TEMPERATURE CONTROL SYSTEM WITH REPLACEMENT MODULE ELECTRIC HEAT PUMP

Abstract

Devices, systems, and methods for controlling a temperature within an interior space of a building, and modifying a pre-existing temperature control system by replacing a gas heater with a heat pump. In one embodiment, a temperature control system includes a cooling unit, a heat pump, and ductwork connecting the cooling unit and the heat pump. In one embodiment, a method of operating a temperature control system includes providing to an interior space of a building heated air with a heat pump, providing cooled air with the heat pump, and providing dehumidified air with the heat pump. The method may further include providing supplemental cool air to the interior with the heat pump. In one embodiment, a method of modifying or retrofitting a pre-existing temperature control system includes replacing a pre-existing gas heater with a heat pump, while retaining a cooling unit and ductwork of the pre-existing system.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is related to and claims the benefit of U.S. Provisional Application No. 63/607,620, filed Dec. 8, 2023, entitled TEMPERATURE CONTROL SYSTEM WITH REPLACEMENT MODULE ELECTRIC HEAT PUMP, and is related to and claims the benefit of U.S. Provisional Application No. 63/561,889, filed Mar. 6, 2024, entitled TEMPERATURE CONTROL SYSTEM WITH REPLACEMENT MODULE ELECTRIC HEAT PUMP, the entirety of both of which is incorporated herein by reference.

GOVERNMENT RIGHTS STATEMENT

N/A.

TECHNICAL FIELD

This disclosure relates to heating and cooling systems, and in particular to replacement of an existing gas heater in an evaporative cooling system with an electric heat pump (replacement module electric heat pump).

BACKGROUND

Heating and cooling systems, either operating in combination or independently, are currently used for climate control within residential and commercial buildings. Some systems include a gas heater, within which natural gas is combusted to generate heat that is then distributed into the building through ductwork and vents. For example, some systems may include a cooling unit and/or a heating unit (such as a gas heater, including a ducted gas heater).

Some gas heaters may be an effective source of heat, but the use of natural gas is falling out of favor and in some places is banned in newly constructed buildings. Other heating options are available, such as heat pumps; however, replacement of legacy gas heaters (and heating and cooling systems of which they are a part) can be cost prohibitive. For example, removal of a cooling unit, heating unit, and associated ductwork, repair of the removal site and preparing it for installation of a new system, and the new system itself can cost tens of thousands of dollars.

SUMMARY

Some embodiments advantageously provide a temperature control system including an electric heat pump. For example, some embodiments provide a temperature control system including replacement module electric heat pump, and methods for replacing a pre-existing ducted gas heater with the replacement module electric heat pump.

In one embodiment, a temperature control system includes a cooling unit, a heat pump, the heat pump being a replacement module electric heat pump, and ductwork connecting the cooling unit and the heat pump.

In one aspect of the embodiment, the cooling unit is an evaporative cooler.

In one aspect of the embodiment, the heat pump includes a fan module and a coil module.

In one aspect of the embodiment, the coil module includes at least one coil, the at least one coil being one of: at least one microchannel coil; and at least one finned tube coil.

In one aspect of the embodiment, the heat pump includes a conditioned air module and an outdoor component. In one aspect of the embodiment, the conditioned air module includes a fan module and a coil module.

In one embodiment, method of operating a temperature control system, the temperature control system including a cooling unit and a heat pump, includes: operating the temperature control system in any of a plurality of modes of operation, wherein the heat pump is a replacement module electric heat pump.

In one aspect of the embodiment, the plurality of modes of operation includes a first mode of operation, a second mode of operation, and a third mode of operation, the first mode of operation includes providing heated air to an interior space of a building with the heat pump; the second mode of operation includes providing cooled air to the interior space of the building with the heat pump; and the third mode of operation includes providing dehumidified air to the interior space of the building with the heat pump.

In one aspect of the embodiment, the plurality of modes of operation further includes a fourth mode of operation, the fourth mode of operation including providing cooled air to the interior space of the building with the cooling unit, the heat pump being in an inactive state.

In one aspect of the embodiment, the second mode of operation further includes providing cooled air to the interior space of the building with the cooling unit.

In one aspect of the embodiment, the cooling unit is an evaporative cooler.

In one aspect of the embodiment, the method further includes switching from a first one of the plurality of modes of operation to any of a different one of the plurality of modes of operation.

In one aspect of the embodiment, the method is performed automatically by a control module.

In one embodiment, a method of retrofitting a pre-existing temperature control system includes: disconnecting and removing a pre-existing heating unit of the pre-existing temperature control system from a building, the pre-existing temperature control system including retained components; installing a replacement module electric heat pump in place of the pre-existing heating unit of the pre-existing temperature control system; and placing the replacement module electric heat pump in operable communication with the retained components of the pre-existing temperature control system.

In one aspect of the embodiment, the replacement module electric heat pump includes a coil module and a fan module.

In one aspect of the embodiment, the replacement module electric heat pump includes a conditioned air component and an outdoor component, the conditioned air component including the coil module and the fan module, and the outdoor component including a compressor.

In one aspect of the embodiment, the step of disconnecting and removing a pre-existing heating unit of the pre-existing temperature control system from a building includes removing the pre-existing heating unit from an overhead space of the building; and the step of installing a replacement module electric heat pump in place of the pre-existing heating unit of the pre-existing temperature control system includes installing the conditioned air component of the replacement module electric heat pump in the overhead space of the building, installing the conditioned air component of the replacement module electric heat pump at a location external to the building, or installing the conditioned air component of the replacement module electric heat pump in a subspace of the building that is different than the overhead space of the building.

In one aspect of the embodiment, the pre-existing heating unit includes an indoor component and an outdoor component, the step of disconnecting and removing a pre-existing heating unit of the pre-existing temperature control system from a building includes removing the indoor component of the pre-existing heating unit from the overhead space of the building, and further includes removing the outdoor component of the pre-existing heating unit from an exterior location of the building; and the step of installing a replacement module electric heat pump in place of the pre-existing heating unit of the pre-existing temperature control system further includes installing the outdoor component of the replacement module electric heat pump at a location external to the building.

In one aspect of the embodiment, the step of installing a replacement module electric heat pump in place of the pre-existing heating unit of the pre-existing temperature control system includes installing the conditioned air component of the replacement module electric heat pump in a subspace of the building that is different than the overhead space of the building and installing the outdoor component of the replacement module electric heat pump at a location external to the building.

In one aspect of the embodiment, the retained components of the pre-existing temperature control system include a cooling unit and ductwork configured to be connected between the cooling unit and the pre-existing heating unit, the method further including not removing the retained components from the pre-existing temperature control system, the step of placing the replacement module electric heat pump in operable communication with the retained components of the pre-existing temperature control system including: connecting the conditioned air component of the replacement module electric heat pump to the ductwork of the pre-existing temperature control system.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of embodiments described herein, and the attendant advantages and features thereof, will be more readily understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:

FIG. 1 shows a simplified image of a temperature control system with an electric heat pump and a first exemplary installation scheme therefor, the system being in a first mode of operation to provide heating from an electric heat pump, in accordance with the present disclosure;

FIG. 2 shows a simplified image of the temperature control system with an electric heat pump and the first exemplary installation scheme therefor, the system being in a second mode of operation to provide cooling (such as from an evaporative cooler), in accordance with the present disclosure;

FIG. 3 shows a simplified image of the temperature control system with an electric heat pump and the first exemplary installation scheme therefor, the system being in a third mode of operation to provide cooling from the electric heat pump and dehumidification, in accordance with the present disclosure;

FIG. 4 shows an exemplary heat pump, in accordance with the present disclosure;

FIG. 5 shows a first embodiment of a heat pump, in accordance with the present disclosure;

FIG. 6 shows a second embodiment of a heat pump, in accordance with the present disclosure;

FIG. 7 shows a further view of the first exemplary installation scheme for the temperature control system, in accordance with the present disclosure;

FIG. 8 shows a second exemplary installation scheme for the temperature control system, in accordance with the present disclosure;

FIG. 9 shows a third exemplary installation scheme for the temperature control system, in accordance with the present disclosure

FIG. 10 shows an exemplary method of retrofitting a pre-existing temperature control system; and

FIG. 11 shows an exemplary method of operating a temperature control system.

DETAILED DESCRIPTION

Before describing in detail exemplary embodiments, it is noted that the embodiments reside primarily in combinations of apparatus components and steps related to retrofitting an existing temperature control system having a ducted gas heater with an electric heat pump. Accordingly, the system and method components have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

In general, the present disclosure relates to an electric, temperature control systems including an electric heat pump, and a method of retrofitting a pre-existing temperature control system with a replacement module electric heat pump to replace a ducted gas heater. The electric heat pump disclosed herein is also referred to as a replacement module electric heat pump because it may be installed in a pre-existing temperature control system to replace another heating unit, such as a ducted gas heater. It will be understood that any reference to an “electric heat pump” or a “heat pump” used herein for simplicity refers to an electric heat pump that is sized, configured, and arranged to replace a gas heater, such as a ducted gas heater, in a pre-existing temperature control system.

In one example, the pre-existing temperature control system may be a heating, ventilation, and air conditioning (HVAC) system. In some embodiments, the modified temperature control system includes an evaporative cooler or other cooling unit, as well as a replacement module electric heat pump. In some embodiments, the modified temperature control system includes only a replacement module electric heat pump. In either embodiment, a gas heater of a pre-existing temperature control system is replaced with a replacement module electric heat pump as disclosed herein. In one embodiment, wherein the temperature control system includes an evaporative cooler or other cooling unit, the heat pump is used in parallel with the evaporative cooler/cooling unit to provide additional cooling on humid days when evaporative/other cooling may not be adequate. In one embodiment, wherein the temperature control system does not include an evaporative cooler/cooling unit, the heat pump provides both heating and cooling in a system that previously could only provide heat via the gas heater.

In some embodiments, the heat pump is an electric heat pump that is powered by electricity and that does not require combustion of a gas to produce heat. During warmer months, the heat pump operates similarly to an air conditioner by removing warm air from an interior space of the building and transferring it outdoors through a compressor. During cooler months, the heat pump uses a refrigerant or water cycle to extract warmth from the outside (that is, the environment external to the building) to provide heating.

In one embodiment, the ductwork and vents of the existing temperature control system do not need to be removed and can be used to fluidly connect the heat pump with the interior spaces of the building and other components of the modified temperature control system. The heat pump is sized and configured to be a direct replacement for the ducted gas heater, with dimensions chosen to suit the installation location and/or use requirements.

In one embodiment, the temperature control system includes a control module to automatically or semi-automatically modify and/or optimize operation of the temperature control system. In one embodiment, the control module includes one or more user interfaces for displaying information and/or receiving commands or input from the user, including, but not limited to, one or more displays, touchscreens, computer or mobile device running application software, knobs, buttons, remote controls, or the like. In one embodiment, the control module is configured to automatically or semi-automatically optimize performance of the temperature control system based on atmospheric dry bulb temperature, wet bulb temperature, and/or conditioned space heat load. In one embodiment, the control module is programmed or programmable to automatically or semi-automatically transition the temperature control system between any of a plurality of modes of operation, including the modes of operation discussed herein (FIGS. 1-3). In one non-limiting example, the control module includes a wall-mounted control panel that is accessible within the interior space of the building in which the temperature control system is installed. Further, in some embodiments, the control module includes processing circuitry that is programmed or programmable to operate the temperature control system 10 in any of a plurality of modes of operation, either automatically or semi-automatically, and/or to switch the temperature control system 10 between modes of operation, either automatically or semi-automatically, such as through the use of one or more sensors (for example, dry bulb temperature sensors, wet bulb temperature sensors, temperature sensors in the interior space of the building, or the like) and/or user input.

Referring now to FIGS. 1-3, and with reference to FIG. 7, operation of a temperature control system is shown. FIG. 1 shows a simplified image of a temperature control system 10 with a replacement module electric heat pump 12, in a stylized representation of a building 14, the system 10 being in a first mode of operation; FIG. 2 shows a simplified image of a temperature control system 10 with an electric heat pump 12, in a stylized representation of a building 14, the system 10 being in a second mode of operation; and FIG. 3 shows a simplified image of a temperature control system 10 with an electric heat pump 12, in a stylized representation of a building 14, the system 10 being in a third mode of operation. In FIGS. 1-3 (and FIG. 7), the temperature control system 10 is shown in a first installation configuration (that is, FIGS. 1-3 and 7 show a first installation scheme).

Continuing to refer to FIGS. 1-3, in one embodiment the temperature control system 10 generally includes a replacement module electric heat pump 12. In some embodiments, the temperature control system also includes a cooling unit 16, such as an evaporative cooler. For example, a pre-existing temperature control system may include an evaporative cooler and a gas heater. As discussed herein, the pre-existing system may be modified wherein the gas heater is removed and replaced with an electric heat pump 12, which is sized and configured to be a direct replacement for the gas heater and to be connected to the pre-existing ductwork and vents. When the pre-existing temperature control system 10 includes a cooling unit 16, the cooling unit remains 16 in place and may be operated in parallel with the heat pump 12. In one embodiment, the heat pump 12 is configured to be installed anywhere in which the gas heater was installed, such as in a roof or under a floor of the building 14.

Continuing to refer to FIGS. 1-3, in one embodiment, the heat pump 12 includes an indoor component 18 and an outdoor component 20. In one embodiment, the indoor component 18 and the outdoor component 20 are in fluid and electrical communication with each other via one or more fluid and electrical conduits 22 (for example, refrigerant tubing, ductwork, and/or vents). Simplified representations of conduits 22 are shown in FIGS. 1-3 and 7, but it will be understood that the conduits 22 may have a size, shape, and/or configuration that is different than what is shown. In one embodiment, the outdoor component 20 includes a compressor 23. Regardless of the installation scheme used, the indoor component 18 of the heat pump also is referred to herein as a “conditioned air module,” as it conditions air before returning the conditioned air to the interior space 24 of the building. In particular, the term “conditioned air module” is used instead of “indoor component” for the installation schemes shown in FIGS. 8 and 9, in which the indoor component 18 of the heat pump is located outside the building 14. In some embodiments, the heat pump 12 includes only an indoor component 18 and is configured to be operably connected (that is, configured to be used with) an outdoor component 20 of the pre-existing temperature control system, which outdoor component 20 may be retained when retrofitting the pre-existing temperature control system with a replacement module electric heat pump 12 having only an indoor component 18.

Continuing to refer to FIGS. 1-3, the heat pump 12 provides heating in cooler weather. In embodiments wherein the temperature control system 10 includes a cooling unit 16, such as an evaporative cooler, the cooling unit 16 handles the bulk of the cooling load and is supplemented on humid days by the cooling provided by the heat pump 12. Further, in warmer weather, cooling is provided by the cooling unit 16. The heat pump 12 is shown in an in-roof position in FIGS. 1-3 and 7; however, it will be understood that the heat pump 12 may be installed in other locations that are suitable for distributing heat/cooling throughout the building 14 and that allows the heat pump 12 to be connected to the ductwork and vents 22.

Table 1 below shows exemplary characteristics of the temperature control system 10 during operation under different conditions:

TABLE 1
Weather	Cold	Hot	Humid	Average COP
Mode	Heating	Cooling	Dehumidifying/cooling	6.2
Efficiency	COP 4	COP 15	COP 3
Run Time	35% PA	25% PA	5% PA

Referring to FIG. 1, in an exemplary first mode of operation, the temperature control system 10 provides heating to an interior space 24 of the building 14. In one embodiment, the heat pump 12 (replacement module electric heat pump) is used to produce heat, such as by removing (adsorbing) heat from outside air and/or from return air and providing it to the interior space 24 of the building 14. For example, in some embodiments, when in the exemplary first mode of operation (heating mode), the heat pump 12 is used to produce heat by removing (adsorbing) heat from outside air and then rejecting that heat into the supply air that is provided to the interior space 24 of the building 14. In one non-limiting example, this first mode of operation may be used when the outside temperature and/or a temperature within the interior space 24 of the building 14 is cooler (for example, cooler than approximately 70° F./21° C., or cooler than a temperature that is comfortable to a user). In some embodiments, the temperature control system 10 includes a cooling unit 16 (for example, as shown in FIG. 1). In other embodiments, the temperature control system 10 does not include a cooling unit 16. In some embodiments, all of the heating for the building 14 is supplied by the heat pump 12. For example, in the winter, the building may be heated using heated air supplied by the heat pump 12 and not from any other component of the temperature control system 10.

Referring to FIG. 2, in an exemplary second mode of operation, the temperature control system 10 is used to produce or supply cooling to the interior space 24 of the building 14. In one embodiment, the heat pump 12 (replacement module electric heat pump) is used to produce cooling, either independently (such as when the temperature control system 10 does not include a cooling unit 16) or in combination with a cooling unit 16. In one embodiment, the cooling unit 16 is an evaporative cooler. However, it will be understood that in some embodiments the temperature control system 10 may not include a cooling unit 16. In embodiments wherein the temperature cooling system 10 does include a cooling unit 16, the heat pump 12 may be used to provide supplemental cooling, whereas the cooling unit 16 (for example, an evaporative cooler) provides the majority of the cooling load. In another embodiment (which may be referred to as a fourth mode of operation), only the cooling unit 16 is used to produce cooling and the heat pump 12 is in an inactive state. When providing cooling in the second mode of operation, the heat pump 12 removes heat from return air to provide cooled supply air. In one embodiment, the extracted heat is vented to the outside (for example, to the environment outside the building 14).

In one non-limiting example, this second mode of operation (and/or the fourth mode of operation) may be used when the outside temperature and/or a temperature within the interior space 24 of the building 14 is warmer (for example, warmer than approximately 70° F./21° C., or warmer than a temperature that is comfortable to a user).

Referring to FIG. 3, in an exemplary third mode of operation, the temperature control system 10 is used to dehumidify and, optionally, to cool to the interior space 24 of the building 14. In one embodiment, the heat pump 12 (replacement module electric heat pump) is used to dehumidify outside air and/or return air before providing the dryer air to the interior space 24 of the building 14. In one non-limiting example, this third mode of operation may be used when the outside temperature and/or a temperature within the interior space of the building is humid (for example, more humid than approximately 30%-50% humidity, or a higher humidity than a level that is comfortable to a user) and/or warmer (for example, warmer than approximately 70° F./21° C., or warmer than a temperature that is comfortable to a user, or when cooling that is supplemental to the cooling provided by the cooling unit is desired). In some embodiments, the temperature control system 10 includes a cooling unit 16 (for example, as shown in FIG. 3). In other embodiments, the temperature control system 10 does not include a cooling unit 16. In some embodiments, the bulk of the cooling load is performed by the cooling unit 16 and the heat pump 12 is used to supplement cooling on humid days by removing moisture from the intake and/or return air.

Referring now to FIG. 4, an exemplary replacement module electric heat pump 12 is shown. For example, the heat pump 12 shown in FIG. 4 may be used in the configurations of any of FIGS. 1-3 and 7. In one embodiment, the heat pump 12 includes an indoor component 18 (as shown in FIG. 4) and an outdoor component 20 (not shown in FIG. 4; generally shown in FIGS. 1-3). In one embodiment, the heat pump 12 generally includes a fan module 30 and a coil module 32. In one embodiment, the fan module 30 and the coil module 32 are part of, or contained within, the indoor component 18. In some embodiments, retrofitting a pre-existing temperature control system includes replacing only an indoor heating unit (for example, a gas heater, such as a ducted gas heater) with the indoor component 18 of the heat pump 12, and retaining (or not removing) an outdoor component of the heating unit of the pre-existing temperature control system. In other words, in some embodiments, the indoor component 18 of the heat pump 12 is configured to be operably connected with remaining components of the pre-existing temperature control system that is retrofitted, including a pre-existing outdoor component of the pre-existing heating unit, a pre-existing cooling unit 16, ductwork 22, and/or other pre-existing system components. In one embodiment, the fan module 30 and the coil module 32 are contained within a common housing 34. In another embodiment, each of the fan module 30 and the coil module 32 is contained within its own housing 34A, 34B, respectively, such that the separate housings 34A, 34B may be installed independently. When installed, the housing 34A of the fan module 30 and the housing 34B of the coil module 32 are collectively referred to as the housing 34. For example, where access to the installation location is difficult or only restricted space is available, the separate housings 34A, 34B allow the temperature control system 10 to be assembled/reassembled in place. In embodiments wherein the fan module 30 and the coil module 32 are contained within separate housings 34A, 34B, the housings may be coupled to each other in a permanent or semi-permanent manner before or during installation (for example, by one or more bolts, by welding, by adhesives, by one or more sealing elements, and/or the like). Additionally or alternatively, the housings 34A, 34B may be coupled to each other in a manner that allows for rapid and easy removal of one housing or the other for maintenance, repair, and/or removal. For example, the housings 34A, 34B may be coupled to each other with one or more clamps, clasps, friction fit elements, thumb screws, and/or the like. In one embodiment, the heat pump 12 includes a backdraft damper 36 and/or other conduit(s) that fluidly connect the fan module 30 with the coil module 32. Additionally, although not shown, in some embodiments the heat pump 12 further includes one or more vents, inlets, outlets, and/or fans for moving air through the heat pump, and/or other components including, but not limited to, valves, conduits, condensate trays, and pumps.

Continuing to refer to FIG. 4, the fan module 30 (which may also be referred to as a fan box) generally includes a fan 38 for moving air through the heat pump 12. In one embodiment, the fan 38 is a medium- to high-pressure motor fan. In one non-limiting example, the fan 38 is a medium-pressure fan that is unique for 150 mm high-flow ducts. In one embodiment, the fan 38 is a medium- to high-pressure motor fan that is capable of delivering increased airflow through the pre-existing ductworks and vents 22 of the building 14 to compensate for the lower temperature air from a heat pump powered coil than a gas combustion coil.

Continuing to refer to FIG. 4, and with reference to FIGS. 5 and 6, the coil module generally includes one or more coils 40 for heating and/or cooling air. The heat pump 12 may include any size, number, and/or configuration of coils 40 that is suitable for the size of the space being heated or cooled (for example, the interior space 24 of the building 14), the size and/or configuration of the installation location, the size and/or configuration of the pre-existing temperature control system, and/or based on other considerations. For example, a first configuration of a heat pump 12 having a larger coil module 32 is shown in FIG. 5 and a second configuration of a heat pump 12 having a smaller coil module 32 is shown in FIG. 6. In one embodiment, the outdoor component 20 of the heat pump 12 is installed external to the building 14 in a location that is convenient for the landscaping, aesthetic appeal, arrangement of fluid and/or electric conduits between the outdoor component 20 and the indoor component 18, and/or based on other considerations.

Continuing to refer to FIG. 4, and with reference to FIGS. 5 and 6, the coil module 32 may be configured for use with a refrigerant (for example, when the heat pump 12 is a direct expansion heat pump) or water (for example, when the heat pump 12 is a hydronic heat pump) to produce hot and/or cold air. Further, in one embodiment the one or more coils 40 are microchannel coils and/or finned tube coils. In one embodiment, the one or more coils 40 include a plurality of microchannel coils, which are used to reduce the overall size of the heat pump 12, such as would be appropriate or preferred for use in small roof, floor, or outside installation locations. In one embodiment, as shown in FIG. 5, the coil(s) 40 are microchannel V-shaped coil(s). In one non-limiting example, the housing 34 (or 34A, 34B) of the indoor component 18 of the heat pump 12 of FIG. 5 has a length of approximately 1,200 mm (±200 mm; or approximately 3.8 ft, ±0.65 ft), a depth of approximately 525 mm (±150 mm; or approximately 1.7 ft, ±0.5 ft), and a height of approximately 794 mm (±160 mm; or approximately 2.5 ft, ±0.5 ft). In one embodiment, the coil(s) 40 include a plurality of microchannel V-shaped coils. In one embodiment, as shown in FIG. 6, the coil(s) are microchannel flat coil(s), which may allow for a reduction in overall size of the heat pump. In one embodiment, the coil(s) 40 include a plurality of microchannel flat coils. In one non-limiting example, the housing 34 (or 34A, 34B) of the indoor component 18 of the heat pump 12 of FIG. 6 has a length of approximately 934 mm (±175 mm; or approximately 3.1 ft, ±0.6 ft), a depth of approximately 512 mm (±150 mm; or approximately 1.7 ft, ±0.5 ft), and a height of approximately 762 mm (±160 mm; or approximately 2.5 ft, ±0.5 ft). However, it will be understood that the indoor component 18 may have sizes, shapes, and configurations other than those shown and described herein, depending on the size, shape, and/or configuration of the coil(s) 40, the fan 38, and/or other components of the indoor component 18, the size of the installation space, and/or other considerations.

Referring again to FIGS. 1-3 and 7, in one non-limiting example, a housing of the outdoor component 20 of the heat pump 12 of the temperature control system 10 of any of the figures has a length of approximately 940 mm (±150 mm; or approximately 3.1 ft, ±0.5 ft), a depth of approximately 320 mm (±75 mm; or approximately 1.0 ft, ±0.25 ft), and a height of approximately 1,430 mm (±300 mm; or approximately 4.7 ft, ±1.0 ft). However, it will be understood that the indoor component 18 may have sizes, shapes, and configurations other than those shown and described herein, depending on the size, shape, and/or configuration of the compressor 23, other components of the indoor component 20, the size of the installation space, and/or other considerations.

Continuing to refer to FIGS. 1-3 and 7, in the first installation scheme the indoor component of the heat pump is located inside the building 14 in which the temperature control system 10 is connected. In some embodiments, the indoor component 18 is in an attic or under-roof area 42 (as shown in FIGS. 1-3 and 7), in a basement, in a living or work area, a utility room, or other interior space of the building 14. Further, in the first installation scheme the outdoor component 20 of the heat pump 12 is located outside the building 14 in which the temperature control system 10 is connected. In some embodiments, the outdoor component 20 is located next to, adjacent, or within a distance from the building 14, on a roof of the building, or otherwise at a location that is external to the interior space of the building 14.

Referring now to FIG. 8, a second exemplary installation scheme for the temperature control system 10 is shown. As in the first installation scheme, in the second installation scheme the outdoor component 20 of the heat pump 12 is located outside the building 14 in which the temperature control system 10 is connected. In some embodiments, the outdoor component 20 is located next to, adjacent, or within a distance from the building 14, on a roof of the building 14, or otherwise at a location that is external to the interior space of the building 14. However, in the second installation scheme the conditioned air module 18 (indoor component, as used in FIGS. 1-3 and 7) of the heat pump 12 is also located outside the building 14 in which the temperature control system 10 is connected. In some embodiments, the conditioned air module 18 is located next to, adjacent, or within a distance from the building 14, on a roof of the building 14, or otherwise at a location that is external to the interior space of the building 14. In one non-limiting example, the building 14 is raised above the ground, such as buildings supported by stilts, risers, pilings, piers, and the like (indicated with reference number 44 in FIG. 8), and/or includes an open basement structure or other open lower space or structure (indicated with reference number 46 in FIG. 8). In this non-limiting example, ductwork and/or vents 22 between the conditioned air module 18 and the interior space 24 of the building pass beneath the interior space portion of the building (for example, within the open basement structure or other lower space, structure, or subspace 46, as shown in FIG. 8). However, other configurations for connecting the conditioned air module 18 to the interior space 24 of the building 14 and/or to the outdoor component 20 of the heat pump 12 other than those shown may be used.

Referring now to FIG. 9, a third exemplary installation scheme for the temperature control system 10 is shown. As in the first and second installation schemes, in the third installation scheme the outdoor component 20 of the heat pump 12 is located outside the building 14 in which the temperature control system 10 is connected. In some embodiments, the outdoor component 20 is located next to, adjacent, or within a distance from the building 14, on a roof of the building, or otherwise at a location that is external to the interior space of the building 14. The conditioned air module 18 (indoor component, as used in FIGS. 1-3 and 7) of the heat pump 12 is also located next to, adjacent, or within a distance from the building 14, on a roof of the building 14, or otherwise at a location that is external to the interior space of the building 14; however, in the third installation scheme, the conditioned air module 18 is located beneath the building 14. In some embodiments, the building 14 is raised above the ground, such as buildings supported by stilts, risers, pilings, piers, and the like (indicated with reference number 44 in FIG. 9). In some embodiments, the building 14 includes an open basement structure or other open lower space or structure (indicated with reference number 46 in FIG. 9). Thus, in the third installation scheme, the conditioned air module 18 is located external to the interior space 24 of the building 14, but is at least partially sheltered, protected, shielded, and/or concealed by a portion of the building 14. In one non-limiting example, ductwork and/or vents 22 between the conditioned air module 18 and the interior space 24 of the building 14 pass beneath the interior space portion of the building (for example, within the open basement structure or other lower space or structure 46, as shown in FIG. 9). However, other configurations for connecting the heat conditioned air module to the interior space of the building 14 and/or to the outdoor component 20 of the heat pump 12 than those shown may be used.

Referring again to FIGS. 1-9, in some embodiments, as noted above, the temperature control system 10 includes a control module 48 to automatically or semi-automatically modify and/or optimize operation of the temperature control system 10. In one embodiment, the control module 48 includes one or more user interfaces for displaying information and/or receiving commands or input from the user, including, but not limited to, one or more displays, touchscreens, computer or mobile device running application software, knobs, buttons, remote controls, or the like. In one embodiment, the control module 48 is configured to automatically or semi-automatically optimize performance of the temperature control system based on atmospheric dry bulb temperature, wet bulb temperature, and/or conditioned space heat load. In one embodiment, the control module 48 is programmed or programmable to automatically or semi-automatically transition the temperature control system 10 between any of a plurality of modes of operation, including the modes of operation discussed herein. In one non-limiting example, the control module 48 includes a wall-mounted control panel that is accessible within the interior space of the building in which the temperature control system is installed (for example, as shown in FIGS. 7-9). Further, in some embodiments, the control module 48 includes processing circuitry that is programmed or programmable to operate the temperature control system 10 in any of a plurality of modes of operation, either automatically or semi-automatically, and/or to switch the temperature control system 10 between modes of operation, either automatically or semi-automatically, such as through the use of one or more sensors (for example, dry bulb temperature sensors, wet bulb temperature sensors, temperature sensors in the interior space of the building, or the like) and/or user input.

Referring now to FIG. 10, an exemplary method 100 of retrofitting a pre-existing temperature control system is shown. In some embodiments, the pre-existing temperature control system is installed in a building. In some embodiments, the method includes retrofitting a pre-existing temperature control system with a replacement module electric heat pump 12. In some embodiments, if the pre-existing temperature control system includes a cooling unit, the method includes retaining (or not removing) the pre-existing cooling unit 16 and retrofitting the pre-existing temperature control system only with a replacement module electric heat pump 12 (for example, replacing a pre-existing heating unit, such as a gas heater, with a replacement module electric heat pump 12). In some embodiments, if the pre-existing temperature control system does not include a pre-existing cooling unit, the method includes retrofitting the pre-existing temperature control system with a replacement module electric heat pump 12 (for example, replacing a pre-existing heating unit, such as a gas heater, with a replacement module electric heat pump 12) and adding a new cooling unit 16. In some embodiments, the method includes retrofitting the pre-existing temperature control system only with a replacement module electric heat pump 12. In some embodiments, retrofitting a pre-existing temperature control system includes replacing only an indoor component of a heating unit (for example, a gas heater) with an indoor component 18 of the replacement module electric heat pump 12. In any embodiment, the resulting retrofitted or modified temperature control system is referred to as the temperature control system 10 disclosed herein.

Continuing to refer to FIG. 10, a pre-existing temperature control system that includes a heating unit, such as a gas heater, is retrofitted with a replacement module electric heat pump 12. In an exemplary first step 110, the heating unit of the pre-existing temperature control system is disconnected from the other components of the pre-existing temperature control system and is removed from the building 14. Some or all of the components of the pre-existing temperature control system may be retained in place, including, but not limited to, a cooling unit 16, conduits, ductwork, and vents 22, hardware, fittings, filters, and/or other system components that are not part of, or not an integrated part of, the pre-existing heating unit.

Continuing to refer to FIG. 10, in an exemplary second step 120, a replacement module electric heat pump 12 is installed. The heat pump 12 may include an indoor component 18 only (and only the indoor component of the pre-existing temperature control system is replaced) or an indoor component 18 and an outdoor component 20 (and both the indoor component and the outdoor component of the pre-existing temperature control system is replaced). In one non-limiting example, this second step 120 includes physically removing at least an indoor component of a heating unit of the pre-existing temperature control system and installing in its place at least the indoor component 18 of the heat pump 12. In another non-limiting example, this second step 120 includes physically removing both an indoor component and an outdoor component of a heating unit of the pre-existing temperature control system and installing in their place both the indoor component 20 and the outdoor component 20, respectively, of the heat pump 12.

Continuing to refer to the exemplary second step 120 of FIG. 10, it will be noted that after the heating unit of the pre-existing temperature control system is removed (the outdoor component and/or the indoor component), the component(s) of the replacement module electric heat pump 12 may be installed in the same location(s) or in different location(s) than the corresponding component(s) of the pre-existing temperature control system. For example, if an indoor component of the pre-existing temperature control system is removed from an interior location of the building 14 (for example, from an attic 42 or overhead space), the indoor component 18 of the heat pump 12 may instead be installed at an outdoor location (for example, external to the building, as shown in FIG. 8) or beneath the building (for example, within a basement or subspace 46, as shown in FIG. 9), as discussed above.

Continuing to refer to FIG. 10, in an exemplary third step 130, the replacement module electric heat pump 12 is placed into operable communication with the retained components of the pre-existing temperature control system to create the temperature control system 10 as discussed herein. For example, the replacement module electric heat pump 12 is placed into operable communication with the cooling unit 16, ductwork 22, and/or other retained components of the pre-existing temperature control system and the interior space 24 of the building. In one embodiment, this exemplary third step 130 includes connecting the indoor component 18 to the conduits, vents, and/or ductwork 22 of the pre-existing temperature control system (for example, using screws, bolts, and/or other known hardware, tape, adhesives, or the like). Pre-existing conduits, vents, and/or ductwork 22 may be retained and used to operably connect the heat pump 12 with a pre-existing cooling unit 16 and/or other pre-existing system components, and/or the interior space 24 of the building 14. However, it will be understood that such connecting elements, hardware, and/or other system components also may be replaced (for example, if damaged, worn, of insufficient length and/or size, or for other reasons). Thus, the retrofitted temperature control system is operable as the temperature control system 10 discussed herein.

Referring now to FIG. 11, an exemplary method 200 of using or operating a temperature control system 10 is shown. In an exemplary first step 210, the method includes operating the temperature control system 10 that has been retrofitted to include a replacement module electric heat pump 12 in any of a plurality of modes of operation, the plurality of modes of operation including, but not being limited to: (1) a first mode of operation in which the heat pump 12 is used or operated to produce heat, such as by removing heat from outside air and/or from returning air, and to provide or supply the heated air to an interior space 24 of a building 14 in which the temperature control system 10 is installed (FIG. 1); (2) a second mode of operation in which the heat pump 12 is used or operated to produce cooled air, such as by removing heat from return air and venting the extracted heat to a location outside the building 14, and to supply the cooled air to the interior space 24 of the building 14 (FIG. 2); and (3) a third mode of operation in which the heat pump 12 is used or operated to dehumidify and, optionally, to cool the interior space 24 of the building 14, such as by dehumidifying (removing moisture from) outside air and/or return air before providing the dryer, dehumidified air to the interior space 24 of the building. Optionally, the plurality of modes of operation also include (4) a fourth mode of operation in which the heat pump 12 is in an inactive state and the cooling unit 16 provides all of the cooling load.

Continuing to refer to FIG. 11, in an exemplary second step 220, the method includes switching the temperature control system 10 from any of the plurality of modes of operation to a different one of the plurality of modes of operation. In one non-limiting example, the temperature control system 10 may be changed from the first mode of operation to the third mode of operation. Both the operating of the temperature control system 10 in any of a plurality of modes of operation (Step 210) and switching between modes of operation (Step 220) may be performed automatically (such as by a control module), semi-automatically (such as by the control module and/or user input or control), and/or manually (such as by user control and/or manipulation of system components).

Embodiments

In one embodiment, a temperature control system includes: a cooling unit; a heat pump; and ductwork connecting the cooling unit and the heat pump.

In one aspect of the embodiment, the cooling unit is an evaporative cooler.

In one aspect of the embodiment, the heat pump includes: a fan module; and a coil module.

In one aspect of the embodiment, the coil module includes at least one coil the at least one coil being one of: at least one microchannel coil; and at least one finned tube coil.

In one aspect of the embodiment, the heat pump includes a conditioned air module and an outdoor component.

In one embodiment, a method of operating a temperature control system, the temperature control system including a cooling unit and a heat pump, includes: providing cool air to an interior space of a building with the cooling unit; providing warm air to the interior space of the building with the heat pump; and dehumidifying air to provide dryer air to the interior space of the building with the heat pump.

In one aspect of the embodiment, the method further includes providing supplemental cool air to the interior space of the building with the heat pump.

In one aspect of the embodiment, the cooling unit is an evaporative cooler.

In one embodiment, retrofitting a pre-existing temperature control system includes: removing a gas heater of the pre-existing temperature control system; and replacing the gas heater of the pre-existing temperature control system with a heat pump.

In one aspect of the embodiment, the heat pump is an electric heat pump including a coil module and a fan module.

In one aspect of the embodiment, the pre-existing temperature control system includes a cooling unit and ductwork connected between the cooling unit and the gas heater, the method further including: not removing the cooling unit or ductwork from the pre-existing temperature control system; and connecting the coil module of the electric heat pump to the ductwork of the pre-existing temperature control system.

In one aspect of the embodiment, the heat pump includes a conditioned air module and an outdoor component, the temperature control system being within an interior space of a building.

In one aspect of the embodiment, the step of replacing the gas heater of the pre-existing temperature control system with a heat pump includes: installing the conditioned air module within an attic of the building; and installing the outdoor component at a location outside the building.

In one aspect of the embodiment, the step of replacing the gas heater of the pre-existing temperature control system with a heat pump includes: installing the conditioned air module at a first location outside the building; and installing the outdoor component at a second location outside the building.

In one aspect of the embodiment, the building is supported by risers or stilts, the step of replacing the gas heater of the pre-existing temperature control system with a heat pump including: installing the conditioned air module at a first location outside the building, the first location being beneath the building; and installing the outdoor component at a second location outside the building.

As used herein, relational terms, such as “first” and “second,” “top” and “bottom,” and the like, may be used solely to distinguish one entity or element from another entity or element without necessarily requiring or implying any physical or logical relationship or order between such entities or elements. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the concepts described herein. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “includes” and/or “including” when used herein, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms used herein should be interpreted as having a meaning that is consistent with their meaning in the context of this specification and the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

It will be appreciated by persons skilled in the art that the present invention is not limited to what has been particularly shown and described herein above. In addition, unless mention was made above to the contrary, it should be noted that all of the accompanying drawings are not to scale. A variety of modifications and variations are possible in light of the above teachings without departing from the scope and spirit of the invention.

Claims

1. A temperature control system comprising:

a cooling unit;

a heat pump, the heat pump being a replacement module electric heat pump; and

ductwork connecting the cooling unit and the heat pump.

2. The temperature control system of claim 1, wherein the cooling unit is an evaporative cooler.

3. The temperature control system of claim 1, wherein the heat pump includes:

a fan module; and

a coil module.

4. The temperature control system of claim 3, wherein the coil module includes at least one coil, the at least one coil being one of:

at least one microchannel coil; and

at least one finned tube coil.

5. The temperature control system of claim 1, wherein the heat pump includes a conditioned air module and an outdoor component.

6. The temperature control system of claim 5, wherein the conditioned air module includes a fan module and a coil module.

7. A method of operating a temperature control system, the temperature control system including a cooling unit and a heat pump, the method comprising:

operating the temperature control system in any of a plurality of modes of operation, wherein the heat pump is a replacement module electric heat pump.

8. The method of claim 7, wherein:

the plurality of modes of operation includes a first mode of operation, a second mode of operation, and a third mode of operation,

the first mode of operation includes providing heated air to an interior space of a building with the heat pump;

the second mode of operation includes providing cooled air to the interior space of the building with the heat pump; and

the third mode of operation includes providing dehumidified air to the interior space of the building with the heat pump.

9. The method of claim 8, wherein the plurality of modes of operation further includes a fourth mode of operation, the fourth mode of operation including providing cooled air to the interior space of the building with the cooling unit, the heat pump being in an inactive state.

10. The method of claim 8, wherein the second mode of operation further includes providing cooled air to the interior space of the building with the cooling unit.

11. The method of claim 7, wherein the cooling unit is an evaporative cooler.

12. The method of claim 7, further comprising switching from a first one of the plurality of modes of operation to any of a different one of the plurality of modes of operation.

13. The method of claim 12, wherein the method is performed automatically by a control module.

14. A method of retrofitting a pre-existing temperature control system, the method comprising:

disconnecting and removing a pre-existing heating unit of the pre-existing temperature control system from a building, the pre-existing temperature control system including retained components;

installing a replacement module electric heat pump in place of the pre-existing heating unit of the pre-existing temperature control system; and

placing the replacement module electric heat pump in operable communication with the retained components of the pre-existing temperature control system.

15. The method of claim 14, wherein the replacement module electric heat pump includes a coil module and a fan module.

16. The method of claim 15, wherein the replacement module electric heat pump includes a conditioned air component and an outdoor component, the conditioned air component including the coil module and the fan module, and the outdoor component including a compressor.

17. The method of claim 16, wherein:

the step of disconnecting and removing a pre-existing heating unit of the pre-existing temperature control system from a building includes removing the pre-existing heating unit from an overhead space of the building; and

the step of installing a replacement module electric heat pump in place of the pre-existing heating unit of the pre-existing temperature control system includes installing the conditioned air component of the replacement module electric heat pump in the overhead space of the building, installing the conditioned air component of the replacement module electric heat pump at a location external to the building, or installing the conditioned air component of the replacement module electric heat pump in a subspace of the building that is different than the overhead space of the building.

18. The method of claim 17, wherein the pre-existing heating unit includes an indoor component and an outdoor component, and wherein:

the step of disconnecting and removing a pre-existing heating unit of the pre-existing temperature control system from a building includes removing the indoor component of the pre-existing heating unit from the overhead space of the building, and further includes removing the outdoor component of the pre-existing heating unit from an exterior location of the building; and

the step of installing a replacement module electric heat pump in place of the pre-existing heating unit of the pre-existing temperature control system further includes installing the outdoor component of the replacement module electric heat pump at a location external to the building.

19. The method of claim 18, wherein the step of installing a replacement module electric heat pump in place of the pre-existing heating unit of the pre-existing temperature control system includes installing the conditioned air component of the replacement module electric heat pump in a subspace of the building that is different than the overhead space of the building and installing the outdoor component of the replacement module electric heat pump at a location external to the building.

20. The method of claim 14, wherein the retained components of the pre-existing temperature control system include a cooling unit and ductwork configured to be connected between the cooling unit and the pre-existing heating unit, the method further including not removing the retained components from the pre-existing temperature control system, the step of placing the replacement module electric heat pump in operable communication with the retained components of the pre-existing temperature control system including:

connecting a conditioned air component of the replacement module electric heat pump to the ductwork of the pre-existing temperature control system.