HEAT PUMP WITH DEHUMIDIFICATION
20210180807 · 2021-06-17
Inventors
Cpc classification
F25B2313/0292
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B2400/0403
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24F3/153
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B30/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B41/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B6/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02B30/70
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F24F3/1405
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24F2003/1446
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24F2003/1452
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B2313/005
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24F11/0008
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B41/24
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B2400/0411
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B13/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B40/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B2313/0212
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F24F3/14
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24F11/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24F3/153
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B13/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B30/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B40/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B41/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B41/26
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B41/31
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
Various embodiments of a heat pump system are disclosed to provide improved and flexible heat pump operation when dehumidification of the conditioned space is required. In one embodiment, a heat pump system includes a heat pump loop comprising a refrigerant circuit that fluidly interconnects (1) a compressor; (2) a source heat exchanger; (3) a source heat exchanger bypass circuit comprising a bypass valve; (4) a space heat exchanger; (5) a reversing valve positioned on the discharge side of the compressor; (6) a reheat circuit comprising a reheat heat exchanger; (7) first and second expansion devices; and (8) first and second expansion device bypass circuits configured to allow refrigerant to bypass the first and second expansion devices, respectively, where the first and second bypass circuits include first and second check valves, respectively; and (9) a 3-way valve configured to selectively direct refrigerant flow to the first expansion device, the reheat circuit, and the second expansion device.
Claims
1. A heat pump system for conditioning air in a space, comprising: a heat pump loop comprising a refrigerant circuit that fluidly interconnects: a compressor; a source heat exchanger for exchanging heat with a source liquid; a space heat exchanger for cooling or heating the air in the space; a reversing valve configured to alternately direct refrigerant flow from the compressor to one of the source heat exchanger and the space heat exchanger and to alternately return flow from the other of the source heat exchanger and the space heat exchanger to the compressor; a reheat circuit comprising a reheat heat exchanger, an upstream leg, a downstream leg, and a reheat bypass valve joining the upstream leg and the downstream leg, wherein the reheat heat exchanger is configured to reheat the air when the system is in a dehumidification mode and operate as an auxiliary condenser when the system is in a heating mode, wherein the space heat exchanger and the reheat heat exchanger are positioned in an air flow path for conditioning the air in the space; an expansion device positioned downstream of the source heat exchanger and upstream of the space heat exchanger; a 3-way valve positioned between the compressor, the reversing valve, and the reheat heat exchanger and configured to direct refrigerant flow from the compressor and selectively to the reversing valve and to the reheat heat exchanger, wherein the reheat bypass valve is positioned between the 3-way valve and the reversing valve to modulate refrigerant flow through the reheat heat exchanger.
2. The heat pump system of claim 1, wherein the compressor is a variable speed compressor.
3. The heat pump system of claim 1, wherein the source heat exchanger is a refrigerant-to-liquid source heat exchanger.
4. The heat pump system of claim 1, wherein the space heat exchanger is a refrigerant-to-air space heat exchanger.
5. The heat pump system of claim 1, wherein the source heat exchanger is operable as either a condenser or an evaporator.
6. The heat pump system of claim 5, wherein the space heat exchanger is operable as either a condenser or an evaporator.
7. The heat pump system of claim 1, wherein the expansion device is a bi-directional expansion device.
8. The heat pump system of claim 7, wherein the bi-directional expansion device is an electronic bi-directional expansion device.
9. The heat pump system of claim 1, wherein the reheat bypass valve is bi-directional.
10. The heat pump system of claim 1, including a variable-capacity liquid pump configured to circulate the source liquid to or from the source heat exchanger.
11. The heat pump system of claim 1, including a variable airflow fan associated with the space heat exchanger.
12. The heat pump system of claim 1, wherein to operate the system in a cooling mode: the 3-way valve is configured to inactivate the reheat circuit and direct refrigerant flow from the compressor and to the reversing valve; and the reversing valve is configured to direct refrigerant flow from the 3-way valve to the source heat exchanger and to return flow from the space heat exchanger to the compressor.
13. The heat pump system of claim 12, wherein the reheat circuit further includes a shutoff leg along the downstream leg to prevent hot gas discharged from the compressor from entering the reheat circuit when the system is operating in the cooling mode.
14. The heat pump system of claim 1, wherein to operate the system in the dehumidification mode: the 3-way valve is configured to direct refrigerant flow from the compressor to the reheat circuit and subsequently to the reversing valve; and the reversing valve is configured to direct refrigerant flow from the reheat circuit to the source heat exchanger and to return flow from the space heat exchanger to the compressor.
15. The heat pump system of claim 1, wherein to operate the system in the heating mode: the 3-way valve is configured to direct refrigerant flow from the compressor to the reheat circuit and subsequently to the reversing valve; and the reversing valve is configured to direct refrigerant flow from the reheat circuit to the space heat exchanger and to return flow from the source heat exchanger to the compressor.
16. The heat pump system of claim 1, further including a controller comprising a processor and memory on which one or more software programs are stored, the controller configured to control operation of the reversing valve, the reheat bypass valve, the 3-way valve, the expansion device, and the compressor.
17. The heat pump system of claim 16, wherein to operate the system in a cooling mode, the controller is configured to: control the 3-way valve to inactivate the reheat circuit and to cause refrigerant flow from the compressor and to the reversing valve; and control the reversing valve to cause refrigerant flow from the 3-way valve to the source heat exchanger and to return flow from the space heat exchanger to the compressor.
18. The heat pump system of claim 16, wherein to operate the system in the dehumidification mode, the controller is configured to: control the 3-way valve to cause refrigerant flow from the compressor to the reheat circuit and subsequently to the reversing valve; and control the reversing valve to cause refrigerant flow from the reheat circuit to the source heat exchanger and to return flow from the space heat exchanger to the compressor.
19. The heat pump system of claim 16, wherein to operate the system in the heating mode, the controller is configured to: control the 3-way valve to cause refrigerant flow from the compressor to the reheat circuit and subsequently to the reversing valve; and control the reversing valve to cause refrigerant flow from the reheat circuit to the space heat exchanger and to return flow from the source heat exchanger to the compressor.
20. The heat pump system of claim 16, wherein the controller is configured to control an opening of the reheat bypass valve to modulate refrigerant flow through the reheat heat exchanger.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
[0038] Although the figures and the instant disclosure describe one or more embodiments of a heat pump system, one of ordinary skill in the art would appreciate that the teachings of the instant disclosure would not be limited to these embodiments. It should be appreciated that any of the features of an embodiment discussed with reference to the figures herein may be combined with or substituted for features discussed in connection with other embodiments in this disclosure.
[0039] The instant disclosure provides improved and flexible heat pump operation when dehumidification of a conditioned space is required. In one embodiment of a vapor compression circuit, a reheat heat exchanger is positioned upstream of a 3-way valve with respect to the refrigerant flow. In another embodiment, a reheat heat exchanger is positioned downstream of the 3-way valve but upstream of a source heat exchanger with respect to the refrigerant flow. In yet another embodiment, a reheat heat exchanger is positioned downstream of a source heat exchanger with respect to the refrigerant flow.
[0040] All three of the foregoing embodiments provide operational flexibility via a modulating, pulse width modulating (PWM) or rapid cycle solenoid valve diverting at least a portion of the refrigerant around the reheat heat exchanger in the dehumidification mode of operation. Alternatively or additionally, an ON-OFF 3-way valve and a bypass valve may be replaced by the modulating, PWM or rapid cycle solenoid 3-way valve. A controller comprising a processor coupled to memory on which one or more software algorithms are stored may process and issue commands to open, partially open, or close any of the valves disclosed herein. Open or closed feedback loops may be employed to determine current and desired valve positions.
[0041] All three of the embodiments may employ variable speed or multi-speed refrigerant and/or source fluid pumps, fan and/or blower motor, and compressor to control dehumidification capability and head pressure. The controller may be configured to operate any or all of these devices to provide the desired system performance. In the heating mode, the reheat heat exchanger may act as an auxiliary condenser or evaporator to enhance system performance and avoid the “cold blow” effect. Any of the expansion valves disclosed herein may be any type of expansion device, including a thermostatic expansion valve, and can be electronic, mechanical, electromechanical, or fixed orifice type. The charge migration or condensation of refrigerant in the reheat heat exchanger can be controlled by a charge compensator or a shutoff valve. The potential oil accumulation in the reheat heat exchanger when the reheat refrigeration circuit is inactive can be controlled by periodically activating the reheat circuit for a short period of time. In at least one of the embodiments described herein, a portion of the existing space heat exchanger may act as a reheat heat exchanger during the dehumidification mode of operation. All of the embodiments described herein provide improved comfort level, system performance, and system reliability.
[0042] Turning now to the drawings and to
[0043] In the embodiment of
[0044] Referring to
[0045] Three-way valve 36 is configured to direct the refrigerant to expansion valve 42 rather than entering the reheat circuit 18. With expansion valve bypass circuit 44 inactive due to the opposite flow orientation of check valve 46, the refrigerant is directed to the expansion valve 42 where the refrigerant is metered, expanded and cooled before entering the space heat exchanger 48. Refrigerant conveyed in the coil of the space heat exchanger 48, which acts as an evaporator when system 10 is in cooling mode, absorbs heat from air flowing over the coil of the space heat exchanger 48 thereby cooling the air for conditioning a space. Refrigerant exiting the space heat exchanger 48 is then conveyed to the reversing valve 22, which directs the refrigerant back to the compressor 20 to start the cycle over again. It should be noted that the coil in the reheat heat exchanger 40 may be filled with subcooled liquid refrigerant.
[0046] Referring to
[0047] If the three-way valve 36 is configured to be adjustable, the three-way valve 36 may control the refrigerant mass flow rate flowing through reheat circuit 18 to provide adjustable outlet air temperature exiting from the coils of the space heat exchanger 48 and reheat heat exchanger 40 for distribution to the air-conditioned space. If the three-way valve 36 is not adjustable, reheat bypass valve 38 may be configured to cause some of the refrigerant flow to bypass the reheat heat exchanger 40 to reduce the mass flow rate entering the reheat heat exchanger 40. The reheat bypass valve 38 may be automatically cycled opened and closed and/or controlled on and off with a PWM signal to modulate the amount of refrigerant flowing through the reheat heat exchanger 40.
[0048] Referring to
[0049] Refrigerant exiting the reheat heat exchanger is then directed to three-way valve 36, which directs the flow to expansion valve 30 while expansion valve bypass circuit 32 is inactive. The expansion valve 30 expands the refrigerant thereby cooling the refrigerant before entering the source heat exchanger 24 while source heat exchanger bypass circuit 26 is inactive (i.e., bypass valve 28 is closed). The source heat exchanger 24 acts as an evaporator to fully evaporate the refrigerant before the refrigerant is directed to the reversing valve 22, which directs the refrigerant to the suction inlet port 50 of the compressor 20 to continue the cycle. With the reheat heat exchanger 40 acting as an auxiliary condenser, system 10 may improve the subcooling and consequently the capacity and efficiency of system 10 while in this heating mode, as well as increase supply air temperature preventing the “cold blow” effect. In cold climates, reheat heat exchanger 40 provides additional heating capacity to avoid auxiliary (e.g. electric) heaters.
[0050] Referring to
[0051] Unlike heat pump system 10, heat pump system 60 does not require expansion valve bypass circuits. And although the reheat heat exchanger is positioned downstream of the space heat exchanger in terms of the direction of air flowing over the coils of these two heat exchangers, the refrigerant connection conduits for the reheat circuit 68 connect with the heat pump loop 66 downstream of the compressor 70 and upstream of the reversing valve 72. Similarly to the previous embodiment, the bypass around source heat exchanger 74 may be applied, but not shown for simplicity.
[0052] Referring
[0053] Referring to
[0054] Refrigerant exiting reheat heat exchanger 90 is directed to open shutoff valve 96. The refrigerant is then directed to reversing valve 72, which directs the refrigerant to source heat exchanger 74 to exchange heat with the source fluid. The refrigerant is then conveyed to the expansion valve 92, which expands and therefore causes the pressure and temperature reduction of the refrigerant, before refrigerant enters space heat exchanger 98. Refrigerant exiting the space heat exchanger 98 acting as an evaporator is then directed to the reversing valve 72, which in turn directs the refrigerant back to the suction inlet port 100 of compressor 70. Thus, air flowing over the space heat exchanger 98 is cooled by the space heat exchanger 98 and then the air is directed to flow over the reheat heat exchanger 98 to add heat to the air to prevent overcooling the air.
[0055] The three-way valve 86 may be adjustable as described above to adjust the refrigerant mass flow rate provided to the reheat circuit 68 for optimum supply air temperature that is distributed to the air-conditioned space. Alternatively, as described above, the three-way valve may not be adjustable. In that case, reheat bypass valve 88 may be configured as a simple on-off valve. As described above, reheat bypass valve 88, may be controlled via a PWM algorithm that controls the mass flow rate of refrigerant entering reheat heat exchanger 90 by cycling reheat bypass valve 88 open and closed according to the algorithm. The capacity (e.g. speed) of the liquid pump 64 circulating the fluid through heat exchanger 74 may be adjusted to control heat rejected by the heat exchanger 74 and system discharge pressure.
[0056] Referring to
[0057] In this mode, hot gaseous refrigerant exiting the discharge outlet port 102 of compressor 70 is directed to three-way valve 86, which in turn directs the refrigerant to reheat heat exchanger 90. The refrigerant is then directed to open shutoff valve 96, after which the refrigerant is directed to reversing valve 72. The refrigerant is then conveyed to space heat exchanger 98, after which the refrigerant is conveyed to the expansion valve 92. The expanded refrigerant of reduced pressure and temperature after passing through the expansion valve 92 is then conveyed to the source heat exchanger 74, which acts as an evaporator. The refrigerant discharged from the source heat exchanger 74 is conveyed to the reversing valve 72, which directs the refrigerant back to the suction inlet port 100 of compressor 70.
[0058] To heat a space, air flowing over the space heat exchanger 98 picks up heat from the space heat exchanger 98 before the air is directed to flow over the reheat heat exchanger 90 to pick up additional heat. Reheat heat exchanger 90 therefore acts as an auxiliary condenser in this heating mode. The extra condenser provided by reheat heat exchanger 90 helps to increase the heat transfer to the air, increase the subcooling of the refrigerant, and increase the capacity and efficiency of heat pump system 60, as well as increase temperature of the air supplied to a conditioned space therefore avoiding a “cold blow” effect. The capacity (e.g. speed) of the liquid pump 64 circulating the fluid through heat exchanger 74 may be adjusted to control heat rejected by the heat exchanger 74 and system discharge pressure.
[0059]
[0060] Heat pump system 110 is schematically similar to heat pump system 10, but instead of employing two different air coils, a larger space coil is employed. In this embodiment, expansion valve bypass circuit 144 and expansion valve 142 of heat pump system 110 are positioned between reheat heat exchanger 140 and space heat exchanger 148 and therefore divide the larger space coil into two parts. One part may be used as a reheat coil and the other part may be used as a main space heating/cooling coil.
[0061] Referring to
[0062] For control purposes, bypass valve 146 may be automatically cycled open and closed and/or controlled on and off with a PWM signal. Refrigerant exiting the space heat exchanger 148 is conveyed to reversing valve 122, which directs the refrigerant to suction inlet port 150 of compressor 120.
[0063] Referring to
[0064] Refrigerant exiting the source heat exchanger 124 acting as a condenser and source heat exchanger bypass circuit 126 are combined and then directed to expansion valve bypass circuit 132. In dehumidification mode, none of the refrigerant enters the expansion valve 130.
[0065] Refrigerant exiting the expansion bypass circuit 132 is directed to reheat heat exchanger 140. Upon exiting reheat heat exchanger 140 and with bypass valve 146 being closed, subcooled refrigerant is directed to expansion valve 142, which meters, expands and cools the refrigerant before the refrigerant enters space heat exchanger 148 acting as an evaporator. Upon leaving space heat exchanger 148, the refrigerant is directed to the reversing valve 122, which then directs the flow back to the suction inlet port 150 of compressor 120. Thus, air flowing over the space heat exchanger 148 is cooled by the space heat exchanger 148 and then the air is directed to flow over the reheat heat exchanger 140 to add heat to prevent overcooling the air.
[0066] Referring to
[0067] Refrigerant leaving reheat heat exchanger 140 is directed to expansion valve 130. Expansion valve bypass circuit 132 and source heat exchanger bypass circuit 126 are not active (i.e., bypass valves 128,134 are closed) when heat pump system 110 is configured in the heating mode. Refrigerant leaving the expansion valve 130 is directed to source heat exchanger 124 acting as an evaporator to exchange heat with the source fluid. Refrigerant leaving source heat exchanger 124 is then directed the reversing valve 122, which directs the refrigerant back to the suction inlet port 150 of compressor 120. The extra condenser provided by reheat heat exchanger 140 helps to increase the heat transfer to the air, increase the subcooling of the refrigerant, and increase the capacity and efficiency of heat pump system 110, as well as increase temperature of the air supplied to a conditioned space therefore avoiding a “cold blow” effect. The capacity (e.g. speed) of the liquid pump 114 circulating the fluid through heat exchanger 124 may be adjusted to control heat rejected by the heat exchanger 124 and system discharge pressure.
[0068] Heat pump loops 16,66,116 include a conduit through which refrigerant flows and which fluidly connects the components of heat pump systems 10,60,110 to one another. Compressors 20,70,120 may each be a variable capacity compressor, such as a variable speed compressor, a compressor with an integral pulse-width modulation option, or a compressor incorporating various unloading options. These types of compressors allow for better control of the operating conditions and management of the thermal load on the heat pump loops 16,66,116.
[0069] Reversing valves 22,72,122 are positioned along the conduit on the discharge side of compressors 20,70,120 and are configured to selectively operate the heat pump loops 16,66,116 in a cooling mode, a dehumidification mode, and a heating mode by controlling the direction of refrigerant flowing in the heat pump loops 16,66,116.
[0070] Source heat exchangers 24,74,124 may each be a refrigerant-to-water, refrigerant-to-brine, or refrigerant-to-air heat exchanger and is not limited to any particular heat exchanger type or configuration. Source heat exchangers 24,74,124 are fluidly connected to a source 15,65,115, and the fluid, usually but not necessarily water, is circulated by pumps 14,64,114. Pumps 14,64,114 may be a variable capacity pump (e.g. a variable speed pump, a pump controlled by PWM signal, a cycling ON/OFF pump, a pump with a bypass circuit or other means of unloading) for a more efficient operation and better system control. Similarly, space heat exchangers 48,98,148 are not limited to any particular heat exchanger type or configuration.
[0071] Expansion valves 30,42,92,130,142 may each be an electronic expansion valve, a mechanical expansion valve, a fixed-orifice/capillary tube/accurator, or any combination of the these. These valves may have bi-directional functionality or may be replaced by a pair of uni-directional expansion devices coupled with the associated bypass check valves to provide refrigerant rerouting when the flow changes direction throughout the refrigerant cycle between cooling and heating modes of operation.
[0072] Valves 28,38,88,96,128,146 may each be electronically controllable, mechanically and/or electromechanically actuated valves, and may have bi-directional flow functionality.
[0073] Referring to
[0074] While specific embodiments have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the disclosure herein is meant to be illustrative only and not limiting as to its scope and should be given the full breadth of the appended claims and any equivalents thereof.