide sensor 222 and the temperature/humidity sensor 226 are connected to the sensor module 206. Thus, data relating to the temperature and humidity at the air inlet 224 can be communicated to the server 146 or to some other remote control arrangement via the radio module 202.

As can be seen, the thermistor 210 and the fan 66 of the condenser 44 are connected to the controller 214. A thermistor 228 in the outlet subchamber 16, the evaporator fan 218 and the compressor 216 are also connected to the controller 214. In turn, the controller 214 is connected to the interface module 212, which is connected to the radio module 202.

Thus, with suitable programming at the server 146 and/or controller 214, or other appropriate arrangement, the air treatment system(s) 13 can be automatically controlled to provide air which has desired temperature, hygiene and humidity characteristics.

It should be noted that the term “air treatment” has been used, instead of “air conditioning”. The reason for this is that the system described herein is capable of doing significantly more than just heating or cooling the air, as is apparent from this description. It is thus to be appreciated that the term “treatment” is to be understood to include heating and cooling, but not to be limited thereto.

In various embodiments, there is provided an air treatment assembly 170 (FIG. 14) that can be mounted in line with the air duct assembly 122 described above.

The air treatment assembly 170 includes a housing 172 that defines an air treatment chamber 174. The housing defines an inlet 178 and an outlet 180. An inlet conduit 176 of the duct assembly 122 is connected to the housing 172 at the inlet 178 to feed air to be treated into the air treatment chamber 174. An outlet conduit 175 is connected to the outlet 180.

Various devices for treating the air and measuring air quality can be mounted in the air treatment chamber 174. For example, a UV emitter 52 can be arranged in the chamber 174 to sterilise the air as it passes through the chamber 174. A hygrometer sensor 182 can be arranged in the chamber 174 to measure the relative humidity of the air as it passes through the chamber 174. Various other sensors, generally indicated at 184 in FIG. 14, can be arranged in the chamber 174 to measure other characteristics of the air. The various components in the air treatment chamber 174 can be operatively connected to the controller 142 so that a quality of the air passing through the chamber 174 can be measured and adjusted.

The air treatment assembly can include a filtration device to filter the air passing through the air treatment chamber. Such a filtration device can be in the form of a HEPA air filter positioned in the inlet 178 or outlet 180 of the air treatment assembly. The filtration device can be positioned elsewhere in the duct assembly 122, depending on convenience and accessibility.

It will be appreciated that the air treatment assembly and associated ducting can be used together with an existing air-conditioning system.

For example, many existing air-conditioning systems do not have provision for introducing fresh air into an area or zone to be conditioned. The reasons for that can simply be a matter of system selection. However, in other cases, the reasons may be associated with the need to maintain a sterile environment. In both cases, the air treatment assembly 170 can be used in parallel with an existing air-conditioning assembly to introduce fresh air into the conditioned environment while maintaining the quality of the air introduced into the conditioned environment.

In other embodiments, the air treatment assembly 170 can be provided as a closed system to treat the air in a conditioned zone.

It will be appreciated that the air treatment assembly can also be in the form of the air handling assembly 10 without the evaporator coil assembly 18. In effect, the outlet subchamber 16 of the air handling assembly 10 is equivalent to the air treatment chamber of the air treatment assembly. Thus, the components or parts of the air treatment 170 can be found in the outlet subchamber 16 of the air handling assembly 10.

It will readily be appreciated that, in a multiple-zone scenario, such as a large dwelling or building containing a number of separate dwellings or offices, the various air conditioning systems provide a modularity that would not be available with current ducted systems. For example, within such an environment, a single air handling assembly can be removed for replacement or maintenance without interfering with the remaining air handling assemblies.

Furthermore, such modularity allows an arrangement containing a number of the air conditioning systems to be installed in a “turnkey” fashion with the air conditioning systems adapted to suit the respective zones associated with the air conditioning systems.

In buildings containing multiple zones, it can be necessary to use a chiller plant to cool the condenser coils. Such chiller plants can be expensive, can occupy a significant amount of space and can harbour bacteria and viruses. Use of the air conditioning systems of the invention in such buildings obviates the need for chiller plants and so can address the disadvantages of chiller plants.

In dwellings such as residences, it is common for high wall split systems to be used. Such high wall split systems do not incorporate the outlet subchamber 16. As such, it is not possible for such high wall split systems to carry out the various air treatment processes described herein.

In the drawings, the air handling assembly 10 is shown to incorporate two evaporator coil assemblies and associated compressors for use with two air conditioning systems. It will readily be appreciated that the air handling assembly 10 can incorporate any number of evaporator coil assemblies and associated compressors depending on the configuration of the zones.

The assembly and system of the invention can include full remote diagnostic control, whereby any fault can be sent electronically to a service support team. An internal IP address can permit levels of remote interrogation to diagnose faults and assess usage for maintenance purposes.

For the purposes of repairs and/or maintenance, the configuration of the assembly of the invention allows for easy access to components. When the assembly of the invention includes ultraviolet germicidal irradiation, for example with the UV emitter 52, the evaporator coil assembly 18 will not require cleaning in the operational life of the assembly. The evaporator fan is configured to slide in and out of the assembly for simple substitution in the event of failure or maintenance.

The use of common reference numerals in the preceding description is intended to refer to like or similar parts for ease of description. The use of such common reference numerals is not intended to indicate that the parts are identical. The parts described in the various embodiments are interchangeable, where practical.

The appended claims are to be considered as incorporated into the above description.

Throughout the specification, including the claims, where the context permits, the term “comprising” and variants thereof such as “comprise” or “comprises” are to be interpreted as including the stated integer or integers without necessarily excluding any other integers.

It is to be understood that the terminology employed above is for description and should not be regarded as limiting. The described embodiments are intended to be illustrative of the invention, without limiting the scope thereof. The invention is capable of being practised with various modifications and additions as will readily occur to those skilled in the art.

Claims

1. An air handling assembly that comprises:

a support structure;

at least one air handling chamber arranged on the support structure, the, or each, air handling chamber including an inlet subchamber and an outlet subchamber, the inlet subchamber being in fluid communication with the outlet subchamber;

a coil assembly arranged on the support structure and interposed between the inlet subchamber and the outlet subchamber so that air passing from the inlet subchamber to the outlet subchamber passes through the coil assembly;

an air inlet in fluid communication with the inlet subchamber; and

an air outlet in fluid communication with the outlet subchamber.

2. The air handling assembly as claimed in claim 1, in which the coil assembly is an evaporator coil assembly.

3. The air handling assembly of claim 1, which includes air treatment apparatus that is arranged in the, or each, outlet subchamber.

4. The air handling assembly of claim 3, wherein the air treatment apparatus includes an air heating apparatus.

5. The air handling assembly of claim 3, wherein the air treatment apparatus includes an infrared emitter that is positioned to direct infrared rays on to the evaporator coil assembly to heat the coil assembly so that air passing through the coil assembly is heated.

6. The air handling assembly of claim 3, wherein the air treatment apparatus includes a disinfecting apparatus to disinfect air in the outlet subchamber.

7. The air handling assembly as claimed in claim 6, wherein the air treatment apparatus includes a UV emitter that is positioned to direct UV rays on to the evaporator coil assembly to disinfect air passing through the coil assembly.

8. The air handling assembly as claimed claim 1, which includes an air extractor that is operable to draw air into the inlet subchamber, via the air inlet, through the coil assembly and into the outlet subchamber and to expel treated air from the outlet subchamber 16, via the air outlet.

9. The air handling assembly as claimed in claim 1, in which the support structure includes a floor, a roof and four sidewalls.

10. The air handling assembly as claimed in claim 9, which includes an intermediate transverse wall interposed between the floor and the roof, and at least one dividing wall extending from the transverse wall to the roof so that the intermediate transverse wall, the roof, the sidewalls, and the at least one dividing wall define at least two air handling chambers.

11. The air handling assembly as claimed in claim 2, in which at least one compressor is arranged on the support structure and is operatively connected to the, or each respective, evaporator coil assembly.

12. An air treatment system that comprises:

an air handling assembly including a support structure; at least one air handling chamber arranged on the support structure, the, or each, air handling chamber including an inlet subchamber and an outlet subchamber, the inlet subchamber being in fluid communication with the outlet subchamber; an evaporator coil assembly arranged on the support structure and interposed between the inlet subchamber and the outlet subchamber so that air passing from the inlet subchamber to the outlet subchamber passes through the coil assembly; an air inlet in fluid communication with the inlet subchamber; and an air outlet in fluid communication with the outlet subchamber;

an air supply duct connected to the air outlet to supply air to a zone in which air is to be conditioned and/or treated;

an air return duct connected to the air inlet to return air to the air handling assembly from the zone; and

a condenser having a housing, the housing having at least one inlet and at least one outlet, a fan for directing air from the, or each, inlet and out through the, or each, outlet, and a condenser coil assembly positioned within the housing and interposed between the inlet and the outlet and operatively connected to the coil assembly.

13. The air conditioning system as claimed in claim 12, which includes a compressor and an expansion valve assembly operatively connected to the evaporator coil assembly and the condenser coil assembly.

14. The air conditioning system as claimed in claim 13, which includes a system controller operatively connected to the expansion valve assembly to control operation of the expansion valve assembly.

15. The air conditioning system as claimed in claim 14, in which an air heating apparatus is arranged in the outlet subchamber and is operatively connected to the system controller so that the system controller can control a temperature of the air being discharged from the air outlet.

16. The air conditioning system as claimed in claim 14, in which an air disinfecting apparatus is arranged in the outlet subchamber and is operatively connected to the system controller so that the system controller can control a disinfection process carried out on the air in the outlet subchamber.

17. The air conditioning system as claimed in claim 14, which includes an air extractor that is operable to draw air into the inlet subchamber, via the air inlet, through the evaporator coil assembly, into the outlet subchamber and to expel conditioned and/or treated air from the outlet subchamber via the air outlet, the air extractor being operatively connected to the system controller so that the system controller can control a volumetric rate of air being discharged from the outlet subchamber.

18. A method of conditioning air, the method comprising the steps of:

displacing air into an inlet subchamber of an air handling chamber having the inlet subchamber and an outlet subchamber with a coil assembly interposed between the inlet and outlet subchambers so that the air passes from the inlet subchamber through the evaporator coil assembly and into the outlet subchamber; and

treating the air in the outlet subchamber before the air is discharged from the outlet subchamber.