JP7536652B2 - Systems, components, and methods for air, heat, and humidity exchangers - Google Patents

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of priority under 35 U.S.C. §119 to U.S. Provisional Patent Application No. 62/620,386, filed January 22, 2018, and the benefit of priority under 35 U.S.C. §120 to U.S. Provisional Patent Application No. 15/228,541, filed August 4, 2016, all of which are incorporated herein by reference in their entireties.

Embodiments of the present disclosure include heat and moisture transfer systems and components thereof, and more particularly include heat and moisture exchangers, membranes for exchangers, methods of manufacturing exchangers, energy recovery ventilators (ERVs) and evaporative cooling systems employing heat and moisture exchange, and gas exchange systems and components thereof.

Heat water vapor exchangers (sometimes called humidifiers, enthalpy exchangers, or energy recovery wheels) have been developed for a variety of applications. These include building ventilation (HVAC), medical and respiratory applications, gas drying or separation, automotive ventilation, aircraft ventilation, and humidification of fuel cell reactants for power generation. In a variety of devices intended for the exchange of heat and/or water vapor between two air streams, it may be desirable to have a thin, inexpensive, heat or moisture transfer material. In some devices, it may be desirable to transfer moisture throughout the material. In some devices, it may be desirable to transfer heat throughout the material. And in some cases, it may be desirable to transfer both heat and moisture from one stream to the other. In each of these applications, it may be desirable that air and contaminants in one stream are not allowed to pass to the other stream.

Planar plate type heat water vapor exchangers may use membrane plates fabricated using individual pieces of planar water permeable membrane (e.g., Nafion®, natural cellulose, sulfonated polymer, or other synthetic or natural membranes) supported by separator material (which may or may not be integrated into the membrane) and/or a frame. The membrane plates are typically stacked, sealed, and configured to accommodate fluid streams flowing in either cross-flow or counter-flow configurations between alternating pairs of plates, limiting cross-flow or cross-contamination of fluid streams while allowing heat and water vapor to transfer through the membrane. In some heat and water vapor exchanger designs, the separate membrane plates may be replaced by a single membrane core made by folding a continuous membrane strip in a concertina, zigzag, or bellows fashion with a series of parallel alternating creases. Similarly, for heat exchangers, a continuous strip of material may be patterned with creases and folded along these creases to form a configuration suitable for heat exchange.

U.S. Patent Application No. 13/426565 (U.S. Patent Application Publication No. 2013/0248160) U.S. Pat. No. 9,562,726 U.S. Pat. No. 7,824,766

The membrane cores may be employed as heat and/or moisture exchangers for ventilation systems, HVAC systems, air filtration systems, energy recovery ventilator (ERV) systems, and evaporative cooling systems. The present disclosure is directed to improvements in existing membranes, methods of fabricating them, membrane cores, systems, methods of fabricating them, and systems utilizing membrane cores.

According to one embodiment, the air handling module may include a housing and an exchanger housed within the housing. The air handling module may further include a first manifold positioned on a first side of the housing and including a first pair of ports arranged on a first end and a second pair of ports arranged on a second end, and a second manifold positioned on a second side of the housing and including the first pair of ports arranged on the first end and the second pair of ports arranged on the second end. The first pair of ports of the first manifold may be in fluid communication with the first pair of ports of the second manifold to move air through the exchanger between the first and second manifolds, and the second pair of ports of the first manifold may be in fluid communication with the second pair of ports of the second manifold to move air through the exchanger between the first and second manifolds.

According to another embodiment, a method of manufacturing a membrane material for an enthalpy exchanger may include imparting an electric charge to microporous particles, coating a first roller and a second roller with the charged microporous particles, conveying a substrate between the first roller and the second roller, and applying heat and pressure to transfer the charged microporous particles from the first roller and the second roller onto the substrate.

According to another embodiment, the air conditioner may include an exchanger including multiple layers of folded membrane material defining a stack of alternating first and second fluid passages, the first fluid passages may be configured to receive a first air flow, and the second fluid passages may be configured to receive a second air flow. The air conditioner may further include a liquid distribution system including a first header including a first distribution channel for delivering a first liquid to the first fluid passage, a second header including a second distribution channel for delivering a second liquid to the second fluid passage, a first plurality of porous members in communication with the first distribution channel and in contact with an inner surface of the first fluid passage, and a second plurality of porous members in communication with the second distribution channel and in contact with an inner surface of the second fluid passage. The first plurality of porous members may be configured to provide a continuous flow of a first liquid onto the inner surface of the first fluid passage, and the second plurality of porous members may be configured to provide a continuous flow of a second liquid onto the inner surface of the second fluid passage.

In another embodiment, the insulating structure may include a rotationally molded shell including an interstitial space and an insulating material disposed within the interstitial space, the insulating material may be one or more of a metal oxide powder, an inorganic oxide powder, a silica powder, a fumed silica powder, and an aerogel powder.

In yet another embodiment, a method for manufacturing a separator may include delivering a mesh sheet between a first continuous belt having a first wavy surface and a second continuous belt having a second wavy surface, mating the first wavy surface with the second wavy surface, applying heat and pressure to the mesh sheet to form a wavy mesh sheet, releasing the wavy mesh sheet from the first and second continuous belts, cooling the wavy mesh sheet, and applying a tension to the wavy mesh sheet as it is released from the first and second continuous belts.

FIG. 2 is a perspective view of an exemplary air handling module having multiple modular features in accordance with an exemplary embodiment of the present disclosure. FIG. 2 illustrates an exploded view of an exemplary air handling module having multiple modular features in accordance with an exemplary embodiment of the present disclosure. FIG. 2 is a cross-sectional perspective view illustrating an inner channel track of an air handling module according to an exemplary embodiment of the present disclosure. FIG. 1 illustrates a cross-sectional perspective view of an inner channel track of an air handling module according to an exemplary embodiment of the present disclosure. FIG. 1 illustrates a cross-sectional perspective view of an inner channel track of an air handling module according to an exemplary embodiment of the present disclosure. FIG. 1 illustrates a cross-sectional perspective view of an inner channel track of an air handling module according to an exemplary embodiment of the present disclosure. FIG. 1 is a perspective view of a rotary damper according to an exemplary embodiment of the present disclosure. FIG. 1 is a perspective view of a rotary damper according to an exemplary embodiment of the present disclosure. FIG. 1 is a perspective view of a rotary damper according to an exemplary embodiment of the present disclosure. FIG. 1 is a perspective view of a rotary damper according to an exemplary embodiment of the present disclosure. FIG. 1 is a perspective view of a rotary damper according to an exemplary embodiment of the present disclosure. FIG. 1 is a perspective view of a rotary damper according to an exemplary embodiment of the present disclosure. FIG. 1 is a perspective view of a rotary damper according to an exemplary embodiment of the present disclosure. FIG. 1 is a perspective view of a rotary damper according to an exemplary embodiment of the present disclosure. FIG. 1 is a perspective view of an access panel according to an exemplary embodiment of the present disclosure. FIG. 1 is a perspective view of an access panel according to an exemplary embodiment of the present disclosure. FIG. 13 is a cross-sectional view of a fan box for facilitating airflow into and out of an air handling module and a replaceable exchanger divider for facilitating a cross-flow airflow pattern in accordance with an exemplary embodiment of the present disclosure. FIG. 13 is a cross-sectional view of a fan box for facilitating airflow into and out of an air handling module and a replaceable exchanger divider for facilitating a cross-flow airflow pattern in accordance with an exemplary embodiment of the present disclosure. FIG. 13 is a cross-sectional view of a fan box for facilitating airflow into and out of an air handling module and a replaceable exchanger divider for facilitating a cross-flow airflow pattern in accordance with an exemplary embodiment of the present disclosure. FIG. 13 is a cross-sectional view of a fan box for facilitating airflow into and out of an air handling module and a replaceable exchanger divider for facilitating a cross-flow airflow pattern in accordance with an exemplary embodiment of the present disclosure. FIG. 13 is a cross-sectional view of a fan box for facilitating airflow into and out of an air handling module and a replaceable exchanger divider for facilitating a cross-flow airflow pattern in accordance with an exemplary embodiment of the present disclosure. FIG. 13 is a cross-sectional view of a fan box for facilitating airflow into and out of an air handling module and a replaceable exchanger divider for facilitating a cross-flow airflow pattern in accordance with an exemplary embodiment of the present disclosure. FIG. 13 is a cross-sectional view of a fan box for facilitating airflow into and out of an air handling module and a replaceable exchanger divider for facilitating a cross-flow airflow pattern in accordance with an exemplary embodiment of the present disclosure. FIG. 13 is a cross-sectional view of a fan box for facilitating airflow into and out of an air handling module and a replaceable exchanger divider for facilitating a cross-flow airflow pattern in accordance with an exemplary embodiment of the present disclosure. FIG. 1 is a perspective view of an exemplary air handling system according to an exemplary embodiment of the present disclosure. FIG. 1 is a perspective view of an exemplary air handling system according to an exemplary embodiment of the present disclosure. FIG. 1 is a cross-sectional perspective view of an exemplary air handling system according to an exemplary embodiment of the present disclosure. FIG. 1 is a cross-sectional perspective view of an exemplary air handling system according to an exemplary embodiment of the present disclosure. FIG. 1 is a perspective view of an exemplary air handling system according to an exemplary embodiment of the present disclosure. FIG. 1 is a cross-sectional view of an exemplary air handling system in an exemplary configuration in accordance with an exemplary embodiment of the present disclosure. FIG. 1 is a cross-sectional view of an exemplary air handling system in an exemplary configuration in accordance with an exemplary embodiment of the present disclosure. FIG. 1 is a cross-sectional view of an exemplary air handling system in an exemplary configuration in accordance with an exemplary embodiment of the present disclosure. FIG. 1 is a cross-sectional view of an exemplary air handling system in an exemplary configuration in accordance with an exemplary embodiment of the present disclosure. FIG. 1 is a cross-sectional view of an exemplary air handling system in an exemplary configuration in accordance with an exemplary embodiment of the present disclosure. FIG. 1 is a cross-sectional view of an exemplary air handling system in an exemplary configuration in accordance with an exemplary embodiment of the present disclosure. FIG. 1 illustrates a psychrometric chart corresponding to operation of an air handling system in accordance with an exemplary embodiment of the present disclosure. FIG. 1 illustrates a psychrometric chart corresponding to operation of an air handling system in accordance with an exemplary embodiment of the present disclosure. FIG. 1 illustrates a psychrometric chart corresponding to operation of an air handling system in accordance with an exemplary embodiment of the present disclosure. FIG. 1 illustrates a psychrometric chart corresponding to operation of an air handling system in accordance with an exemplary embodiment of the present disclosure. FIG. 1 illustrates a psychrometric chart corresponding to operation of an air handling system in accordance with an exemplary embodiment of the present disclosure. FIG. 1 is a perspective view of an exemplary process for manufacturing a membrane for an exchanger according to an exemplary embodiment of the present disclosure. FIG. 1 is a perspective view of an exemplary process for manufacturing a membrane for an exchanger according to an exemplary embodiment of the present disclosure. FIG. 2 is a perspective view of one layer of a separator according to an exemplary embodiment of the present disclosure. 1A-1D are perspective views of an exemplary process for manufacturing a separator according to an exemplary embodiment of the present disclosure. 1A-1D are perspective views of an exemplary process for manufacturing a separator according to an exemplary embodiment of the present disclosure. 1A-1D are perspective views of an exemplary process for manufacturing a separator according to an exemplary embodiment of the present disclosure. 1A-1D are perspective views of an exemplary process for manufacturing a separator according to an exemplary embodiment of the present disclosure. FIG. 1 is a perspective view of an air filter with a separator according to an exemplary embodiment of the present disclosure. FIG. 1 is a perspective view of an air filter with a separator according to an exemplary embodiment of the present disclosure. FIG. 1 is a perspective view of an air filter with a separator according to an exemplary embodiment of the present disclosure. FIG. 1 is a perspective view of an evaporative cooling and/or vapor regenerative liquid desiccant air conditioner module according to an exemplary embodiment of the present disclosure. FIG. 1 is a perspective view of an evaporative cooling and/or vapor regenerative liquid desiccant air conditioner module according to an exemplary embodiment of the present disclosure. FIG. 1 is a perspective view of an evaporative cooling and/or vapor regenerative liquid desiccant air conditioner module according to an exemplary embodiment of the present disclosure. FIG. 1 is a perspective view of a liquid distribution system including first and second distribution headers and associated components according to an exemplary embodiment of the present disclosure. FIG. 1 is a perspective view of a liquid distribution system including first and second distribution headers and associated components according to an exemplary embodiment of the present disclosure. FIG. 1 is a perspective view of a liquid distribution system including first and second distribution headers and associated components according to an exemplary embodiment of the present disclosure. FIG. 1 is a perspective view of a liquid distribution system including first and second distribution headers and associated components according to an exemplary embodiment of the present disclosure. FIG. 1 is a perspective view of a liquid distribution system including first and second distribution headers and associated components according to an exemplary embodiment of the present disclosure. 1 is a perspective view of an exemplary configuration of an evaporated liquid desiccant hexagonal shaped exchange module according to an exemplary embodiment of the present disclosure. FIG. 1 is a perspective view of an exemplary configuration of an evaporated liquid desiccant hexagonal shaped exchange module according to an exemplary embodiment of the present disclosure. FIG. FIG. 1 is a perspective view of a multi-function remote energy harvesting system according to an exemplary embodiment of the present disclosure. FIG. 2 illustrates a psychrometric chart corresponding to operation of an evaporative cooling and/or vapor regenerative liquid desiccant air conditioner module in accordance with an exemplary embodiment of the present disclosure. FIG. 1 is a perspective view of a wall panel formed from a rotationally molded shell according to an exemplary embodiment of the present disclosure. FIG. 1 is a perspective view of a wall panel formed from a rotationally molded shell according to an exemplary embodiment of the present disclosure. FIG. 1 is a perspective view of a wall panel formed from a rotationally molded shell according to an exemplary embodiment of the present disclosure. FIG. 1 is a perspective view of a wall panel formed from a rotationally molded shell according to an exemplary embodiment of the present disclosure. 1 is a perspective view of the interior and exterior surfaces of a building formed from building panels made from rotationally molded shells in accordance with an exemplary disclosed embodiment; FIG. 1 is a perspective view of the interior and exterior surfaces of a building formed from building panels made from rotationally molded shells in accordance with an exemplary disclosed embodiment; FIG. FIG. 1 is a perspective view of a three-way wall connector formed from a rotationally molded shell in accordance with an exemplary embodiment of the present disclosure. FIG. 1 is a perspective view of a corner wall connector formed from a rotationally molded shell in accordance with an exemplary embodiment of the present disclosure. FIG. 1 is a perspective view of a three-way floor connector formed from a rotationally molded shell in accordance with an exemplary embodiment of the present disclosure. FIG. 1 is a perspective view of a three-way roof connector formed from a rotationally molded shell in accordance with an exemplary embodiment of the present disclosure.

Reference will now be made in detail to the exemplary embodiments of the present disclosure described above and illustrated in the accompanying drawings.

Air Handling Module, Air Handling System, and Rotary Damper Figure 1 illustrates an air handling module 100 according to the present disclosure. In some embodiments, the air handling module 100 may be an energy recovery ventilation (ERV) system that utilizes return air (RA) from a space or building to pre-condition outside air (OA) for an HVAC system. The air handling module 100 may include a housing 120 having a top 130, a bottom 140, and a side 110. Additionally, the air handling module 100 may include a first pair of ports 103, 104 fluidly connected to a second pair of ports 101, 102, and a third pair of ports 107, 108 fluidly connected to a fourth pair of ports 105, 106.

The fan box 181 may be coupled to the port 101 and may house one or more fans 189 configured to draw outside air (OA) from the ports 103 and/or 104 through the exchanger 213. The fan box 186 may be coupled to the port 106 and may house one or more fans 189 configured to draw return air (RA) from the port 108 through the filter 191. The access panel 177 may be attached to and detached from the port 107 via a panel connector 107. The connector 107 may include any suitable connection mechanism, such as, for example, latches, screws, and the like. The access panel 177 may be attached and detached from the port 107 to provide access for replacement of the filter 191.

Ports 101-108 may serve as interchangeable attachment points for a number of additional structures, such as, for example, metal ducts of an HVAC system, intake rain screens, roof curbs, and/or other fluidly connected components. Ports 101-108 may include any suitable means, including, for example, mechanical latches, flanges, friction fits, interference fits, removable fasteners, and the like, to allow components to be easily connected and disconnected from air handling module 100.

The air handling module 100 may also include ports 109 that may provide access to electrical, power, and economizer sections of the air handling module 100. The housing 120 may include multiple exterior and interior ports configured to facilitate a modular hydronic distribution and collection system. For example, in some embodiments, the housing 120 may include a side drain port 112, a side liquid desiccant drain port 118, a top drain port 133, a top liquid desiccant port 137, a top liquid desiccant port 138, and a top evaporation port 139. These ports of the hydronic distribution collection system may serve as interchangeable attachment points for multiple components, including, for example, the condensate drain, evaporative water supply, evaporative water drain, liquid desiccant supply, liquid desiccant drain, refrigerant line conduits, cold water conduits, steam lines, and/or other fluidly connected hydronic components of the HVAC system. In some embodiments, the ports may be threaded and incorporate gasketed seals.

The housing 120 may also include multiple external and internal ports configured to facilitate a modular system for components for local communication networks, electrical power distribution, and power distribution. For example, in some embodiments, the housing 120 may include a side duct port 114 and a top duct port 134. The air handling module 100 may facilitate modular connection to additional air handling modules 100 via a top anchor port 136 and a bottom anchor port 146.

2 illustrates an exploded view of an air handling module 200 according to the present disclosure. As shown in FIG. 2, the air handling module 200 may include an exchanger 213 configured to transfer heat and moisture from the treated air flow. The exchanger 213 may be constructed from any number of suitable materials to facilitate various air treatment and conditioning purposes, including, but not limited to, plastic plates, metal plates, enthalpy ceramic porous plates, cellulose plates, and various combinations thereof. The exchanger 213 may be housed within an exchanger housing 211. The air handling module 200 may also include an integrated electrical cabinet. For example, in some embodiments, the air handling module 200 may include a controller 250 configured to be easily attached and detached to the housing 211, electrical disconnect 252, and actuator 232. An electrical access panel 259 may cover the electrical cabinet and may be disconnected from the air handling module 200 to provide access to the electrical cabinet via a latch 256 and disconnect handle 254.

2, air handling module 200 may further include one or more exchanger dividers 240. Exchanger dividers 240 may be configured to direct air flow into and out of exchanger 213. Exchanger dividers 240 may facilitate various air flow configurations and may be interchangeable with air handling module 200 depending on the application. In some embodiments, for example, exchanger dividers 240 may facilitate cross air flow with respect to air handling module 200. In other embodiments, for example, exchanger dividers 240 may facilitate parallel air flow.

As described in more detail below, each manifold 220 beside exchanger partition 240 may include an internal air channel track and air directing device 222 to further facilitate modularization of air handling functions. Air handling module 200 may also include a heat exchanger 292 and a filter 291 housed within manifold 220. In some embodiments, heat exchanger 292 may be a suitable coil heat exchanger, such as, for example, a condenser coil, an evaporator coil, a cold water coil, a hot water coil, and a steam coil. Filter 291 may be any suitable particulate filter. It should be understood that in other embodiments, filter 291 may further include or be substituted with various other components, such as, for example, a UV light, an anti-drip filter, a droplet separator, and a gas absorption filter. As described above, the air handling modules of the present disclosure may facilitate interchangeable connection of various structures, such as, for example, metal ducts, rain screens, roof curbs, and/or other fluidly connected components of an HVAC system.

As shown in FIG. 2, the manifold 220 includes multiple ports that serve as interchangeable attachment points for multiple structures, including, for example, a fan box 280 attached via one or more latches 282, a rain suction screen 260, a metal duct 262, and an access panel 270 attached via one or more latches 272. The manifold 220 may further include an open port that receives a rotary damper 230. The rotary damper 230 may be controlled by an actuator 232.

3a-3d illustrate perspective views of a manifold 300 of an air handling module according to the present disclosure. As described above, the manifold 300 may include multiple interchangeable attachment points for fluidly connecting various components of an HVAC system, including, for example, a fan box, metal ducting, a suction screen, a roof curb, an access panel, and/or others. The manifold 300 may include a top channel track 320 and a bottom channel track 322. The channel track 320 and the bottom channel track 322 may be separated by a manifold divider 324 positioned between the air directing device 310 and the tracks 320, 322. The manifold 300 may further include a top slide channel 350, a bottom slide channel 352, and an economizer track 360. In one embodiment, the economizer track 360 may be a bearing track for a rotary damper.

The top slide channel 350 may receive an exchanger 390. The exchanger 390 may slide in and out of the top slide channel 350 as indicated by arrow 390a. The exchanger 390 may be comprised of any suitable heat transfer device, such as, for example, a condenser, an evaporator, a fluid heat exchanger, and a steam humidifier. In one embodiment, the exchanger 390 may be a suitable coil heat exchanger, such as, for example, a condenser coil, an evaporator coil, a cold water coil, a hot water coil, and a steam coil. The manifold 300 includes an inlet 392 and an outlet 394 to facilitate the flow of a heat transfer medium to and from the exchanger 390.

A heat transfer medium, including, for example, liquid refrigerant, steam, cold water, or hot water, may enter the exchanger 390 through an inlet 392 and exit the exchanger through an outlet 394. The bottom slide channel 350 may receive a filter 391. The filter 391 may slide in and out of the bottom slide channel 352 as indicated by arrow 391a. The filter 391 may be any suitable particulate filter. It should be understood that in other embodiments, the filter 391 may further include or be substituted with various other components, such as, for example, a UV light, an anti-drip filter, a droplet separator, and a gas absorbing filter.

The manifold 300 may also include a top drain port 332, a bottom drain port 342, and a side drain port 312. The top drain port 332 may facilitate access to the top slide channel 350 and provide a modular hydronic collection system for the top slide channel 350. It should be understood that an installer may access the top drain port 332 at the installation site depending on the site requirements. The top drain port 332 may be sealed by an insulating plug 338. The bottom drain port 342 may facilitate access to the bottom slide channel 352 and provide a hydronic collection system for the bottom slide channel 352. The side drain port 312 may provide additional access and hydronic collection points for the top channel track 320 in a direction perpendicular to the top drain port 332. In one embodiment, the top drain port 332 may have a threaded configuration. For example, the top drain port 332 may be threaded with a British Standard Parallel Pipe (BSPP) style with an integrated sealing washer. Those skilled in the art will appreciate that BSPP is compatible with other international standards including NPT, NPTS, and BSPT, allowing for a global distribution model.

The manifold 300 may further include top and bottom anchor ports 336 and 346 configured to provide structural connections to adjacent manifolds or various structural supports. The manifold 300 also includes a number of air ports 303, 304, 305, and 306. As shown in FIG. 3c, in one embodiment, the duct 362 may be connected to the manifold 300 through port 305, and port 306 may be covered by an access panel 376. The access panel 376 may include one or more latches 370 and seals 371 to provide an airtight connection to the port 306.

Ports 303 and 304 may be positioned vertically relative to one another. Similarly, ports 305 and 306 may be positioned vertically relative to one another. Such a configuration may facilitate multi-directional installation of components on manifold 300 and easy access to adjacent ports. Additionally, ports 303, 304, 305, and 306 may provide an easily replaceable and configurable manifold 300 for connecting to various HVAC and air handling components. Manifold 300 may facilitate a number of different field installation configuration options. Those skilled in the art will appreciate that any suitable number of access ports to manifold 300 oriented in any suitable configuration and positioned in any suitable arrangement of manifold 300, including, for example, on the exterior, upper, and lower surfaces, are contemplated in the present disclosure.

In some embodiments, a fan box 380 housing one or more fans 389 may be attached to the manifold 300 via the port 304. The fan box 380 may include one or more latches 382 and seals 381 to provide an airtight connection to the port 304.

As shown in Figures 4a-4h, the air handling module 100 may also include a rotary damper 430. The rotary damper 430 may include a rotatable semi-cylindrical member 471. The rotary damper 430 may be configured to allow air to flow in a direction along the axis of rotation of the semi-cylindrical member 471. The rotary damper 430 may also be configured to allow air to flow in a direction other than along the axis of rotation of the semi-cylindrical member 471. For example, the rotary damper 430 may allow air to flow normal to the axis of rotation of the semi-cylindrical member 471. A single rotary damper 430 may not require a pair of faces and a bypass damper to operate in unison.

The rotary damper 430 may have at least four potential modes within the air handling module 100. The first mode may be to facilitate a full or partial economizer bypass around the exchanger 213 to directly supply outside air (OA) as the supply air (SA), thereby providing free cooling to the building or enclosure. The second mode may be to facilitate a full or partial defrost bypass around the exchanger 213 to prevent icing from cold outside air (e.g., below freezing). The third mode may be to facilitate a full or partial bypass around the exchanger 213 to modulate the sensible to latent heat ratio of the supply air through the wraparound air handling module. The fourth mode may be to facilitate a regenerative cycle within the exchanger 213 to drive off water vapor, carbon dioxide, and/or other VOC contaminants. Other uses and modes of the rotary damper 430 will be apparent to those skilled in the art, and any such functions may be used in the practice of the present disclosure.

The rotary damper 430 may include a semi-cylindrical member 471, a shaft mounting plate 486 (which may be secured by bolts 487), and a shaft 484 with a utility tube 485 disposed therein. The shaft 484 may be directly connected to a rotary damper actuator 432 for continuous clockwise and/or counterclockwise rotation. The semi-cylindrical member 471 may include an end wall 478 with an integrated seal channel 483, an outer surface 476 with an integrated seal channel 482, an inner surface 477, and an end ring 479 with an integrated seal channel 481. In some embodiments, the rotary damper 430 may be made of insulating material and/or may be a hollow structure filled with insulating material such as, for example, urethane foam, metal oxide, or fiberglass, to improve insulation and avoid condensation or icing.

The rotary damper 430 may be structurally positioned between the manifold 400 and the exchanger divider 440. The rotary damper 430 may be fluidly positioned between two air inlets. The first air inlet to the rotary damper 430 is at the exchanger 213 and may be physically located in the bottom channel track 422 of the manifold 400, represented by arrow 466. The second air inlet is located at the exchanger divider 440 and may be attached to the port 401, represented by arrow 467. The rotary damper 430 outlet may be fluidly positioned at and facing the port 404.

For example, the rotary damper 430 may be a rotary air damper configured to selectively control the source of supply air (SA). In some embodiments, the rotary damper 430 may be positioned in the bottom channel track 422 of the manifold 400 as shown in Figures 4a-4h. The rotary damper 430 may be configured to selectively deliver treated air exiting the exchanger 213 as the supply air (SA) or directly deliver outside air (OA) as the supply air (SA). The rotary damper 430 may comprise a manifold section 400 and an exchanger diaphragm section 440 rotatably coupled to the manifold section 400. The exchanger diaphragm section 440 may comprise a semi-cylindrical member 471 having a first opening 473 fluidly connected to the manifold section 400 and a second opening 472 on a side of the semi-cylindrical member 471. In some embodiments, the rotary damper 430 can be disposed within a conventional duct or HVAC system.

The rotary damper 430 may allow air to flow in a direction along the X axis of rotation of the semi-cylindrical member 471. The rotary damper 430 may also allow air to flow in a direction other than along the X axis of rotation of the semi-cylindrical member 471. The side of the semi-cylindrical member 471 opposite the second opening may block air flow.

FIG. 4c is a perspective view of a rotary damper 430 according to the present disclosure. The rotary damper 430 may facilitate a fluid inlet 472 along the X-axis shaft 484 as well as a fluid inlet 473 perpendicular to the X-axis shaft 484. The fluid outlet 474 may pass through an end ring 479 having an end sealing channel 481 integrated therein that houses an end ring seal 490.

Figure 4d is another perspective view of a rotary damper 430 according to the present disclosure. The fluid inlet 472 may pass through an end ring 479 having an end sealing channel 481 integrated therein that houses an end ring seal 490. The rotary damper 430 may facilitate a fluid outlet 475 along the X-axis shaft 484, as well as a fluid outlet 474 perpendicular to the X-axis shaft 484.

4e, the semi-cylindrical member 471 may be rotated about the X-axis shaft 484 to a first position to adjust the direction of fluid flow through the first opening 422 represented by the fluid inlet 473 and the second opening 404 represented by the fluid outlet 468. For example, the semi-cylindrical member 471 may be rotated to a first position where the second fluid outlet 468 faces the outlet port 404 for the supply air (SA) flow. In the first position, the treated air exiting the exchanger 213 may be directed through the manifold 400 and the first opening 422 and then through the second opening 404 of the semi-cylindrical member 471 and then exit the air handling module 100 as supply air (SA). The outside air (OA) entering the air handling module 100 may be blocked by an end wall 478 of the semi-cylindrical member 471 opposite the second opening 404 and facing the direction of the outside air (OA) flow. An end wall seal 489 may prevent or inhibit the fluid flow 473 from leaking through the port opening 401.

4f, the semi-cylindrical member 471 may be rotated about the X-axis shaft 484 to a second position to adjust the direction of fluid flow through the third opening 401 represented by the fluid inlet 473 and the second opening 404 represented by the fluid outlet 468. The semi-cylindrical member 471 may seal the passage 422 and thus block fluid flow through the exchanger 213. The outside air (OA) flow entering the air handling module 100 may enter the semi-cylindrical member 471 and be delivered directly as supply air (SA). The rotation of the semi-cylindrical member 471 may be controlled by any suitable power source, such as, for example, the rotary motor 432. The end wall seal 489 may prevent or inhibit the fluid flow 473 from leaking through the port opening 401.

As shown in FIG. 4g, the semi-cylindrical member 471 may also be rotated about the X-axis shaft 484 to a third position to facilitate installation or removal of the air filter or coil 390. The filter or coil 390 may slide in and out along the bottom slide channel 452 as shown by arrow 391a. In this embodiment, the end wall seal 489 may be positioned parallel to the bottom slide channel 452. The rotary damper actuator 432 may include a manual override so that the semi-cylindrical member 471 may be manually positioned to minimize the risk of injury or damage during operation.

Figure 4h is a side view of a rotary damper 430 according to the present disclosure. The rotary damper 430 may facilitate a fluid inlet 472 along the X-axis shaft 484, and even a fluid inlet 473 in a direction other than along the X-axis shaft 484. The fluid outlet 474 may pass through an end ring 479 having an end sealing channel 481 integrated therein that houses an end ring seal 490.

Existing HVAC or ERV systems may employ multiple air dampers to control the direction of airflow. Each damper may be dedicated to controlling the direction of a single source of airflow. Typically, conventional air dampers have a rectangular or square shaped frame with movable louvers to allow and block airflow. The rotary damper 430 of the present disclosure may be positioned at the intersection of two different airflows and adjust the direction of both airflows by rotating the semi-cylindrical member 471. As a result, the rotary damper 430 of the present disclosure eliminates the need for multiple or separate air dampers. The semi-cylindrical member 471 of the rotary damper 430 may be rotated any desired amount to proportionally control the airflow and/or volume of air passing through the rotary damper 430 and change the mixture ratio.

5a and 5b illustrate perspective views of an access panel 570 according to the present disclosure. As described above, the access panel 570 may be easily attached and detached to the air port of the air handling module 500. The access panel 570 may include one or more latches 572 for engaging and retaining the access panel 570 on an inner surface 577 of the air handling module 500. In one embodiment, the latches 572 may include a screw and thread configuration for engaging and disengaging the latches 572 by tightening or loosening the screws. The access panel 570 may also include a seal 573 disposed on the access panel seal channel. The seal 573 may engage an outer surface 576 of the air handling module 500 to provide an airtight connection between the access panel 570 and the port. In other embodiments, a single twist handle (not shown) may actuate the latches 572 in a straight line or in a semicircle. The access panel 570 can be operated in any orientation to allow full, replaceable access to the internal components of the air handling module.

6a-6h illustrate the modularity of the air handling module of the present disclosure by showing an example configuration of the air handling module. FIG. 6a illustrates a cross-sectional view along the dashed line shown in FIG. 1 of an air handling module 600 in a first configuration according to the present disclosure. The air handling module 600 may include a fan box 686 coupled to the port 606 and a fan box 681 coupled to the port 601. The fan box 686 and the fan box 681 may be configured to draw and extract airflow into the housing 620. The air handling module 600 may include an air-to-air heat exchanger 612 housed within the housing 620. The air handling module 600 may also include a first pair of ports 601-602 fluidly connected to a second pair of ports 603-604. One or both of the second pair of ports 603-604 may receive outside air (OA). Air may flow through the housing 620 and be discharged from the air handling module 600 through one or both of the first pair of ports 601-602 as supply air (SA). The air handling module 600 may further include a third pair of ports 605-606 fluidly connected to a fourth pair of ports 607-608. One or both of the fourth pair of ports 607-608 may receive return air (RA). Exhaust air (EA) may be discharged from the air handling module 600 through one or both of the third pair of ports 605-606.

Outdoor air (OA) enters the housing 620, which may have sides 610, through port 603 and may flow through opening 613, while the paired port 604 may be sealed by an access panel 674. The air directing device 622 and exchanger divider 640 may direct the outdoor air (OA) through the filter 691a, the exchanger 612, and the supply air coil 692a. The exchanger 612 may be any exchanger suitable for facilitating various air treatment and conditioning purposes, including, but not limited to, sensible plate type, enthalpy plate type, wheel type, heat pipe, indirect evaporative type, direct evaporative type, liquid desiccant type, carbon dioxide scrubbing, VOC scrubbing, and various other types of exchangers known to those skilled in the art. One or more fans 689 may be positioned inside the fan box 681 and may draw supply air (SA) from the exchanger 612 through opening 611 and exhaust through port 601, while the paired port 602 may be sealed by an access panel 672. One or more fans 689 may be positioned inside the fan box 686 and may draw exhaust air (EA) from the exchanger 612 and exhaust through port 606, while the paired port 605 may be sealed by an access panel 675. A rotary damper 631 seals the bypass opening 623 and port 609 may be sealed by an access panel 679.

Return air (RA) enters the air handling module 600 through port 608, while the mating port 607 may be sealed by an access panel 677. The air directing device 622 and exchanger divider 640 may direct the return air (RA) through the filter 691b, the exchanger 612, and the exhaust coil 692b. The supply air coil 692a and the exhaust coil 692b may be any heat transfer device suitable for facilitating various air treatment and conditioning purposes, including, but not limited to, a condenser coil, an evaporator coil, a chilled water coil, a hot water coil, a steam coil, a carbon dioxide scrubber, and/or a VOC scrubber.

Figure 6b illustrates a cross-sectional view of the air handling module 600 in a second configuration according to the present disclosure. As shown in Figure 6b, the fan box 686 may be coupled to the port 606 and the fan box 681 may be coupled to the port 601. The fan box 686 and the fan box 681 may be configured to push and pull airflow into and out of the housing 620. One or both of the third pair of ports 605-606 may receive outside air (OA). The air may flow through the housing 620 and be discharged from the air handling module 600 through one or both of the fourth pair of ports 607-608 as supply air (SA). One or both of the first pair of ports 601-602 may receive return air (RA). Exhaust air (EA) may flow through the housing 620 and be discharged from the air handling module 600 through one or more of the second pair of ports 603-604.

One or more fans 689 of the fan box 686 push outside air (OA) through the housing 620 and the exchanger 612 into the port 606, while the paired port 605 may be sealed by the access panel 675. The air directing device 622 and the exchanger divider 640 may direct the outside air (OA) through the filter 691a, the exchanger 612, and the supply air coil 692b. One or more fans 689 of the fan box 681 push return air (RA) through the opening 611, the housing 620, and the exchanger 612 into the port 601, while the paired port 602 may be sealed by the access panel 672. The air directing device 622 and the exchanger divider 640 may direct the return air (RA) through the filter 691b, the exchanger 612, and the exhaust coil 692c. Supply air (SA) may exit through port 608, while the mating port 607 may be sealed by an access panel 677. Exhaust air (EA) may flow through opening 613 and exit through port 603, while the mating port 604 may be sealed by an access panel 674. A rotary damper 631 seals the bypass opening 623, and port 609 may be sealed by an access panel 679.

Figure 6c illustrates a cross-sectional view of the air handling module 600 in a third configuration according to the present disclosure. As shown in Figure 6c, the fan box 688 may be coupled to the port 608 and the fan box 681 may be coupled to the port 601. The fan box 688 and the fan box 681 may be configured to push and pull airflow into the housing 620. One or both of the second pair of ports 603-604 may receive outside air (OA). The air may flow through the housing 620 and be discharged from the air handling module 600 through one or both of the first pair of ports 601-602 as supply air (SA). One or both of the fourth pair of ports 607-608 may receive return air (RA). Exhaust air (EA) may flow through the housing 620 and be discharged from the air handling module 600 through one or more of the third pair of ports 605-606.

Outside air (OA) may enter the housing 620 through port 604 and flow through opening 613, while the paired port 603 may be sealed by an access panel 673. The air director 622 and exchanger divider 640 may direct the outside air (OA) through the filter 691a, the exchanger 612, and the supply air coil 692a. One or more fans 689 in the fan box 681 may draw supply air (SA) from the exchanger 612, through opening 611, and out through port 601, while the paired port 602 may be sealed by an access panel 672. The rotary damper 631 and optional rotary damper 634 may seal the bypass opening 623, and the access panel 679 may seal the port 609. One or more fans 689 may be positioned inside the fan box 688 and push return air (RA) through the housing 620 and exchanger 612 into port 608, while the paired port 607 may be sealed by an access panel 677. The air director 622 and exchanger divider 640 may direct the return air (RA) through the filter 691b, the exchanger 612, and the exhaust coil 692b. Exhaust air (EA) may exit through port 605, while the paired port 606 may be sealed by an access panel 676.

Figure 6d illustrates a cross-sectional view of an air handling module 600 in a fourth configuration according to the present disclosure. The embodiment of Figure 6d presents a configuration of the air handling module 600 where one air stream may bypass the exchanger 612 to facilitate economizer, defrost, and/or carbon dioxide scrubbing regeneration functions. The economizer function may be an energy-efficient means of increasing ventilation due to the lower pressure drop when bypassing the exchanger 612. The economizer function may be run during calm weather to reduce the need for mechanical cooling. Additionally, the economizer function may reduce respiratory issues by providing a higher percentage of outside air.

As shown in FIG. 6d, fan box 688 may be coupled to port 608 and fan box 681 may be coupled to port 601. Fan box 688 and fan box 681 may be configured to push and pull airflow into housing 620. One or both of second port pairs 603-604 may receive outside air (OA). Air may flow through housing 620 and be discharged from air handling module 600 through one or both of first port pairs 601-602 as supply air (SA). One or both of fourth port pairs 607-608 may receive return air (RA). Exhaust air (EA) may flow through housing 620 and be discharged from air handling module 600 through one or more of third port pairs 605-606.

Outside air (OA) may enter the housing 620 through port 604 and flow through opening 613, while the paired port 603 may be sealed by an access panel 673. Rotary damper 631 and optional rotary damper 634 may be actuated to block the air path to the exchanger 612 and redirect the outside air (OA) through bypass opening 623. One or more fans 689 in the fan box 681 may draw supply air (SA) through bypass opening 623 and out port 601, while the paired port 602 may be sealed by an access panel 672. One or more fans 689 in the fan box 686 push return air (RA) through the housing 620 and exchanger 612 into port 608, while the paired port 607 may be sealed by an access panel 677. The air director 622 and exchanger divider 640 may direct the return air (RA) through the filter 691b, the exchanger 612, and the exhaust coil 692b. The exhaust air (EA) may exit through port 605, while the mating port 606 may be sealed by an access panel 676.

One of the main problems that fixed plate air-to-air exchangers have can be frost formation on the inside of the exchanger in cold conditions. Enthalpy exchangers can have a lower frost threshold temperature compared to sensible heat exchangers because they can transfer moisture between two air streams. The rotary damper of the present disclosure can allow air bypass in the air handling module and prevent frost formation in the exchanger. The rotary damper can modulate the amount of outside air volume by reducing or eliminating the cold air flow through the exchanger. As a result, the rotary damper improves the performance of the exchanger and results in a higher temperature of the air supplied into the room or building. In an exemplary embodiment, when the temperature of the exhaust air (EA) falls below an adjustable frost control set point (e.g., 28°F), the rotary damper 631 can be activated to maintain the temperature above the frost control set point. By keeping the exhaust air (EA) above the frost control set point (e.g., 28°F), frost can be prevented from forming in the exchanger 612.

6e illustrates a cross-sectional view of the air handling module 600 in a fifth configuration according to the present disclosure. As shown in FIG. 6e, the fan box 682 may be coupled to the port 602 and the fan box 686 may be coupled to the port 606. The fan box 686 and the fan box 682 may be configured to draw and extract airflow into the housing 620. One or both of the second pair of ports 603-604 may receive outside air (OA). The air director 622 and the exchanger divider 640 may direct the outside air (OA) through the filter 691a, the exchanger 612, and the supply air coil 692a. The air may flow through the housing 620 and be discharged from the air handling module 600 through one or both of the first pair of ports 601-602 as supply air (SA). One or both of the fourth pair of ports 607-608 may receive return air (RA). Exhaust air (EA) may flow through housing 620 and exit air handling module 600 through one or both of third port pairs 605-606.

One or more fans 689 may be positioned inside the fan box 682 and may draw supply air (SA) from the exchanger 612, through the opening 611, and exhaust through port 602, while the paired port 601 may be sealed by an access panel 671. Return air (RA) enters the housing 620 through port 607, while the paired port 608 may be sealed by an access panel 678. The air director 622 and exchanger divider 640 may direct the return air (RA) through the filter 691b, the exchanger 612, and the exhaust coil 692b. One or more fans in the fan box 686 may draw exhaust air (EA) from the exchanger 612 and exhaust through port 606, while the paired port 605 may be sealed by an access panel 675.

FIG. 6f illustrates a cross-sectional view of an air handling module 600 in a sixth configuration according to the present disclosure. The embodiment of FIG. 6f presents a configuration of the air handling module 600 where the replaceable exchanger 612 can facilitate a cross-flow air pattern within the air handling module 600. A fan box 686 can be coupled to the port 606 and can be configured to push and push airflow into the housing 620. A fan box 682 can be coupled to the port 602 and can be configured to pull and pull airflow into the housing 620 in series with the fan box 686. Return air (RA) can enter the housing 620 through one or both of the fourth port pair 607-608, be channeled through the housing 620, and exit as exhaust air (EA) through one or both of the second port pair 603-604. Return air (RA) may be conveyed through and exit the housing 620 as exhaust air (EA) by a remote HVAC system fan or a building pressure differential. One or both of the third pair of ports 605-606 may receive outside air (OA). The air may flow through the housing 620 and be discharged from the air handling module 600 through one or both of the first pair of ports 601-602 as supply air (SA).

Outside air (OA) enters the housing 620 through port 606, while the paired port 605 may be sealed by an access panel 675. The air directing device 622 and the exchanger divider 640 may direct the outside air (OA) through the filter 691a, the exchanger 612, and the supply air coil 692a. One or more fans 689 in the fan box 686 may push the outside air (OA) through the exchanger 612 and out of the port 602 as supply air (SA), while the paired port 601 may be sealed by an access panel 671. One or more fans 689 in the fan box 682 may pull the supply air (SA) out of the port 602 in series with the fan box 686. Return air (RA) enters the housing 620 through port 607, while the paired port 608 may be sealed by an access panel 678. The air director 622 and exchanger divider 640 may direct the return air (RA) through the filter 691b, the exchanger 612, and the exhaust coil 692b. The exhaust air (EA) may exit through port 603, while the mating port 604 may be sealed by an access panel 674.

6g illustrates a cross-sectional view of an air handling module 600 in a seventh configuration according to the present disclosure. As shown in FIG. 6g, replaceable exchanger 612 can facilitate a cross-flow air pattern within air handling module 600. Fan box 681 can be coupled to port 601 and can be configured to draw and extract airflow into housing 620. Fan box 684 can be coupled to port 604 and can be configured to draw and extract airflow into housing 620. One or both of third port pair 605-606 can receive outside air (OA). Air can flow through housing 620 and be expelled from air handling module 600 through one or both of first port pair 601-602 as supply air (SA). Return air (RA) may enter the housing 620 through one or both of the fourth pair of ports 607-608, be conveyed through the housing 620, and exit as exhaust air (EA) through one or both of the second pair of ports 603-604.

Outside air (OA) enters the housing 620 through port 605, while the paired port 606 may be sealed by an access panel 676. The air directing device 622 and the exchanger divider 640 may direct the outside air (OA) through the filter 691a, the exchanger 612, and the supply air coil 692a. One or more fans 689 in the fan box 681 may push the outside air (OA) through the exchanger 612 and out of the port 601 as supply air (SA), while the paired port 602 may be sealed by an access panel 672. Return air (RA) enters the housing 620 through port 608, while the paired port 607 may be sealed by an access panel 677. The air directing device 622 and the exchanger divider 640 may direct the return air (RA) through the filter 691b, the exchanger 612, and the exhaust coil 692b. One or more fans 689 positioned inside the fan box 684 may draw exhaust air (EA) out of the port 604, while the mating port 603 may be sealed by an access panel 673.

Figure 6h illustrates a cross-sectional view of an eighth configuration of air handling module 600 according to the present disclosure. As shown in Figure 6h, replaceable exchanger 612 can facilitate a cross-flow air pattern within air handling module 600. Fan box 681 can be coupled to port 601 and can be configured to draw and pull airflow into housing 620. Fan box 688 can be coupled to port 608 and can be configured to push and push airflow into housing 620. One or both of third port pair 605-606 can receive outside air (OA). Air can flow through housing 620 and be expelled from air handling module 600 through one or both of first port pair 601-602 as supply air (SA). Return air (RA) may enter the housing 620 through one or both of the fourth pair of ports 607-608, be conveyed through the housing 620, and exit as exhaust air (EA) through one or both of the second pair of ports 603-604.

Outside air (OA) enters the housing 620 through port 606, while the paired port 605 may be sealed by an access panel 675. The air directing device 622 and the exchanger divider 640 may direct the outside air (OA) through the filter 691a, the exchanger 612, and the supply air coil 692a. One or more fans 689 in the fan box 681 may draw the outside air (OA) through the exchanger 612 and exhaust it out of the port 601 as supply air (SA), while the paired port 602 may be sealed by an access panel 672. Return air (RA) enters the housing 620 through port 608, while the paired port 607 may be sealed by an access panel 677. The air directing device 622 and the exchanger divider 640 may direct the return air (RA) through the filter 691b, the exchanger 612, and the exhaust coil 692b. One or more fans 689 in the fan box 688 may push return air (RA) into the port 608, while the paired port 607 may be sealed by an access panel 677. The return air (RA) may be pushed by the fan box 688 through the exchanger 612 and exhausted as exhaust air (EA) through port 604, while the paired port 603 may be sealed by an access panel 673.

7a illustrates a perspective view of multiple air handling modules coupled together to form an air handling system according to the present disclosure. As shown in FIG. 7a, the air handling system 700 may include multiple air handling modules 710 stacked together. The air handling modules 710 may operate in parallel with one another to achieve a combined air conditioning effect greater than that of a single air handling unit with a desired level of redundancy. The air handling modules 710 may include a lightweight plastic construction to facilitate hand transportation by one or more installation personnel 799 without the use of cranes and other heavy equipment. The weight of the air handling modules 710 may preferably be less than 100 pounds.

The bottom 740 of the air handling module 710 may be stacked on top of the top 730 of the adjacent air handling module 710. As described above, the ports of the air handling module 710 may serve as interchangeable attachment points for various structures, such as, for example, HVAC system fan boxes, metal ducts, intake rain screens, roof curbs, access panels, and/or other fluidly connected components. Components may be easily attached and detached from the ports to accommodate multiple combinations for customizable air handling module 710 according to site requirements.

One or more ports 706 of the air handling module 710 may serve as interchangeable attachment points for a fan box 786 housing one or more fans 789, and one or more ports 701 of the air handling module 710 may serve as interchangeable attachment points for a fan box 781 housing one or more fans 789. The fan boxes 781 and 786 may direct airflow into and out of the air handling module 710 through the ports 701 and 706 to which they are attached, respectively. The fan boxes 781 and 786 may be easily attached and detached from the ports 701 and 706 using a standard screwdriver or wrench. The fan boxes 781 and 786 may also include integrated power and communication bus wire harnesses that connect to either of the ports to provide a "plug and play" configuration.

Each pair of ports 707-708 may include an access panel 778 that can be easily attached and detached using a standard screwdriver or wrench. This dual nature of the ports facilitates multiple directions of airflow and can be customized in its location. In some embodiments, multiple ports can be aligned to facilitate installation of a single four-sided rectangular duct. As shown in FIG. 7a, the elongated flanges that define the profile of a port (e.g., port 707) may be flush along the top side 730 and bottom side 740.

7b illustrates a perspective view of multiple air handling modules coupled together to form an air handling system according to the present disclosure. As shown in FIG. 7a, the air handling system 700 may include multiple air handling modules 710 positioned vertically and stacked adjacent to each other. The air handling modules 710 may operate in parallel with each other to achieve a combined air conditioning effect greater than that of a single air handling unit with a desired level of redundancy. The air handling modules 710 of the air handling system 700 may be vertically oriented to facilitate fluid flow in evaporative cooling and/or vapor regenerative liquid desiccant air conditioning applications and carbon dioxide scrubbing systems.

The fan 789 in the fan housing 786 may draw in return air (RA) that is circulated for conditioning through a single common duct 757 that is coupled to the port 707 of the air handling module 710. The return air (RA) may pass through an exchanger in the air handling module 710 and exit the air handling module 710 as supply air (SA) through a single common duct 756 that is coupled to the port 706 of the air handling module 710. The fan 789 in the fan housing 781 may draw in outside air (OA) into the air handling module 710 through one or more inlet rain screens 764 that are coupled to the port 704 of the air handling module 710. The outside air (OA) may pass through an exchanger in the air handling module 710 and exit the air handling module 710 as exhaust air (EA) through one or more inlet rain screens 761 that are coupled to the port 701 of the air handling module 710.

Figure 8a illustrates a cross-sectional perspective view as indicated by the dashed lines shown in Figure 7b of an air handling system 800 according to the present disclosure. As shown in Figure 8a, the air handling system 800 may include multiple air handling modules 812a-812c stacked in a vertical configuration. Each of the air handling modules 812a-812c may contain multiple internal and external ports that facilitate a multi-function hydronic distribution and collection system.

The port 839 may be connected to an evaporation water pipe 853 having a sealed thread, and may facilitate the ingress, distribution, and egress of feed water through the plurality of housings 820a-820c via the evaporation water pipe 853. The exchanger 213 may be contained within each housing 820a-820c and may include a plurality of plates arranged in a stacked configuration, a portion of which may have a spaced apart configuration. A first and second series of discrete alternating passages may be defined in the spaced apart portions.

The evaporated water 825 may be delivered to the exchanger 213. The evaporated water 825 may flow by gravity down a first series of discrete alternating passages until it reaches a first drain conduit 832, which may collect the evaporated water 825 flowing from the first series of passages. The first drain conduit 832 may be entirely outside the exchanger 213 and adjacent the first and second ends of the plurality of plates. The first drain conduit port 832 may be connected to an evaporated water drain pipe 859 having a sealed thread, which may facilitate the ingress, distribution, and egress of water through the plurality of housings 820a-820c.

The port 837 may be connected to a liquid desiccant tube 851 having a sealed thread, and may facilitate the ingress, distribution, and discharge of the liquid desiccant 826 through the plurality of housings 820a-820c via the liquid desiccant tube 851. The liquid desiccant 826 may be delivered to the exchanger 213. The liquid desiccant 826 may flow by gravity down a second series of discrete alternating passages until it reaches a second drain conduit 838, which may collect the liquid desiccant 826 flowing from the second series of passages. The second drain conduit 838 may be entirely outside the exchanger 213 and adjacent the first and second ends of the plurality of plates. The second drain conduit 838 may be connected to a liquid desiccant drain pipe 855 having a sealed thread, and may facilitate the ingress, distribution, and discharge of the liquid desiccant through the plurality of housings 820a-820c.

In some embodiments, the side liquid desiccant drain ports 818a-818c and 819a-819c may be connected to drain tubes 819a-819c having sealed threads, providing additional or alternative outlets for the liquid desiccant through the drain tubes 819a-819c. In some embodiments, an aqueous solution of an alkylamine, other reversibly binding aqueous solution, lithium chloride, or combinations thereof may flow through the exchanger 213.

In some embodiments, the ports of the air handling modules 812a-812c that facilitate a multi-function hydronic distribution and collection system may be threaded. It should be appreciated that these ports may serve as interchangeable attachment points for multiple components, including the HVAC system condensate drain, evaporative water supply, evaporative water drain, liquid desiccant supply, liquid desiccant drain, refrigerant line conduit, cold water conduit, steam line, reversibly coupled aqueous scrubbing line, and/or other fluidly connected hydronic components. These components may be easily attached and detached from the ports, allowing for customized configurations at the installation site. Gasketed seals may be incorporated between the components and the ports. In some embodiments, the ports may be threaded according to National Taper Pipe (NPT), American Standard Straight Pipe for Mechanical Joints (NPSM), American Standard Straight Pipe (NPS), and British Standard Parallel Pipe (BSPP) with integrated sealing washers to ensure international compatibility with British Standard Tapered Pipe (BSTP) standards. In some embodiments, the bottom conduit ports 844a-c may be attached to supply and return coils 858 and 869 to distribute liquid between the multiple housings 820a-c. The supply coil ports 861a-861c and the return coil ports 863a-863c can form access points between the conduit ports 844a-844c.

Figure 8b illustrates a cross-sectional perspective view of the air handling system along dashed line "8B" of Figure 7a. As shown in Figure 8b, the air handling system 800 may include multiple adjacently stacked air handling modules 812a-812c. The air handling modules 812a-812c may house multiple internal and external ports that may facilitate (a) multi-function structural connectivity, (b) "plug and play" power distribution, and (c) "plug and play" communication buses. The air handling system communication buses and power distribution may provide a single point of control connection for synchronous operation of multiple air handling modules.

Air handling modules 812a-812c may be structurally connected via anchor bolts 865 that mate with anchor ports 846. Anchor ports 846 may also provide a multi-function structural connection with the ground or support base 867. In some embodiments, anchor ports 846 that are not utilized may be sealed and secured with insulating threaded plugs 864. In some embodiments, anchor ports 846 may be threaded. Anchor ports 846 may serve as interchangeable attachment points for multiple mounting structures, such as, for example, structural anchor bolts, module interconnect clamps, module seals, and heat sensitive plug seals. These mounting structures may be easily attached and detached from anchor ports 846, allowing for customized configurations at the installation site.

The power wires 827 may be connected to power conduit fittings 833 at threaded ports 834, which may facilitate "plug and play" power distribution. A power harness 843 may transmit power between the top conduit port 834 and the bottom conduit port 844. The electrical and economizer bypass enclosures 857a-857c may house multiple devices and accommodate multiple combinations of module orientations and various numbers according to site requirements.

Electrical enclosure 857a may provide a single point electrical disconnect 852 for air handling system 800. Electrical enclosure 857b may provide a single point power distribution 848 for powering central controller 849. Electrical enclosure 857c may be empty. In some embodiments, the anchor port 844c that may not be utilized in the power distribution may be sealed and secured with an insulated threaded plug 864. The power distribution includes a power conduit, an electrical disconnect handle, a module ground point, and a wire harness connector.

Signal wire 835 may be connected to signal conduit fitting 841 at threaded port 834, which may facilitate a "plug and play" communication bus. Signal harness 831 may transmit signals between top conduit port 834 and bottom conduit port 844. Electrical enclosure 857b may house a central controller 849 to which all other air handling modules 812 of air handling module system 800 may be slaved. In some embodiments, multiple components, including, for example, fan boxes, may be linked to the "plug and play" communication bus and power distribution via AHU power and signal harness 881 and fan power and signal harness 880. Interchangeable attachment points may be interchangeable for multiple components, including, for example, communication bus wire conduits, sensor probes, and communication bus harness connectors.

Gasketed seals may be incorporated between the anchor and threaded ports and their mating components. In some embodiments, the anchor and threaded ports may have threads according to the National Taper Pipe (NPT), American Standard Straight Pipe for Mechanical Joints (NPSM), American Standard Straight Pipe (NPS), and British Standard Parallel Pipe (BSPP) standards with integrated sealing washers to ensure international compatibility with the British Standard Tapered Pipe (BSTP) standards.

9a illustrates a perspective view of an air handling system 900 according to the present disclosure. As shown in FIG. 9a, an energy recovery module 912a may be fluidly serially coupled to a wrap-around dehumidifying module 914a to form a dual plate air handling module 900a. Ports 904a and 905a of the energy recovery module 912a may be coupled to ports 901a and 908a of 904b of the dehumidifying module 914a, respectively. The dual plate air handling module 900b may include an energy recovery module 912b fluidly serially coupled to a wrap-around dehumidifying module 914b, and the dual plate air handling module 900c may include an energy recovery module 912c fluidly serially coupled to a wrap-around dehumidifying module 914c. A plurality of dual plate air handling modules 900a-900c may be stacked in a vertical configuration to form the dual plate air handling system 900. Air handling modules 900a-900c can be configured to operate in parallel with one another to achieve a combined air conditioning effect greater than or equal to that of a single air handling unit with a desired level of redundancy.

A fan 989 in the fan housing 986 may draw in outside air (OA) through the inlet rain screen 964, and the outside air (OA) may enter the energy recovery module 912a at port 904a. The outside air (OA) may be exhausted as supply air (SA) through port 906. A single common supply air (SA) duct 956 may be connected to multiple ports 906. A single common rectangular return duct 957 may be connected to multiple ports 907, and a fan 989 in the fan housing 985 may draw in return air (RA) through the single common return duct 957. The return air (RA) may exit as exhaust air (EA) through the inlet rain screen at port 905.

The air handling module 914 may have a lightweight plastic construction to facilitate hand transportation by one or more installation personnel 999 without the use of cranes and other heavy equipment. The weight of the air handling module 914 may preferably be 100 pounds or less.

9b-6g illustrate the modularity of the air handling system of the present disclosure by showing example configurations of the air handling system. FIG. 9b illustrates a cross-sectional view of a dual plate air handling system 900 according to the present disclosure. As shown in FIG. 9b, the air handling system 900 may include a sensible heat exchanger 916 in series with an enthalpy exchanger 915 to facilitate frost-free operation of the air handling module 900 at low temperatures. The air handling module 900 may include a fan box 981 coupled to the port 901 and a fan box 988 coupled to the port 908. The fan box 981 and the fan box 988 may be configured to draw and push airflow into and out of the housing 920 of the air handling system 900.

The air handling system 900 may include a series of air-to-air heat exchangers 916 and 915 housed within a housing 920. The air handling system 900 may also include a first pair of ports 901-902 fluidly connected to a second pair of ports 903-904. One or both of the second pair of ports 903-904 may receive outside air (OA). Air may flow through the housing 920 and be discharged from the air handling system 900 through one or both of the first pair of ports 901-902 as supply air (SA). The air handling system 900 may further include a third pair of ports 905-906 fluidly connected to a fourth pair of ports 907-908. One or both of the fourth pair of ports 907-908 may receive return air (RA). Exhaust air (EA) may be discharged from the air handling system 900 through one or both of the third pair of ports 905-906.

Outside air (OA) enters the housing 920, which may have sides 910, through port 904, while the paired port 903 may be sealed by an access panel 973. The air director 922 and exchanger divider 940 may direct the outside air (OA) through the filter 991a, the heat exchanger 916, the enthalpy exchanger 915, and the supply air coil 992a. One or more fans 989 may be positioned inside the fan box 981 and may draw supply air (SA) through the exchangers 916, 915, and exhaust through the port 901, while the paired port 902 may be sealed by an access panel 972. A rotary damper 941 may seal the bypass opening 923a, and an access panel 979 may seal the port 909. One or more fans 989 may be positioned inside the fan box 988 and push return air (RA) through exchangers 916, 915 into port 908 and out port 906, while the paired port 907 may be sealed by an access panel 977. The air director 922 and exchanger divider 940 may direct the return air (RA) through filter 991b, enthalpy exchanger 915, heat exchanger 916, and exhaust coil 992b. The supply air coil 992a and exhaust coil 992b may be any heat transfer device suitable for facilitating various air handling and air conditioning purposes, including, but not limited to, condenser coils, evaporator coils, chilled water coils, hot water coils, and/or steam coils. Exhaust air (EA) may exit port 905, while the paired port 906 may be sealed by an access panel 976.

9c illustrates a cross-sectional view of another dual plate air handling system 900 according to the present disclosure. As shown in FIG. 9c, the air handling system 900 may consist of an energy recovery module 912a serially coupled to a wrap-around dehumidification module 914b. Ports 901a and 908a of the energy recovery module 912a may be fluidly connected to ports 904b and 905b, respectively, of the dehumidification module 914b. The dual plate air handling system of FIG. 9c may provide energy savings and load reduction of outdoor air-only enthalpy recovery. Additionally, the sensible/latent heat ratio control of the wrap-around dehumidification may provide lower dew points in applications with neutral temperatures, which may eliminate the need for space reheat.

The dual plate air handling system of FIG. 9c may include an exchanger 915 housed in a housing 920a of an energy recovery module 912a fluidly connected in series with an exchanger 916 housed in a housing 920b of a dehumidification module 914b. Paired ports 903a-904a of the energy recovery module 912a may be fluidly connected to paired ports 905b-906b of the dehumidification module 914b. One or both of the paired ports 903a-904a may receive outside air (OA). Air may flow through the energy recovery module 912a and the dehumidification module 914b (and exchangers 915, 916) and be discharged as supply air (SA) from one or both of the paired ports 905b-906b. The paired ports 907a-908a of the energy recovery module 912a may be fluidly connected to the paired ports 905a-906a of the energy recovery module 912a. One or both of the paired ports 907a-908a may receive return air (OA). Exhaust air (EA) may be discharged from one or both of the paired ports 905a-906a.

Outdoor air (OA) enters the housing 920a of the energy recovery module 912a, which may have a side 910a, through port 904a, while the paired port 903a may be sealed by an access panel 973. The air directing device 922a and the exchanger divider 940a may direct the outdoor air (OA) through the energy recovery exchanger 915. The outdoor air (OA) may exit the housing 920a through port 901a and enter the housing 920b of the dehumidification module 914b, which may have a side 910b, through port 904b. The air directing device 922b, the exchanger divider 940b, and the sealed ports 908b, 901b may direct a first pass of the outdoor air (OA) through the sensible heat exchanger 916 and the coil 922a. One or more fans 989 in the fan box 986 may draw in outside air (OA) through coils 922b, which may be arranged in series with coils 922a, and back through the sensible heat exchanger 916 for a second pass. The air may then be exhausted through port 906b as supply air (SA). The fan box 985 may be fluidly coupled to port 905a. One or more fans 989 positioned inside the fan box 985 may draw in return air (RA) through port 907a, while the mating port 908a may be sealed. The air director 922a and exchanger divider 940a may direct the return air (RA) through the exchanger 915 and exhaust coil 992c.

In some embodiments, exhaust coil 992c may be a condenser-type coil configured to insulate from evaporator coils 992a and 992b. Rotary damper 934a may seal bypass opening 923a, and rotary damper 934b may seal bypass opening 923b. Air drawn in by fan box 985 may be exhausted through port 905a as exhaust air (EA), while mating port 906a may be sealed.

FIG. 9d illustrates a cross-sectional view of another configuration of the dual plate air handling system of FIG. 9c according to the present disclosure. As shown in FIG. 9d, the dual plate air handling module 900 may be arranged to provide energy savings and load reduction through the enthalpy exchanger 915. It may also provide a bypass 923b around the wrap-around heat exchanger 916 to vary the sensible/latent heat ratio according to changing site requirements. The rotary damper 934b may be opened to allow air flow through the bypass opening 923b while blocking air flow through a path directed by the air directing device 922b and the exchanger divider 940b for the first pass of the OA through the exchanger 916 as shown in FIG. 9c. As such, the rotary damper 934b may facilitate the OA bypassing the sensible heat exchanger 916. Sealed ports 908b-901b may direct outside air (OA) through coil 992b and then through sensible heat exchanger 916. One or more fans 989 in fan box 986 may draw this outside air (OA) through sensible heat exchanger 916 in a single pass. The air may then be exhausted through port 906b as supply air (SA). In some embodiments, coil 992a may be closed or turned off to prevent freezing due to lack of airflow.

9e illustrates a cross-sectional view of another dual plate air handling system according to the present disclosure. As shown in FIG. 9e, the dual plate air handling system 900 may include an energy recovery module 912a coupled in series with a wrap-around dehumidifier module 914b and optionally configured to facilitate circulating return air (RA) entering through port 938. This arrangement may result in enthalpy recovery, sensible/latent heat ratio control, low dew point air delivered at room neutral temperature, and energy savings and reduced load on circulating air conditioning during non-occupied periods. The dual plate air handling system of FIG. 9e may include a port 938 and a return air (RA) port rotary damper 936. The rotary damper 936 may be actuated to open and seal the port 938. When the rotary damper 936 is opened, the port 938 may be fluidly connected to the mating ports 905b-906b of the dehumidifier module 914b.

FIG. 9f illustrates a cross-sectional view of another configuration of the dual plate air handling system of FIG. 9e according to the present disclosure. As shown in FIG. 9f, the rotary damper 936 can be operated to facilitate a variable percentage of the recirculated return air (RA) to mix with the outside air (OA) through the port 938. This arrangement can result in energy savings and load reduction of the enthalpy recovery dedicated to the outside air. Additionally, the sensible/latent heat ratio control of the wraparound dehumidification can lower the dew point in applications with neutral temperatures, which can eliminate the need for space reheat. A variable percentage of recirculated air conditioning can be incorporated to reduce energy during non-occupied periods and/or increase space comfort levels. The rotary damper 936 can be at least partially opened to allow the return air (RA) to enter through the port 938. When the rotary damper 936 is at least partially open, the port 938 may be fluidly connected to the ports 901a and 904b, and the return air (RA) entering through the port 938 may mix with the outside air (OA). The mixture of the outside air (OA) and the return air (RA) may then be provided to the dehumidification arrangement 914b through the port 904b. The amount of the return air (RA) mixed with the outside air (OA) may be modulated by the rotary damper 936.

Air directing device 922b, exchanger divider 940b, and sealed ports 908b-901b may direct a mixture of outside air (OA) and return air (RA) through sensible heat exchanger 916 and coils 992a in a first pass. One or more fans 989 in fan box 986 may draw this mixture through coils 922b and back through sensible heat exchanger 916 in a second pass. The air may then be exhausted through port 906b as supply air (SA). Rotary dampers 934a and 931a may seal bypass opening 923a, and rotary dampers 934b and 931b may seal bypass opening 923b.

FIG. 9g illustrates a cross-sectional view of another configuration of the dual plate air handling system of FIG. 9e according to the present disclosure. As shown in FIG. 9e, the rotary damper 936 can be operated to facilitate the entry of recirculated return air (RA) through port 938. This arrangement can provide sensible/latent heat ratio control of wraparound dehumidification, lowering the dew point in temperature-neutral applications, which can eliminate the need for space reheat. Variable percentage recirculation air conditioning can be incorporated to reduce energy during unoccupied periods and/or increase space comfort levels. For example, many winter homes are vacant during the humid summer months, so controlling the dew point can be more important than controlling the temperature in reducing mold and eliminating odors. As shown in FIG. 9g, the rotary damper 936 can be opened to allow the entry of return air (RA) through port 938 into the housing 920b. Rotary damper 934b may be opened to allow airflow through bypass opening 923b to facilitate return air (RA) bypassing sensible heat exchanger 916. Air director 922b, heat exchanger divider 940b, and sealed ports 908b-901b may direct the return air (RA) through coil 992b and sensible heat exchanger 916. One or more fans 989 in fan box 986 may draw this return air (RA) through sensible heat exchanger 916. The air may then be exhausted through port 906b as supply air (SA). One or more fans 989 in fan box 985 may draw outside air (ORA) through port 907, through exchanger 915, and through exhaust coil 992b. The air director 922a and the exchanger divider 940a may direct the outside air (OA) through the exchanger 915 and the exhaust coil 992b. The air drawn in by the fan box 985 may then be exhausted as exhaust air (EA) through the port 905a, while the mating port 906a may be sealed. The rotary damper 934a may be closed to seal the bypass opening 923a.

Figure 10a illustrates a psychrometric chart corresponding to the operation of the air handling system of Figure 9b according to the present disclosure. Figures 9b and 10a show a first air flow from outside air (OA) to supply air (SA) and a second air flow from return air (RA) to exhaust air (EA). As shown in Figure 10a, the first air flow may traverse points A, B, C, and D, and the second air flow may traverse points E, F, and G. Figure 10a is a chart showing estimated temperature and humidity levels for the first and second air flows as they traverse these points.

The first and second air flows may pass through the heat exchanger 916 and the enthalpy exchanger 915 in a countercurrent orientation. Point E may represent typical winter return air conditions from the conditioned space. The second air flow may enter the inlet port of the enthalpy exchanger 915 at point E in FIG. 10a and flow through the enthalpy exchanger 915 to point F. The first air flow may simultaneously flow from point B to point C through the enthalpy exchanger 915 in a countercurrent orientation with respect to the second air flow flowing through the enthalpy exchanger 915 from point E to point F. Moisture and heat capacity may be transferred from the second air flow to the first air flow as the second air flow flows through the enthalpy exchanger 915 from point E to point F and the first air flow flows through the enthalpy exchanger 915 from point B to point C.

The second air flow may also enter the inlet port of the heat exchanger 916 at point F in FIG. 10a and flow through the heat exchanger 916 to point G. The first air flow may flow through the heat exchanger 916 from point A to point B simultaneously in a countercurrent orientation with respect to the second air flow. Heat capacity may be transferred from the second air flow to the first air flow as the second air flow flows through the heat exchanger 916 from point F to point G and the first air flow flows through the heat exchanger 916 from point A to point B. The first air flow may exit the enthalpy exchanger 915 at point C and enter the exhaust coil 922a. The first air flow may receive heat from the exhaust coil 992c and be heated to point D.

Figure 10b illustrates a psychrometric chart corresponding to the operation of the air handling system of Figure 9c according to the present disclosure. Figures 9c and 10b show a first air flow from outside air (OA) to supply air (SA) and a second air flow from return air (RA) to exhaust air (EA). As shown in Figure 10b, the first air flow may traverse points A, B, C, D, E, and F, and the second air flow may traverse points G, H, and I. Figure 10b is a chart showing estimated temperature and humidity levels for the first and second air flows as they traverse these points.

The first and second air flows may pass through the enthalpy exchanger 915 in a countercurrent orientation. Point G may represent typical summer return air conditions from the conditioned space. The second air flow may enter the inlet port of the enthalpy exchanger 915 at point G in FIG. 10b and flow through the enthalpy exchanger 915 to point H. The first air flow may simultaneously flow from point A to point B through the enthalpy exchanger 915 in a countercurrent orientation with respect to the second air flow flowing through the enthalpy exchanger 915 from point G to point H. Moisture and heat capacity may be transferred from the first air flow to the second air flow as the second air flow flows through the enthalpy exchanger 915 from point G to point H and the first air flow flows through the enthalpy exchanger 915 from point A to point B. The second air stream may exit the enthalpy exchanger 915 at point H and flow through the exhaust coil 992c. The second air stream may receive heat from the exhaust coil 992c and be heated to point I.

The first airflow may also enter the inlet port of the heat exchanger 916 and flow through the heat exchanger 916 where it is sensibly cooled to point C. The first airflow may exit the enthalpy exchanger 915 at point C and flow through the evaporator coil 992a. The first airflow may be cooled and dehumidified by the evaporator coil 992 to point D. The first airflow may then be directed through another evaporator coil 992b. The first airflow may be cooled and dehumidified by the evaporator coil 992b to point E. The first airflow may again be directed through the heat exchanger 916 and sensibly heated to point F.

Figure 10c illustrates a psychrometric chart corresponding to the operation of the air handling system of Figure 9d according to the present disclosure. Figures 9d and 10c show a first air flow from outside air (OA) to supply air (SA) and a second air flow from return air (RA) to exhaust air (EA). As shown in Figure 10c, the first air flow may traverse points A, B, and E, and the second air flow may traverse points G, H, and I. Figure 10c is a chart showing estimated temperature and humidity levels for the first and second air flows as they traverse these points.

The first and second air flows may pass through the enthalpy exchanger 915 in a countercurrent orientation. Point A may represent typical summer outdoor conditions. The first air flow may enter the inlet port of the enthalpy exchanger 915 at point A in FIG. 10c and flow through the enthalpy exchanger 915 to point B. The second air flow may enter the inlet port of the enthalpy exchanger 915 at point G in FIG. 10c and flow simultaneously from point G to point H in a countercurrent orientation with respect to the first air flow. Moisture and heat capacity may be transferred from the first air flow to the second air flow as the first air flow flows through the enthalpy exchanger 915 from point A to point B and the second air flow flows through the enthalpy exchanger 915 from point G to point H. The first air flow may then flow through the evaporator coil 992b and be cooled and dehumidified to point E. The second air stream may exit the enthalpy exchanger 915 at point H and flow through the exhaust coil 992c. The second air stream may receive heat from the exhaust coil 992c and be heated to point I.

Figure 10d illustrates a psychrometric chart corresponding to the operation of the air handling system of Figure 9f according to the present disclosure. Figures 9f and 10d show a first airflow from outside air (OA) to supply air (SA), a second airflow from return air (RA) to exhaust air (EA), and a third airflow of the supply air (SA). As shown in Figure 10d, the first airflow may cross points A and B, the second airflow may cross points H, I, and J, and the third airflow may cross points C, D, E, F, and G. Figure 10d is a chart showing estimated temperature and humidity levels for the first, second, and third airflows as they cross these points.

The first and second air flows may pass through the enthalpy exchanger 915 in a countercurrent orientation. Point A may represent typical summer outdoor conditions. The first air flow may enter the inlet port of the enthalpy exchanger 915 at point A in FIG. 10d and flow through the enthalpy exchanger 915 to point B. The second air flow may enter the inlet port of the enthalpy exchanger 915 at point H in FIG. 10d and flow simultaneously from point H to point I in a countercurrent orientation with respect to the first air flow. Moisture and heat capacity may be transferred from the first air flow to the second air flow as the first air flow flows through the enthalpy exchanger 915 from point A to point B and the second air flow flows through the enthalpy exchanger 915 from point H to point I. The second air stream may exit the enthalpy exchanger 915 at point I and flow through the exhaust coil 992c. The second air stream may receive heat from the exhaust coil 992c and be heated to point J.

The partial volume flows of the outside air (OA) of the first air stream and the return air (RA) of the second air stream may mix to form a third air stream in the form of supply air (SA) at point C. The third air stream may enter the inlet port of the heat exchanger 916 at point C in FIG. 10d, flow through the heat exchanger 916, and be sensibly cooled to point D. The third air stream may then flow through an evaporator coil 992a and be cooled and dehumidified to point E. The third air stream may then flow through another evaporator coil 992b and be cooled and dehumidified to point F. The third air stream may then re-enter the heat exchanger 916 at point F, flow through the heat exchanger 916, and be sensibly heated to point G.

Figure 10e illustrates a psychrometric chart corresponding to operation of the air handling system of Figure 9g according to the present disclosure. Figures 9g and 10e show a first airflow from outside air (OA) to exhaust air (RA) and a second airflow from return air (RA) to supply air (SA). As shown in Figure 10e, the first airflow may traverse from point H to J and the second airflow may traverse from point A to D. Figure 10e is a chart showing estimated temperature and humidity levels for the first and second airflows as they traverse these points.

The first and second air flows may flow through the enthalpy exchanger 915 and the heat exchanger 916, respectively, but may not undergo a change of state since the opposing air flows may not flow in a countercurrent orientation. Point A may represent a typical summer return air condition. The second air flow may flow through the evaporator coil 992b, the heat exchanger 916, and the evaporator coil 992c, and may be cooled and dehumidified to point D. The first air flow may enter the enthalpy exchanger 915 at point H, flow through the enthalpy exchanger 915, flow through the exhaust coil 992c, receive heat from the exhaust coil 992c, and be heated to point J.

Those skilled in the art will appreciate that the air handling system of the present disclosure may be modular with respect to the power and speed of the airflow delivered and supplied by the system. For example, as shown in Figures 7a-7b, multiple air handling modules may be stacked (horizontally or vertically) to increase the power, speed, and capacity of the airflow associated with the system. The power, speed, and noise of the airflow may be moderated by adjusting the fan speed of the fan box. In some embodiments, the air handling system may be coupled to an existing HVAC unit. One or more air handling modules may be coupled to an HVAC unit to increase the capacity of the HVAC unit. In one such embodiment, the air handling system may operate as a pre-treatment stage to remove heat and moisture from the air supplied to the HVAC unit.

Exchanger Membranes and Related Manufacturing Methods The enthalpy exchangers of the present disclosure may embody a variety of configurations depending on the desired application, among other factors. For example, the enthalpy exchanger may be a planar plate type heat and moisture exchanger. The enthalpy exchanger may consist of membrane plates, each made from a planar water-permeable membrane. The membrane plates may be stacked and sealed and may be configured to accommodate airflow in a counter-flow configuration between alternating plate pairs. This may facilitate the transfer of heat and water vapor through the membrane while preventing the airflows from mixing or otherwise contacting each other. In other embodiments, the enthalpy exchanger may include membrane plates arranged and configured to accommodate airflow in a cross-flow configuration between alternating plate pairs.

In some embodiments, the membrane may allow heat, but not moisture, to be transferred across the material from one air stream to the other. In addition to or instead of membrane plates, the membrane of an enthalpy exchanger may comprise a single membrane core made by folding a continuous strip of membrane in a concertina, zigzag, or bellows fashion with a series of parallel alternating folds.

The present disclosure also contemplates an enthalpy exchanger that may be in a rotating wheel configuration. The enthalpy exchanger may include a membrane constructed with a large number of parallel pores or openings, such as a honeycomb structure, through which air passes. The enthalpy exchanger may be formed by wrapping or stacking the membrane into a wheel shape with an air passageway parallel to the axis of the wheel.

The membranes or transfer media of the present disclosure may be used to form heat and moisture transfer bodies, such as enthalpy exchangers, and may include a substrate having microporous particles embedded therein. The substrate may include fibrous materials, including, for example, natural cellulose fibers, as well as synthetic thermoplastic fibers, such as polyvinyl alcohol polymer fibers, bicomponent fibers, and microfibers. The substrate may include any type of fibrous material capable of retaining a substantial amount of liquid and microporous particles. The substrate may be formed by conventional papermaking processes that make sorbent or desiccant paper having a sorbent or desiccant therein. In some embodiments, additives, such as reinforcing fibers, may be added to the substrate.

Examples of fibrous materials suitable for use as substrates may include wood pulp, cellulose fibers, synthetic thermoplastic organic fibers, and mixtures thereof. Inorganic fibers such as glass or metal fibers and rock wool may also be used in conjunction with the fibrous structure organic fibers. Substrates also include synthetic organic thermoplastic fibers, which may include polymeric fibers such as polyethylene, polypropylene, polystyrene, polyvinyl chloride, polyester, rayon (cellulose acetate), acrylic, copolymers of acrylonitrile monomers, halogenated monomers, styrene copolymers, and mixtures of such polymers. Suitable synthetic thermoplastic organic fibers may be in staple form (chopped yarn), fabricated form (finely divided staple form), or extruded/precipitated form. In some embodiments, the substrate may include one or more of softwood fibers such as Rayonier Poroganier, fiberglass, bicomponent fibers such as T-201 bicomponent fibers, acrylic fibers such as Vonnel microfibers, and PVA fibers such as Kuralon.

The microporous particles may be embedded within a substrate and may include any material capable of efficiently retaining liquid through capillary action, surface tension, or other mechanisms. The microporous particles may be activated for adsorption by removing water from a hydrated precursor. The microporous material may be capable of efficiently adsorbing/desorbing the moisture in a countercurrent airflow. The microporous material may also be capable of efficiently adsorbing/desorbing the moisture in a crosscurrent airflow.

The substrate in which the microporous particles are embedded may have liquid sorption capabilities for liquids such as, for example, lithium chloride, water, lithium bromide, triethylene glycol, calcium chloride, potassium formate, zinc carbon, zinc chloride, alkali, nickel oxyhydroxide, lithium copper oxide, lithium iron disulfide, lithium manganese dioxide, lithium chromium oxide, lithium silicone, mercury oxide, zinc air, silver oxide, magnesium, NiCd, lead acid, NiMH, NiZn, AgZn, LiFePO4, lithium ions, and mixtures thereof. In some embodiments, the liquid may be lithium chloride, with the amount of lithium chloride in solution being 8.3% wt. or less.

The microporous particles may include activated alumina, silica gel, molecular sieves, porous titania, or zeolites, activated carbon, and the like, as well as mixtures of these compounds. In some embodiments, the microporous particles may include transition aluminas such as gamma alumina, which are advantageous in terms of their inert properties, low cost, and high commercial availability. One example of a commercially available gamma alumina is VGL15, produced by U.O.P. Corporation.

An exemplary system and process for producing a substrate for use as a membrane or transfer medium according to the present disclosure will be described with reference to FIGS. 11a and 11b. As shown in FIGS. 11a and 11b, a roll of substrate 1201 may be continuously fed into a coating chamber 1200. As substrate 1201 is fed through coating chamber 1200, substrate 1201 may be embedded with microporous particles and exit coating chamber 1200 as membrane or transfer medium 1206. Film 1206 may be continuously collected and rolled into a roll of membrane 1260.

The substrate 1201 may be a thermoplastic sheet formed from thermoplastic fibers, such as polypropylene. In some embodiments, additives, such as reinforcing fibers, may be added to the thermoplastic sheet. Alternatively, the substrate 1201 may include paper formed from natural fibers, such as wood pulp or cellulose.

The microporous particles embedded within the substrate 1201 may include a transition alumina, such as gamma alumina. In some embodiments, the membrane 1206 may comprise a thermoplastic sheet including gamma alumina, and in other embodiments, the membrane 1206 may comprise a paper including gamma alumina. In this disclosure, the membrane 1206 may be fabricated by coating any suitable substrate with or embedding any suitable microporous particles, as described above.

The coating chamber 1200 may include a housing 1210 that encloses a first calendar roller 1212 and a second calendar roller 1214. A first coating apparatus 1216 may be positioned near the first calendar roller 1212, and a second coating apparatus 1218 may be positioned near the second calendar roller 1214. Each of the first coating apparatus 1216 and the second coating apparatus 1218 may be configured to spray microporous particles in powder form (e.g., gamma alumina) onto the respective calendar rollers 1212, 1214. The first coating apparatus 1216 and the second coating apparatus 1218 may be connected to a source 1220 of powdered microporous particles via a suitable supply line 1222. The powdered microporous particles are delivered from a source 1220 through a supply line 1222 and can be sprayed from the first coating device 1216 and the second coating device 1218 by any suitable means, including, for example, compressed air.

The first and second coaters 1216, 1218 may impart a positive charge onto the microporous particles 1222 as the microporous particles 1222 are sprayed from the first and second coaters 1216, 1218 onto the first and second calendar rollers 1212, 1214. Each of the first and second calendar rollers 1212, 1214 may be electrically grounded. As such, the powdered microporous particles may be electrostatically coated onto the first and second calendar rollers 1212, 1214.

Those skilled in the art will appreciate that the first coating device 1216 and the second coating device 1218 can be configured to control the rate at which the charged microporous particles are sprayed and to control the charge rate of the powdered microporous particles as they exit the devices 1216, 1218. The first coating device 1216 and the second coating device 1218 can comprise any device suitable for use in electrostatic coating. For example, in some embodiments, the first coating device 1216 and the second coating device 1218 can include a powder coating spray gun. A high degree of uniformity can be achieved because a monolayer of the microporous particles 1222 can adhere to the rollers 1212, 1214. This uniformity can be achieved because the high potential between the microporous particles 1222 and the rollers 1212, 1214 can exponentially decrease after the first monolayer is deposited. The electrically charged cloud of sprayed microporous particles 1222 may form a nearly complete coverage of these monolayer microporous particles 1222 on the top roller 1212 and the bottom roller 1214. In some embodiments, the loading of microporous particles 1222 on the thermoplastic substrate sheet 1201 may be as high as 90% by weight. It should be understood that in other embodiments, the loading of microporous particles 1222 on the substrate 1201 may be 50% to 90% by weight, and in some embodiments, the loading of microporous particles 1222 on the substrate 1201 may be 50% to 60% by weight.

Each of the first and second calendar rollers 1212 and 1214 may be configured to embed the powdered microporous particles into the substrate 1201. The substrate 1201 may be fed between the rollers 1212 and 1414, and the rollers 1212 and 1414 may rotate in a direction toward the feed direction of the substrate 1226. The rollers 1212, 1214 may include a hard anti-stick material and may be configured to be heated to a suitable temperature. In some embodiments, the rollers 1212, 1214 may be formed from hardened steel. One skilled in the art will appreciate that the rollers 1212, 1214 may be diamond coated. As the rollers 1212, 1214 rotate, they may press against the top and bottom surfaces of the substrate 1230, embedding the powdered microporous particles from the rollers 1212, 1214 into the surface of the substrate 1201.

The heat and pressure between the rollers 1230 may transfer the powdered microporous particles from the rollers 1212, 1214 onto the substrate 1201 by impregnating the substrate 1201 with the microporous particles. In some embodiments, the rollers 1212, 1214 may be heated to a temperature at or near the melting point of the thermoplastic fibers forming the thermoplastic substrate, embedding the thermoplastic fibers in the microporous particles and improving the bonding and concentration of the microporous particles on the substrate. For example, when coating a polypropylene substrate with microporous particles, the rollers 1212, 1214 may be heated to a temperature up to but not exceeding the melting point of polypropylene (160° C.). Line speeds of over 10 meters per minute may be achieved. In some embodiments, the water pressure at the nip for an 8-inch wide film may be between 2,000 psi and 5,000 psi, preferably 4,000 psi. A metered calendar may be advantageous in controlling the thickness of the film.

The rollers 1212, 1214 may be straight rollers. One skilled in the art will appreciate that in other embodiments, the rollers 1212, 1214 may have an arched configuration that can accommodate bending of the rollers under pressure, for example, especially when impregnating a wide substrate. The rollers 1212, 1214 may be arched in shape to accommodate pressure while maintaining a linear contact surface. The rollers 1212, 1214 may be metering rollers configured to meter the amount of powdered microporous particles transferred onto the sheeting structure 1201. The rollers 1212, 1214 may include wells or cups etched on the coating surface of the rollers 1212, 1214 that carry a specific amount of powdered microporous particles. The wells or cups of the rollers 1212, 1214 may meter that specific amount of powdered microporous particles transferred onto the sheeting structure 1201 where the thickness of the microporous particles is uniform and consistent. In other embodiments, the rollers 1212, 1214 may have a substantially smooth coated surface.

The coating chamber 1200 may also include one or more doctor blades 1232 in contact with the coating surfaces of the first and second calendar rollers 1212, 1214. The doctor blade 1232 may be configured to remove excess microporous particles 1234 coated on the first and second calendar rollers 1212, 1214 by wiping the first and second calendar rollers 1212, 1214 as it rotates about the doctor blade 1232. By removing excess microporous particles on the first and second calendar rollers 1212, 1214, the doctor blade 1232 may also even out the distribution of the microporous particles coated on the rollers 1212, 1214 and reduce smearing of the microporous particles.

The doctor blade 1232 may be formed from any suitable material, including, for example, steel or plastic. It should also be appreciated that the doctor blade 1232 may be adjusted depending on the conditions of the coating process. For example, the radial position of the doctor blade 1232 relative to the rollers 1212, 1214, the position of the doctor blade 1232 relative to the longitudinal axis of the rollers 1212, 1214, the angle at which the doctor blade 1232 contacts the rollers 1212, 1214, and the pressure applied by the doctor blade 1230 may be adjusted to address the placement and extent of excess microporous particles to be removed.

In some embodiments, the shroud 1236 may be coupled to the edges of each of the first and second calendar rollers 1212 and 1214. The shroud 1236 may extend along the longitudinal axis of each of the rollers 1212, 1214 and cover a portion of the coating surface of the rollers 1212, 1214 adjacent to the edges. The shroud 1236 may prevent the microporous particles from coating the portion of the coating surface covered by the shroud 1236. Thus, the shroud 1236 may frame the coating surface of the rollers 1212, 1214 to match a given width of the substrate 1201 on which the microporous particles are to be deposited. Thus, the shroud 1236 may reduce the amount of microporous particles that are wasted by contacting the substrate 1201 while the edges of the rollers 1212, 1214 may be coated and not transferred. The shroud 1236 may be adjustable in length relative to the longitudinal axis of the rollers 1212, 1214 to accommodate various widths of the substrate 1201. Those skilled in the art will also appreciate that the shroud 1232 may be formed from any suitable material having electrical insulation and anti-stick capabilities to avoid the microporous particles from coating the shroud 1236.

The first coating device 1216 and the second coating device 1218 can be arranged with respect to the first calendar roller 1212 and the second calendar roller 1214 to adjust the coating characteristics of the microporous particles on the substrate 1201. For example, depending on the desired direction in which the powdered microporous particles should be sprayed onto the first calendar roller 1212 and the second calendar roller 1214, the position of the first coating device 1216 can be angled with respect to the first calendar roller 1212 and the position of the second coating device 1218 can be angled with respect to the second calendar roller 1214. In some embodiments, the first coating apparatus 1216 may be angled upward so that the spray end of the first coating apparatus 1224 points toward the upper portion of the first calender roller 1212, and the second coating apparatus 1218 may be angled downward so that the spray end of the second coating apparatus 1218 points toward the lower portion of the second calender roller 1214. The angle between the first coating apparatus 1216 and the longitudinal axis of the feed direction of the substrate 1201 may be about 45°, and the angle between the second coating apparatus 1218 and the longitudinal axis of the feed direction of the substrate 1201 may be about -45°.

The first and second coaters 1216, 1218 may be adjusted to any suitable angle with respect to the first and second calendar rollers 1212, 1214, respectively. In other embodiments, for example, the first coater 1216 may be angled downward so that the sprayer end of the first coater 1224 points toward the lower portion of the first calendar roller 1212, and the second coater 1218 may be angled upward so that the sprayer end of the second coater 1225 points toward the upper portion of the second calendar roller 1224.

Angling the positions of the first and second coating devices 1216 and 1218 with respect to the first and second calendar rollers 1212 and 1214 can improve the uniformity of the powdered microporous particles spray-coated on the first and second calendar rollers 1212 and 1214, which in turn can result in a more uniform distribution of the microporous particles embedded within the substrates 1202 and 1204. In contrast, the first and second coating devices 1216 and 1218 positioned horizontally (i.e., substantially parallel to the longitudinal axis of the feed direction of the substrate 1201) with respect to the first and second calendar rollers 1212 and 1214, respectively, can result in non-uniform deposition and coating of the powdered microporous particles on the first and second calendar rollers 1212 and 1214. This, in turn, can result in uneven distribution and smearing of the microporous particles embedded within the substrate 1201. Uneven distribution and smearing of the microporous particles that can be caused by positioning the first and second coating devices 1216, 1218 horizontally can be avoided by adjusting the proximity of the first and second coating devices 1212, 1214 relative to the first and second calendar rollers 1212, 1214, the rate at which the powdered microporous particles are sprayed, and the charge rate of the powdered microporous particles as they exit the device.

The X-axis (horizontal) adjustment of the first coating device 1212 and the second coating device 1214 can be made via micrometers 1241, 1243. The Y-axis (vertical) adjustment of the first coating device 1212 and the second coating device 1214 can be made via micrometers 1242, 1244. The angle adjustment of the first coating device 1212 and the second coating device 1214 can be made via micrometers 1245, 1246.

In other embodiments, the first and second coating devices 1216 and 1218 may be positioned vertically (i.e., substantially perpendicular to the longitudinal axis of the feed direction of the substrate 1201) with respect to the first and second calendar rollers 1212 and 1214, respectively. This configuration may avoid excessive deposition of the powdered microporous particles on the substrate 1201.

The proximity of the first and second coating devices 1216 and 1218 relative to the first and second calendar rollers 1212 and 1214 can also affect the density and distribution of the powdered microporous particles spray coated onto the first and second calendar rollers 1212 and 1214. In some embodiments, the first coating device 1216 may be positioned 3 to 12 inches from the first calendar roller 1212 on an 8 inch wide roller, and the second coating device 1218 may be positioned 3 to 12 inches from the second calendar roller 1214 on an 8 inch wide roller. The width of the rollers and spray pattern can be adjusted to accommodate different distances between the rollers and the coating devices. Positioning the first and second coating devices 1216, 1218 closer to the first and second calender rollers 1212, 1214 may focus the spray profile of the powdered microporous particles and concentrate the amount of powdered microporous particles coated on a particular surface area of the first and second calender rollers 1212, 1214. Positioning the first and second coating devices 1216, 1218 farther from the first and second calender rollers 1212, 1214 may spread the spray profile of the powdered microporous particles and coat more of the surface area of the first and second calender rollers 1212, 1214 with the powdered microporous particles. The spread spray profile may also increase the amount of powdered microporous particles that pass by the first and second calender rollers 1212, 1214 and cannot be electrostatically attracted.

The coating chamber 1210 may also include a recovery system 1264 configured to return powdered microporous particles that are not impregnated into the substrate 1201 from the coating chamber 1210 back to the source 1220. The recovery system 1264 allows for a process of recycling and reusing the non-impregnated coating material. The recovery system 1264 may include one or more outlet ports 1265 disposed in the coating chamber 1200 that are connected to the source 1220 via a suitable conduit 1264. As the powdered microporous particles are sprayed from the first and second coating devices 1212 and 1214, the powdered microporous particles that may not have been coated on the first and second calendar rollers 1212 and 1214 or deposited on the substrate 1201 may be collected from the coating chamber 1200 and returned to the source 1220. The microporous particles exit through exit port 1265 and can be delivered to source 1220 through conduit 1264 by any suitable means, including, for example, a vacuum source.

Those skilled in the art will appreciate that the process for producing the membrane of the present disclosure may obviate the need to use additives such as retention aids and binders (e.g., polyvinyl alcohol, hydrophilic latex, and starch) to embed and retain the microporous particles within the fiber matrix of the substrate 1201. The process of the present disclosure may produce the membrane 1206 by embedding the microporous particles within the substrate 1201 without or by reducing the amount of additives on the substrate 1201, the roller 1212, or the microporous particles. Thus, the unconsumed microporous particles 1222 in the coating chamber that are not deposited on the substrate 1201 may be recovered and reused via the recovery system 1264 without the need for any additional conditioning or other processing of the recovered microporous particles. In some embodiments, for example, about 20-30% of the powdered microporous particles sprayed from the first coater 1216 and the second coater 1218 may be electrostatically coated onto the rollers 1212, 1214. Of this amount of material deposited on the rollers, approximately 30-40% of the microporous particles coated on the rollers 1212, 1214 may be deposited on the substrate 1201. The remaining microporous particles 1234 deposited on the rollers 1212, 1214 but not applied to the substrate 1201 may be wiped off the rollers 1212, 1214 by a doctor blade. This material, along with the material not deposited on the rollers 1212, 1214, may be continuously recycled and reused in preparing the membrane 1206.

11b, the film 1206 exiting the coating chamber 1200 may be delivered through a cooling stage 1268. The cooling stage 1268 may comprise any suitable cooling mechanism that cools the film 1201 as it passes from the heated calendar rollers 1212, 1214 of the coating chamber 1200. The cooling stage 1268 may comprise one or more devices for directing fresh or cold air, such as, for example, air knives, onto the top and bottom surfaces of the film 1201. In other embodiments, the cooling stage 1268 may comprise one or more outfeed rollers on or between which the film 1206 may be calendared. The outfeed rollers may be cooled to ambient or below temperature. By cooling the film 1206 immediately upon exiting the coating chamber 1200, the cooling stage 1268 may set the warm film 1206, control shrinkage, and prevent wrinkling and other surface defects on the film 1206.

Following the cooling stage 1268, the membrane 1206 enters a winding stage 1270. The winding stage 1270 may include multiple rollers or festoons that may deliver the membrane sheet 1206 to a winder 1272 that is configured to wind the membrane sheet 1206 into a roll. The rollers and winder 1272 of the winding stage 1270 may be configured to apply a constant tension to the membrane sheet 1206 as it is wound into the roll of membrane 1260. The tension applied to the membrane sheet 1206 may be approximately 2 pounds per linear foot in warm conditions. If the membrane sheet 1206 is subjected to a tension significantly higher than 10 pounds per linear foot in warm conditions, the membrane sheet 1206 may develop surface defects, such as microfractures, which may result in undesirable increased water permeability of the membrane sheet 1206. If the membrane sheet 1206 is not tensioned at all, or is tensioned at a level significantly less than 1 pound per linear foot, it can disrupt the deposition of the microporous particles on the membrane sheet 1206, including the uniformity and distribution of the microporous particles on the surface of the sheet 1206.

The membrane 1206 produced by the disclosed manufacturing process may have a number of advantageous properties when used as a substrate for heat and/or moisture transfer applications, such as enthalpy exchangers. The coating surface of the first calendar roller 1212 may contact the entire top surface of the substrate 1202, and the coating surface 1204 of the second calendar roller 1214 may contact the entire bottom surface of the substrate 1201. In this configuration, the entire surface area of the substrate 1201 may be impregnated with microporous particles. The rollers 1212, 1214 may promote complete coverage of the membrane 1206 with the microporous particles. The rollers 1212, 1214 may also promote homogeneous and uniform embedding of the microporous particles into the surface of the substrate 1201 in combination with the doctor blade 1232 and the shroud 1236. In some embodiments, the microporous particles may form a thin layer on the surface of the membrane 1206, for example about 1 mil thick on each side of the substrate 1201, and the microporous particles may comprise 80-90 weight percent of the impregnated substrate material.

As a substrate material for heat and/or moisture transfer applications, it may be desirable for the membrane 1206 to be impermeable to air. In some embodiments of the present disclosure, the membrane 1206 may be formed from paper coated with gamma alumina. In other embodiments, the membrane 1206 may be formed from a thermoplastic sheet coated with gamma alumina. Although alumina may act as a natural release agent, any voids or unevenly coated areas will result in the membrane material immediately adhering.

Membranes 1206 formed from gamma alumina coated paper may have a wide pore size distribution. An example of a commercially available gamma alumina is VGL15 produced by U.O.P. Corporation. The selected porosity of the gamma alumina coated paper may allow moisture flow across the membrane 1206 but block air flow. Thus, the gamma alumina coated paper may accommodate both heat and moisture transfer across the membrane 1206.

Preferred microporous particles may be transition aluminas such as gamma alumina due to their inert properties, charge properties, low cost, and high commercial availability. These materials may be activated for adsorption by removing water from hydrated precursors. Preferred surface area ranges may be 100 m ² /gm to 250 m ² /gm. Preferred pore volume ranges may be 1.30 cc/g to 1.40 cc/g. Preferred loose bulk densities optimized for spraying and providing charged particles may be 150 kg/m ³ to 200 kg/m ^3. Friability index values of 9-10 may be preferred. The higher the Friability Index, the easier the product will be to break up and rapidly accept a charge after entering the coating equipment. The Friability Index may be a function of the calcination conditions. The Friability Index is the relative loss of >20 micron particles in a nominal 5 wt% slurry caused by ultrasonic treatment.

The membrane 1206 formed from the gamma alumina coated thermoplastic sheet of the present disclosure may have a pore volume of about 1.36 cc/g. The porosity of the gamma alumina coated thermoplastic sheet may restrict the flow of both air and water across the membrane 1206. Thus, the gamma alumina coated thermoplastic sheet may only accommodate heat transfer across the membrane 1206. The microporous particles may be any material that can efficiently retain liquid through capillary action and surface tension while allowing for the impartation of an electric charge. The microporous material may also efficiently adsorb/desorb said moisture to a countercurrent airflow. Examples of such microporous particles include, for example, activated alumina, silica gel, molecular sieves, porous titania or zeolites, activated carbon, and mixtures thereof.

A single monolayer of microporous particles on the top side and a monolayer of microporous particles on the bottom side with roller coating coverage of greater than 99% may be achievable. Heat transfer coefficients may match or exceed aluminum foil of comparable thickness as the large surface area collapses the boundary layer for fluid flow. A preferred heat transfer coefficient may exceed 59-64 w/ ^m2 ·K at an air velocity of 3 m/s. A preferred film thickness may be between 3 and 7 mils. High tear resistance may be achievable utilizing polyethylene or polypropylene reinforced with various fiber types. The porous particles may be physically embedded and held in place on the thermoplastic surface by the particle's physical porous structure. A preferred weight range for the substrate before application of the microporous particles may be 15 to 35 grams per square meter. A preferred weight range for the substrate after application of the microporous particles may be 60 to 130 grams per square meter.

The surfaces of gamma alumina coated paper and gamma alumina coated thermoplastic sheets may have high wettability because gamma alumina can adsorb large amounts of moisture. Additionally, the thermoplastic fibers of the gamma alumina coated thermoplastic sheets have low surface tension and may promote sheet flow of moisture, including water and liquid desiccants such as lithium chloride, along the surface of the membrane 1206. By promoting the flow of liquid desiccant along the surface of the membrane 1206, the thermoplastic fibers may promote air-liquid surface interactions, resulting in high transfer efficiency from the membrane 1206. In some embodiments, the thermoplastic sheets may be corona treated before being coated with gamma alumina. Corona treating the surface of the thermoplastic sheet may further promote bonding of the gamma alumina to the sheet and enhance the wetting properties of the membrane 1206.

Although the membrane 1206 of the present disclosure is described in the application as a substrate for heat and moisture transfer applications, such as enthalpy exchangers, one of ordinary skill in the art will appreciate that the membrane 1206 may be used in other applications. For example, in some applications, the membrane 1206 may be used as a battery separator material in an electrochemical cell.

The membrane 1206 may be processed under suitable post-manufacturing treatment. In some embodiments, the membrane 1206 may be treated with a desiccant to enhance the adsorptive properties of the membrane 1206 and further reduce its water permeability. For example, the membrane 1206 may be exposed to a brine solution containing a liquid hygroscopic salt desiccant, such as lithium chloride, and dried such that the desiccant is absorbed and retained by the membrane 1206.

The membrane 1206 may be folded and joined at several edge locations to form multiple open exchangers for various applications, including heat and/or water vapor exchangers. These exchangers may be suitable for use as exchangers in energy recovery ventilator (ERV) applications. These exchangers may also be used in heat and/or moisture applications, air filter applications, gas dryer applications, flue gas energy recovery applications, sequestration applications, gas/liquid separator elements, automotive outside air treatment applications, carbon dioxide scrubbing applications, aircraft outside air treatment applications, and fuel cell applications. These exchangers may typically be disposed within a housing.

For example, in a heat and/or moisture transfer application, such as an enthalpy exchanger, the membrane 1206 may be folded, layered, and sealed at several edge locations to form an exchanger having multiple membrane layers with multiple inlet and outlet passages in an interleaved configuration, as described in U.S. Patent Nos. 5,233, 5,193, 5,211, 5,229, 5,314, 5,321, 5,337, 5,413, 5,541, 5,551, 5,627, 5,714, 5,721, 5,731, 5,822, 5,926, 5,962, 5,982, 6,171, 6,226, 6,327, 6,226, 6,327, 6,226, 6,226, 6

The membrane 1206 may be coated with a bonding material. In a preferred embodiment, a thermoplastic material may be extruded onto the edges of the membrane 1206. The thermoplastic material may act as a bonding agent. The membrane 1206 may be folded and sealed at select portions of the edges by welding (e.g., ultrasonically, vibrating, or thermally) the thermoplastic coated portions of the edges.

In some embodiments, the thermoplastic is extruded onto the edges of both the top and bottom surfaces of the membrane 1206, and the extruded thermoplastic material on the top surface and the extruded thermoplastic material on the bottom surface may extend outward and join. In other embodiments, the thermoplastic material is extruded onto the edges of only one of the top and bottom surfaces of the membrane 1206, and the extruded thermoplastic material may extend outward, wrap around the edge of the membrane 1206, and join to the other of the top and bottom surfaces.

The thermoplastic material may be any suitable thermoplastic including, for example, polyethylene. The width of the thermoplastic material extruded onto the membrane 1206 may be approximately 0.125-0.25 inches, but may be adjusted to any other suitable width to obtain a suitable bond area between the folds of the membrane 1206. Microporous particles such as gamma alumina impregnated within the surface of the substrate 1201 may protect the membrane 1206 from potential damage that may otherwise occur due to the high heat of the edge coating process. For example, gamma alumina deposited on the substrate 1201 may insulate the substrate 1201 from the high heat of the extruded polyethylene.

Separators for Exchangers and Related Manufacturing Methods The enthalpy exchangers of the present disclosure may include a membrane 1206 and a separator. The separator may be positioned between layers of membrane 1206. The separator may be evacuated into some or all of the passages between adjacent membrane layers to aid in fluid flow distribution and/or help maintain separation distances of the membrane layers. In some embodiments, the separator may be a corrugated netting formed from a thermoplastic material. The separator may be formed from any suitable material, including, for example, corrugated aluminum inserts, plastic molded inserts, and mesh inserts. In some embodiments, the separator may include a porous material, such as a porous felt, to facilitate wicking and wetting of the membrane 1206. As described in more detail below, the separator may be inserted during the folding and joining process of the membrane 1206 in forming the enthalpy exchanger. Alternatively, the separator may be inserted between the membrane layers after the enthalpy exchanger is formed. In particular, separators can be inserted between adjacent membrane layers after membrane 1206 is folded, but before selected edges of membrane 1206 are joined.

12 is a perspective view of one layer 1302 of the separator 1300. The separator 1302 may be a corrugated mesh material 1304 formed from a thermoplastic material such as, for example, polypropylene or polyethylene. One skilled in the art will appreciate that the corrugated mesh material 1304 may be formed from any other suitable thermoplastic material. The corrugated mesh material 1304 preferably has a weight of less than 3 pounds/1000 square feet, and more preferably less than 1.5 pounds/1000 square feet. Utilizing a thermoplastic material to form the corrugated mesh material 1304 may be advantageous because the thermoplastic material is resistant to most forms of corrosion and may allow operation in airstreams that contain corrosive chemicals. Additionally, the thermoplastic material may be compatible with most forms of heat and vapor film.

The corrugated mesh material 1304 may include a first plurality of long fiber members 1306 extending along a first plane (X-plane) in a sinusoidal pattern. The corrugated mesh material 1304 may also include a second plurality of long fiber members 1308 extending along a second plane transverse to or at an angle to the first plane (Y-plane) and may connect to the first plurality of long fiber members 1306. The second plurality of long fiber members 1308 are preferably substantially straight and may connect to the first plurality of long fiber members 1306 at a 90° angle with respect to the X-plane. The separator structure 1300 provides adequate spacing between the layers of the membrane 1206.

The sinusoidal filament members 1306 may have an amplitude Z. The amplitude Z may define discrete fluid flow channels within the exchanger passages. In some embodiments, the amplitude Z may be 0.8 mm for type "F" flutes with 125 flutes per foot. In other embodiments, the amplitude Z may be 1.6 mm for type "E" flutes with 95 flutes per foot. Additionally, the amplitude Z may be 3.2 mm for type "B" flutes with 49 flutes per foot. Additionally, the amplitude Z may be 4.0 mm for type "C" flutes with 41 flutes per foot. The size of the openings 1310 in the corrugated mesh material 1304 formed between the filament members 1306, 1308 may be selected depending on the desired moisture permeability, pressure drop, and separator strength.

For example, decreasing the distance between adjacent sinusoidal wave-shaped long fiber members 1306 and/or the distance between adjacent connector long fiber members 1308 may decrease the size of the opening 1310 and increase the structural strength of the separator 1300. However, decreasing the size of the opening 1310 may limit the desired moisture permeability across the membrane 1206 and contribute to an increase in the pressure drop of the fluid, such as air, flowing through the exchanger passages. Increasing the distance between adjacent sinusoidal wave-shaped long fiber members 1306 and/or the distance between adjacent connector long fiber members 1308 may increase the size of the opening 1310. The increased size of the opening 1310 may accommodate the desired moisture permeability across the membrane 1206, which may result in a lower pressure drop of the fluid flowing through the exchanger passages. However, increasing the size of the opening 1310 may decrease the structural strength of the separator 1300.

In a preferred embodiment, the Y-axis filament members 1308 may have similar distance and strength as the X-axis filaments 1306. Filament connections may occur at the apex of each curve. Strand thickness may range from 4-20 mils. The separator 1300 may withstand a pressure differential of 12 inches wg at 72°F.

The separator 1300 may be used in any suitable heat and moisture exchanger design. The corrugated mesh 1304 of the separator 1300 may be produced through an extrusion process. The corrugated mesh 1304 of a thermoplastic material may preferably be biaxially oriented, which may be lighter in weight and more flexible than an extruded square mesh. The orientation "stretches" the extruded square mesh in the X and Y directions under controlled conditions, which may form a strong, flexible, lightweight mesh. The biaxially oriented corrugated mesh 1304 may have improved performance over known heat and moisture vapor separator materials and techniques.

The openings 1310 in the corrugated mesh material 1304 increase the membrane surface area to the airflow and in some applications may facilitate faster vapor transfer than separators made of corrugated sheet materials such as foil, plastic, or paper. In addition, water vapor in the airflow flowing through the exchanger passages separated by the corrugated mesh material 1304 may, on average, travel a shorter distance to interact with the membrane 1206 compared to passages with a corrugated sheet separator. Furthermore, the biaxially oriented corrugated mesh material 1304 may facilitate fluid transfer in both the X and Y planes. However, the airflow entering the corrugated sheet separator may only travel in a straight line path. The bidirectional airflow provided by the biaxially oriented corrugated mesh material 1304 may allow for a wider range of geometries in the context of heat and moisture exchangers. The corrugated mesh material 1304 may utilize less material than a corrugated sheet separator, which may achieve cost savings and better performance in smoke/fire tests.

An exemplary process for manufacturing a separator 1400 according to the present disclosure will now be described with reference to FIGS. 13a-13d. A roll of thermoplastic netting 1402 may be continuously delivered to a corrugation chamber 1404. The corrugation chamber 1404 may include a housing 1406 that encloses a first continuous belt 1408 and a second continuous belt 1410. The first continuous belt 1408 includes a first wavy surface 1412 having corrugation crests and troughs, and the second continuous belt 1410 includes a second wavy surface 1414 having corrugation crests and troughs. The corrugation crests of the first wavy surface 1412 may meet with the corrugation troughs of the second wavy surface 1414, and the corrugation crests of the second wavy surface 1414 may meet with the corrugation troughs of the first wavy surface 1412. The corrugating chamber 1404 may further include a first drive unit 1416 configured to drive the first continuous belt 1408 and a second drive unit 1418 configured to drive the second continuous belt 1410 in synchronous motion. Each of the drive units 1416, 1418 may include one or more pulleys or rollers 1426, 1428 rotatably driven by a suitable power source, such as, for example, a motor. The continuous belts 1408, 1410 run on the pulleys 1426, 1428, which may rotate and drive the continuous belts 1408, 1410 to mate the first wavy surface 1412 and the second wavy surface 1414.

In some embodiments, the diameter of the rollers 1426, 1428 may be at least 0.5 meters. The wavy belts 1408, 1410 may have an amplitude between 1.5 mm and 6 mm, and a width between 250 mm and 1000 mm. The continuous belts 1408, 1410 may be initially formed with a sinusoidal profile and then precisely cut to length at the apexes of the flutes.

The continuous belts 1408, 1410 may be welded end to end to form a continuous loop using micro laser welding techniques. In some embodiments, alignment and corrugation spacing may be maintained through micro laser welding utilizing fixtures to maintain tolerances while performing the micro welding. Maintaining acceptable spacing patterns and tolerances may prevent cutting or tearing of the biaxial mesh material. In other embodiments, the welding method may include WIG, plasma, electron beam or laser welding. The continuous belts 1408, 1410 may be made from 17-7 or 17-4 stainless steel, which has high resistance to repeated flexing and fatigue resistance. The infeed web tension may be maintained between 5 and 20 pounds per linear foot. Higher web tension may result in thinner sinusoidal corrugated strands. The residence time between the entrance and exit nips is between 5 and 30 seconds depending on the thickness of the strand.

As the mesh material 1420 is fed through the first and second continuous belts 1408, 1410, it may be forced between the first wavy surface 1412 and the second wavy surface 1414 of the continuous belts 1408, 1410. Heat and pressure from the continuous belts 1408, 1410 may corrugate the mesh material 1420 and form the sinusoidal wave member 1306 of the separator 1300. Heat may be applied to the portion of the continuous belts 1408, 1410 where the mesh material 1420 enters. For example, a heat source such as an infrared lamp 1422 may be positioned near the entrance portion 1424 of the continuous belts 1408, 1410 to heat the wavy surfaces 1412, 1414 when they first contact and apply pressure to the sheeting material 1420. Additionally or alternatively, the pulleys 1426, 1428 near the inlet portion 1424 of the continuous belts 1408, 1410 may be heated, for example, via heating elements in the cores of the pulleys 1426, 1428, which may transfer heat to the wavy surfaces 1412, 1414 of the continuous belts 1408, 1410. In some embodiments, the wavy surfaces 1412, 1414 may be heated to approximately 240°F to 260°F for polypropylene and 180°F to 220°F for polyethylene.

Those skilled in the art will appreciate that other combinations of time, pressure, temperature, and line speed may be used to form the mesh material of the present disclosure. Any such combination of parameters that may enable the separator 1430 to be formed into a desired shape and to substantially retain this shape through subsequent processing, assembly, and use is suitable.

The corrugated mesh material 1432 may be released and collected as the material 1432 exits the output portion 1434 of the continuous belts 1408, 1410. The corrugated mesh material 1432 may be cooled near the output portion 1434 of the continuous belts 1408, 1410 to harden the corrugations. In some embodiments, a cooling source 1438, such as, for example, one or more air knives, may be positioned near the output portion 1434 of the continuous belts 1408, 1410 to cool the corrugated mesh material 1432. The one or more air knives may direct air at or below ambient temperature, such as, for example, 80° F. to 120° F., at the top and bottom surfaces of the corrugated mesh material 1432. Additionally or alternatively, the pulleys 1426, 1428 near the output portions 1434 of the continuous belts 1432, 1410 may be cooled, for example, via cooling elements in the cores of the pulleys 1426, 1428, to remove heat from the corrugated mesh material 1432.

Once the corrugated netting 1432 has cooled and been released from the continuous belts 1408, 1410, the corrugated netting 1432 may be collected by a collector 1442. The collector 1442 may include multiple rollers or festoons 1448 that may deliver the corrugated netting 1432 to a winder 1446 configured to wind the corrugated netting 1432 onto a roll 1444. The rollers 1448 and winder 1446 of the collector 1442 may be configured to apply a constant tension on the corrugated netting 1432 as it is wound onto the roll 1444. The tension applied on the corrugated netting 1432 may be less than about 0.5 pounds per linear foot. The retriever 1442 may apply tension to the corrugated mesh material 1432 to, for example, prevent surface irregularities such as wrinkles, and maintain alignment of the sinusoidal members 1306 along the longitudinal axis of the corrugated mesh material 1432.

The process for manufacturing the separator 1432 according to the present disclosure may provide numerous advantages and improvements over known methods for manufacturing corrugated web material. Known processes may use corrugating rollers to form a corrugated profile in the material fed between the rollers. However, these known processes may have limitations related to the surface area provided by the corrugating rollers to corrugate the web material. The continuous belts 1408, 1410 of the present disclosure may provide a larger corrugating surface compared to known corrugating rollers. The larger corrugating surface area of the continuous belts 1408, 1410 may accommodate a higher output speed of the corrugated web material and may improve the uniformity and alignment of the corrugated profile of the corrugated web material. The continuous belts 1408, 1410 may also accommodate a larger heating surface area for forming corrugations on the web material. The larger heating surface area may allow the continuous belts 1408, 1410 to heat a larger area of the web material over a wider temperature range.

For example, a higher temperature profile and a larger area may improve the setting of the corrugations on the web, allow for higher amplitudes of the corrugations, and strengthen the corrugations against deformation (i.e., increase the shape memory of the corrugations). Additionally, the continuous belts 1408, 1410 may provide a dwell section between the heating and cooling sections that may facilitate setting the corrugated web. The continuous belts 1408, 1410 may also produce a corrugated web 1432 with a thicker sinusoidal waveform and connecting members 1306, 1308 compared to the corrugated web 1432 produced by known corrugating rollers. The process of the present disclosure may utilize a significantly longer dwell time during which the long fibers can be fully heated and then fully cooled before being released, unlike conventional corrugating roller systems. Additionally, the tension applied to the corrugated web by the collector 1442 may maintain the alignment of the sinusoidal waveform members 1306 and improve the uniformity of the corrugated web 1432.

Although the separator 1432 of the present disclosure is described in an application as an isolation structure for a membrane layer of a heat and moisture transfer body, such as an enthalpy exchanger, one skilled in the art will appreciate that the separator 1432 may be utilized as an isolation structure in a variety of other applications. For example, in some applications, the separator 1432 may serve as an isolation structure for air filters known in the art. As shown in FIGS. 14a-14c, the air filter 1500 may include a filter material 1504, such as any suitable fibrous material capable of removing solid particles, including dust, pollen, mold, and bacteria, from the air. In some embodiments, the filter material 1504 may comprise the membrane 1206 described above. The air filter 1500 may include an input side 1514 for receiving air to be filtered and an exhaust side 1516 through which the filtered air exits the air filter 1500. The filter material 1504 may be folded to form a plurality of pleats 1508. As shown in Figures 14a-14c, the air filter 1500 may also include a separator 1300 positioned on the exhaust side 1516 of the air filter 1500 and folded over the pleats 1508 of the filter material 1504.

An air filter with a separator 1300 according to the present disclosure may provide numerous advantages and improvements over known air filters. Existing air filters may employ multiple bridge structures that may be spaced apart and contact adjacent pleats of filter material via adhesive or welds. The bridge structures may generally be positioned on the input side of the air filter. This configuration may restrict airflow through the air filter and reduce the filtration performance of the air filter. The separator 1300 of the present disclosure may improve airflow through the air filter. The corrugated mesh material 1304 of the separator 1300 may be more open than existing bridge structures to accommodate more airflow through the filter material. For example, 97-98% of the surface area of the corrugated mesh material 1304 may be open, providing unlimited airflow. Additionally, the sinusoidal corrugations and connecting members 1306, 1308 of the corrugated mesh material 1304 may be thinner than existing bridge structures, providing less restriction to airflow. In some embodiments, for example, the sinusoidal waveforms and connecting members 1306, 1308 may be approximately 1/16 inch thick. The separator 1300 may result in a spacing structure that may be less dense, lighter, and smaller than existing bridge structures.

The compression characteristics of the separator 1300 may also improve the performance of the air filter. As the input side of the air filter receives air, the pleats of the filter material may fan out or open to increase the capacity of the filter material to filter particles from the input air. The separator 1300 disposed on the discharge side of the air filter may receive and compress the load from the pleats that are open to the input side.

As described above, an enthalpy exchanger may be formed from the membrane 1206 and the separator 1300. For example, the membrane 1206 and the separator 1300 may form an enthalpy exchanger as described in U.S. Patent No. 6,399,343, which is incorporated herein by reference.

Air Conditioner Modules and Systems Figures 15a-15h illustrate perspective views of an evaporative cooling and/or vapor regenerating liquid desiccant air conditioner module 1600 and its associated components according to an embodiment of the present invention. The present disclosure may be directed to air conditioner modules and systems configured to perform various air treatment operations. Such air treatment operations may include, but are not limited to, (1) modifying the moisture and/or heat capacity of the air being treated, (2) absorbing carbon dioxide (CO ₂ ), formaldehyde, and other volatile organic compounds (VOCs) from the air being treated, (3) regenerating weak liquids of liquid desiccant being treated, (4) regenerating spent liquid sorbents of reversibly bound aqueous solutions being treated, (5) recovering moisture and/or heat capacity between two separate air streams, and (6) modifying the heat capacity of a working liquid using indirect/direct evaporative cooling.

The air conditioner module 1600 may include an exchanger housing 211 and an exchanger 213. The entire exchanger 213 may be housed inside the exchanger housing 211. The exchanger 213 may be formed from a membrane 1206 including a thermoplastic sheet with embedded gamma alumina. The exchanger 213 may include a plurality of plates 1615 arranged in a stacked configuration with a plurality of intermittently sealed plate edges 1620. A portion of the plates 1615 may be spaced apart to include a first series of discrete alternating passages 1613 and a second series of discrete alternating passages 1614.

A first air flow 1680 may be passed through a first series of passages 1613 and a second air flow 1681 may be passed through a second series of passages 1614 in a counter-flow configuration with respect to the first air flow 1680. The first air flow 1680 and the second air flow 1681 may be maintained physically separate from one another while maintaining thermal contact therebetween so that heat can pass freely therebetween. The air conditioner module 1600 may include a first liquid supply conduit 1622 secured to a first liquid threaded inlet 1636 and a second liquid supply conduit 1624 secured to a second threaded inlet 1638. The first liquid 1626 and the second liquid 1628 may be pumped into the first liquid supply conduit 1622 and the second liquid supply conduit 1624, respectively. The first liquid 1626 and the second liquid 1628 may pass through adjacent air conditioner modules 1600 via first liquid return conduits 1623 and second liquid return conduits 1625, respectively.

The first liquid 1626 may exit the air conditioner module 1600 through a first liquid threaded outlet 1640, and the second liquid 1628 may exit the air conditioner module 1600 through a second liquid threaded outlet 1642. These return conduits may be used to facilitate the supply of the first liquid 1626 and the second liquid 1628 to the multiple air conditioner modules and to flush impurities that may accumulate from the module 1600. With appropriate modifications, the air conditioner of the present disclosure may be adapted by selecting the first and second air flows and the type of liquid delivered to use the air conditioner in a variety of applications, including, for example, but not limited to, indirect evaporative cooling, direct evaporative cooling, liquid desiccant dehumidification, carbon dioxide scrubbing, VOC scrubbing, hot water liquid desiccant generation, indirect vapor liquid desiccant regeneration, hot water regeneration of scrubbing reversibly bound aqueous solution, indirect vapor regeneration of scrubbing reversibly bound aqueous solution, and the like.

The conduits 1622, 1623, 1624, and 1625 may pass through a liquid distribution system that includes a stacked arrangement of plates that include a first distribution header 1632 and a second distribution header 1634. Figures 15d-15h illustrate perspective views of the first distribution header 1632 and the second distribution header 1634 and their associated components according to the present disclosure. In some embodiments, the distribution headers 1632 and 1634 may be made from silicone, urethane, thermoplastic, vital, Teflon, or other non-corrosive sealing materials. The headers 1632 and 1634 may include a silicone leaf with a porous member 1630. The first distribution header 1632 and the second distribution header 1634 may be sealed together by a compression plate 1645 that is connected together by a compression rod 1644 that passes through the headers 1632 and 1634.

15g, for example, the membrane 1206 of the exchanger 213 may be positioned between a first distribution header 1632 and a second distribution header 1634. The membrane 1206 may also include a plurality of membrane conduit holes 1672 aligned with the conduits 1622, 1623, 1624, and 1625. A first liquid 1626 may be delivered into the first distribution header 1632 and discharged onto the membrane 1206 through the conduits 1622 or 1623 and through the membrane conduit holes 1672 aligned with the conduits 1622 or 1623. A second liquid 1628 may be delivered into the second distribution header 1634 and discharged onto the membrane 1206 through the conduits 1624 or 1625 and through the membrane conduit holes 1672 aligned with the conduits 1624 or 1625. Suitable alignment mechanisms, such as, for example, pointed teeth, may be coupled to the headers 1632 and 1634, the membrane conduit holes 1672, and the holes 1640 and 1638 in the exchanger housing 211 to maintain alignment and registration of the components of the liquid distribution system.

The first distribution header 1632 may include a first liquid feeder channel 1648 and a plurality of feeder holes 1652. The porous member 1630 may be inserted into the feeder hole 1652, for example, by a press fit. The porous member 1630 may be, for example, a porous wick or a pipette-shaped porous insert for delivering liquid to the membrane 1206 of the exchanger 213. The porous member 1630 may be in direct contact with the inner membrane surface of the first series of fluid passages 1613. The second distribution header 1634 may include a second liquid feeder channel 1650 and a plurality of feeder holes 1652. The porous member 1630 may also be inserted into the feeder hole 1652 of the second distribution header 1634. The first liquid 1626 and the second liquid 1628 may be dispensed directly onto the membrane surface of the first passage 1613 and the second passage 1614 through the porous member 1630, with the liquid maintaining intimate contact at the transition from the feeder hole 1652 to the membrane surface.

The liquid may be dispersed without forming droplets that may become entrained in the air stream. Droplet entrainment may occur through unrestrained transition between the feeder holes 1652 and the membrane surface without the porous member 1630. The porous member 1630 may provide protection from the aerodynamic forces exerted by airflow at the liquid outlet from the feeder holes 1652. These porous members 1630 may be advantageous for strongly hygroscopic liquid desiccants and strongly carbon dioxide absorbing alkylamine solutions. Strong liquid desiccants are highly polar in nature and may then be even more susceptible to entrainment in the absence of the porous member 1640 to maintain fluid flow at the transition to the membrane surface. Small amounts of alkylamine solution entrained in the air stream may generate unpleasant amine odors inside the building enclosure.

Dispensing liquid through the porous member 1630 may be accomplished without spanning or bridging of the liquid across the respective air streams along the inner surfaces of the first and second passages 1613, 1614. Spanning or bridging may occur through unrestrained transitions between the feeder holes 1652 and the membrane surface in the absence of the porous member 1630. The porous member 1630 may provide protection from aerodynamic forces exerted by the flowing air streams, which may optionally focus the streams into various concentrated streams after wetting of the membrane surface. In the absence of the porous member 1630, aerodynamic forces from the flowing air streams may favor one of the two inner surfaces of the fluid passages 1613, 1614, causing non-uniform flow and degrading performance. The strong polarity of many liquids may further exacerbate the spanning and bridging phenomena.

Dispensing liquid through the porous member 1630 can also be accomplished without flow rate variations through the multiple feeder holes 1652. Flow variations can occur through unrestrained transitions inside the feeder holes 1562 because of variations in inlet/outlet effects, diameter, length, or wall friction. The porous member 1630 can deliver liquid to the membrane surface in a uniform manner across the multiple feeder holes 1652. This uniform resistance can ensure that each feeder hole 1652 has the same amount of liquid flowing through it. The porous member 1630 can reduce distribution header pressure and associated pump energy. The distribution headers 1632, 1634 can operate at pressures below 1 psi while still providing full control of the variable flow rate. Additionally, precise dispensing of liquid through the porous member 1630 can promote uniform wetting characteristics on the inner membrane surface of the passages 1613, 1614. The distribution headers 1632 and 1634 and the porous member 1630 can be fluidly connected to one of the six sides of the exchanger 213. Liquid dispensing can be accomplished without blocking or interfering with the first air flow 1680 or the second air flow 1681.

The porous member 1630 may include an inlet 1654 that passes through the wall of the first distribution header 1632 and into the first liquid feeder channel 1648. The porous member 1630 may also include an outlet 1656 that passes through the wall of the first distribution header 1632 and is positioned outside the first distribution header 1632. The first liquid 1626 may enter the pores of the porous member 1630 at the inlet 1654. The first liquid 1626 may pass through the porous member 1630 and exit the pores of the porous member 1630 at the outlet 1656 that is in direct contact with the inner membrane surface of the first passageway 1613. The porous member 1630 may provide a continuous flow of the first fluid 1626 from the first end to the second end of the first passageway 1613 while the first fluid 1626 is in contact with the first air flow 1680.

The second liquid 1628 may enter the pores of the porous member 1630 at the inlet 1654. The second liquid 1628 may pass through the porous member 1630 and exit the pores of the porous member 1630 at the outlet 1656 in direct contact with the inner membrane surface of the second passageway 1614. The porous member 1630 may provide a continuous flow of the second fluid 1628 from the first end to the second end of the second passageway 1614 while the second fluid 1628 is in contact with the second air flow 1681.

The porous member 1630 may comprise any suitable material capable of capillary action, including, for example, ceramic, metal, or plastic such as polypropylene or polyethylene. The porous member 1630 may have an average controlled pore size between 25 and 60 microns, preferably 30 microns. The porous member 1630 may comprise microporous particles selected from porous titania, transition alumina, silica gel, molecular sieves, zeolite, activated carbon, porous polypropylene, or porous polyethylene. The porous member 1630 may also comprise a width substantially equal to the spacing between the plates 1615 to facilitate direct contact and capillary action on the inner walls of the plates 1615. The movement of the liquid flow may be controlled by a porous link between the headers 1632, 1634 and the membrane wall 1206, thereby avoiding the formation of droplets by the blown air flow that may entrain the continuous flow of liquid in the passing air flow 1680, 1681.

The disclosed headers 1632, 1634 provide continuous liquid flow through the porous member 1630 by a combination of capillary action, surface tension, adhesion, and little or no additional head pressure above a given fluid column height, with the porous member 1630 in intimate contact with the membrane wall 1206. Liquid may pass through the porous member 1630 via a tortuous path, resulting in a uniform deposition of flow characteristics regardless of where an individual porous member 1630 is located in the system.

As shown in FIG. 15h, the headers 1632 and 1634 may be formed from a silicone leaf. The porous member 1630 may be pressed into the silicone leaf to provide a controlled delivery of liquid onto the membrane wall 1206. The components of the first distribution header 1632 and the second distribution header 1634 may provide a low flow rate of liquid under low pressure. The first distribution header 1632 and the second distribution header 1634 may deliver a continuous flow 1658 of liquid onto the membrane wall 1206 of the first passage 1613 and the second passage 1614 at a time, thereby enabling an ultra-low flow air conditioner. The continuous flow 1658 of liquid may flow down the membrane wall 1206 of the first passage 1613 and the second passage 1614 in a direction perpendicular to the first air flow 1680 and the second air flow 1681. The headers 1632 and 1634 may be integrated into the exchanger 213 during the folding or layering process of the membrane 1206. For example, in one embodiment, the header 1632 may be positioned on the layer of the membrane 1206 after the folding or layering step of the membrane 1206. The headers 1632 and 1634 may be positioned on the layer of the membrane 1206 manually or by an automated process, such as, for example, a 3D printing step during the folding step.

The membrane 1206 of the exchanger 213 may be formed from a thermoplastic sheet including a porous material, such as, for example, gamma alumina, disposed along at least a portion of the inner surface of the first series of passages 1613 and/or the second series of passages 1614. The thermoplastic sheet including the porous material on both sides may be about 4 to 7 mils thick. The porous material of the membrane 1206 may pull liquid up from the porous member 1630 via capillary action, resulting in a uniform flow of the first liquid 1626 and the second liquid 1628 by gravity from the first distribution header 1632 and the second distribution header 1634 to the first and second ends of the plurality of plates 1615. As described above, the surface of the thermoplastic sheet coated with a porous material, such as, for example, gamma alumina, may form the membrane 1206, and the porous material, such as gamma alumina, may facilitate the flow of a large amount of liquid into the pore structure and may be highly wettable as it may adsorb a large amount of moisture. This may also provide a larger surface area for heat transfer within the first and second plurality of passages 1613 and 1614, improving cooling of the first and second air flows 1680 and 1681. Additionally, the liquid delivery provided by the alternating wettable membrane 1206 and first and second header arrays 1632 and 1634 may promote liquid entrapment on the membrane walls and inhibit undesirable liquid entrainment within the air flows 1680 and 1681.

The air conditioner module 1600 may also include a liquid recovery system for recovering the first liquid 1626 and the second liquid 1628 flowing from the plurality of first passages 1613 and the plurality of second passages 1614. The liquid recovery system may include a first liquid drain conduit 1616 for recovering the first liquid 1626 flowing from the first passage 1613 and a second liquid drain conduit 1618 for recovering the second fluid 1628 flowing from the second passage 1614.

The first and second liquid drain conduits 1616, 1618 may be located entirely outside the exchanger 213 and adjacent the second ends of the plurality of plates 1615. By being entirely outside the exchanger 213, the first and second liquid drain conduits 1616, 1618 may facilitate low manufacturing costs and a compact form factor, and may be easily and efficiently serviced. The external liquid drain conduits 1616, 1618 may be optimized (e.g., by size and/or number) given a desired number of air conditioner modules 1600 are implemented and the expected fluid flow corresponds to a given building design condition. A reservoir-less design may also reduce cost and weight, reduce the number of required seals, and reduce the possibility of mold growth.

Although not shown, suitable systems may be coupled to the exchanger 213 to recover, treat, and recycle the refrigerant and liquid desiccant delivered through the exchanger 213. For example, water or water vapor from the first passage 1613 may be recovered and recycled through a suitable outlet duct. In some embodiments, the recovered water may be further cooled via a refrigerant or the like before being delivered to the exchanger 213. In addition, the cooled weak liquid desiccant from the second plurality of passages 1614 may be recovered and sent through a suitable outlet duct to a regenerator, such as, for example, a boiler. The strong liquid desiccant from the regenerator may then be recycled back to the exchanger 213. In some embodiments, the exchanger 213 may be used as a regenerator rather than a traditional boiler.

The exchanger 213 may include at least one separator 1300 disposed on each of the inner surfaces of the first and second passages 1613 and 1614 to maintain a space therebetween. The separator 1300 may be formed from a high temperature thermoplastic capable of withstanding high temperatures (e.g., between 212°F and 300°F) in applications where the exchanger 213 is used in a vapor regenerated liquid desiccant module. In some embodiments, the separator 1300 may have a height of 0.062 inches to ensure no fluid bridges and optimize heat transfer. The first and second distribution headers 1632 and 1634 may deliver a plurality of replaceable first and second liquids 1626 and 1628, such as, for example, strong liquid desiccant, weak liquid desiccant, direct evaporation water, indirect evaporation water, hot water, cooling tower water, condensate, germicidal cleaning agent, or combinations thereof. The delivered liquid may also include materials that absorb or adsorb certain air pollutants, such as, for example, carbon dioxide scavengers, formaldehyde absorbents, materials that absorb other pollutants, and combinations thereof.

The air conditioner module 1600 may provide multiple, interchangeable air conditioning effects to the first air flow 1680 and the second air flow 1681. The air flows may be conditioned by the air conditioner module 1600 to provide, for example, (1) dehumidified or humidified process air, (2) sensibly cooled or heated process air, (3) indirect and/or direct evaporative cooling process air, (4) indirect and/or direct evaporative cooling working fluid using outside air, (5) remote heat and/or moisture recovery between the exhaust air and the outside air, (6) weak desiccant steam and/or hot water regeneration, and (7) weak desiccant direct and/or indirect combustion air regeneration.

In some embodiments, the exchanger 213 may be utilized in evaporative liquid desiccant air conditioning applications. For example, the exchanger 213 may be used in the air handling module described in FIG. 8a and the air conditioner module described in FIGS. 15a-15h. In such applications, the exchanger 213 may be used in modules that can provide evaporative cooling and vapor heating air conditioners.

The membrane 1206 of the exchanger 213 may be formed from a thermoplastic sheet embedded with gamma alumina. A first air stream 1680 may pass through the first plurality of passages 1613 of the exchanger 213. The first air stream 1680 may be, for example, outside air and may be exposed to direct evaporative cooling in the first plurality of passages 1613. To that end, a refrigerant, such as, for example, water, may flow over the membrane walls that define the first plurality of passages 1613. The refrigerant may cool the outside air 1680. The outside air 1680 may evaporate the refrigerant and be discharged from the first plurality of passages 1613 as cool, moist air.

The second air flow 1681 may pass through the second plurality of passages 1614 of the exchanger 213. The second air flow 1681 may be supply air and may be dehumidified as it passes through the second plurality of passages 1614.

In some embodiments, the fresh supply air stream 1681 may be ultra-dry air exiting the second plurality of passages 1614 and passed through a direct evaporative device using vapor compression-based cooling at 55° F. and 100% humidity to bring it to supply conditions. In other embodiments, the supply air stream 1681 may be cooled moist air exiting the first plurality of passages 1613 and passed back through the second plurality of passages 1614. In further embodiments, the supply air stream 1681 may be a separate flow of air, such as recirculated air exiting the system, for example, from a building. In such embodiments, the cool moist air from the first plurality of passages 1613 may indirectly cool the recirculated supply air stream 1681, whereby the cool moist air may remove heat from the recirculated supply air stream 1681 through the membrane wall 1206. To remove moisture from the supply air stream 1681, a liquid desiccant such as, for example, lithium chloride may flow over the membrane walls 1206 defining the second plurality of passages 1614. The flow of lithium chloride contained entirely within the porosity of the gamma alumina embedded within the membrane 1206 may dehumidify the supply air stream 1681 by adsorbing moisture from the supply air stream 1681.

As described above and illustrated in FIGS. 15d-15h, the exchanger 213 may also include a first liquid distribution header 1632 and a second liquid distribution header 1634 configured to deliver refrigerant and liquid desiccant onto the internal membrane wall 1206 forming the first and second plurality of passages 1613 and 1614 of the exchanger 213. The first liquid distribution header 1632 may deliver a refrigerant, such as water, along the first plurality of passages 1613. The porous member 1630 may deliver a continuous flow of water onto the internal membrane wall 1206 forming the first plurality of passages 1613, and the water may flow down the membrane wall 1206 in a direction perpendicular to the ambient air flow 1680.

The second liquid distribution header 1634 may deliver a liquid coolant, such as, for example, lithium chloride, along the second plurality of passages 1614. The porous member 1630 may deliver a continuous flow of lithium chloride onto the interior membrane wall 1206 forming the second plurality of passages 1614, and the lithium chloride may flow down the membrane wall 1206 in a direction perpendicular to the supply air flow 1681. In some embodiments, the water flow delivered by the header 1632 may be 1/16 inch, and the lithium chloride flow delivered by the header 1634 may be 1/16 inch.

The air conditioner module 1600, including the exchanger 213 and the first and second liquid distribution headers 1632 and 1634, may also be configured to provide indirect evaporative cooling. In such a configuration, a liquid refrigerant, such as water, may be delivered onto the interior membrane walls 1206 of both the first and second plurality of passages 1613 and 1614. As a result, the supply air flow 1681 may be cooled, but relatively humid.

In some embodiments, the air conditioner module 1600 may function as a highly efficient liquid desiccant regenerator. The first liquid 1626 delivered to the air conditioner module 1600 may be a weak liquid desiccant, such as lithium chloride. The lithium chloride may be in contact with a first air stream 1680, which may be atmospheric air. The second air stream 1681 may be directly heated and physically separate from the first air stream, while maintaining thermal contact to allow heat to pass freely between them and to allow the lithium chloride to be heated directly through the membrane wall 1206. The lithium chloride may be heated to drive off and thereby regenerate some of the water vapor already absorbed within the evaporatively cooled module. The regenerated liquid desiccant may be returned to the air conditioner module 1600 to remove the moisture again. The water vapor may be released from the regenerator module 1600 into the atmosphere.

The regenerator module 1600 may implement one or more energy sources for heating the second air stream 1681. In one embodiment, steam from a boiler may be applied directly to the second air stream 1681 in a closed loop to provide uniform heat (e.g., 212°F) across the membrane wall 1206. Condensate that forms and flows down the membrane wall may be collected and reheated. The steam may provide uniform thermal heating across the membrane surface, thereby creating ideal regeneration conditions to drive off water molecules from the lithium chloride.

In another embodiment, hot water between 160°F and 210°F may be used in the regenerator module 1600 to regenerate the lithium chloride. The hot water may be distributed via the second distribution header 1634 and directly warm the lithium chloride through the membrane wall 1206. In some embodiments, the hot water may be combined with steam heat depending on the energy available in a given period of time. In other embodiments, the second air stream is heated via direct flame combustion between 200°F and 300°F, thereby regenerating the lithium chloride.

The desiccant regenerator module 1600 previously described can provide substantial surface area to flow with the weak lithium chloride into the reject air stream. This large surface area serves to lower the temperature of the heat required and reduce energy usage compared to existing regenerative boilers. Additionally, the exchanger 213 comprises the same materials and components, thus allowing the regenerator module 1600 to change operating modes and provide different functions for the entire building (e.g., during different seasons).

In a preferred embodiment of the air handling system, a further air handling module consisting of a sensible heat air-to-air plate exchanger (not shown) may preheat the first air stream, further enhancing the rejection of water molecules from the liquid desiccant, and return through said sensible heat air-to-air plate exchanger. This embodiment advantageously reduces the amount of thermal energy lost from the first air stream 1680 to the atmosphere.

Although not shown, a suitable system may be coupled to the exchanger 213 to recover, treat, and recycle the refrigerant and liquid desiccant delivered through the exchanger 213. For example, water or water vapor from the first passage 1613 may be recovered and recycled through a suitable threaded port. In some embodiments, the recovered water may be further cooled via a refrigerant or the like before being delivered to the exchanger 213. Additionally, the cooled weak liquid desiccant from the second plurality of passages 1614 may be recovered and sent through a suitable threaded port to a regenerator, such as, for example, a boiler. The strong liquid desiccant from the regenerator may then be recycled back to the exchanger.

Multiple functions and multiple modes may be alternated depending on the operating requirements of the conditioned building space. The exchanger 213 with alternating header arrays 1632 and 1634 and supply system may be instantly configured to provide indirect evaporative cooling. In such a configuration, liquid refrigerant such as water may be delivered onto the membrane walls of both the first and second multiple passages 1613 and 1614.

The evaporative liquid desiccant air conditioner modules 1600 can be stacked adjacently in a vertical orientation to form an evaporative liquid desiccant air conditioner system. With reference to FIG. 8a, for example, in each module 812a, 812b, and 812c, the air conditioner module 1600 can house the components of the air conditioner module 1600 described in FIGS. 15a-15h.

15i illustrates a perspective view of an evaporative liquid desiccant hexagonal exchange module 1660 according to the present disclosure. The exchange module 1660 may accommodate airflow in a counter-flow configuration. The exchange module 1660 may include a plurality of plates 1615 arranged in a stacked configuration with a plurality of intermittently sealed plate edges 1620. A portion of the plates 1615 may be spaced apart and include a first series of discrete alternating passages 1613 and a second series of discrete alternating passages 1614. A first airflow 1680 may be passed through the first series of passages 1613 and a second airflow 1681 may be passed through the second series of passages 1614 in a counter-flow configuration with respect to the first airflow 1680. The exchange module 1660 may include an airflow divider 1662 for separating the first airflow 1680 and the second airflow 1681.

The exchange module 1660 may include a first liquid supply conduit 1622 secured to a first liquid threaded inlet 1636 and a second liquid supply conduit 1624 secured to a second threaded inlet 1638. The first liquid 1626 and the second liquid 1628 may be pumped into the first liquid supply conduit 1622 and the second liquid supply conduit 1624, respectively. The first liquid distribution header 1632 may deliver the first liquid 1626 from the first liquid supply conduit 1622 to the first series of passages 1613. The second liquid distribution header 1634 may deliver the second liquid 1628 from the second liquid supply conduit 1624 to the second series of passages 1614. The first liquid distribution header 1632 and the second liquid distribution header 1634 can be positioned within the first passage 1613 and the second passage 1614 of the plate 1615. Positioning the first liquid distribution header 1632 and the second liquid distribution header 1634 within the first passage 1613 and the second passage 1614 can form a compact shape and maintain a hexagonal shape that is compatible with applications that utilize existing hexagonal counterflow plate exchangers.

The exchange module 1660 may also include a liquid recovery system for recovering the first liquid 1626 and the second liquid 1628 flowing from the plurality of first passages 1613 and the plurality of second passages 1614. The liquid recovery system may include a first liquid drain conduit 1616 for recovering the first liquid 1626 flowing from the first passage 1613 and a second liquid drain conduit 1618 for recovering the second fluid 1628 flowing from the second passage 1614. The first liquid drain conduit 1616 and the second liquid drain conduit 1618 may be located entirely outside the exchanger 213 and adjacent the second ends of the plurality of plates 1615.

15j illustrates a perspective view of another configuration of an evaporative liquid desiccant hexagonal shape exchange module 1660 according to the present disclosure. As shown in FIG. 15j, the first liquid distribution header 1632 and the second liquid distribution header 1634 can be positioned outside the first passage 1613 and the second passage 1614 of the plate 1615. Positioning the first liquid distribution header 1632 and the second liquid distribution header 1634 outside the first passage 1613 and the second passage 1614 can provide an unobstructed path for counterflow for the first air flow 1680 and the second air flow 1681.

The present disclosure contemplates a multi-function remote energy recovery system. With reference to FIG. 15k, in some embodiments, a system 1690 may be implemented to perform multi-function remote energy recovery. The system 1690 may be configured to recover heat and moisture between two or more desorbed air streams. The system 1690 may include a first liquid desiccant recovery and exchange module 1691 and a second liquid desiccant recovery and exchange module 1692. The first liquid desiccant recovery and exchange module 1691 and the second liquid desiccant recovery and exchange module 1692 may embody the exchange module 1660 described in FIG. 15i and FIG. 15j.

A first air flow 1680, which may be, for example, process supply air to a building, may pass through a first liquid desiccant recovery and exchange module 1691 and may be dehumidified and cooled by a first liquid 1626, which may be, for example, a strong desiccant, and a second air flow 1681, which has passed through the first liquid desiccant recovery and exchange module 1691, may be, for example, cooled by a second liquid 1628, which may be, for example, water that evaporates into the atmosphere, etc.

With respect to the second liquid desiccant recovery and exchange module 1692, a first air flow 1680, which may be, for example, exhaust air from a building, may pass through the module 1692. A first liquid 1626, which may be a weak desiccant, may extract energy from the exhaust air at a remote location, while a second air flow 1681, which may be, for example, water that evaporates into the atmosphere, etc., that has passed through the second liquid desiccant recovery and exchange module 1692, may simultaneously cool the exhaust air.

The first liquid desiccant recovery and exchange module 1691 may be connected to the second liquid desiccant recovery and exchange module 1692 via a conduit pipe, and an enthalpy pump may facilitate the flow of liquid desiccant between the modules 1691, 1692. A first liquid drain conduit 1616 on the first exchange module 1691 may collect the weak desiccant. The weak desiccant may be sent to the second exchange module 1692 via a weak desiccant pump 1664 powered by a motor 1665. The weak desiccant may be delivered to the second exchange module 1692 via a weak desiccant conduit 1668.

A first liquid drain conduit 1616 on the second exchange module 1692 may collect the strong desiccant. The strong desiccant may be sent to the first exchange module 1691 via a strong desiccant pump 1666 powered by a motor 1667. The strong desiccant may be delivered to the first exchange module 1691 via a strong desiccant conduit 1670. A second liquid drain conduit 1618 connected to each of the first exchange module 1691 and the second exchange module 1692 collects excess water that cannot be evaporated, which may be returned to the liquid distribution headers 1632, 1634 of the modules 1691, 1692.

In some embodiments, the evaporative cooling liquid desiccant air handling unit of the present disclosure may process outside air at a temperature of approximately 86°F and a humidity ratio of 135 grains. The liquid desiccant used may be a 45% lithium chloride solution. 600 cfm may be passed through the air handling unit with a 0.063 inch gap between the plates. The resulting supply air exiting the unit may have a temperature of 80°F and a humidity ratio of 35 grains.

Water or saltwater, such as lithium chloride, may be the most common solvent used to remove inorganic contaminants, such as formaldehyde and other VOCs. In some embodiments, the evaporative cooling and steam regeneration module 1600 of the present disclosure may function independently or simultaneously as a regenerative scrubber system.

In some embodiments, referring to FIG. 15k, an air handling system 1690 may be implemented to control carbon dioxide (CO ₂ ), formaldehyde, and volatile organic compounds (VOC) emissions from building enclosures. The CO ₂ liquid sorbent flows through the exchanger and may be regenerated by thermal means to release and capture absorbed CO _2. Amines are well known for reversible reactions with CO ₂ , making them ideal for CO ₂ capture from several gas streams, including combustion exhaust gases. Systems for controlling and removing CO ₂ from breathable air supplies may be utilized in submarines, spacecraft, space suits, and various types of building enclosures. In this regard, selective CO ₂ absorption by water-soluble alkanolamines is energy intensive and the sorbents may be corrosive.

Physical absorption of contaminant molecules may depend on the properties of the gas stream and liquid solvent, such as density and viscosity, as well as the specific properties of the contaminant in the gas and liquid stream, including diffusivity and equilibrium solubility. For most regenerating solvents, these properties may be temperature dependent. Lower temperatures generally favor absorption of gas by the solvent. Absorption may be enhanced by a larger contact surface area, a higher liquid-to-gas ratio, and a higher concentration in the gas stream. Chemical absorption may be limited by reaction rate, but the rate-limiting step is typically the physical absorption rate, not the chemical reaction rate. A cold solution of an alkylamine may bind _CO2 , but the binding may be reversed at higher temperatures. The integrated indirect evaporation of the present disclosure may cool the amine solution, while the integrated secondary air flow path indirectly charged with steam may heat the amine solution. This may generate a temperature difference large enough to continuously remove most of the carbon dioxide from the process air stream. This may be done in concert with the removal of lithium chloride water vapor, reducing the need for outside air.

Carbon dioxide from the process air stream is absorbed by the amine solution, which is then regenerated by heating, and the resulting desorbed carbon dioxide can be discarded in a second gas stream. The concentrated gas stream can then be released to the atmosphere or solidified by a combination of compression and low-temperature condensation.

Amines and other organics are often coated with a thin layer but can prove subject to physical losses due to carryover or entrainment as vapor or liquid. Amine dispensing can be accomplished without generating microdroplets that can be entrained in the air stream. In an absorption cycle, a parallel portion of the excess water vapor in the air can then be absorbed by a mixture of an alkylamine and an aqueous solution of lithium chloride. It may be advantageous to run the absorption portion of the cycle at atmospheric wet bulb temperature. Indirect evaporation in summer conditions and indirect free airside cooling in winter conditions can result in low energy utilization for carbon dioxide scrubbing. The air that passes through the adsorber can then be returned or supplied to the building with negligible amounts of its original carbon dioxide and water vapor.

For regeneration purposes for reuse, the exchanger may be indirectly heated via hot water or steam to a temperature of 200° F. or slightly above. Carbon dioxide, formaldehyde, VOC compounds, and chemical absorption water contained in the reversibly combined aqueous solution may be driven off. The warm aqueous solution of alkylamines may then be cooled by indirect evaporation and process air. A liquid-to-liquid heat exchanger (not shown) may be used to preheat the solution contained in conduit 1668 and precool the solution contained in conduit 1670. The liquid-to-liquid heat exchanger may be made of a material compatible with the corrosive salts and strong alkylamine solutions, including, for example, polymers, stainless steel, nickel, titanium, or carbon.

The system 1690 of the present disclosure may be used to absorb carbon dioxide and desorb in a more concentrated form into another gas stream. With this application, carbon dioxide may be expelled from an enclosed environment to the atmosphere, but the resulting concentrated air stream may provide other opportunities and uses. The system 1690 of the present disclosure may help occupants improve their health, productivity, and comfort, improve mental and/or physical task performance, increase alertness, quality of life, and enjoyment, reduce drowsiness, and assist in curing and preventing illness by reducing the percentage of carbon dioxide in the enclosed space to beneficial and safe levels.

Formaldehyde is a common indoor pollutant that is an irritant and is classified as a carcinogen. While adsorption techniques are safe, stable, and can efficiently remove formaldehyde, their short life span and low adsorption capacity can limit indoor applications. The system 1690 of the present disclosure can remove undesirable air contaminant molecules via absorption into a liquid solvent, reaction with an adsorbent or reagent solution, or by inertial or diffusive collision.

The system 1690 of the present disclosure may remove inorganic smoke, vapors, and gases (e.g., chromic acid, hydrogen sulfide, ammonia, chlorides, fluorides, and _SO2 ), volatile organic compounds (VOCs), and PM including particulate matter (PM) having an aerodynamic diameter of 10 micrometers (μm) or less ( _PM10 ), PM having an aerodynamic diameter of 2.5 μm or less ( _PM2.5 ), and hazardous air pollutants (HAP) in particulate form ( _PMHAP ).

Absorption may be used as a raw material and/or product recovery technique in the separation and purification of gas streams containing high concentrations of VOCs, especially water-soluble compounds such as methanol, ethanol, isopropanol, butanol, acetone, and formaldehyde. Hydrophobic VOCs may be absorbed using amphiphilic block copolymers that are dissolved in water. However, as an emission control technique, it may be more common to use it to control inorganic gases rather than VOCs. When using absorption as a primary control technique for organic vapors, the spent solvent must be easily regenerated or disposed of in an environmentally acceptable manner in accordance with Environmental Protection Agency regulations.

The suitability of gas absorption as a pollution control method may generally depend on the following factors: (1) the availability of a suitable solvent, (2) the required removal efficiency, (3) the contaminant concentration in the inlet vapor, (4) the capacity required to handle the waste gas, and (5) the recoverable value of the contaminant or the disposal cost of the non-recoverable solvent.

The air handling and scrubbing system 1690 may maintain indoor air quality at acceptable levels within various enclosed spaces by providing comfortable, healthy conditions and cleanliness. HVAC systems may represent a significant portion of a building's energy budget, especially in extreme climates. The system 1690 of the present disclosure may provide a practical, modular, and scalable system for removing contaminants from the circulating air within the HVAC system, utilizing renewable absorbents and continuous absorption-desorption cycles that are isothermally cooled and isothermally heated, respectively.

Treating large volumes of indoor air with low concentrations of organic and inorganic contaminants may require large volumes of absorbent materials to be in intimate contact with the large volumes of circulating indoor air. It may also be advantageous to use an air handling system, such as air handling unit 100, that is scalable and relatively compact in size for easy installation in existing buildings by human operators. Furthermore, different buildings may have different airflow requirements and contaminant levels. To efficiently and practically manufacture and deploy air handling systems that can be adapted to a variety of buildings, it may be advantageous to provide a modular air handling system design based on one size that is easily manufactured and combined to provide a scalable solution to different building sizes and air quality requirements. It may also be advantageous to create an air handling system that is easily integrated with existing HVAC systems rather than replacing existing infrastructure.

Buildings according to the present disclosure may include, but are not limited to, office buildings, residential buildings, stores, malls, hotels, hospitals, restaurants, airports, train stations, and/or schools. Vehicles according to the present disclosure may include, but are not limited to, automobiles, ships, trains, airplanes, or submarines.

The scrubbing system 1690 of the present disclosure may be configured to remove undesirable gases, vapors, and pollutants generated within a human occupied space by occupants, including, but not limited to, volatile organic compounds (VOCs) and _CO2 . Other pollutants that may be removed include, but are not limited to, carbon monoxide, sulfur oxides, and/or nitrous oxides.

Referring to FIG. 15k, a multi-function air handling and scrubbing system 1690 may be configured to remove carbon dioxide. The system 1690 may include a first carbon dioxide scrubbing module 1691 and a second regeneration module 1692. The first module 1691 and the second module 1692 may embody the exchange module 1660 described in FIG. 15i and FIG. 15j.

A first air stream 1680, which may be, for example, process supply air to a building, passes through a first carbon dioxide scrubbing module 1691, and the carbon dioxide may be removed and cooled by a first liquid 1626, which may be, for example, an aqueous solution of an alkylamine, and then a second air stream 1681, which has passed through the first carbon dioxide scrubbing module 1691, may be cooled by a second liquid 1628, which may be, for example, water that evaporates into the atmosphere, etc.

With respect to the second regeneration module 1692, a first air stream 1680, which may be, for example, atmospheric air, may pass through the module 1692. The first liquid 1626, which may be carbon dioxide saturated alkylamine, may release carbon dioxide while the air stream 1681 may be, for example, running vapor saturated in a closed loop (not shown) and may simultaneously heat the saturated alkylamine.

The first carbon dioxide scrubbing module 1691 may be connected to the second regeneration module 1692 via a conduit pipe, and a liquid pump may facilitate the flow of alkylamine between the modules 1691, 1692. A first liquid drain conduit 1616 on the first exchange module 1691 may collect the saturated alkylamine. The saturated alkylamine may be sent to the second regeneration module 1692 via a saturated alkylamine pump 1664 powered by a motor 1665. The saturated alkylamine may be delivered to the second regeneration module 1692 via a saturated alkylamine conduit 1668.

A first liquid drain conduit 1616 on the second exchange module 1692 may collect the regenerated alkylamine. The regenerated alkylamine may be sent to the first exchange module 1691 via a regenerated alkylamine pump 1666 powered by a motor 1667. The regenerated alkylamine may be delivered to the first exchange module 1691 via a regenerated alkylamine conduit 1670. A second liquid drain conduit 1618 connected to each of the first exchange module 1691 and the second exchange module 1692 collects excess water that cannot be evaporated, and the excess water may be returned to the liquid distribution headers 1632, 1634 of the modules 1691, 1692.

15l illustrates a psychrometric chart corresponding to the operation of the evaporative cooling and/or vapor regenerating liquid desiccant air conditioner module of the present disclosure. FIG. 15l shows a first airflow from outside air (OA) to supply air (SA), a second airflow from return air (RA) to exhaust air (EA), and a third regenerating airflow. The first airflow may traverse points C and D, the second airflow may traverse points A and B, and the third airflow may traverse points C, E, and F. FIG. 15l is a chart showing estimated temperature and humidity levels for the first, second, and third airflows as they traverse these points.

The first and second air flows may flow through the heat exchanger in a countercurrent orientation. Point A may represent summer return air conditions from the conditioned space. The second air flow may enter the inlet port of the heat exchanger at point A in FIG. 15l and flow through the heat exchanger to point B. The second air flow may be exposed to a liquid desiccant solution that may flow along the membrane surface of the heat exchanger. The liquid desiccant may serve to dehumidify the second air flow. The first air flow may simultaneously flow through the heat exchanger from point C to point D in a countercurrent orientation with respect to the second air flow. Heat capacity may be transferred from the second air flow to the first air flow as the second air flow flows through the heat exchanger from point A to point B and the first air flow flows through the heat exchanger from point C to point D. The third regeneration air stream may be heated by a heat source from point C to point E and may draw moisture from the liquid desiccant solution from point E to point F, which may flow along the membrane surface of the heat exchanger. Drawing moisture from the liquid desiccant solution from point E to point F may reconcentrate the liquid desiccant solution.

The exchanger 213 of the present disclosure may be used in various types of heat and water vapor exchangers. For example, as noted above, the exchanger 213 may be used in an energy recovery ventilator to transfer heat and water vapor between air streams entering and leaving a building. This may be accomplished by passing the streams on opposite sides of the inverted pleat exchanger 213. The membrane 1206 of the exchanger 213 may allow heat and moisture to transfer from one stream to the other while substantially preventing the air streams from mixing or crossing. Other potential uses for the exchanger 213 may include, but are not limited to, those described in U.S. Patent No. 6,399,323, which is incorporated herein by reference.

Rotationally Molded Hollow Shells Figures 16a-d illustrate perspective views of a rotationally molded shell 1700 according to the present disclosure. The shell 1700 may include interstitial spaces 1701 filled with insulating material 1702. The insulating material 1702 may include powdered metal oxides, powdered inorganic oxides, silica powder, fumed silica powder, and/or aerogel powder. Powdered ceramics may be superior to traditional urethane foams because the thermal performance of the foam degrades when inert gases trapped inside the pore structure escape over time. Powdered ceramics may provide insulation and prevent heat buildup.

The walls of the shell 1700 may be rotationally molded (rotomolded). The shell 1700 may be formed from crosslinked or non-crosslinked polyolefins, including, for example, polyethylene (PE), polypropylene, filled polypropylene, polybutylene (PB), crosslinked polyethylene (PEX), polyamide, polysulfone, polyetherketone, polyethylene terephthalate (PET), and mixtures thereof. The walls of the rotationally molded shell 1700 may be further modified with additives, fillers, and reinforcements, including, for example, boron fiber, carbon fiber, glass fiber, Kevlar fiber, silanes, titanates, chlorides, bromine, phosphorus, metal salts, calcium carbonate, silica, clay, chromates, carbon black, pigments, or combinations thereof. In some embodiments, the exterior and interior walls of the shell 1700 may be formed from a non-brittle thermoplastic, such as polypropylene. Polypropylene may also be carbon impregnated to provide UV protection and thermal deformation.

In some embodiments, the interstitial space 1701 of the shell 1700 may be placed under vacuum and filled with loose, unformed powder insulation 1702 for additional insulation. Thermal conductivity may be measured to be less than 0.010 W/(m·K), and preferably less than 0.004 W/(m·K) under vacuum.

In some embodiments, the filled shell 1700 can be used to create building components such as, for example, wall panels 1703. A typical wall using 2x4 wall studs may be 3.5 inches thick, with ½ inch thick drywall and ½ thick exterior plywood and/or siding inside, for a total wall thickness of 4.5 inches. Assuming a modest 4 inches of vacuum insulation, a wall panel 1703 formed from the filled shell 1700 can yield an R-value of 100 or more.

In other embodiments, the air handling, energy recovery, and dehumidification modules of the present disclosure may be insulated by forming the components of the modules with a filled rotationally molded shell 1700. For example, the components of the modules may be rotationally molded (rotomolded), including the exchanger housing, air director, manifold, fan box, access panel, and electrical system access panel. The rotationally molded components may include an exterior wall, an interior wall, and a hollow interstitial space between the exterior and interior walls. The hollow interstitial space may be filled with a suitable insulating material, including, for example, a powdered ceramic, such as fumed silica or preferably an aerogel powder. The rotomolded components of the modules may be lighter than existing components of the air handling and conditioning system. As a result, the modules of the present disclosure may be easily moved and transported by operators without the use of heavy machinery and the like.

The shell 1700 may also be useful in the construction of building walls, building basements, building roofs, aircraft shells, automotive enclosures, HVAC air handling modules, energy recovery ventilators, and air ducts. It may be advantageous to have molding features that allow multiple interconnected hollow shells to snap-fit together or otherwise structurally seal in these applications.

As shown in Figures 16a-16d, wall panels 1703 may be formed from a rotationally molded shell 1700 having interstitial spaces 1701 filled with insulation 1702. Wall panels 1703 may include electrical conduits, communication bus conduits, electrical outlets, water lines, hot water lines, window wells, skylight wells, shelves, structural supports, and wall hangers.

The wall panel 1703 may include an inner surface 1704, an outer surface 1705, an interconnecting left side 1706, an interconnecting right side 1707, an interconnecting top side 1708, and an interconnecting bottom side 1709. In some embodiments, the interstitial space 1701 may be under vacuum and the insulation 1702 may provide the necessary compressible structure to keep the inner surface 1704 and the outer surface 1705 from collapsing inward. The wall panel 1703 may be manufactured under vacuum, such that the shell 1700 is free of all defects and may be manufactured from a thermoplastic that prevents molecules from passing through or leaking in. The interstitial space 1701 of the wall panel 1703 may be linked to a centralized vacuum generator through multiple sealed and interconnected ports. Furthermore, the partial vacuum may be maintained throughout the life of the building structure where age, wear, and tear may cause micro-fractures or penetrations into the wall panel 1703, reducing or eliminating the original partial vacuum.

The partial vacuum controlled by the centralized vacuum generator can be adjusted given the temperature gradient between the inside and outside of the building. During periods of very cold or very hot, a higher vacuum may be desired, while a lower or no vacuum may be desired during periods of more moderate environmental temperatures. The ability to maintain and/or vary the thermal resistance of the walls of the structure can be advantageous by optimizing the energy properties in specific locations due to specific environmental conditions.

In some embodiments, the wall panel 1703 may include a hydronic distribution and return system 1710. The hydronic distribution and return system 1710 may use multiple interconnecting ports on the horizontal, vertical, and side surfaces of the wall panel 1703. The ports may serve as interchangeable attachment points for multiple structures including, for example, hot water lines, potable water lines, refrigerant lines, sewer/septic tanks, liquid desiccant lines, cold water lines, steam lines, vacuum lines, and/or other fluidly connected hydronic components found in commercial, residential, or industrial buildings. Additionally, the ports may be threaded and/or incorporate gasketed seals. These ports may be easily attached and detached to and from multiple appliances including, for example, sinks, bathtubs, toilets, cleaning machines, dishwashers, boilers, condensers, and evaporators.

The hot water circulation distribution and return system 1710 may be positioned along the bottom of the wall panel 1703 and may include a sewer conduit with at least two ports at each end and at least one port disposed in between. For example, a first sewer edge port 1717 may be positioned on the left side 1706, a second sewer edge port 1717 may be positioned on the right side 1707, and a third inner port 1719 may be positioned on the inner surface 1704. The sewer pipe 1718 may be freely disposed within the sewer conduit and may allow for a suitable pipe angle to facilitate gravity drainage.

The wall panels 1703 may include a hot water line 1713 with interconnecting first and second edge ports 1712 and an interior port. The wall panels 1703 may also include a potable water line 1715 with interconnecting first and second edge ports 1714 and an interior port 1716. These ports may be threaded and/or incorporate gasketed seals between the wall panels 1703 to maintain seals, pressure, and vacuum conditions between the liquids. In some embodiments, the port may have threads according to the National Taper Pipe (NPT), American Standard Straight Pipe for Mechanical Joints (NPSM), American Standard Straight Pipe (NPS), and British Standard Parallel Pipe (BSPP) standards with integrated sealing washers to ensure international compatibility with the British Standard Tapered Pipe (BSTP) standards.

The present disclosure contemplates any suitable number of tubes and ports for the wall panel 1703, and the ports may be arranged in any suitable location on the wall panel 1703, including, for example, on the exterior, upper, and lower surfaces. The conduit and sealed port connections of the hydronic distribution and return system 1710 may additionally serve as a means to bleed fluids from the interstitial spaces 1701 of the wall panel 1703 linked to a centralized vacuum generator.

In some embodiments, the wall panel 1703 may include a communication bus 1720. The communication bus 1720 may use multiple interconnecting ports on the horizontal, vertical, and side surfaces of the wall panel 1703. The interconnecting ports may serve as attachment points for multiple communication line types including, for example, electrical wires, communication bus lines, sensor probe lines, wire harness connectors, TV cables, DSL/Internet cables, telephone lines, security/camera wires, and combinations thereof. The communication bus 1720 may include a communication bus conduit 1723 with interconnecting first and second edge ports 1722 and an inner port 1724.

The present disclosure contemplates any suitable number of bus bars and bus ports for the wall panel 1703, and the ports may be arranged in any suitable location on the wall panel 1703, including, for example, on the exterior, upper, and lower surfaces. The conduit and sealed port connections of the communication bus 1720 may additionally serve as a means to bleed fluids from the interstitial spaces 1701 of the wall panel 1703 linked to a centralized vacuum generator.

In some embodiments, the wall panel 1703 may include a power distribution section 1730. The power distribution section 1730 may use multiple interconnecting ports on the horizontal, vertical, and side surfaces of the wall panel 1703. The interconnecting ports may serve as attachment points for multiple wire types, including, for example, AC power lines, DC power lines, ground wires, light switches, appliance outlets, and wire harness connectors. The power distribution section 1730 may include a receptacle conduit 1733 with interconnecting first and second edge ports 1732 and an inner port 1734. The power distribution section 1730 may also include a lighting conduit 1736 with interconnecting first and second edge ports 1735 and an inner port 1737.

The present disclosure contemplates any suitable number of power conduits and ports for the wall panel 1703, and the ports may be arranged in any suitable location on the wall panel 1703, including, for example, on the exterior, upper, and lower surfaces. The conduit and sealed port connections of the power distribution system 1730 may additionally serve as a means to bleed fluids from the interstitial spaces 1701 of the wall panel 1703 linked to a centralized vacuum generator.

In some embodiments, the wall panel 1703 may include an air distribution system 1740. The air distribution system 1740 may use multiple interconnecting ports with ducts. The interconnecting ports of the air distribution system 1740 may be positioned on the horizontal, vertical, and side surfaces of the wall panel 1703. The interconnecting ports serve as attachment points for multiple structures, including, for example, diffuser vents, return vents, supply and exhaust fans, metal ducts, access panels, and/or other fluidly connected components of the HVAC system. The first air duct 1761 may have at least two duct ports 1742 disposed at each end of the air duct 1761 and at least one inner port 1743 therebetween. The second air duct 1762 may have at least two duct ports 1744 disposed at each end of the air duct 1762 and at least one inner port 1745 therebetween. The third air duct 1763 may have at least two duct ports 1746 disposed at each end of the air duct 1763 and at least one inner port 1747 therebetween.

The evaporative liquid desiccant air conditioner modules 1600, 1660 may be positioned between the first air duct 1761 and the second air duct 1762 and may connect the first air duct 1761 with the second air duct 1762 to provide sensible cooling, dehumidification, heating, humidification, and ventilation to an enclosure such as a building. The air conditioner modules 1600, 1660 may be connected to and powered through the first fluid port 1748 and the second fluid port 1749.

For example, a first portion of the air duct 1761 may carry outside air through the air conditioner modules 1600, 1660, and a first portion of the air duct 1762 may deliver conditioned outside air to the space through the inner air duct port 1745. A second portion of the air duct 1761 may draw return air through the inner air duct port 1743 and through the air conditioner module 1600, and stale air may be exhausted through the second portion of the air duct 1762. A first fluid port 1748 may flow strong lithium chloride salt to dry outside air, while a second fluid port 1749 may flow water for indirect evaporative cooling of the outside air using the return air.

Although not shown, one or more air movement systems may be coupled to the centralized system via sealed ducts. Additionally, natural ventilation and natural buoyancy of the air may be a means to deliver conditioned outside air into the building or enclosure. In some embodiments, the size of the air conditioner modules 1600, 1660 may encompass most, if not all, of the interstitial space of the wall panels 1703 depending on the requirements of the particular location. The present disclosure contemplates any suitable number of air ducts and ports to the wall panels 1703, and the ports may be arranged in any suitable location on the wall panels 1703, including, for example, on the exterior, upper, and lower surfaces. The ducts and sealed port connections of the air distribution system 1740 may additionally serve as a means to bleed fluid from the interstitial space 1701 of the wall panels 1703 linked to a centralized vacuum generator.

In some embodiments, the wall panel 1703 may include a structural connector 1750 including a plurality of interconnecting ports and tabs on the horizontal and vertical sides of the wall panel. The interconnecting ports and tabs may align and attach a plurality of adjacent wall panels 1703 and may include, for example, structural anchor bolts, module interconnect clamps, module seals, tongue and groove hermetic seals, and combinations thereof. For example, the male interconnecting tab 1752 on the left interconnecting side 1706 may be structurally hermetically sealed to the female interconnecting tab 1753 on the right side 1707. A plurality of structural pinholes 1754 may structurally lock the wall panel 1703 in place and keep the panel 1703 from coming loose. These structural pinholes 1754 may be grooved, which may facilitate the expansion and contraction of the panel 1703 as environmental conditions change. The interconnecting ports and structural tabs of the structural connector 1750 may additionally serve as a means to evacuate fluid from the interstitial spaces 1701 of the wall panels 1703 linked to a centralized vacuum generator.

The present disclosure contemplates any suitable type of interior texture or color 1771 applied to the inner surface 1704 during the molding process. Drywall found in typical building wall construction may be eliminated. Additionally, the surface of the wall panel 1703, molded from, for example, polypropylene, may have its surface color changed after manufacture/installation by using a primer specific to low surface energy plastics.

As shown in FIG. 16c, a number of components may be installed on the wall panel 1703 to complete the look and function of the interior. For example, a sewer cover plate 1781 may be mounted over the sewer inner port 1719. A communication cover plate 1782 may be mounted over the communication bus inner port 1724. A receptacle cover plate 1783 may be mounted over the receptacle inner port 1734. A lighting cover plate 1784 may be mounted over the lighting inner port 1737. A first HVAC grille 1785 may be mounted over the first air duct inner port 1743. A second HVAC grille 1786 may be mounted over the second air duct inner port 1745. A third HVAC grille 1787 may be mounted over the third air duct inner port 1747.

As shown in FIG. 16d, the present disclosure contemplates any suitable type of exterior texture or color 1772 on the exterior surface 1705 of the wall panel 1703. Exterior siding, trim, stucco, and various other elements typically found on exterior building wall construction may be eliminated. Additionally, the surface of the wall panel 1703, molded from, for example, polypropylene, may have its surface color changed after manufacture/installation by using a primer specific to low surface energy plastics.

The first air duct exterior port 1764 may connect to the first air duct 1761 with the first air duct port 1742 on the end of the first air duct 1761. The second air duct exterior port 1765 may connect to the second air duct 1762 with the second air duct port 1744 on the end of the second air duct 1744. The present disclosure contemplates any suitable number of exterior components to facilitate the purpose and intent of a particular building type or enclosure.

As shown in FIG. 16e, the present disclosure contemplates the use of a rotationally molded hollow shell 1700 on all interior and exterior surfaces of a building enclosure using interlocking structural tabs and multiple interconnecting ports. For example, multiple basement wall panels 1797 may be attached side-by-side to multiple three-sided wall connectors 1790. Wall panels 1703 may be positioned in a substantially side-by-side orientation to form the roof of a commercial, residential, or industrial building. In such a configuration, the roof may be formed from lightweight, durable panels 1703 and may be capable of accommodating all types of weather conditions, including hail. Textures, colors, and port placements may be selected to provide underfloor air distribution and underfloor utility distribution.

Floor panels 1794 may be attached horizontally to three-way floor connectors 1792. Wall panels 1703 may be attached vertically to three-way roof connectors 1793. Interior wall panels 1795 may be attached to three-way wall connectors 1790. Roof panels 1796 may be connected vertically to three-way roof connectors 1793. All interconnecting ports may be maintained throughout the transition between the various types of rotationally molded hollow shells 1700. For example, structural additives such as carbon fiber may be added to the below grade basement panels 1797 or roof panels 1796 to accommodate high structural loads. Numerous modifications and variations in the combination of these wall panel types may be readily apparent to one skilled in the art and may be combined to form a wide range of building shapes and sizes.

16f illustrates an exterior perspective view of a building system 1725 comprising a plurality of rotationally molded hollow shells 1700 having gap sections 1701 filled with insulation 1702. As shown in FIG. 16f, a ground wire 1799 references the molded hollow shell 1700, which is particularly advantageous for use in underground environments. A corner wall connector 1791 may be attached to a plurality of wall panels 1703 to form an exterior corner. The present disclosure contemplates any suitable type of exterior structure, such as, for example, windows, doors, air intakes, underground window wells, and exhausts. A window panel 1798 may be attached to a plurality of wall panels 1703. Numerous modifications and variations in the combination of these wall panel types would be readily apparent to one skilled in the art and may be combined to form a wide range of building shapes and sizes.

As shown in FIG. 16g, a three-way wall connector 1790 may be formed from a rotationally molded hollow shell 1700 having an interstitial space 1701 filled with insulation 1702. The three-way wall connector 1790 may include an interconnecting inner surface 1704, an outer surface 1705, an interconnecting left side 1706, an interconnecting right side 1707, an interconnecting top side 1708, and an interconnecting bottom side 1709. All interconnecting ports may be maintained throughout the transition between the various types of rotationally molded hollow shells 1700 facilitated by the three-way wall connector 1790.

As shown in FIG. 16h, the corner wall connector 1791 may be formed from a rotationally molded hollow shell 1700 having an interstitial space 1701 filled with insulation 1702. The corner wall connector 1791 may include two exterior surfaces 1705, an interconnecting left side 1706, an interconnecting right side 1707, an interconnecting top side 1708, and an interconnecting bottom side 1709. All interconnecting ports may be maintained throughout the transition between the various types of rotationally molded hollow shells 1700 facilitated by the corner wall connector 1791.

As shown in FIG. 16i, a three-way floor connector 1792 may be formed from a rotationally molded hollow shell 1700 having an interstitial space 1701 filled with insulation 1702. The three-way floor connector 1792 may include an outer surface 1705, an interconnecting inner surface 1704, an interconnecting left side 1706, an interconnecting right side 1707, an interconnecting top side 1708, and an interconnecting bottom side 1709. All interconnecting ports may be maintained throughout the transition between the various types of rotationally molded hollow shells 1700 facilitated by the three-way floor connector 1792.

As shown in FIG. 16j, a three-sided roof connector 1793 may be formed from a rotationally molded hollow shell 1700 having an interstitial space 1701 filled with insulation 1702. The three-sided roof connector 1793 may include an extended outer surface 1705, an interconnecting inner surface 1704, an interconnecting left side 1706, an interconnecting right side 1707, an interconnecting top side 1708, and an interconnecting bottom side 1709. All interconnecting ports may be maintained throughout the transition between the various types of rotationally molded hollow shells 1700 facilitated by the three-sided roof connector 1793.

Numerous modifications and variations will readily occur to those skilled in the art. The disclosure is not limited to the exact construction and operation illustrated and described. All suitable modifications and equivalents may be used and are within the scope of the disclosure.

99b Evaporator coil 100 Air handling module 101, 102 Ports 103, 104 Ports 105, 106 Ports 107, 108 Ports 107 Panel connector 109 Ports 110 Side 112 Side drain port 114 Side duct port 118 Side liquid desiccant drain port 120 Housing 130 Top 133 Top drain port 134 Top duct port 136 Top anchor port 137 Top liquid desiccant port 138 Top liquid desiccant port 139 Top evaporation port 140 Bottom 146 Bottom anchor port 177 Access panel 181 Fan box 186 Fan box 189 Fan 191 Filter 200 Air handling module 211 Exchanger housing 213 Exchanger 220 Manifold 222 Air director 230 Rotary damper 232 Actuator 240 Exchanger divider 250 Controller 252 Electrical disconnect 254 Disconnect handle 256 Latch 259 Electrical access panel 260 Intake rain guard 262 Metal duct 270 Access panel 272 Latch 280 Fan box 282 Latch 291 Filter 292 Heat exchanger 300 Manifold 303, 304, 305, 306 Air port 310 Air director 312 Side drain port 320 Top channel track 322 Bottom channel track 324 Manifold divider 332 Top drain port 336 Top anchor port 338 Insulation plug 342 Bottom drain port 346 bottom anchor port 350 top slide channel 352 bottom slide channel 360 economizer track 362 duct 370 latch 371 seal 376 access panel 380 fan box 381 seal 382 latch 389 fan 390 exchanger 390a arrow 390 air filter or coil 391 filter 391a arrow 392 inlet 394 outlet 400 manifold, manifold section 401 port 401 third opening 404 port 404 second opening 422 bottom channel track 422 first opening 422 passageway 430 rotary damper 432 rotary damper actuator 432 rotary motor 440 exchanger partition 440 exchanger partition section 452 bottom slide channel 466 arrow 467 arrow 468 fluid outlet 471 rotatable semi-cylindrical member 472 second opening 472 fluid inlet 473 first opening 473 fluid inlet 473 fluid flow 474 fluid flow 474 fluid outlet 475 fluid outlet 476 outer surface 477 inner surface 478 end wall 479 end ring 481 seal channel 482 seal channel 483 seal channel 484 shaft 485 utility tube 486 shaft mounting plate 487 bolt 489 end wall seal 490 end ring seal 500 air handling module 570 access panel 572 latch 573 seal 576 outer surface 577 inner surface 600 air handling module 601 port 601-602 ports 603-604 ports 606 ports 605-606 ports 607-608 ports 609 ports 610 sides 611 openings 612 air to air heat exchanger 613 openings 620 housing 622 air directing device 623 bypass openings 631 rotary damper 634 rotary damper 640 exchanger divider 671 access panel 672 access panel 673 access panel 674 access panel 675 access panel 676 access panel 677 access panel 678 access panel 679 access panel 681 fan box 682 fan box 686 fan box 688 fan box 689 fan 691a filter 691b filter 692a supply air coil 692b exhaust air coil 692c Exhaust coil 700 Air handling system 701 Port 706 Port 707-708 Port 710 Air handling module 730 Top 740 Bottom 757 Common duct 761 Intake rain guard 764 Intake rain guard 778 Access panel 781 Fan box 781 Fan housing 786 Fan box 789 Fan 799 Installation personnel 800 Air handling system 812 Air handling module 812a-812c Air handling module 818a-818c, 819a-819c Side liquid desiccant drain port 819a-819c Drain pipe 820a-820c Housing 825 Evaporated water 826 Liquid desiccant 827 Power line 831 Signal harness 832 first drain conduit 833 power conduit fitting 834 threaded port 834 top conduit port 834 threaded port 835 signal wire 837 port 838 second drain conduit 839 port 841 signal conduit fitting 843 power harness 844 bottom conduit ports 844a-844c bottom conduit ports 846 anchor port 848 single point power distribution 849 central controller 851 liquid desiccant tube 852 single point electrical disconnect 853 evaporative water tube 855 liquid desiccant drain tube 857a-857c electrical and economizer bypass enclosure 858 supply coil tube 861a-861c supply coil ports 863a-863c return coil ports 864 insulated threaded plug 865 Anchor bolts 867 Support base 869 Return coil tubing 880 Fan power and signal harness 881 AHU power and signal harness 900 Air handling system 900a Dual plate air handling module 900b Dual plate air handling module 900c Dual plate air handling module 901-902 Ports 901a, 908a Ports 901b Sealed ports 903-904 Ports 903a-904a Paired ports 904b, 905b Ports 905-906 Ports 905b-906b Paired ports 904a, 905a Ports 905a-906a Ports 905b-906b Ports 906 Ports 906b Ports 907 Ports 907a-908a Ports 908 Ports 908b sealed port 909 port 910 side 910a side 910b side 912a energy recovery module 912b energy recovery module 912c energy recovery module 914 air handling module 914a wraparound dehumidification module 914b wraparound dehumidification module 914b dehumidification arrangement 914c wraparound dehumidification module 915 enthalpy exchanger 915 energy recovery exchanger 916 sensible heat exchanger 916 wraparound heat exchanger 920 housing 920a housing 920b housing 922 air directing device 922a air directing device 922a coil 922b air directing device 922b coil 923a bypass opening 923b bypass opening 931a Rotary damper 931b Rotary damper 934a Rotary damper 934b Rotary damper 936 Return air (RA) port rotary damper 938 Port 940 Exchanger partition 940a Exchanger partition 940b Exchanger partition 941 Rotary damper 956 Single common supply air (SA) duct 957 Single common rectangular return duct 964 Intake rain guard 972 Access panel 973 Access panel 976 Access panel 977 Access panel 979 Access panel 981 Fan box 985 Fan housing 986 Fan housing 988 Fan box 989 Fan 991a Filter 991b Filter 992a Supply air coil 992b Exhaust coil 992c Exhaust coil 999 Installation personnel 1200 Coating chamber 1201 Substrate 1201 Sheeting structure 1201 Thermoplastic substrate sheet 1202 Substrate 1204 Coating surface 1206 Film or transfer medium 1210 Housing 1210 Coating chamber 1212 First calender roller 1212 Top roller 1214 Second calender roller 1214 Bottom roller 1216 First coating device 1218 Second coating device 1220 Supply 1222 Supply line 1222 Microporous particles 1224 First coating device 1225 Second coating device 1226 Substrate 1230 Substrate 1230 Doctor blade 1232 Doctor blade 1234 Microporous particles 1236 Shroud 1241, 1243 Micrometer 1242, 1244 Micrometer 1245, 1246 Micrometer 1264 Recovery system 1264 Conduit 1265 Exit port 1268 Cooling stage 1270 Winding stage 1272 Winder 1300 Separator 1302 Layer 1304 Corrugated mesh 1306 Filament member 1306 Sinusoidal wave member 1308 Filament member 1310 Aperture 1400 Separator 1402 Thermoplastic mesh 1404 Corrugation chamber 1406 Housing 1408 First continuous belt 1410 Second continuous belt 1412 First corrugated surface 1414 Second corrugated surface 1416 First drive unit 1418 Second drive unit 1420 Mesh 1422 Infrared lamp 1424 inlet section 1426, 1428 pulley or roller 1430 separator 1432 corrugated mesh material 1434 output section 1438 cooling source 1442 collector 1444 roll 1446 winder 1448 roller or festoon 1500 air filter 1504 filter material 1508 pleats 1514 input side 1516 output side 1600 evaporative cooling and/or vapor regenerative liquid desiccant air conditioner module 1613 first series of discrete alternating passages 1614 second series of discrete alternating passages 1615 plate 1616 first liquid drain conduit 1618 second liquid drain conduit 1620 plate edge 1622 first liquid supply conduit 1623 First liquid return conduit 1624 Second liquid supply conduit 1625 Second liquid return conduit 1626 First liquid 1628 Second liquid 1630 Porous member 1632 First distribution header 1634 Second distribution header 1636 First liquid threaded inlet 1638 Second threaded inlet 1640 First liquid threaded outlet 1642 Second liquid threaded outlet 1644 Compression rod 1645 Compression plate 1648 First liquid feeder channel 1650 Second liquid feeder channel 1652 Feeder hole 1654 Inlet 1656 Outlet 1660 Evaporative liquid desiccant hexagonal shaped exchange module 1662 Air flow divider 1664 Weak desiccant pump 1665 Motor 1666 Regenerative alkylamine pump 1667 motor 1668 weak desiccant duct 1670 duct 1672 membrane duct hole 1680 first air stream 1680 outside air 1681 second air stream 1681 supply air stream 1690 system 1691 first liquid desiccant recovery and exchange module 1692 second liquid desiccant recovery and exchange module 1700 rotationally molded shell 1701 interstitial space 1702 insulation 1703 wall panel 1704 inner surface 1705 outer surface 1706 interconnecting left side 1707 interconnecting right side 1708 interconnecting top side 1709 interconnecting bottom side 1710 hot water circulation distribution and recovery system 1712 first and second edge ports 1713 hot water pipe 1714 First and second edge ports 1715 potable water line 1716 inside port 1717 First and second sewer edge ports 1718 sewer line 1719 third inside port 1720 communication bus 1722 First and second edge ports 1723 communication bus conduit 1724 inside port 1725 building system 1730 power distribution 1732 First and second edge ports 1733 receptacle conduit 1734 inside port 1735 First and second edge ports 1736 lighting conduit 1737 inside port 1740 air distribution system 1742 duct port 1743 inside port 1744 duct port 1745 inside port 1746 duct port 1747 inside port 1748 1749 1st fluid port 1750 2nd fluid port 1750 Structural connector 1752 Male interconnect tab 1753 Female interconnect tab 1754 Structural pinhole 1761 1st air duct 1762 2nd air duct 1763 3rd air duct 1764 1st air duct outer port 1765 2nd air duct outer port 1771 Interior texture or color 1772 Exterior texture or color 1781 Sewer cover plate 1782 Communications cover plate 1783 Receptacle cover plate 1784 Lighting cover plate 1785 1st HVAC grille 1786 2nd HVAC grille 1787 3rd HVAC grille 1790 3 side wall connector 1791 Corner wall connector 1792 3 side floor connector 1793 3 side roof connector 1794 Floor panel 1795 Interior wall panel 1796 Roof panel 1797 Basement wall panel 1798 Window panel 1799 Ground wire

Claims (5)

Housing and
an exchanger housed within the housing;
a first manifold positioned on a first side of the housing and including a first pair of ports disposed on a first end and a second pair of ports disposed on a second end;
a second manifold positioned on a second side of the housing and including a first pair of ports disposed on a first end and a second pair of ports disposed on a second end,
a first pair of ports and a second pair of ports of the first manifold and a first pair of ports and a second pair of ports of the second manifold configured to replaceably mount a structure to the air handling module;
a first pair of ports of the first manifold in fluid communication with a first pair of ports of the second manifold to move air between the first and second manifolds through the exchanger, and a second pair of ports of the first manifold in fluid communication with a second pair of ports of the second manifold to move air between the first and second manifolds through the exchanger ;
An air handling module, the air handling module being configured to be coupled with one or more additional air handling modules to operate in parallel to achieve a combined air conditioning effect greater than the air conditioning effect of a single air handling module. The air handling module of claim 1, wherein the structure includes one or more of a fan box, a duct, a rain cover, a roof curb, and an access panel. The air handling module of claim 1, further comprising at least one rotary damper positioned in one of the first manifold and the second manifold, the rotary damper configured to selectively deliver treated air exiting the exchanger as supply air or directly deliver outside air as supply air. The air handling module of claim 3, wherein the rotary damper includes a rotatable semi-cylindrical member, the rotary damper configured to deliver airflow in a direction along an axis of rotation of the semi-cylindrical member and to deliver airflow in a direction perpendicular to the axis of rotation. The air handling module of claim 1, further comprising a plurality of internal ports and a plurality of external ports for a hot water circulation distribution and return system.

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