HEAT PUMP SYSTEM WITH DEHUMIDIFICATION

Abstract

This disclosure relates generally to a system to dehumidify and alternately heat or cool a first space. For example, embodiments of the present disclosure supply air to enclosed and/or controlled environments, where the air is supplied with a desired temperature and/or humidity. Some embodiments of the present disclosure dynamically maintain the desired temperature and/or humidity of the enclosed and/or controlled environment. Embodiments of the present disclosure selectively engage an operational mode to provide or dynamically maintain the desired temperature and/or humidity of the enclosed and/or controlled environment. The system includes an indoor unit with a first coil and a second coil. The first indoor coil and the second indoor coil are in fluid communication. A control module is in electrical communication with the indoor unit and a plurality of solenoid valves to control a position of the solenoid valves between an open position and a closed position.

Description

CROSS REFERENCE TO RELATED MATTER

This application is a continuation-in-part to U.S. application Ser. No. 18/090,775, filed Dec. 29, 2022, entitled SYSTEMS AND METHODS FOR DEHUMIDIFICATION, AIR CONDITIONING, AND CONTROLLED PROVISION OF CO₂ (“the '775 application”). The entire disclosure of the '775 application is hereby incorporated herein.

TECHNICAL FIELD

This disclosure relates generally to dehumidification and air conditioning systems. More specifically, this disclosure relates to the systems capable of dehumidification and conditioning of the air of an enclosed space, and methods of use thereof.

SUMMARY

In various aspects, systems and methods are provided for conditioning the air of enclosed spaces. In particular, systems and methods are provided to dehumidify and/or condition (i.e., heat or cool) the air of an enclosed space. The disclosed system and methods are configured to dehumidify the air of an enclosed space with little to no change in the temperature of the air.

For example, embodiments of the present disclosure supply air to enclosed and/or controlled environments, where the air is supplied with a desired temperature and/or humidity. Additionally, some embodiments of the present disclosure dynamically maintain the desired temperature and/or humidity of the enclosed and/or controlled environment. Embodiments of the present disclosure selectively engage an operational mode to provide or dynamically maintain the desired temperature and/or humidity of the enclosed and/or controlled environment.

These objectives are achieved by providing systems, devices, and methods that operate on the vapor compression principle and employ two evaporator coils within an indoor unit (i.e., an indoor heat exchanger). The systems and devices additionally include solenoid valves within the indoor unit for directing a flow of refrigerant (e.g., hot refrigerant) through a second coil inside the indoor unit to heat the air that has been dehumidified by a first coil, when in dehumidification mode. In the dehumidifying mode, air that is cooled by passing through the first coil is then heated by the second coil to produce dehumidified air at the approximate desired temperature of the returned air. Further, the systems and devices include a control module to selectively engage and control the operational modes of embodiments of the present disclosure.

For example, the second evaporator coil can be disposed in serial air flow after a blower of the indoor unit. Embodiments of the present disclosure can provide a single system that is capable of cooling, heating, and/or dehumidifying the supplied air without cooling an enclosed space below a desired temperature.

The disclosed systems are compact and simplified, energy and cost efficient to manufacture, and can easily be installed by a qualified HVAC professional. The disclosed systems also avoid the costs and hassle of installing additional dehumidifiers to maintain the climate of an enclosed space. Further, the disclosed systems and methods are energy and cost-efficient in their operations.

Other aspects of the disclosed subject matter, as well as features and advantages of various aspects of the disclosed subject matter, should be apparent to those of ordinary skill in the art through consideration of the ensuing description, the accompanying drawings, and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 illustrates a schematic overview of a system according to embodiments of the present disclosure.

FIG. 2 illustrates a wiring diagram of a control module according to embodiments of the present disclosure.

FIGS. 3-5 illustrate decision trees or hierarchies for prioritizing tasks by a control module according to embodiments of the present disclosure.

FIG. 6 illustrates a schematic block diagram of the control module of FIG. 2 according to embodiments of the present disclosure.

FIG. 7 schematically illustrates the system of FIG. 1 in a cooling mode.

FIG. 8 illustrates a flowchart of an exemplary method of cooling according to embodiments of the present disclosure.

FIG. 9 schematically illustrates the system of FIG. 1 in a heating mode.

FIG. 10 illustrates a flowchart of an exemplary method of heating according to embodiments of the present disclosure.

FIG. 11 schematically illustrates the system of FIG. 1 in a dehumidification mode.

FIG. 12 illustrates a flowchart of an exemplary method of dehumidification according to embodiments of the present disclosure.

DETAILED DESCRIPTION

Typically, in enclosed spaces/controlled environments, a comfortable climate requires precise control over not only the air temperature but also the humidity level within the enclosed space. Air conditioning systems for cooling and maintaining the air temperature within an enclosed space are frequently used for this purpose.

Often, when the temperature of the air is warmer than comfortable for most people, systems exist to dehumidify the air in an attempt to bring the temperature of the air down. These systems are typically installed alongside pre-existing air condition systems. Additionally, when the temperature of an enclosed space is comfortable for most people, the air is undesirably humid.

Embodiments of the present disclosure address and solve these and other issues. Disclosed are systems and devices having air conditioning capabilities to heat, cool, and/or dehumidify the air inside (or being delivered to) an enclosed space. In some embodiments, the disclosed systems are dynamic and responsive to, at least, (i) user provided settings and/or controls, and (ii) measurements of the enclosed space, where the measurements include one or more of a temperature and a humidity level for the enclosed space. In some embodiments, the enclosed space includes one space. In some embodiments, the enclosed space includes a plurality of spaces, such as a first space, a second space, a third space, etc. The plurality of spaces may be connected (i.e., in fluid communication) as part of a larger facility.

FIG. 1 illustrates a schematic overview of a system 100 according to embodiments of the present disclosure. In some embodiments, the system 100 includes an outdoor unit 10, an indoor unit or air handler 20, solenoid valves 22a/b, a control module 30, and a plurality of monitors 40. In some embodiments, the control module 30 and plurality of monitors 40 are installed within an enclosed space to monitor and measure the air to be conditioned (e.g., heated, cooled, and/or dehumidified). For example, the control module 30 and/or any one of the plurality of monitors 40 can be installed on a wall of the enclosed space. The control module 30 and the plurality of monitors 40 can be connected to (i.e., in electrical communication with) each other through low-voltage wiring. Additionally, the control module 30 and the plurality of monitors 40 can be connected to (i.e., in electrical communication with) the outdoor unit 10, the indoor unit 20, and the solenoid valves 22a/b via low-voltage wiring.

Though not illustrated in FIG. 1, the outdoor unit 10 can include a compressor 11, at least one coil 13, a condensing fan 15, and a motor for the condensing fan 17 (see FIGS. 7-9). In some embodiments, the at least one coil is an evaporator coil. In some embodiments, the at least one coil includes two coils—an evaporator coil and a condensing coil. The outdoor unit 10 can also include a reversing valve 18.

The indoor unit 20 can include a first coil 24, a fan or blower 26, and a second coil 28. In some embodiments, the second coil 28 is contained within an evaporator coil cabinet (not illustrated). In some embodiments, the fan 26 is connected to the (i.e., in electrical communication with) control module 30 via low-voltage wiring. In some embodiments, the indoor unit 20 further includes a return air orifice, to pull air (e.g., outside air) into the indoor unit 20 to interact with and be conditioned by the first coil 24 and/or the second coil 28. The indoor unit 20 can also include a supply air orifice to deliver conditioned air to an enclosed space 50. In some embodiments, the indoor unit 20 is constructed to have fit plenums for duct work for the supply and air return orifices.

In some embodiments, the second coil 28 is installed or mounted on top of, that is vertically arranged with, the first coil 24. The first coil 24 is installed below the second coil 28 so that when the system 100 is running a dehumidification mode (discussed more fully below), condensation dripping from the first coil 24 will not contact a hot second coil 28 and be re-vaporized. Such re-vaporization would undesirably reintroduce humidity that was purposefully taken out of or removed from the air in the dehumidification mode. In other embodiments, the first and second coils can be installed in other positions.

In some embodiments, the second coil 28 is installed in serial air flow within the indoor unit 20. For example, the second coil 28 can be disposed in serial air flow after the fan 26. In this arrangement, air coming through the return air orifice will pass first over the first coil 24 to be conditioned (i.e., heated or cooled). In a conditioning mode (e.g., heating and/or cooling), the conditioned air will be passed through to the enclosed space 50 without being affected by the second coil 28.

The indoor unit 20 is connected to the outdoor unit 10 via a plurality of refrigeration lines. Specifically, the first coil 24 is connected to the outdoor unit via a first refrigeration line 12 and a second refrigeration line 14. The second refrigeration line 14 also connects the second coil 28 to the outdoor unit 10, as well as providing fluid communication between the first and second coils 24, 28. A third refrigeration line 16 connects the outdoor unit 10 to the second coil 28. The second coil 28 can be connected to the outdoor unit 10 via standard suction and liquid lines, in addition to the third refrigeration line 16.

Disposed along at least one of the first, second, and third refrigeration lines 12, 14, 16 are a plurality of solenoid valves 22a/b. For example, the plurality of solenoid valves 22a/b may include two solenoid valves 22a/b. In some embodiments, the solenoid valves 22a/b are disposed along the same refrigeration line 12, 14, 16. In some embodiments, the solenoid valves 22a/b are disposed along different refrigeration lines 12, 14, 16. For example, as illustrated, the solenoid valves 22a/b are disposed along the same refrigeration line 14.

In some embodiments, the solenoid valve 22a defaults to an open position (i.e., normally open) to allow refrigerant to flow between the outdoor unit 10 and the first and second coils 24, 28 of the indoor unit 20. The solenoid valve 22b may default, correspondingly, to a closed position (i.e., normally closed) to ensure the refrigerant freely flows between the outdoor unit 10 and the coils 24, 28 of the indoor unit 20. In some embodiments, such as when the system 100 is running a dehumidification mode, the control module 30 changes the positions of one or both of the solenoid valves 22a/b. That is, the control module 30 will activate both solenoids to change the position of solenoid valve 22a to a closed position and/or solenoid valve 22b to an open position.

When the solenoid valve 22a is in the closed position, the flow of refrigerant to the second indoor coil 28 is stopped, such as during a cooling mode. Because the solenoid valve 22b is now in the open position, the flow of refrigerant is redirected from the first indoor coil 24 to the second indoor coil 28.

The control module 30 is in electric communication with the outdoor unit 10, the indoor unit 20, the plurality of monitors 40, and the solenoid valves 22a/b. In some embodiments, the control module 30 is configured to control a position of the solenoid valves 22a/b, between an open and closed position. The control module 30 controls the position of the solenoid valves 22a/b in response to measurements taken by at least one of the plurality of monitors 40.

Specifically, the plurality of monitors 40 can include a thermostat 42 and a humidistat 44, among others. The control module 30 is configured to receive signals from each of the plurality of monitors 40 and, in response, send signals to the outdoor unit 10, the indoor unit 20, and/or the solenoid valves 22. The signals received by the control module 30 contain information relating to measured temperature and humidity for the enclosed space 50. The control module 30 is also configured to start, stop, and/or change an operational mode of the system 100 in response to the received signals.

In some embodiments, the indoor unit 20 engages the first coil 24 for heating in a standard heating mode. Hot refrigerant generated by a compressor of the outdoor unit 10 can be circulated through the first coil 24 to heat the first coil 24. For example, the hot refrigerant can be circulated to the first coil 24 via the second refrigeration line 14, through a reversing valve, and through solenoid valve 22a which is in the default open position. Air can be passed over the hot first coil 24 to heat the air, where the heated air can then be passed to an enclosed space 50, thereby heating the enclosed space 50. The system 100 also includes a thermostat 42. When the temperature of the enclosed space 50 satisfies a threshold value (measured by the thermostat 42), the control module 30 will turn off the heating mode. In some embodiments, the threshold value is a temperature of approximately 65° F. to 85° F., such as 68° F., 70° F., 75° F., 79° F., 80° F., 83° F., or a temperature falling within a range defined by any two of the foregoing values.

The hot refrigerant will then travel back to the outdoor unit 10. The fan or blower of the outdoor unit 10 can blow air over the coil of the outdoor unit 10 to assist in cooling the refrigerant. Once the refrigerant has cooled sufficiently, it is in condition to be compressed again to a hot liquid and recirculated through the first coil 24 until the temperature of the enclosed space satisfies a desired level.

Another mode of the system may be a dehumidification mode. In the dehumidification mode for the system 100, the outdoor unit 10 and the second coil 28 of the indoor unit 20 are both activated. Additionally, the solenoid valves 22a/b will be activated and changed from an open and/or closed position to an open and/or closed position, respectively. The activation of the solenoid valves 22a/b will change the flow of refrigerant from the first coil 24 to the second coil 28 rather than to the outdoor unit 10. That is, flow that is typically sent through the compressor discharge instead is directed to the second indoor coil 28. Flowing the refrigerant through the second coil 28 will cause the second coil 28 to heat and the first coil 24 to cool. Air will pass through the return air orifice of the indoor unit 20 and will cool within the indoor unit 20. Specifically, the air will be cooled as it contacts a cold first coil 24.

The cooled and dehumidified air will then pass a heated second coil 28 to be neutralized before directed to the enclosed space. Neutralizing the cooled and dehumidified air brings the air “back to temperature” before directing the air to the enclosed space. This allows the system to dehumidify the enclosed space to a desired humidity level without undesirably cooling the temperature of the enclosed space. By warming the dehumidified air before cycling it to the enclosed space, both the temperature and the humidity of the enclosed space can be dynamically maintained. Air can be neutralized using hot refrigerant from the discharge line of the outdoor compressor to the second indoor coil, and/or by electric resistance heat so that the cooled air is warmed and balanced before traveling to the enclosed space through duct work.

As the air is cooled, humidity (i.e., water) in the air will condense and drain out of the indoor unit 20. In a dehumidification mode, the air coming through the return air orifice will be passed over the first coil 24 to be cooled and dehumidified. The dehumidified air will then be passed over the second coil 28 to bring the dehumidified air to a desired temperature before being introduced to the enclosed space.

The dehumidified and cooled air will pass over a hot second coil 28 of the indoor unit 20 and be warmed to a desired or threshold temperature. In some embodiments, the desired or threshold temperature corresponds to a user-set temperature. In some embodiments, the user-set temperature is approximately 65° F. to 85° F., such as 68° F., 70° F., 75° F., 79° F., 80° F., 83° F., or a temperature falling within a range defined by any two of the foregoing values. The dehumidified and warmed air will then be passed to the enclosed space 50 via the supply air orifice 25.

Also disclosed is a cooling mode. In the cooling mode of the system 100, the compressor 11 sends refrigerant to the coil of the outdoor unit 10. The blower or fan of the outdoor unit 10 passes air over the coil to cool the coil and the refrigerant. The cooled refrigerant will be circulated to the first coil 24, thereby cooling the first coil 24 of the indoor unit 20. A return air orifice and blower 26 of the indoor unit 20 will force and pass air over the cooled first coil 24. The air will be cooled and then directed into an enclosed space via a supply air orifice.

The cooled refrigerant will be circulated through solenoid valve 22a back to the compressor 11, where the refrigerant will be compressed or pressurized. The hot refrigerant will be cycled back to the coil of the outdoor unit 10, where the hot refrigerant will be cooled by action of the outdoor fan or blower. Cooled refrigerant can again cycle through the first coil 24 to cool an enclosed space. As before, the thermostat will continue to monitor and measure the temperature of the enclosed space. When the temperature of the enclosed space satisfies a threshold value (i.e., a desired user-set temperature), the control module 30 will terminate the cooling mode.

FIGS. 3-5 illustrate decision trees or hierarchies for prioritizing tasks by a control module according to embodiments of the present disclosure. FIG. 3 illustrates a decision tree for the control module (abbreviated as “CM” in FIG. 3) to activate/deactivate various aspects of the disclosed system. The system may determine if a desired temperature is reached 305. If the desired temperature is not reached, the control module will activate a heating or cooling mode 310. Activating the heating or cooling mode will activate the compressor 11 and indoor unit 325. Similarly, the system may determine if a desired humidity level is reached 315. If the desired humidity level is not reached, the control module will activate a dehumidification mode 330 as described herein to activate solenoid valve(s) and redirect the flow of refrigerant within the system. If the desired humidity level 315 has been reached or satisfied, the control module will turn off the system 320.

As shown in FIG. 4, a desired temperature of the enclosed space can be set by a user, 405. A thermostat (see thermostat 42 of FIG. 1) monitors and measures the temperature of the enclosed space, 410. When the temperature of the enclosed space does not satisfy a threshold value (i.e., does not satisfy the desired user-set temperature), the thermostat will signal to the control module (e.g., control module 30) to run a heating or cooling mode, 415. The signal sent to the control module can contain information relating to the temperature of the enclosed space.

Based on the signal received by the control module from the thermostat, the control module will selectively activate a heating or cooling mode for the system, 420. For example, if the signal received indicates the temperature of the enclosed space is above the desired user-set temperature, the control module can selectively activate the cooling mode of the system. In activating the heating or cooling mode, the control module will selectively activate or engage components of the indoor unit and the outdoor unit, 425. For example, the control module will activate at least the compressor 11 of the outdoor unit. In some embodiments, the control module 30 may also activate one or both solenoid valves, 425.

During execution and activation of the heating or cooling mode, the thermostat will continue to monitor and measure the temperature of the enclosed space, 430. Additionally, the thermostat will continue to relay the measured temperature to the control module. When the temperature of the enclosed space satisfies the threshold value (i.e., satisfies the desired user-set temperature), the control module will terminate or deactivate the heating or cooling mode, 435.

A similar sequence of events or decisions is illustrated in FIG. 5, regarding the humidity of the enclosed space. In some embodiments, the control module will prioritize a temperature of the enclosed space instead of a humidity. In such embodiments, the control module will first execute the sequence or decisions illustrated in FIG. 4 and then execute the sequence or decisions illustrated in FIG. 5. In other configurations, the sequences can be executed simultaneously or nearly simultaneously.

Specifically, a user provides or establishes a desired humidity level for the enclosed space, 505. In some embodiments, a humidistat (see humidistat 44 of FIG. 1) can monitor and measure the humidity of the enclosed space, 510. The humidistat can also send a signal to the control module containing information relating to the humidity of the enclosed space (i.e, the measured humidity). If the measured humidity value is equal to or below the desired humidity level, 515 (e.g., the humidity level of the enclosed space is below or at a threshold value), the control module will either keep the system off or terminate the system mode (i.e., terminate a dehumidification mode), 520.

If the measured humidity of the enclosed space is above a predetermined value (i.e., the desired user-set humidity level), the control module will activate the dehumidification mode of the system, 525. Specifically, the control module will activate the compressor 11 of the outdoor unit, the second coil of the indoor unit, and the solenoid valves. Activating the solenoid valves will cause the flow of refrigerant through the system to change, such that hot refrigerant is flowing through the second coil of the indoor unit, 530.

During execution of the dehumidification mode, the humidistat will continue to monitor and measure the humidity of the enclosed space. Additionally, the humidistat will continue to send signals to the control module regarding the humidity of the enclosed space. Once the humidity level has satisfied a threshold value, 535 (i.e., the desired user-set humidity level), the control module will terminate or deactivate the dehumidification mode, 540. If the humidity level does not satisfy the threshold value, the control module will continue running the dehumidification mode, 550, and determining if the user-set humidity level has been satisfied, 535. That is, the control module will check the measured humidity of the enclosed space, as received by the control module from the humidistat 44, to ensure it matches (and/or comes within a small range of error) of the user-desired humidity. In some embodiments, the control module will then check the temperature of the enclosed space to ensure it continues to satisfy the desired user-set temperature. If the temperature does not satisfy the desired user-set temperature, the system may activate the cooling or heating mode, 545.

According to another aspect, the present embodiments also include one or more control modules 30, such as those described herein. Control modules 30 may be used in a system 100 for dehumidification and air conditioning of an enclosed space 50. FIG. 2 illustrates a wiring diagram 35 for a control module 30 and FIG. 6 illustrates a block diagram 37 of a control module 30 according to embodiments of the present disclosure. Disclosed control modules 30 can be configured to analyze and command, energize, or activate various components of the system 100 depending on the user (i.e., control) settings, indicated and measured by one of the plurality of monitors 40 (e.g., a thermostat 42 and/or a humidistat 44).

The disclosed control modules 30 can be connected to (i.e., in electrical communication with) the outdoor and indoor units 10, 20 via low-voltage wiring. The control modules 30 can also be connected to (i.e., in electrical communication with) the plurality of monitors 40, such as the thermostat 42 and humidistat 44, via low-voltage wiring. In some embodiments, the control modules 30 can communicate with the plurality of monitors 40, the outdoor unit 10, and the indoor unit 20 via WiFi, Bluetooth, network signaling, ethernet connection, other appropriate communication protocols, etc.

As illustrated, the control module 30 can include at least one microprocessor unit 32, at least one storage device 36, at least one transceiver 38, and a plurality of terminal connections 39. The plurality of terminal connections 39 provide the sites for low-voltage wiring to connect the control module 30 to various components of the system 100 (e.g., the outdoor/indoor units 10, 20 and the plurality of monitors 40). In some embodiments, the control module 30 includes communication protocols to allow the control module 30 to communicate, engage, and interface with various components of the system 100.

The at least one microprocessor unit 32 can include a plurality of microprocessor units 1, 2, 3, etc. The control module 30 can include as many microprocessor units 32 as appropriate to adequately and automatically carry out the described function and operational modes for the system 100. In some embodiments, the microprocessor unit(s) 32 is configured to receive a signal from one of the plurality of monitors 40. The microprocessor unit(s) 32 is also configured to send a signal to at least one component of the system 100 (e.g., the outdoor unit 10, indoor unit 20, etc.) in response to the received signal. In other embodiments, microprocessor unit(s) 32 are not provided.

In some embodiments, the microprocessor unit(s) 32 receives and processes the signal from one of the plurality of monitors 40. In some embodiments, the microprocessor unit(s) 32 send a signal to one or more transceivers 38 and the one or more transceivers 38 send and/or relay the signal to one or more components of the system 100.

In some embodiments, the control module 30 (e.g., the microprocessor unit(s) 32 of the control module 30) sends one or more signals containing information relating to (i) an operational mode of/for the system 100, (ii) a measurement of the enclosed space 50, and/or (iii) a change in the operational mode for the system 100. In some embodiments, the microprocessor unit(s) 32 send a signal to one or more transceivers 38 and the one or more transceivers 38 send and/or relay the signal to one or more components of the system 100.

Also disclosed are methods for dehumidification and conditioning of air provided to an enclosed space. FIGS. 7, 9, 11 schematically illustrate the flow of air and/or refrigerant through the system during the dehumidification and conditioning modes. FIGS. 8, 10, and 12 illustrate flowcharts of example methods according to embodiments of the present disclosure.

FIG. 7 schematically illustrates the flow of air and/or refrigerant and FIG. 8 illustrates a flowchart of an example method 600 for cooling an enclosed space according to embodiments of the present disclosure. In some embodiments, the method 600 includes flowing liquid refrigerant from a compressor 11 to an expansion valve, at 610. For example, liquid refrigerant flows from the compressor 11 of the outdoor unit 10 to an expansion valve.

The method 600 also includes expanding the liquid refrigerant via the expansion valve to generate cold gaseous refrigerant, at 615. At 620 of the method 600, the cold gaseous refrigerant cools a first coil 24 of the indoor unit 20. In some embodiments, the cold gaseous refrigerant is circulated to and through the first indoor coil 24 via a refrigeration line, 12.

The cold gaseous refrigerant will warm as it cools the coil (i.e., as the refrigerant absorbs thermal energy from the coil, the refrigerant warms). The method 600 further includes passing air over the cooled coil 24, thereby cooling the air, at 625. Specifically, as the air passes over the cooled coil 24, thermal energy is transferred from the air to the coil. As the thermal energy transfers to the coil 24, the coil 24 begins to warm. This cooled air can then be directed to an enclosed space, thereby cooling the enclosed space. For example, the cooled air can be forced out of a supply air orifice of the indoor unit 20 and into the enclosed space.

The method 600 includes flowing warm gaseous refrigerant (back) to the compressor 11, at 630. For example, the warmed gaseous refrigerant may be directed to the compressor 11 of the outdoor unit 10 via a first solenoid valve 22a having a default open position. In some embodiments, the gaseous refrigerant may be circulated to the compressor 11 via refrigeration line 16. At 635, the method additionally includes condensing the warm gaseous refrigerant to a liquid to again be expanded, such that the cycle can be repeated as necessary.

The refrigerant utilized in the cooling mode will continue to circulate in this way (e.g., condensation to a warm liquid and expansion to a cold gas) until a desired or set temperature has been achieved within the enclosed space. Upon reaching the desired temperature, the cooling mode will automatically shut off until again activated by the control module.

FIG. 9 schematically illustrates a flow of air and/or refrigerant and FIG. 10 illustrates a flowchart of an example method 700 for heating an enclosed space according to embodiments of the present disclosure. In some embodiments, the method 700 includes a substantial reversal of the flow of refrigerant through the system described with respect to method 600 illustrated in FIG. 8. For example, when the temperature of an enclosed space falls below a desired or set value, the control module (see FIGS. 2 and 6) will automatically turn on the heating mode. In some embodiments, the method 700 includes flowing gaseous refrigerant to a compressor 11, at 710. The method 700 additionally includes compressing the gaseous refrigerant to generate hot liquid refrigerant, at 715. The method 700 also includes heating a first coil 24 of the indoor unit 20, at 720. In some embodiments, the hot liquid refrigerant is circulated to the first coil 24 via refrigeration line 12 or 14.

The first indoor coil 24 is heated by the hot liquid refrigerant flowing through the coil 24. That is, as the hot liquid refrigerant flows through the first indoor coil 24, thermal energy from the hot liquid refrigerant is transferred to the first indoor coil 24. This transfer of thermal energy heats the first indoor coil 24 and causes the hot liquid refrigerant to cool slightly. The method 700 further includes, at 725, passing air over the heated indoor coil 24, thereby heating the air. The air may be directed to the heated indoor coil 24 via a return air or air intake orifice. As the air passes over the heated coil 24, the air absorbs thermal energy from the heated coil 24. This causes the air to be heated and the indoor coil to cool 24.

The heated air can then be directed to an enclosed space to thereby heat the enclosed space to a desired temperature. In some embodiments, the heated air is directed to the enclosed space via ductwork. The method 700 further includes flowing cooled liquid refrigerant to a reversing valve, at 730. In some embodiments, the cooled liquid refrigerant has cooled sufficiently to be recompressed to a hot liquid. The cooled liquid refrigerant can be circulated to the reversing valve via, for example, refrigeration line 16.

In some embodiments, the cooled liquid refrigerant is passed through an expansion valve and is expanded a cold gas. This gaseous refrigerant can then be cycled through the compressor, coil, and expansion valve again to heat the air of the enclosed space until the temperature of the enclosed space satisfies a threshold value (i.e., a desired temperature). The temperature of the enclosed space will be monitored and measured by a thermostat, which is in electrical communication with a control module.

The heated air in the heating mode will continue to circulate in this way until a desired or set temperature has been achieved within the enclosed space. Upon reaching the desired temperature, the heating mode will automatically shut off until again activated by the control module.

FIG. 11 schematically illustrates a flow of air and/or refrigerant and FIG. 12 illustrates a flowchart of an example method 800 for dehumidifying an enclosed space according to embodiments of the present disclosure. In some embodiments, the method 800 includes heating a second indoor coil 28, at 805. The method 800 also includes cooling a first coil 24, at 810. In some embodiments, the second coil 28 is installed in serial air flow after a blower 26 of the first coil 24. For example, the second coil 28 can be installed after the blower 26 and prior to a supply air orifice of the indoor unit. This positions the second coil 28 “in front of” (from an air flow perspective) the supply air orifice. Such a position allows air flowing through the indoor unit 20 to be re-heated or neutralized before directing the air into an enclosed space. The second coil 28 is connected to the outdoor unit 10 through standard capillary suction and liquid lines, as well as an additional refrigeration line 16.

In some embodiments, and similar to the cooling mode described above, cooling the first indoor coil 24 includes flowing cold gaseous refrigerant through the first coil 24 and transferring thermal energy from the first coil 24 to the gaseous refrigerant. The cold refrigerant can be circulated to the first coil 24 via refrigeration line 14. The gaseous refrigerant will warm as it passes through and cools the first coil 24. The method 800 further includes condensing water from air as it is passed over the cooled first coil 24, at 915. Again, similar to the cooling mode described above, as the air passes over the cooled first coil 24, the first coil 24 will absorb thermal energy from the air. Additionally, any water or humidity present in the air will be cooled alongside the air and condense on the first coil 24.

The condensed water will collect and drain out of the indoor unit 20. In this way, the disclosed systems and methods dehumidify air being delivered to an enclosed space. The method 800 also includes neutralizing the cooled and dehumidified air by passing it over the hot second coil 28, at 820. Hot refrigerant that is typically directed to the compressor 11 discharge can be re-directed to the second indoor coil 28 by one or more solenoid valves 22a, 22b. The hot refrigerant will circulate through refrigeration line 16 to the second coil 28. As already explained, as the air passes over the heated second coil 28, it will be warmed with an undesirable reintroduction of humidity. The air will be warmed to the set temperature, as determined by a thermostat.

The method 800 further includes delivering the neutralized and dehumidified air to the enclosed space, at 825. In some embodiments, the method 800 is executed and controlled by the system illustrated in FIG. 1. A humidistat monitors and measures the humidity of the enclosed space and, in some embodiments, is configured to send a signal to the control module in response to the measured humidity. The control module can be configured to automatically run the dehumidification mode of the system when the measured humidity satisfies a threshold value.

Though not illustrated, in some embodiments, the methods 600, 700, 800 can additionally include monitoring and/or measuring the temperature and/or humidity of the enclosed space. Further, the methods 600, 700, 800 may also include running an operational mode (i.e., cooling, heating, and/or dehumidification) in response to the measured temperature and/or humidity of the enclosed space. In some embodiments, selecting and running the operational mode is automatically carried out by the control module. Specifically, the control module can be configured to send signals to the outdoor unit and/or the indoor unit to start, stop and/or change an operational mode.

As discussed, the control module and the system are configured to dynamically respond to measured values (e.g., temperature, humidity levels, etc.) of the enclosed space. For example, as humidity levels rise above a threshold or desired value (e.g., 65%), the control module automatically activates the dehumidification mode of the system. After running the dehumidification mode, the system may monitor and measure another value of the enclosed space (e.g., temperature). In response to the subsequent measurement, the control module can automatically activate the appropriate operational mode, such as the heating mode, to ensure the enclosed space maintains the desired and set parameters.

Examples

The following illustrative example refers to the system illustrated in FIG. 1. A user provides set parameter values for an enclosed space. Specifically, the user provides a temperature of 70° F. and a humidity of 65%. The control module receives the user-provided values and receives a measured value for each parameter (temperature and humidity) from the plurality of monitors 40. In some embodiments, the control module 30 requests the measured values for each parameter from the plurality of monitors.

In response to the received measured values for each parameter, the control module 30 automatically selects and runs an operational mode of the system (see FIGS. 7-12). For example, the control module 30 can select the heating operational mode for the system if the measured temperature parameter is below the user-provided value of 70° F. To run the selected operational mode, the control module 30 also activates one or more components of the system. In the heating mode, for example, the control module 30 activates the outdoor unit and the first coil of the indoor unit to provide hot air to the enclosed space.

Once the user-provided value of 70° F. has been achieved, the control module 30 will assess the measured value for each of the other parameters and evaluate whether they match the user-provided value. For example, the control module 30 may assess the measured value of humidity for the enclosed space. If the measured value of humidity is above the user-provided value of 65%, the control module 30 will activate one or more components of the system to run the dehumidification mode. Specifically, the control module 30 will activate the first coil to cool and dehumidify the air, and the second coil to neutralize the air prior to cycling it through the enclosed space.

In other embodiments, the control module 30 can prioritize the measured values for each parameter to evaluate whether they match the user-provided value. For example, the control module 30 may prioritize achieving the desired temperature, and therefore prioritize an air condition (e.g., heating or cooling) mode. Once the user-provided value for the desired temperature has been achieved, the control module 30 will assess the other measured values for each parameter and evaluate whether they match the user-provided value. For example, the control module 30 may then assess the measured humidity of the enclosed space. The control module 30 can continuously, nearly continuously, or intermittently check one or more of the measured values for each parameter. In other embodiments, the control module 30 may be programmed to prioritize a particular parameter, and in yet other embodiments the control module 30 may allow a user to select a parameter to prioritize.

The control module 30 will continue the measuring, assessing, evaluating, and activating of system components to maintain the user-provided values for each parameter of the enclosed space. In this way, the control module can automatically run the appropriate operational mode without any user interference.

While particular embodiments have been illustrated and described herein, it should be understood that various other changes and modifications may be made without departing from the spirit and scope of the claimed subject matter. Moreover, although various aspects of the claimed subject matter have been described herein, such aspects need not be utilized in combination.

In one embodiment, the terms “about” and “approximately” refer to numerical parameters within 10% of the indicated range. The terms “a,” “an,” “the,” and similar referents used in the context of describing the embodiments of the present disclosure (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein is intended merely to better illuminate the embodiments of the present disclosure and does not pose a limitation on the scope of the present disclosure. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the embodiments of the present disclosure.

Groupings of alternative elements or embodiments disclosed herein are not to be construed as limitations. Each group member may be referred to and claimed individually or in any combination with other members of the group or other elements found herein. It is anticipated that one or more members of a group may be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is deemed to contain the group as modified thus fulfilling the written description of all Markush groups used in the appended claims.

Certain embodiments are described herein, including the best mode known to the author(s) of this disclosure for carrying out the embodiments disclosed herein. Of course, variations on these described embodiments will become apparent to those of ordinary skill in the art upon reading the foregoing description. The author(s) expects skilled artisans to employ such variations as appropriate, and the author(s) intends for the embodiments of the present disclosure to be practiced otherwise than specifically described herein. Accordingly, this disclosure includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the present disclosure unless otherwise indicated herein or otherwise clearly contradicted by context.

Specific embodiments disclosed herein may be further limited in the claims using consisting of or consisting essentially of language. When used in the claims, whether as filed or added per amendment, the transition term “consisting of” excludes any element, step, or ingredient not specified in the claims. The transition term “consisting essentially of” limits the scope of a claim to the specified materials or steps and those that do not materially affect the basic and novel characteristic(s). Embodiments of this disclosure so claimed are inherently or expressly described and enabled herein.

Although this disclosure provides many specifics, these should not be construed as limiting the scope of any of the claims that follow, but merely as providing illustrations of some embodiments of elements and features of the disclosed subject matter. Other embodiments of the disclosed subject matter, and of their elements and features, may be devised which do not depart from the spirit or scope of any of the claims. Features from different embodiments may be employed in combination. Accordingly, the scope of each claim is limited only by its plain language and the legal equivalents thereto.

Claims

1. A system to dehumidify and alternately heat or cool a first space, the system comprising:

an outdoor unit comprising an outdoor heat exchanger, the outdoor heat exchanger comprising an outdoor coil and a fan;

an indoor unit comprising:

a first indoor heat exchanger, the first indoor heat exchanger comprising a first indoor coil and a fan, the first indoor coil operable as a condenser in a heating mode or an evaporator in a cooling mode,

a second indoor heat exchanger, the second indoor heat exchanger comprising a second indoor coil, wherein the first indoor coil and the second indoor coil are in fluid communication;

a first refrigeration line from the first indoor coil to the outdoor coil, the first refrigerant line to transport refrigerant from the first indoor coil to the outdoor coil when the first indoor coil is operating as an evaporator;

a compressor in fluid communication with the first refrigeration line, the compressor for pressurizing gaseous refrigerant when the first indoor coil is operating as an evaporator;

a second refrigeration line from the outdoor coil to the first indoor coil, the second refrigeration line in communication with the first refrigeration line and an expansion valve, the expansion valve for reducing the pressure of the gaseous refrigerant when the first indoor coil is operating as an evaporator, the second refrigeration line to provide liquid refrigerant to the first indoor coil;

a third refrigeration line from the outdoor coil to the second indoor coil, the third refrigeration line to provide liquid refrigerant to the second indoor coil; and

wherein the second indoor coil is in communication with a fan to blow hot air from the second indoor coil, mixed with cool air from the first indoor coil, into the first space to dehumidify the first space.

2. The system of claim 1, wherein the compressor is located within the outdoor unit and wherein the outdoor unit further comprises a reversing valve.

3. The system of claim 1, further comprising a plurality of monitors installed within the first space.

4. The system of claim 2, further comprising a control module in electrical communication with the plurality of monitors, wherein the control module controls an operational mode of the system based on signals received from at least one of the plurality of monitors.

5. The system of claim 1, further comprising a plurality of solenoid valves, one of the plurality of solenoid valves disposed along one of the first, second, or third refrigeration lines.

6. The system of claim 5, further comprising a control module in electrical communication with the plurality of solenoid valves.

7. The system of claim 1, further comprising a control module in electrical communication with the outdoor unit and the indoor unit.

8. The system of claim 7, further comprising a user interface in electrical communication with the control module, the user interface allowing a user to select a desired temperature and/or humidity for the first space.

9. A method to dehumidify and alternately heat or cool a first space, the method comprising:

achieving a temperature for the first space; and

achieving a humidity level for the first space without changing the temperature for the first space.

10. The method of claim 9, wherein achieving a humidity level for the first space comprises:

cooling a first coil;

passing air over the cooled first coil, causing water to condense from the air and produce dehumidified air;

passing air over a hot second coil, neutralizing the dehumidified air; and

directing the neutralized air to the first space.

11. The method of claim 9, wherein the steps are taken in the following order:

passing air over the cooled first coil, causing water to condense from the air and produce dehumidified air;

passing air over a hot second coil, neutralizing the dehumidified air; and

directing the neutralized air to the first space.

12. The method of claim 9 further comprising:

monitoring a humidity level for the first space; and

monitoring a temperature for the first space.

13. The method of claim 9, wherein each of the humidity level and temperature are monitored by a control module.

14. The method of claim 12, wherein the temperature ranges from approximately 65° F. to 85° F., such as 68° F., 70° F., 75° F., 79° F., 80° F., 83° F., or a temperature falling within a range defined by any two of the foregoing values.

15. The method of claim 12, wherein the humidity level ranges from approximately 60% to 85%, such as 63%, 65%, 68%, 70%, 75%, 77%, 80%, 83%, or a humidity level within a range defined by any two of the foregoing values.

16. A control module to control functions to dehumidify and alternately heat or cool a first space, the control module comprising:

a first microprocessor in electronic communication with a thermostat and/or a humidistat;

low voltage wiring connecting the control module to an indoor unit and an outdoor unit; and

a second microprocessor in electrical communication with the indoor unit, the outdoor unit, and/or the first microprocessor,

the second microprocessor configured to alter an operational mode of the indoor unit and/or the outdoor unit in response to at least one signal received from the first microprocessor.

17. The control module of claim 16, wherein the second microprocessor is additionally in electrical communication with a plurality of solenoid valves incorporated into the indoor unit.

18. The control module of claim 17, wherein the plurality of solenoid valves are disposed along a first, second, and/or third refrigeration line,

the first, second, and/or third refrigeration lines connecting the indoor unit to the outdoor unit.

19. The control module of claim 17, wherein the control module is configured to control a position of each solenoid valve of the plurality of solenoid valves, the position of each solenoid valve associated with a flow of refrigerant through a first, second, and/or third refrigeration line.

20. The control module of claim 17, wherein the control module is configured to control a position of each solenoid valve of the plurality of solenoid valves from a first default position associated with a first mode and a second activated position associated with a second mode.

21. The control module of claim 20, wherein the first mode is a conditioning mode and the second mode is a dehumidification mode.