AN AIR CONDITIONING SYSTEM

Abstract

The present invention relates to a heat exchanger arrangement for use with an air conditioning system of the type comprising a condenser, an expansion device, an evaporator and a compressor connected in a refrigeration circuit filled with refrigerant. The heat exchanger arrangement comprises a collector arrangement for collecting condensate fluid that has condensed on the evaporator as condensate fluid. The heat exchanger arrangement also comprises a first heat exchanger configured for facilitating the transfer of heat from an airflow flowing to the condenser, to condensate received from the evaporator.

Claims

1. A heat exchanger arrangement for use with an air conditioning system comprising a condenser, an expansion device, an evaporator and a compressor connected in a refrigeration circuit filled with refrigerant, the heat exchanger arrangement comprising: a collector arrangement for collecting condensate fluid that has condensed on the evaporator as condensate fluid; and a first heat exchanger, the first heat exchanger being configured for facilitating the transfer of heat from an airflow flowing to the condenser, to condensate received from the evaporator, wherein the heat exchanger arrangement comprises a second heat exchanger configured for facilitating the transfer of heat from refrigerant to condensate received from the evaporator, and wherein the second heat exchanger is located within a container associated with, and located at an upper portion of, the first heat exchanger.

2. A heat exchanger arrangement according to claim 1 wherein the collector arrangement, the first heat exchanger and a coolant outlet are connected in fluid communication via a coolant pathway, the coolant outlet being located downstream of the first heat exchanger in the coolant pathway for, in use, expelling waste coolant that has received heat from the first heat exchanger.

3. A heat exchanger arrangement according to claim 2, wherein the coolant pathway includes a recirculation loop extending from an inlet downstream of the first heat exchanger to an outlet upstream of the first heat exchanger and whereby, in use, a portion of the condensate supplied to the first heat exchanger is recirculated condensate supplied through the recirculation loop.

4. A heat exchanger arrangement according to claim 3, wherein the portion of recirculated condensate supplied to the first heat exchanger is less than 10% of the total volumetric flow of condensate supplied to the first heat exchanger.

5. (canceled)

6. A heat exchanger arrangement according to claim 2, wherein the coolant pathway comprises an open-loop configuration whereby no portion of the condensate flow is recirculated through the first heat exchanger.

7. A heat exchanger arrangement according to claim 2 wherein the coolant pathway is configured to deliver substantially all condensate collected by the collector arrangement to the first heat exchanger.

8. A heat exchanger arrangement according to claim 2 wherein the coolant pathway is configured to minimise condensate temperature increase between the collector arrangement the first heat exchanger.

9. A heat exchanger arrangement according to claim 2 wherein the coolant pathway is configured such that the first heat exchanger is immediately downstream of the collector arrangement.

10. A heat exchanger arrangement according to claim 1, wherein the heat exchanger arrangement is configured for guiding the flow of fluid from the first heat exchanger to the second heat exchanger.

11. A heat exchanger arrangement according to claim 10, wherein the second heat exchanger is connected to the coolant pathway downstream of the first heat exchanger and upstream of the coolant outlet.

12. A heat exchanger arrangement according to claim 1 wherein the first heat exchanger includes a plurality of coolant passageways extending between a pair of coolant tanks comprising a lower coolant tank and an upper coolant tank, wherein the second heat exchanger is located within the upper coolant tank and the heat exchanger arrangement further including a conduit for delivering condensate collected from the evaporator to the lower coolant tank.

13. A heat exchanger arrangement according to claim 1, the first heat exchanger comprising a plurality of elongate pipes.

14. A heat exchanger arrangement according to claim 1, wherein the first heat exchanger defines a cooling surface configured to, in use, overlie an airflow inlet on a condenser.

15. A heat exchanger arrangement according to claim 13, wherein the first heat exchanger is configured to, in use, facilitate flow of liquid coolant across the airflow inlet.

16. A heat exchanger arrangement according to claim 1 comprising a kit configured for retrofitting the heat exchanger arrangement to an existing air-conditioner system and the kit being configured to facilitate connection of the first heat exchanger to a condenser air intake of an existing air-conditioner system.

17. (canceled)

18. (canceled)

19. A method of improving the efficiency of an air-conditioning system comprising a condenser, an expansion device, an evaporator and a compressor connected in a refrigeration circuit filled with refrigerant, the method comprising the steps of: a. collecting chilled condensate from the evaporator in a collector arrangement; b. guiding the condensate to a first heat exchanger whereby the condensate is used to cool an airflow cooling the condenser; and c. guiding the condensate to a second heat exchanger whereby the condensate is used to cool refrigerant in the refrigerant circuit and wherein the condensate guided to the second heat exchanger first passes through the first heat exchanger, the second heat exchanger being located within a container associated with, and located at an upper portion of, the first heat exchanger.

20. A method according to claim 19 including the step of installing the first heat exchanger at an airflow inlet of a condenser associated with an existing air-conditioning system.

21. A method according to claim 19 including the step of guiding condensate to a waste outlet after receiving heat from both the first and second heat exchangers.

22. A method according to claim 21 wherein a portion of condensate flow is recirculated through the first or second heat exchangers before being guided to the waste outlet.

23. (canceled)

24. (canceled)

25. An improved air-conditioning system comprising: a condenser; an expansion device; an evaporator; and a compressor, wherein the condenser, expansion device, evaporator, and compressor are connected in fluid communication in a refrigeration circuit filled with refrigerant; and wherein the improved air-conditioning system further includes a heat exchanger arrangement comprising: a first heat exchanger, the first heat exchanger being configured for facilitating the transfer of heat from an air flow flowing towards the condenser to condensate fluid received from the evaporator, wherein the heat exchanger arrangement comprises a second heat exchanger configured for facilitating the transfer of heat from refrigerant to condensate received from the evaporator, and wherein the second heat exchanger is located within a container associated with, and located at an upper portion of, the first heat exchanger.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0126] The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.

[0127] Notwithstanding any other forms which may fall within the scope of the present invention, a preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:

[0128] FIG. 1 shows a schematic view of a first embodiment of an improved air-conditioning system and a first embodiment of a heat exchanger arrangement, with the refrigerant being cooled by the second heat exchanger on exit from the compressor.

[0129] FIG. 2 shows a schematic view of a second embodiment of an improved air-conditioning system and a first embodiment of a heat exchanger arrangement, with the refrigerant being cooled by the second heat exchanger on exit from the condenser.

[0130] FIG. 3 shows a close up schematic view of a first embodiment of an improved air-conditioning system of FIG. 1 showing a first embodiment of a heat exchanger arrangement and a condenser.

[0131] FIG. 4 shows a schematic side view of a first embodiment of a heat exchanger arrangement, a condenser fan and a condenser illustrating their relative layout.

[0132] FIG. 5 shows a perspective view of a first embodiment of a heat exchanger arrangement.

[0133] FIG. 6 shows a perspective view of a second embodiment of a heat exchanger arrangement showing a primary coolant tank and portion of a first heat exchanger, with a second heat exchanger and a third heat exchanger located within the primary coolant tank.

[0134] FIG. 7 shows a perspective view of a third embodiment of a heat exchanger arrangement showing a secondary coolant tank in which the second heat exchanger is located.

[0135] FIG. 8 shows a pressure - enthalpy diagram comparing a conventional air-conditioning system with an air-conditioning system according to the present invention (denoted as the IP Hybrid Cycle).

[0136] FIG. 9 shows a heat exchanger assembly as part of a heat exchanger arrangement according to a particular embodiment of the present invention.

[0137] FIG. 10 shows a cross-sectional perspective of the heat exchanger assembly illustrated in FIG. 9

[0138] FIG. 11 is a scatter plot of power consumption against ambient temperature for control air-conditioning system.

[0139] FIG. 12 is a scatter plot of power consumption against ambient temperature for air-conditioning system fitted with ‘Kinetik’ device according to the present invention.

DETAILED DESCRIPTION

[0140] With reference to the above drawings, in which similar features are generally indicated by similar numerals, an improved air-conditioning system according to a first aspect of the invention is generally indicated by the numeral 1000, and a heat exchanger arrangement is generally indicated by the numeral 2000.

[0141] In one embodiment now described, there is provided an improved air-conditioning system 1000 that comprises a heat exchanger arrangement 2000. The air-conditioning system 1000 comprises a condenser 1100 cooled by a condenser fan 1110, an expansion device 1200 such as an expansion valve, an evaporator 1300 and a compressor 1400. The condenser 1100, expansion device 1200, evaporator 1300 and compressor 1400 connected in fluid communication in a refrigeration circuit 1500 that is filled with refrigerant. The condenser 1100 is cooled by airflow created by a condenser fan 1110.

[0142] The heat exchanger arrangement 2000 comprises a collector arrangement 2100, a condensate conduit 2150 and a first heat exchanger 2200. The collector arrangement 2100 is preferably a trough 2105 that is configured for collecting condensate that has condensed on the evaporator 1300 as chilled condensate fluid, and the condensate conduit 2150 is configured for guiding the collected condensate to the first heat exchanger 2200.

[0143] The first heat exchanger 2200 preferably comprises a pair of primary coolant tanks 2210 in which the collected condensate is received. The primary coolant tank 2210 are in fluid communication with each other via a plurality of heat exchanger tubes 2220. The chilled condensate fluid is received into an inlet 2212 in the lower primary coolant tank 2210a shown as arrow B in the figures.

[0144] The first heat exchanger 2200 is located in the airflow created by the condenser fan 1110, so that it cools the airflow (shown as arrows A in FIGS. 2, 3 and 6) flowing towards the condenser 1100, thereby facilitating the transfer of heat from the airflow A to the condensate fluid received from the evaporator, thereby heating the condensate fluid. In this way, the chilled condensate fluid is used to cool the airflow flowing towards the condenser 1100.

[0145] It is envisaged that where the condenser fan 1110 is blowing the airflow A towards the condenser, then the first heat exchanger 2200 will be located between the condenser fan 1110 and the condenser 1100. However, where the condenser fan is pulling air through the condenser 1100, then the first heat exchanger 2200 will be located on an opposed side of the condenser from the condenser fan 1110. In instances where the condenser fan is located between the condenser and the airflow inlet (i.e. pulling air from the inlet and pushing air toward the condenser) the first heat exchanger 2200 will be located on the opposite side of the condenser fan from the condenser. In any configuration, it will be appreciated that the first heat exchanger will be located in the airflow inlet so as to cool the incoming air before contacting the condenser.

[0146] By cooling the airflow A the temperature differential (i.e. drop) of the refrigerant in the refrigerant circuit across the condenser is increased, which allows for increased efficiency is in the air conditioning system.

[0147] It is envisaged that the evaporator will be typically located higher up than the condenser (for example high up on a wall), allowing for a significant head of condensate fluid to be built up, and creating a steady flow of condensate fluid from the evaporator to the first heat exchanger 2200 via the condensate conduit 2150. However, in cases where the evaporator 1300 is not located sufficiently elevated from the condenser 1100, or the drag within the condensate conduit 2150 is too high for the pressure created by the head of the condensate to overcome, it is envisaged that the heat exchanger arrangement 1000 can be provided with a coolant pump 2300 (as shown in FIG. 7). The coolant pump 2300 can be controlled by a control system 3000 that ensures that condensate is pumped towards the first heat exchanger when the condensate liquid reaches a certain height, as may be indicated by a level sensor 3100.

[0148] It is envisaged that the control system 3000 can further be configured to control a condensate flow valve 2152 along the condensate conduit 2150, as well as an overflow valve 2230 from the primary coolant tanks 2210.

[0149] The first heat exchanger 2200 includes a plurality of coolant passageways comprising a plurality of elongate copper tubes 2220. As condensate flows into the first heat exchanger 2200 it will fill up the lower primary coolant tank 2210a, the heat exchanger tubes 2220, and the upper primary coolant tank 2210b. Once the first heat exchanger 2200 is full, in use, condensate fluid that is in the heat exchanger tubes 2220 will be heated up by heat transfer from the airflow A passing over the heat exchanger tubes 2220. Heat exchanger tubes 2220 therefore define a cooling surface which contacts incoming airflow A and cools airflow A prior to entering the condenser.

[0150] The heated condensate fluid will rise (shown as arrow Y in FIG. 3) towards the upper primary coolant tank 2210b. The airflow A in turn is cooled before it engages the condenser, reducing the condensing temperature, and in turn decreasing the compressor discharge pressure, which in turn considerably diminishes the electricity usage of the compressor.

[0151] Condensate fluid or coolant that has flowed into the upper primary coolant tank 2210b can then either be allowed to flow to the environment via a coolant outlet comprising an overflow valve 2230 (shown as arrow E in FIG. 3), or it can be utilised in a second heat exchanger 2400. The second heat exchanger 2400 is configured for facilitating the transfer of heat from refrigerant in the refrigeration circuit 1500 to the condensate as a coolant. In this regard, it is envisaged that the second heat exchanger 2400 can operate in two different embodiments.

[0152] In a first embodiment, it is envisaged that heated refrigerant will be received into the second heat exchanger 2400 via a conduit (shown as arrow C in FIGS. 3, 5, 6) by the second heat exchanger 2400 at a relatively high temperature from the compressor 1400. This embodiment is shown in FIG. 1. In this regard, the collector arrangement 2100, first heat exchanger 2200, second heat exchanger 2400 and outflow valve 2230 are connected in fluid communication via a coolant pathway which extends from collector arrangement 2100, along condensate conduit 2150 and from lower tank 2210a, through pipes 2200, through upper tank 2210b and through overflow valve 2230.

[0153] In a second embodiment shown in FIG. 2, it is envisaged that the refrigerant will be received into the second heat exchanger 2400 at inlet 2440 (also shown as arrow C in the figures) via a conduit by the second heat exchanger 2400 at a relatively lower temperature from the condenser 1100. This embodiment is shown in FIG. 2.

[0154] As illustrated, the coolant pathway includes an ‘open-loop’ configuration whereby none of the condensate is recirculated through the heat exchangers, i.e. all of the condensate entering the first heat exchanger 2200 is ‘fresh’ coolant provided from the collector arrangement 2100. Moreover, the coolant pathway is configured such that all of the coolant collected by collector arrangement 2100 is provided to the first heat exchanger 2200. The first heat exchanger 2200 is also positioned directly downstream of the collector arrangement 2100 i.e. condensate conduit 2150 extends directly between the collector arrangement 2100 and the lower tank 2210a of the first heat exchanger 2200. In this regard there are no intermediary components located upstream of the first heat exchanger which may act to warm the condensate supplied to first heat exchanger 2200 (other than unavoidable warming which can occur during passage along condensate conduit 2150).

[0155] The refrigerant will pass through the second heat exchanger 2400 and exit the second heat exchanger 2400 at outlet 2450 (shown as arrow D in the figures).

[0156] As noted in the foregoing, the second heat exchanger can be connected upstream of the condenser (i.e. between the compressor and condenser) or downstream of the condenser (i.e. between the condenser and expander device). In some instances, either alternative may provide similar results. In other instances, the installer may opt for one alternative over the other depending on the type of air conditioning system being used. By way of example, where an air-conditioning system includes a condenser fan that is control by an inverter, the speed of the condenser fan will increase or decrease depending on the temperature of the refrigerant supplied to the condenser. In this instance, it may be appropriate to connect the second heat exchanger either upstream or downstream of the condenser because the inverter is capable of controlling fan speed to achieve an optimum cooling effect.

[0157] In alternative systems where an inverter is not present, the condenser fan is typically configured to switch on at a threshold refrigerant temperature and switch off of the refrigerant supplied to the condenser drops below the threshold temperature. In this instance, connecting the second heat exchanger upstream of the condenser could reduce the refrigerant temperature below the trigger temperature causing the condenser fan to cut off thereby having the effect of terminating or reducing airflow over the first heat exchanger and reducing the advantages provided by the present invention. Accordingly, where the condenser fan is not controlled by an inverter arrangement, it may be desirable to connect the second heat exchanger downstream of the condenser so as not to undesirably trigger condenser fan cut-off.

[0158] Two embodiments of a second heat exchanger are shown in the accompanying figures. A first embodiment is shown in FIGS. 1, 2, 3, 5 and 6, the second heat exchanger 2400 comprises a coiled pipe 2410 of preferably heat conductive material that extends into and is received within the upper primary coolant tank 2210b, and which forms a conduit for the refrigerant. Heat is transferred from the relatively hot refrigerant in the coiled pipe 2410 to the relatively cool condensate in the upper primary coolant tank 2210b. This embodiment relies on the fact that the heated coolant will rise into the upper primary coolant tank 2210b.

[0159] A second embodiment is shown in FIG. 7, wherein a secondary storage tank 2420 is provided for the condensate to flow into after it has flowed out of the upper primary coolant tank 2210b. The coiled pipe 2410 is located within the secondary storage tank 2420. The primary coolant tanks 2210 and the secondary storage tank 2420 are connected to each other via a conveying conduit 2430. In a preferred embodiment, a control valve 3200, is located along the conveying conduit 2430, and is controllable by the control system 3000. In this embodiment, the coolant liquid used for cooling of the refrigerant in the second heat exchanger 2400 is separated from the coolant liquid used for cooling of the airflow A by the first heat exchanger 2200.

[0160] It is further envisaged that the air-conditioning system 1000 can comprise a connection 2154 to a municipal water supply for receiving water from the municipal water supply to top up the coolant in the primary coolant tanks 2210 and/or the secondary coolant tank 2420. The flow of water from the municipal water connection 2154 is preferably controllable by a control valve 2156. The control valve 2156 is also preferably controllable by the control system 3000. It is envisaged that municipal water flow may be used to supplement the flow of condensate on days where humidity is low and condensate flow is subsequently also low.

[0161] In alternative embodiments (not shown) it is envisaged that the heat exchanger arrangement 2000 can comprise a separate fan (not shown) configured for moving air over the first heat exchanger towards the condenser.

[0162] It is further envisaged that the heat exchanger arrangement can include a drainage outlet (not shown) and drainage closure located at a low point of the primary coolant tank and/or the secondary coolant tank for draining liquid coolant. The drainage closure can be removed from the deck drainage outlet to drain coolant from the primary coolant tanks 2210 and/or the secondary coolant tank 2420, for example for the purposes.

[0163] In another embodiment shown in FIG. 6, it is envisaged that the improved air-conditioning system 1000 can also comprise a third heat exchanger 2500. It is envisaged that the third heat exchanger will comprise a conductive pipe 2510 that is configured for receiving water from a municipal water supply, and is configured to be heated up by heat transfer from the heated coolant (which in turn has been heated by the heat transfer from the refrigerant). The pre-heated water can then be directed to a premises to increase the efficiency of the water heating at the premises.

[0164] It is envisaged that the conductive pipe 2510 of the third heat exchanger can extend into and be received by either the upper primary coolant tank 2210b or the secondary storage tank 2420.

[0165] It is envisaged that the heat exchanger arrangement 1000 will preferably be retrospectively settable to existing air-conditioning systems, and for this reason it is envisaged that the first heat exchanger will be dimensioned and configured to be inserted into the air flow created by the condenser fan, and mounted there. The heat exchanger arrangement 1000 preferably comprises mounting formations (not shown) for mounting any of the first heat exchanger, and the secondary coolant tanks in place.

Principles of Operation - Thermodynamic Cycle

[0166] A single stage vapour compression direct expansion (DX) air-conditioning system typically consists of four major components, namely a rotary scroll compressor, an air cooled condenser, an expansion valve and a DX evaporator. In a conventional system, the cycle starts with a mixture of liquid and vapour refrigerant entering the evaporator. Heat from warm air (for example inside a building) is absorbed by an evaporator DX coil (not shown). During this process, the state of the refrigerant is changed from a liquid to a gas and becomes superheated at the evaporator exit. Super heating is required to prevent slugs of liquid refrigerant from reaching the compressor and causing damage to the compressor.

[0167] The superheated vapour then enters the compressor, where it’s pressure is increased, thereby also increasing the temperature of the refrigerant, before it flows to the condenser. In conventional vapour compression refrigeration systems, the condensing pressure is designed to allow for condensation of the refrigerant at a high ambient temperature. If the condenser fan is not controlled by an inverter type control arrangement, then energy is wasted in partial load when the ambient temperature is low and a high condensing temperature is not required. By utilising a heat exchanger arrangement 2000 in an improved air-conditioning system 1000 according to the invention, this allows for pre-cooling of the air before it reaches the condenser coil, allowing the condenser to reject more heat. As a result, cooling capacity of the air-conditioning system increases while energy demand and usage fall. As head pressure at the exit of the compressor is lowered, then refrigerant condensing temperatures are reduced. This allows the compressor to use less energy in compressing the refrigerant to a low pressure, and to save energy as it runs for less time in a given air-conditioning period.

[0168] The lowering of the temperature of the ambient air before it engages with the condenser coil creates a cooler operating environment for the air cooled condenser which allows the condenser to reject additional heat to the atmosphere. In turn, the compressor head pressure is reduced, for example from point (3) to point (b) on FIG. 8.

[0169] Further, in conventional systems, the superheated refrigerant would enter the air cooled condenser where a reduction in the refrigerant temperature takes place and causes it to cool down from its superheated state so that the refrigerant is sub cooled as it enters the expansion valve. Sub cooling prevents a flash gas formation before the expansion valve and ensures that the designed evaporator performance range is achieved.

[0170] However, by utilising an air-conditioning system 1000 according to the present invention, refrigerant coming from the condenser is received into the second heat exchanger 2400, allowing for the increased sub-cooling of the refrigerant before entering the expansion device. This enhances the system refrigeration effect, and in turn its coefficient of performance, and also enables this air-conditioning system 1000 to deal with higher load demand. This is demonstrated in FIG. 8 by the changing replacing point (1) with point (a) in the refrigeration cycle.

[0171] Accordingly, the high pressure sub cooled refrigerant is allowed to flow through the expansion valve at point (c) of FIG. 8, which serves to reduce its pressure.

[0172] Turning to FIGS. 9 and 10, there is illustrated a heat exchanger assembly 4000 suitable for convenient retrofitting onto the outdoor unit of an existing air-conditioner system. Heat exchanger assembly 4000 is part of a larger heat exchanger arrangement 2000 (as exemplified in FIGS. 1-3) which also includes a collector arrangement and a conduit for delivering liquid condensate from an evaporator to heat exchanger assembly 4000.

[0173] Heat exchanger assembly 4000 includes an upper coolant tank 4210b and a lower coolant tank comprising an inlet manifold pipe 4210a. As illustrated in FIG. 10, upper coolant tank 4210b contains the second heat exchanger which is formed from a copper coil 4400 to facilitate heat transfer from hot refrigerant driven through coil 4400 to the condensate within upper coolant tank 4210b.

[0174] A plurality of sixteen coolant passageways comprising elongate copper pipes 4220 extend between inlet manifold pipe 4210a and upper coolant tank 4210b. It will, however, be appreciated that the number of pipes 4220 can and will vary depending on the size of the air conditioner unit intended with use with the heat exchanger assembly 4000. Copper pipes 4220 are adapted by way of their size and shape to substantially overlie the condenser fan airflow inlet on an outdoor unit of an air conditioner unit.

[0175] Each elongate pipe 4220 includes a kinked portion 4220b, an upper portion 4220a located above the kinked portion 4220b and a lower portion 4220c positioned below the kinked portion 4220b. Kinked portion 4220b is positioned nearer to the lower coolant tank 4210a such that the majority of the length of each pipe 4220 is comprised of the upper portion 4220a. Kinked portion 4220b is angled relative to the upper and lower portions 4220a, 4220c so as to offset lower portion 4220c from an axis defined by upper portion 4220a. Upper and lower portions 4220a, 4220c are therefore generally parallel but not co-axial. The kinked portions 4220b of pipes 4220 offset the lower coolant tank 4210a from a plane collective defined by upper portions 4220a. This allows for upper portions 4220a to be located in desired close proximately to a condenser fan inlet without the lower coolant tank contacting the outdoor unit or obstructing placement of the assembly. In this manner, the provision of kinked portions 4220b enables the majority of pipes 4220 to be located more closely to the condenser air inlet therefore facilitating the condenser-cooling provided by the present invention.

[0176] Kinks 4220b are also advantageous insofar as they enable the upper and lower ends of pipes 4220 to enter the upper and lower tanks 42 in a generally straight orientation as opposed to an angled entry which may otherwise be required in order to provide the desired offset. Straight entry of the pipe ends into the tanks advantageously facilitates welding processes thereby reducing manufacturing cost as well as reducing stress points in the welded connections improving overall robustness.

[0177] The lower coolant tank comprised by inlet manifold pipe 4210a includes an inlet port 4211a for connection to a condensate supply conduit extending from the collector arrangement (not shown). Upper coolant tank 4210b includes a pair of ports 4211b and 4211c which provide inlet and outlet ports for connection to a refrigerant circuit. Upper coolant tank 4210b further includes a coolant outlet 4211d for expelling waste coolant that has received heat from the first heat exchanger pipes 4220 and the second heat exchanger coil 4400.

[0178] It will be appreciated with reference to FIGS. 9 and 10 that the present invention can advantageously provide a unitary heat exchanger assembly enabling convenient installation of the heat exchanger arrangement. The present invention may be provided in a ‘kit’ which included the heat exchanger assembly, collector arrangement and the necessary piping to connect the coolant pathway. In contrast to previous systems, the first and second heat exchangers of the present invention are conveniently housed within a single component, namely heat exchanger assembly 4000 in FIGS. 9 and 10.

[0179] Furthermore, it is noted that by precooling the air before passing the condenser coil and sub cooling the refrigerant before entering the evaporator, the refrigeration effect of the air conditioning system increases. Therefore the compressor will be turned off for longer periods during operation of the air conditioning system than a conventional air conditioning system.

Simulation and Test Data

[0180] Mathematical modelling was carried out in order to determine efficiencies achievable by an air conditioning system of the present invention. These simulated actual weather conditions in Sydney, Australia over the year, and theoretical energy savings achievable, together with expected load fulfilment by using an air- conditioning system according to the present invention, and using copper heat exchanger tubes 2220, are shown in Table 1a and Table 1b below.

TABLE-US-00001 Mathematical modelling of energy savings achievable in Sydney Conventional IP Hybrid Month Compressor [kWh] Fans [kWh] Total [kWh] Compressor [kWh] Fans [kWh] Total [kWh] January 344.3 46.8 391.1 241.4 65.7 307.1 February 309.8 41.2 351 223.2 59.9 283.1 March 308 43.7 351.7 213.8 60.8 274.5 April 0 0 0 0 0 0 May 0 0 0 0 0 0 June 0 0 0 0 0 0 July 0 0 0 0 0 0 August 0 0 0 0 0 0 Septemb er 0 0 0 0 0 0 October 0 0 0 0 0 0 Novembe r 294.8 43 337.8 193.2 56.1 249.3 Decembe r 319.4 42.9 362.3 224.4 60.4 284.8 Total 1,576.20.00 217.7 1,793.80.00 1,095.90.00 302.9 1,398.80.00 Average 131.3 18.1 149.5 91.3 25.2 116.6

TABLE-US-00002 Mathematical modelling of expected load fulfilment in Sydney Load fulfilment Conventional (reference) IP Hybrid % of time: 100 100 % of energy: 100 100 COP Average COP [-]: 4.27 5.2 Energy consumption Fans [kWh]: 218 303 Compressor [kWh]: 1,576 1,096 Total [kWh]: 1,794 1,399 Savings Yearly energy savings [kWh]: - 395 Yearly energy savings [%]: - 22

[0181] In addition, real testing was carried out in Sydney between 20 Dec. 2016 to 12 Feb. 2017. Testing was conducted using an embodiment of the present invention generally illustrated in FIG. 2. That is, the second heat exchanger was connected downstream of the condenser (and upstream of the expander device). The embodiment used was equivalent to the embodiment illustrated in FIGS. 9 and 10. The elongate pipes of the testing apparatus were formed from copper and included a kinked portion. Insulation material was used to cover the lower coolant tank.

[0182] Testing involved a ‘side-by-side’ assessment of two identical 7.1 kW split system Mitsubishi air-conditioning systems. The present invention (termed ‘IP Hybrid’ or ‘Kinetik’) was used with one of the air conditioning systems and the other system used as a control. The indoor units of the two air conditioning systems were respectively installed into two adjacent and identical rooms located at the University of Western Sydney. The two outdoor units were located outside the rooms and exposed to the same ambient temperature. The air-conditioning units were each set to automatically maintain a temperature of 23° C. The air conditioning systems were run 24 hours a day and power consumption of each air conditioning system was recorded every hour, on the hour, so as to compare electricity consumption with and without the use of a heat exchanger arrangement according to the present invention. Power consumption data was also compared against ambient temperature at the time of each power consumption measurement to investigate the effect of ambient temperature on potential power savings.

[0183] Particular regard was had to power consumption between the hours of 8am to 6pm as these are the peak periods for air conditioner usage when ambient temperature is high. Table 2 below displays average power consumption and ambient temperature at the 11 measurements (i.e. at 8am, 9am, 10am....5pm, 6pm). Testing was interrupted on 10.sup.th January 2017 and between 20.sup.th -31.sup.st January 2017 and therefore data for these dates is not included below.

TABLE-US-00003 Test results and ambient temperature of real testing of air conditioning system carried out between 20/12/2016 - Dec. 2, 2017 Time stamp Conventional (kW) Kinetik (kW) Western Syd Uni -Kingswood Campus temperatures (°C.) 20/12/2016 0.94 0.63 32.29 21/12/2016 0.70 0.55 28.29 22/12/2016 0.55 0.45 25.18 23/12/2016 0.65 0.51 28.18 24/12/2016 0.68 0.64 28.95 25/12/2016 0.74 0.55 29.66 26/12/2016 1.02 0.65 32.75 27/12/2016 0.94 0.62 31.10 28/12/2016 1.12 0.72 33.45 29/12/2016 1.24 0.74 37.59 30/12/2016 0.79 0.53 32.25 31/12/2016 1.09 0.68 32.70 Jan. 01, 2017 0.64 0.57 28.25 Feb. 01, 2017 0.60 0.45 24.52 Mar. 01, 2017 0.58 0.54 26.26 Apr. 01, 2017 0.62 0.52 26.66 May 01, 2017 0.59 0.45 24.10 Jun. 01, 2017 0.54 0.45 24.03 Jul. 01, 2017 0.68 0.68 28.90 Aug. 01, 2017 0.95 0.62 31.63 Sep. 01, 2017 1.14 0.72 33.80 Nov. 01, 2017 1.27 0.84 37.59 Dec. 01, 2017 0.86 0.59 30.04 13/01/2017 1.57 0.91 36.96 14/01/2017 1.13 0.65 36.18 15/01/2017 0.72 0.57 28.55 16/01/2017 0.94 0.68 31.95 17/01/2017 1.50 0.87 36.47 18/01/2017 1.40 0.84 21.22 19/01/2017 0.41 0.33 21.22 Jan. 02, 2017 0.36 0.39 24.85 Feb. 02, 2017 0.53 0.52 27.68 Mar. 02, 2017 0.38 0.42 24.63 Apr. 02, 2017 0.73 0.61 32.63 May 02, 2017 0.59 0.45 38.00 Jun. 02, 2017 1.10 0.79 35.05 Jul. 02, 2017 0.33 0.37 23.87 Aug. 02, 2017 0.49 0.54 26.83 Sep. 02, 2017 0.72 0.58 32.69 Oct. 02, 2017 1.63 1.04 38.94 Nov. 02, 2017 1.62 1.03 39.13 Dec. 02, 2017 0.89 0.65 32.58

[0184] As illustrated in Table 2, it was observed that on almost every day of testing, the air conditioner system fitted with a ‘Kinetik’ heat exchanger arrangement according to the present invention was able to maintain the 23° C. set temperature between the hours of 8am-6pm, using less power than the identical air conditioner system which wasn’t fitted with the present invention.

[0185] A sum of total power consumption between the hours of 8am to 6pm across the whole experiment is shown and compared in table 3 below along with a comparison of the peak consumption observed across the whole duration of the experiment.

TABLE-US-00004 Comparison of total consumption between 8am - 6pm and comparison of highest observed power consumption Total consumption 8am - 6pm Peak consumption 24 × 7 Standard consumption (kWh) 420 2.72 Kinetik consumption (kWh) 304 1.56 Variance (kWh) 116 1.16 Variance (%) 28% 43%

[0186] As illustrated in Table 3, it was observed that the present invention provided a 28% reduction in total power consumption between 8am - 6pm over the course of the testing. It was also observed that the air conditioning system fitted with the heat exchanger arrangement of the present invention drew a peak energy supply 43% lower than the control air conditioning system.

[0187] It was therefore observed that the present invention provided a significant improvement in efficiency which was found to increase with higher ambient temperature. A regression analysis of the measured data was performed to calculate a trend line, as illustrated in FIGS. 11 and 12. FIG. 11 is a scatter plot of power consumption against ambient temperature for control air-conditioning system. FIG. 12 is a scatter plot of power consumption against ambient temperature for air-conditioning system fitted with ‘Kinetik’ device according to the present invention.

[0188] As illustrated in FIGS. 11 and 12, power consumption was observed to increase on days of higher ambient temperature. However the control system was found to increase kW consumption with temperature in a quadratic correlation as shown by the line of best fit in FIG. 11. In contrast, the system fitted the present invention increased kW consumption in a more linear correlation as indicated by the line of best fit shown in FIG. 12. Accordingly, a much larger increase in power consumption was required to maintain the set 23° C. inside temperature when using the control air conditioner system, as ambient temperature increased, as compared to when using the air conditioner system fitted with the present invention. In addition to improving efficiency, the present invention also resulted in a much lower ‘peak’ energy consumption.

[0189] The trend lines indicated in FIGS. 11 and 12 enable a side-by-side comparison of predicted power consumption for each system on a range of ambient temperatures. These are shown below in table 4.

TABLE-US-00005 Regression modelling of power consumption at different ambient temperatures Temperature 25 30 35 40 Standard 0.46 0.67 1.00 1.44 Kinetik 0.40 0.55 0.71 0.88 Variance (kWh for 1 hour) 0.05 0.13 0.29 0.56 Variance (%) 11% 19% 29% 39%

[0190] As illustrated in Table 4, the regression analysis modelled an 11% power saving at 25° C. ambient temperature whereas a 39% power saving was modelled where ambient temperature is 40° C. It is further expected by the applicant that efficiencies in regions with increased humidity (for example close to the equator) could achieve even better results.

Interpretation

[0191] Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment, but may. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to one of ordinary skill in the art from this disclosure, in one or more embodiments.

[0192] Similarly it should be appreciated that in the above description of example embodiments of the invention, various features of the invention are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various inventive aspects. This method of disclosure, however, is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the claims following the Detailed Description of Specific Embodiments are hereby expressly incorporated into this Detailed Description of Specific Embodiments, with each claim standing on its own as a separate embodiment of this invention.

[0193] Furthermore, while some embodiments described herein include some but not other features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the invention, and form different embodiments, as would be understood by those in the art. For example, in the following claims, any of the claimed embodiments can be used in any combination.

[0194] As used herein, unless otherwise specified the use of the ordinal adjectives “first”, “second”, “third”, etc., to describe a common object, merely indicate that different instances of like objects are being referred to, and are not intended to imply that the objects so described must be in a given sequence, either temporally, spatially, in ranking, or in any other manner.

[0195] In the description provided herein, numerous specific details are set forth. However, it is understood that embodiments of the invention may be practiced without these specific details. In other instances, well-known methods, structures and techniques have not been shown in detail in order not to obscure an understanding of this description.

[0196] In describing the preferred embodiment of the invention illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as “forward”, “rearward”, “radially”, “peripherally”, “upwardly”, “downwardly”, and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms.

[0197] For the purposes of this specification, the term “plastic” shall be construed to mean a general term for a wide range of synthetic or semisynthetic polymerization products, and generally consisting of a hydrocarbon-based polymer.

[0198] As used herein the term “and/or” means “and” or “or”, or both.

[0199] As used herein “(s)” following a noun means the plural and/or singular forms of the noun.

[0200] In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word “comprise” or variations such as “comprises” or “comprising” are used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.

[0201] Any one of the terms: including or which includes or that includes as used herein is also an open term that also means including at least the elements/features that follow the term, but not excluding others. Thus, including is synonymous with and means comprising.

[0202] Thus, while there has been described what are believed to be the preferred embodiments of the invention, those skilled in the art will recognize that other and further modifications may be made thereto without departing from the spirit of the invention, and it is intended to claim all such changes and modifications as fall within the scope of the invention. For example, any formulas given above are merely representative of procedures that may be used. Functionality may be added or deleted from the block diagrams and operations may be interchanged among functional blocks. Steps may be added or deleted to methods described within the scope of the present invention.

[0203] Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms.

[0204] Finally, it is to be understood that the invention described herein is susceptible to variations, modifications and/or additions other than those specifically described and it is to be understood that the invention includes all such variations, modifications and/or additions which fall within the spirit and scope of the present disclosure.