PTAC Unit with Dynamic Intelligent Air Management System and Method of Use

Abstract

A refrigerated air conditioning unit partitioned into an inside plenum and an outside plenum and having a single refrigeration loop, a single evaporator, and a recirculated air stream, the unit also having a dynamic intelligent air management system (DIAMS) internal to the unit that is cooperatively configured and operable to continuously introduce preconditioned fresh air directly into the recirculated air stream whenever the unit is operating and to exercise control over a mixed air flow discharged from the unit into an identified space to achieve a desired air temperature and humidity within the identified space.

Claims

1-25. (canceled)

26. A refrigerated air conditioning unit partitioned into an inside plenum and an outside plenum and having a single refrigeration loop, a single evaporator, and a recirculated air blower operable to produce a recirculated air stream into an identified space whenever the unit is operating, the unit further comprising: a fresh air duct, a fresh air blower, and a dynamic intelligent air management system (DIAMS) internal to the unit that are cooperatively configured and operable to continuously introduce a preconditioned fresh air stream directly into the recirculated air stream whenever the unit is operating and to exercise control over a mixed air flow discharged from the unit into the identified space to achieve a desired temperature and humidity within the identified space; wherein the fresh air duct comprises an inlet section, a damper section and a fresh air blower section into which a stream of fresh air is drawn from outdoors by the fresh air blower and is preconditioned and then discharged from the fresh air blower into a preconditioned fresh air redirection and distribution guide to be redirected, distributed and discharged across the inside plenum to intermix the preconditioned fresh air stream with the recirculated air stream; wherein the damper section of the fresh air duct comprises a damper that is opened fully by a damper motor controlled by a digital controller of the DIAMS and remains open whenever the recirculated air blower is operating but is closed by the damper motor whenever the fresh air blower is not operating to prevent noise, dust and other airborne debris from entering the identified space; and wherein the fresh air duct further comprises at least one fresh air filtering apparatus that is located between the damper and the fresh air blower and is accessible from inside the identified space.

27. The refrigerated air conditioning unit of claim 26 wherein the damper motor is controlled by the digital controller of the DIAMS to keep the damper open when the fresh air blower is operating but the single refrigeration loop is not operating.

28. The refrigerated air conditioning unit of claim 26 wherein the damper motor is configured and controlled by the digital controller of the DIAMS to open the damper when the unit is operating and to close the damper when the unit is not operating.

29. The refrigerated air conditioning unit of claim 26 further comprising at least one air purification apparatus.

30. The refrigerated air conditioning unit of claim 29 wherein the fresh air duct comprises at least one air purification apparatus.

31. The refrigerated air conditioning unit of claim 30 wherein the at least one air purification apparatus is located between the fresh air inlet and the damper.

32. The refrigerated air conditioning unit of claim 26 wherein the at least one fresh air filtering apparatus is selected from the group consisting of: filter screens; activated carbon, fiberglass or cotton filters; and ultrafiltration apparatus.

33. The refrigerated air conditioning unit of claim 30 wherein the at least one air purification apparatus are selected from the group consisting of electrostatic precipitators and ultraviolet sterilization apparatus.

34. The refrigerated air conditioning unit of claim 26 wherein the fresh air duct further comprises at least one preheater.

35. The refrigerated air conditioning unit of claim 34 wherein the at least one preheater is configured to preheat the fresh air stream using at least one electrical resistance heating element.

36. The refrigerated air conditioning unit of claim 26 wherein the fresh air blower is configured to discharge preconditioned fresh air into a preconditioned fresh air discharge section further comprising a preconditioned fresh air redirection guide, a preconditioned fresh air distribution guide, a plurality of laterally spaced-apart air distribution baffles, and a laterally extending deflector.

37. The refrigerated air conditioning unit of claim 36 wherein the fresh air duct sequentially redirects the preconditioned fresh air stream through at least two substantially perpendicular bends prior to intermixing the preconditioned fresh air stream with the recirculated air stream.

38. The refrigerated air conditioning unit of claim 26 wherein the DIAMS comprises a digital controller that is communicatively linked to a damper motor, a fresh air blower, a first temperature and humidity sensor positioned to sense the temperature and humidity of the fresh air stream, a second temperature and humidity sensor positioned to sense the temperature and humidity of the recirculated air stream, and a control panel with a display screen.

39. The refrigerated air conditioning unit of claim 26 wherein the digital controller is configured to communicate with the damper motor to selectively open and close a damper located in the fresh air stream to thereby allow or block air flow past the damper.

40. The refrigerated air conditioning unit of claim 26 wherein the digital controller is configured to communicate with the fresh air blower to control the speed of the fresh air blower.

41. The refrigerated air conditioning unit of claim 26 further comprising a first temperature and humidity sensor located in the fresh air stream and upstream of the fresh air blower.

42. The refrigerated air conditioning unit of claim 41 further comprising a second temperature and humidity sensor positioned to sense the temperature and humidity of the recirculated air stream.

43. The refrigerated air conditioning unit of claim 26 wherein the refrigerated air conditioning unit is selected from the group consisting of PTAC, VTAC, split and unitary air conditioners.

44. The refrigerated air conditioning unit of claim 26 when operated in an operational mode selected from the group consisting of: fresh air control in heat, cool or fan mode; humidity control in dry mode; and heat recovery venting.

45. The refrigerated air conditioning unit of claim 26 having a rated volumetric throughput, wherein the preconditioned fresh air stream is introduced into the recirculated air stream at a second volumetric throughput that ranges from about four percent (4%) to about fourteen percent (14%) of the rated volumetric throughput.

46. A refrigerated air conditioning unit having a single refrigeration loop and a single evaporator to selectively control air temperature and humidity within an identified space, the subject unit comprising: a fresh air duct further comprising a normally open internal damper; a variable speed fresh air blower positioned to draw a stream of fresh outside air through the fresh air duct; an apparatus useful for preconditioning the stream of fresh outside air passing through the fresh air duct; and a preconditioned fresh air redirection and distribution guide configured to receive and intermixing the stream of preconditioned fresh outside air with a stream of recirculated air drawn from within the identified space.

47. The refrigerated air conditioning unit of claim 46 wherein the preconditioned fresh air redirection and distribution guide further comprises an air redirection guide, a lateral air guide, a lateral air deflector and an air limiter that cooperate to subject the stream of preconditioned fresh outside air to at least two substantially perpendicular changes in flow direction following discharge from the variable-speed fresh air blower.

48. The refrigerated air conditioning unit of claim 46 wherein the lateral air guide further comprises a plurality of laterally spaced, angularly disposed baffles.

49. A method of operating a refrigerated air conditioning unit having a single refrigeration loop and a single evaporator to selectively control air temperature and humidity within an identified space, the method including: providing within the subject unit a fresh air duct comprising a normally open internal damper; providing a variable speed fresh air blower positioned to draw a stream of fresh outside air through the fresh air duct; preconditioning the stream of fresh outside air drawn through the fresh air duct before the fresh air stream reaches the fresh air blower; and thereafter discharging the preconditioned stream of fresh air from the fresh air blower; and distributing the preconditioned stream of fresh air to be intermixed inside the subject unit with a stream of recirculated air drawn from within the identified space.

50. The method of claim 49 wherein the stream of fresh air is preconditioned by filtration or ultrafiltration.

51. The method of claim 50 wherein the stream of fresh air is preconditioned by filtration or ultrafiltration through filters comprising activated carbon, fiberglass or cotton.

52. The method of claim 50 wherein the stream of fresh air is preconditioned by filtration or ultrafiltration a first time before reaching the damper and a second time between the damper and the fresh air blower.

53. The method of claim 50 wherein the stream of fresh air is preconditioned by ultra-filtration.

54. The method of claim 49 wherein the stream of fresh air is preconditioned by purification.

55. The method of claim 49 wherein the stream of fresh air is preconditioned by filtration and purification.

56. The method of claim 54 wherein the stream of fresh air is purified by electrostatic precipitation.

57. The method of claim 54 wherein the stream of fresh air is purified by ultraviolet sterilization.

58. The method of claim 49 wherein the stream of fresh air is preconditioned by preheating.

59. The method of claim 58 wherein the stream of fresh air is preheated using a heat source having electrical resistance heating elements.

60. The method of claim 49 comprising sensing the humidity of the stream of fresh air, sensing the humidity within the identified space, and, where the humidity of the fresh air stream is lower than the humidity within the identified space and the humidity within the identified space is higher than a desired setpoint, using a dynamic intelligent air management system (DIAMS) internal to the refrigerated air conditioning unit to increase the speed of the variable speed fresh air blower to lower the humidity within the identified space.

61. The method of claim 49 comprising sensing the humidity of the stream of fresh air, sensing the humidity within the identified space, and, where the humidity of the fresh air stream is higher than the humidity within the identified space and the humidity within the identified space is lower than a desired setpoint, using a dynamic intelligent air management system (DIAMS) internal to the refrigerated air conditioning unit to increase the speed of the variable speed fresh air blower to increase the humidity in the identified space.

62. The method of claim 49 comprising sensing the humidity of the stream of fresh air, sensing the humidity within the identified space, and, where both the humidity of the fresh air stream and the humidity within the identified space are higher than a desired setpoint, using a dynamic intelligent air management system (DIAMS) internal to the refrigerated air conditioning unit to maintain the damper in its normally open position and using the single refrigeration loop to lower the humidity within the identified space.

63. The method of claim 49 wherein the stream of fresh air is preconditioned by fragrance injection.

64. The method of claim 49 wherein the stream of fresh air is preconditioned to control odors present within the identified space.

65. The method of claim 49 wherein the fresh air stream has a volumetric throughput that is controlled primarily by the variable speed fresh air blower when the normally open internal damper is open.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The apparatus of the invention is further described and explained in relation to the following drawings wherein:

[0020] FIG. 1 is a front perspective view of a PTAC (rear cover removed) configured in accordance with one embodiment of the present invention;

[0021] FIG. 2 is a front perspective view as in FIG. 1 with the front cover also removed;

[0022] FIG. 3 is a front perspective view depicting an embodiment of the fresh air duct of the DIAMS in accordance with one embodiment of the invention with a fresh air filter exploded forwardly as it would be if removed for cleaning, replacement or other servicing;

[0023] FIG. 4 is an exploded front perspective view as in FIG. 3, also diagrammatically depicting stream lines associate with the flow of fresh air through the DIAMS;

[0024] FIG. 5 is an enlarged rear perspective view of a section of the fresh air duct with the side panel removed, taken and modified from FIG. 4 to reveal one embodiment of a temperature and humidity sensor, damper and fresh air blower of the invention;

[0025] FIG. 6 is an enlarged, exploded front perspective view of the inlet section of a fresh air duct, taken from FIG. 4, with the fresh air inlet filter and the fresh air preheater exploded from the inlet section in which they are located in one embodiment of the invention; and

[0026] FIG. 7 is an enlarged, exploded front perspective view of the fresh air blower section of the fresh air duct of one embodiment of the invention.

[0027] It should be understood and appreciated that the accompanying drawings are simplified in some cases for illustrative purposes and are not drawn to scale.

DETAILED DESCRIPTION OF AN EMBODIMENT

[0028] The structure and operation of one satisfactory embodiment of the invention is further described and explained in relation to FIGS. 1-7 of the invention. Referring to FIG. 1, PTAC 10 has a single refrigeration loop and one evaporator, and is depicted with DIAMS 12 of the invention installed internally to PTAC 10 and the rear cover removed. DIAMS 12 is supported in part by frame member 15 and by transverse partition 24 (visible and further identified in FIG. 2). PTAC 10 further comprises a front cover having an inlet grill 14 configured to receive recirculated air from an identified interior space and an upwardly and outwardly directed set of discharge vents 16 through which a mixture of preconditioned fresh air and recirculated air are discharged back into the identified space. Temperature and humidity sensor 20 is provided to sense the temperature and humidity of air inside the identified space and communicate the information to a digital controller desirably underlying and linked electronically to display panel 18, which is preferably a user-interactive touch pad.

[0029] Referring to FIG. 2, the front cover is removed and various components of DIAMS 12 that are internal to PTAC unit 10 are more visible. In addition to components previously identified above in relation to FIG. 1, PTAC 10 incorporates DIAMS 12 and other parts of a single loop refrigeration system as might be present in a conventional PTAC unit or in another similarly configured refrigerated air conditioning unit. For example, outside plenum 90 contains outside exchanger (condenser) 26, compressor 32 and fan 34, which are separated from inside plenum 92 by transverse partition 24. Inside plenum 92 contains inside exchanger (evaporator) 28 and horizontally mounted, recirculated air blower 30 that draws recirculated room air into the unit as indicated by arrows 48 to be passed by or through inside exchanger 28 before being discharged back into the indicated interior space as shown by laterally spaced apart arrows 54.

[0030] Now referring to FIG. 2 in conjunction with FIGS. 3-7, arrows 36 indicate a fresh air stream being drawn into DIAMS 12 from outside PTAC unit 10 into fresh air inlet section 56 of the fresh air duct. In general terms, the “fresh air duct” comprises as its constituent parts (best seen in FIGS. 3, 4) inlet section 56, damper section 58, fresh air blower section 60, and preconditioned fresh air redirection and distribution guide 64. Preconditioned fresh air redirection and distribution guide 64 further comprises air redirection guide 62, lateral air guide 65, lateral air deflector 66 and air limiter 67.

[0031] As the fresh air stream enters inlet section 56 it is first preconditioned by passing through filter 68 that slidably engages the rear portion of inlet section 56 and is easily serviceable from outside. The filtered fresh air stream is then directed forwardly through inlet section 56 as indicated by arrow 38 past electrical preheater 78 (FIG. 6) and through damper section 58 containing pivotable damper 72 controlled by motor 74 (FIGS. 3, 7). Because damper 72 is open whenever fresh air blower 84 (FIGS. 5, 7) is drawing fresh air into inlet section 56, the filtered and preheated fresh air stream is then drawn into the suction side of fresh air blower 84 disposed inside fresh air blower section 60. As best seen in FIGS. 5, 7, damper section 58 also comprises temperature and humidity sensor 86, which senses and electronically communicates to the digital controller preferably underlying display panel 18 the temperature and humidity of the fresh air stream entering blower section 60.

[0032] Preconditioned fresh air redirection and distribution guide 64 is provided to redirect and distribute preconditioned fresh air being discharged from fresh air blower section 60 into and through air redirection guide 62 as indicated by stream lines 42, 44 and then laterally through lateral air guide 65 in a substantially horizontal flow path across the width of inside plenum 92 above inside exchanger 28 as shown by arrows 46. Referring to FIGS. 2-4, lateral air guide 65 preferably further comprises a plurality of laterally spaced, angularly disposed baffles 88 (FIG. 4) that assist in distributing, balancing and redirecting the preconditioned fresh air stream passing through lateral air guide 65 across the width of the recirculating air stream and against lateral air deflector 66 to deflect the distributed and balanced air flow downwardly through into the front section of inside plenum 92 as indicated by arrows 50. In so doing, the preconditioned air stream travels through at least two substantially perpendicular changes in flow direction after being discharged from blower section 60. Introducing preconditioned fresh air downwardly into the front section of inside plenum 92 (arrows 50) promotes intermixing of the preconditioned fresh air (arrows 50) and recirculating air streams (arrows 48 entering the unit from the identified space through front cover inlet grill 14 of FIG. 1) before being drawn into the suction side of horizontally disposed blower 30 as indicated by arrows 52. As shown in FIG. 2, as the intermixed streams of preconditioned fresh air and recirculating air pass through inside plenum 92, they are cooled or heated by inside exchanger 28, depending upon the operational mode of PTAC 10, after which intermixed air stream 52 passes through and is discharged by blower 30 back into the identified space as indicated by arrows 54 shown in FIG. 2.

[0033] Referring to FIGS. 6 and 7, air filter 68 and fresh air preheater 78 are preferably disposed inside housing 76 of inlet section 56 and stabilizer 82 desirably secures side panel 80 to the drive motor housing disposed inside blower 84 of fresh air blower section 60. A second fresh air filter 70 slidably engages a slot provided behind side panel 80 to facilitate insertion and removal of air filter 70 for servicing from inside the identified space.

[0034] The logic preprogrammed into a digital controller provided as part of DIAMS 12 and underlying interactive display or “touch pad” 18 of PTAC 10 is desirably configured to receive data from temperature and humidity sensors 20, 86 and use that data to determine a preferred mode of operation of PTAC 10 as set forth below. Appropriate electronic instructions are then communicated to damper motor 74 and to motor-driven blower 84 as well as to display 18 and to the other control elements of PTAC 10 as needed to implement the preferred mode of operation to achieve a desired temperature and humidity level with the identified space within which PTAC 10 is installed. An example of satisfactory control protocols and operational sequences for modes of operation of DIAMS 12 as installed in PTAC 10 including: fresh air control in “heat mode”, “cool mode” or “fan mode” configurations; humidity control; and heat recovery venting is set forth below:

EXAMPLE

DIAMS Control

[0035] When a switch on the digital controller is ON, it allows the touch pad button to turn on/off the DIAMS system.

[0036] Fresh air intake consists of 3 variable speed settings of: Low, Mid and High for the fresh air blower.

[0037] “OD” designates “outdoor” and “ID” designates “indoor.”

[0038] “Temp” designates temperature and “Hum” designates humidity.

[0039] “RH” designates relative humidity.

[0040] “Comfort” refers to a level that is presumed to be reasonably comfortable to an occupant of an identified space in which the DIAMS unit is installed.

[0041] Logic: [0042] 1) Cool mode: [0043] 1. OD temp.mid zone, fresh air blower runs at High. [0044] (If OD-Hum is above comfort RH, fresh air blower run at Mid; If RH high above comfort RH, fresh air blower runs at Low) [0045] 2. OD Temp.mid zone, fresh air blower runs at Mid. [0046] (If OD-Hum is below Low RH, fresh air blower runs at High. If above comfort RH, fresh air blower runs at Low.) [0047] 3. OD Temp.=high zone, fresh air blower runs at Low. [0048] (If OD-Hum is below Low RH, fresh air blower runs at High; If above comfort RH, fresh air blower runs at Low.) [0049] 4. OD Temp.=very high zone, fresh air blower runs at Low. [0050] 2) Heat mode: [0051] 1. OD Temp.Very Low, fresh air blower off, but damper remains open to admit minimal flow of fresh air drawn into unit by suction of main blower. [0052] 2. OD Temp.<Low, fresh air blower runs at Low. [0053] (If OD-Hum is above Low RH, fresh air blower runs at Mid.) [0054] 3. OD Temp.=Low, fresh air blower runs on at Mid. [0055] (If OD-Hum is above Low RH, fresh air blower runs at High.) [0056] 4. OD Temp.=Mid, fresh air blower runs at High. [0057] (If OD-Hum is above comfort RH, Fresh air blower runs at Mid; If high above comfort RH, Fresh air blower runs at Low.) [0058] 3) Fan mode: [0059] 1. Fresh air blower runs at High. [0060] (If OD-Hum is above comfort RH, Fresh air blower runs at Mid, If high above comfort RH, Fresh air blower runs at Low.)

Humidity Control

[0061] a) ID humidity must be controlled within defined range of % RH for optimal comfort at all time.

[0062] b) When ID HUM=comfort RH, the unit run in dehumidify (Dry) mode.

[0063] c) Dehumidify (Dry) mode [0064] 1) ID Fan low speed [0065] 2) Compressor and OD Fan turns on and off at preset intervals, ID fan run in low fan speed continually.

[0066] d) When ID HUM=Low RH, exit dehumidify mode and back to the original preset mode. [0067] Note: if there is a cool demand, unit run until demand fulfilled then enter into dehumidify mode.

Heat Recovery Venting (HRV)

[0068] Heat recovery in general terms means the recovery and re-use of unwanted energy. In this case, re-use of energy is the reuse of residue energy left behind in the inside exchanger after the system operates in cooling or heating mode.

Steps of Operation

[0069] 1. Unit operates in cooling or heating mode.

[0070] 2. When unit achieved target value, unit compressor stops operation. Refrigerant in the inside exchanger remains cool or heated.

[0071] 3. The fresh air system operates, driving fresh intake air from the outside through the inside exchanger, thus recovering and using the residue cool or heat from the indoor coil.

We call this “heat recovery venting,” utilizing unwanted energy to re-cool or re-heat the identified space.

[0072] Those of ordinary skill in the art may, upon reading this disclosure, appreciate that some of the apparatus and control features disclosed here are similarly applicable to vertical packaged air conditioning (“VTAC”), split or other unitary units. Other alterations and modifications of the invention will likewise become apparent to those of ordinary skill in the art upon reading this specification in view of the accompanying drawings, and it is intended that the scope of the invention disclosed herein be limited only by the broadest interpretation of the appended claims to which the inventor and/or Applicant are legally entitled.