US20110179813A1

US20110179813A1 - Evaporative cooler with centrifugal fan

Info

Publication number: US20110179813A1
Application number: US12/695,663
Authority: US
Inventors: Jerry Chun Fan
Original assignee: Champion Cooler Corp
Current assignee: Champion Cooler Corp
Priority date: 2010-01-28
Filing date: 2010-01-28
Publication date: 2011-07-28

Abstract

Evaporative coolers are disclosed. An evaporative cooler includes a cooler housing, a centrifugal fan, and a motor. The cooler housing defines an interior region, a single air inlet, and an air outlet. The single air inlet is positioned to permit air flow into the interior region generally along an inlet axis. The air outlet is positioned to permit air flow from the interior region generally along an outlet axis. The inlet axis and outlet axis are angled with respect to one another. The centrifugal fan is mounted within the interior region of the cooler housing. The centrifugal fan is oriented to rotate about a vertical axis that is substantially orthogonal to the inlet and outlet axes. The motor is mounted within the interior region of the cooler housing and is coupled to the centrifugal fan. The motor is configured to rotate the centrifugal fan about the vertical axis.

Description

FIELD OF THE INVENTION

This invention relates generally to evaporative coolers, and more particularly to evaporative coolers having centrifugal fans.

BACKGROUND OF THE INVENTION

Evaporative coolers may be used to cool air by causing air to flow across a wet evaporative media. The effectiveness of an evaporative cooler may depend in part on the ability of the cooler to move air through the evaporative cooler and the ability of the cooler to manage the evaporation of water into the air flowing through the evaporative cooler.
Numerous advances in the effectiveness of evaporative coolers have been proposed over the year. Improvements in evaporative coolers are nevertheless desired.

SUMMARY OF THE INVENTION

Aspects of the present invention relate to evaporative coolers. An evaporative cooler in accordance with aspects of the present invention includes a cooler housing, a centrifugal fan, and a motor. The cooler housing defines an interior region, a single air inlet, and an air outlet. The single air inlet is positioned to permit air flow into the interior region of the cooler housing generally along an inlet axis. The air outlet is positioned to permit air flow from the interior region of the cooler housing generally along an outlet axis. The inlet axis and outlet axis are angled with respect to one another such that the general direction of air flow into the interior region of the cooler housing through the single air inlet differs from the general direction of air flow from the interior region of the cooler housing through the air outlet. The centrifugal fan is mounted within the interior region of the cooler housing. The centrifugal fan is oriented to rotate about a vertical axis that is substantially orthogonal to the inlet and outlet axes. The motor is mounted within the interior region of the cooler housing and is coupled to the centrifugal fan. The motor is configured to rotate the centrifugal fan about the vertical axis.
In accordance with another aspect of the present invention, a method is disclosed for configuring an evaporative cooler having a pump configured to pump water to evaporative media. A cooler housing is provided, the cooler housing defining an interior region, a single air inlet positioned to permit air flow into the interior region of the cooler housing generally along an inlet axis, and an air outlet positioned to permit air flow from the interior region of the cooler housing generally along an outlet axis, the inlet axis and outlet axis being angled with respect to one another such that the general direction of air flow into the interior region of the cooler housing through the single air inlet differs from the general direction of air flow from the interior region of the cooler housing through the air outlet. A centrifugal fan is mounted within the interior region of the cooler housing such that the centrifugal fan is oriented to rotate about a vertical axis that is substantially orthogonal to the inlet and outlet axes. Finally, a motor is mounted within the interior region of the cooler housing such that the motor is configured to rotate the centrifugal fan about the vertical axis.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is best understood from the following detailed description when read in connection with the accompanying drawing. Included in the drawing are the following figures:

FIG. 1 is a perspective view of an embodiment of an evaporative cooler in accordance with an aspect of the present invention;

FIG. 2 is a front view of the evaporative cooler of FIG. 1;

FIG. 3 is a right side view of the evaporative cooler of FIG. 1;

FIG. 4 is a cross-sectional top view of the evaporative cooler of FIG. 1 along the line 4-4 in FIG. 3;

FIG. 5 is a cross-sectional side view of the evaporative cooler of FIG. 1 along the line 5-5 in FIG. 2;

FIG. 6 is an exploded perspective view of the fan and motor assembly of the evaporative cooler of FIG. 1;

FIG. 7 is a back view of the evaporative cooler of FIG. 1 along the line 7-7 in FIG. 3;

FIG. 8 is an enlarged side view of the evaporative cooler of FIG. 5, showing a float of the evaporative cooler at a high water level;

FIG. 9 is an enlarged side view of the evaporative cooler of FIG. 5 showing a float of the evaporative cooler at a low water level;

FIG. 10 is a perspective view of the float of the evaporative cooler of FIG. 1;

FIG. 11 is a cross-sectional back view of another embodiment of an evaporative cooler in accordance with an aspect of the present invention, showing a float at a high water level;

FIG. 12 is a cross-sectional back view of the evaporative cooler of FIG. 11 showing a float at a low water level;

FIG. 13 is a perspective view of the float of the evaporative cooler of FIG. 11; and

FIG. 14 is a top view of the display of the evaporative cooler of FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

Although the invention is illustrated and described herein with reference to specific embodiments, the invention is not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the invention.
The invention is best understood from the following detailed description when read in connection with the accompanying drawing figures, which show exemplary embodiments of the invention selected for illustrative purposes. The invention will be described with reference to the figures. Such figures are intended to be illustrative rather than limiting and are included herewith to facilitate the explanation of the present invention.
As an overview, FIGS. 1-12 show an embodiment of an evaporative cooler, generally referenced by numeral 100, in accordance with an aspect of the present invention. Broadly, evaporative cooler 100 includes a cooler housing 102, fan 120, motor 130, pump system 140, and float 160. Additional details of evaporative cooler 100 will be provided herein.
Cooler housing 102 defines the interior region of evaporative cooler 100. Cooler housing 102 further defines an air inlet 106 for permitting air flow into the interior region of cooler 100, and an air outlet 110 for permitting air flow out of the interior region of cooler 100. Air inlet 106 permits air flow generally along an inlet axis (indicated by inlet axis 107), while air outlet 110 permits air flow generally along an outlet axis (indicated by outlet axis 111).
Cooler housing 102 includes a side wall 104 and a front wall 108. Side wall 104 defines air inlet 106, and front wall 108 defines air outlet 110. Cooler housing 102 may optionally include only a single air inlet 106. Including only one air inlet 106 may improve air flow through cooler housing 102. Specifically, air flow through a primary inlet opening (as opposed to air flow through plural openings positioned about the cooler housing) is believed to reduce the generation of air turbulence and to promote an air flow pattern more like laminar flow.
As illustrated in FIGS. 1-3, cooler housing 102 may be shaped such that the height of side and front walls 104 and 108 is longer than their width. This shape may provide for a larger volume of cooled air within the interior region of cooler housing 102 or an increased capacity of the cooler to deliver cooled air while at the same time reducing the floor space or area or footprint required for evaporative cooler 100.
Additionally, side and front walls 104 and 108 may define air inlet and outlet 106 and 110 such that the height of air inlet and outlet 106 and 110 is longer than their width. This shape may provide for a larger volume of air flow into and out of cooler housing 102. It will be understood, however, that the shape of cooler housing 102 illustrated in FIGS. 1-5 is illustrative and not limiting and may be selected from a wide variety of shapes. Cooler housing 102 may therefore have any shape or size as dictated by non-functional, ornamental, and aesthetic considerations.
Cooler housing 102 may further include an inlet grating 112 covering air inlet 106 and an outlet grating 114 covering air outlet 110, as illustrated in FIGS. 1-3. Inlet grating 112 may be angled to direct air flow into the interior region of housing 102 along the general direction of inlet axis 107. Inlet grating 112 may be coupled to evaporative media 113. Evaporative media 113 may cover the entire area of air inlet 106. Thus, air flowing into the interior region of cooler housing 102 may pass through evaporative media 113. Outlet grating 114 may be angled to direct air flow out of the interior region of housing 102 along the general direction of outlet axis 111. Outlet grating 114 may further be adjustable. For example, vertical vanes of outlet grating 114 may be movable to direct air flowing from cooler housing 102 in different directions. Accordingly, a user of cooler 100 may use outlet grating 114 to control the direction of air flow out of the interior region of cooler housing 102 through air outlet 110.
As illustrated in FIGS. 1 and 4, inlet axis 107 and outlet axis 111 are angled with respect to one another. This may allow the general direction of air flow through air inlet 106 into the interior region of cooler housing 102 to differ from the general direction of air flow through air outlet 110 from the interior region of cooler housing 102. In an exemplary embodiment, cooler housing 102 has a roughly rectangular horizontal cross-section, as illustrated in FIGS. 1 and 4. Preferably, side wall 104 and front wall 108 are oriented such that the inlet axis 107 of air inlet 106 and the outlet axis 111 of air outlet 110 form an angle of between approximately 45° and 135° with respect to each other, and more preferably approximately 90° with respect to each other, though other angles can be optionally selected. Angling inlet axis 107 with respect to outlet axis 111 may provide for better cooling and/or flow of air in cooler housing 102 and/or air flow in the vicinity of the cooler housing 102 in a room or space to be cooled.
Cooler housing 102 receives water for use in evaporative cooling. In an exemplary embodiment, cooler housing 102 defines a receptacle for receiving water in the interior region of cooler housing 102. The receptacle may be formed in a bottom portion of cooler housing 102, as illustrated in FIG. 5. The receptacle for receiving water may be defined in part by the outer walls of cooler housing 102. Alternatively, cooler housing 102 may include a separate structure defining the receptacle such as, for example, a basin positioned in the interior region of cooler housing 102. The receptacle may extend up to the bottom edges of air inlet 106 and/or air outlet 110.
Cooler housing 102 may further include a water access port 116 for allowing a user to provide water to the interior region of cooler housing 102, as illustrated in FIGS. 4 and 5. A user may pour water through water access port 116. Water access port 116 may further include a door for closing water access port 116 during operation of evaporative cooler 100. Water received in the receptacle defined by cooler housing 102 may be used to cool the air flowing through cooler housing 102 by the process of evaporation. The evaporative cooling process of evaporative cooler 100 will be described herein.
Cooler housing 102 may be formed from a single integral piece of material, or from multiple pieces of material. Suitable materials for forming cooler housing 102 include, for example, acrylonitrile butadiene styrene (ABS), high-impact polystyrene (HIPS), polypropylene, polystyrene, and other suitable polymers or plastics. Other suitable materials for forming cooler housing 102 will be known to one of ordinary skill in the art from the description herein. Cooler housing 102 may be formed, for example, by injection molding.
Fan 120 blows air out of cooler housing 102. As illustrated in FIGS. 4-6, for example, fan 120 is mounted within the interior region of cooler housing 102. In an exemplary embodiment, fan 120 is a centrifugal fan, and is oriented to blow air outward with respect to the axis of rotation 122 of fan 120. The axis of rotation 122 of fan 120 may be a vertical axis with respect to cooler housing 102. The axis of rotation 122 of fan 120 may further be substantially orthogonal to inlet and outlet axes 107 and 111.
Fan 120 includes a number of fan blades 124. Fan blades 124 are angled with respect to the direction of rotation of fan 120, as illustrated in FIG. 4. For example, fan 120 may have forward facing blades, such that fan blades 124 angle in the direction of rotation of fan 120 as they extend outward in the radial direction. In FIG. 4, fan 120 may preferably rotate counterclockwise, such that fan blades 124 are forward facing. Fan 120 may alternatively have backward facing blades, such that fan blades 124 angle in the direction opposite the direction of rotation of fan 120 as they extend outward in the radial direction. Fan blades 124 may further be curved, as illustrated in FIG. 4.
Fan 120 is positioned to facilitate air flow through cooler housing 102. As illustrated in FIG. 4, for example, fan 120 may be configured to receive air from the interior region of cooler housing 102 in a central location of fan 120, e.g., in an area corresponding to the axis of rotation 122 of fan 120. Fan 120 may be positioned within cooler housing 102 such that the general direction of air flow through air inlet 106 into the interior region of cooler housing 102 is toward fan 120. Additionally, fan 120 may be positioned directly adjacent air outlet 110, as illustrated in FIG. 4. Fan 120 may further include a fan housing 126 disposed around at least a portion of fan 120, such that fan housing 126 forms a fan scroll. Optionally, fan housing 126 may be integrally formed with cooler housing 102, such that cooler housing 102 forms a fan scroll. The above features may promote the blowing of air out of cooler housing 102 by fan 120 and promote easier manufacturing of evaporative cooler 100.
As illustrated in FIGS. 5 and 6, fan 120 may be shaped such that the height of fan 120, extending along the axis of rotation 122 of fan 120, is longer than the diameter of fan 120. This shape may provide for a larger volume of air blown out of cooler housing 102 by fan 120. It will be understood, however, that the shape of fan 120 illustrated in FIGS. 5 and 6 is illustrative and not limiting. Fan 120 may have any shape or size.
Suitable materials for forming fan 120 include, for example, a combination of acrylonitrile butadiene styrene (ABS) and fiberglass or a combination of nylon and fiberglass. Other suitable materials for forming fan 120 will be known to one of ordinary skill in the art from the description herein. Fan 120 may be formed, for example, by injection molding.
Motor 130 rotates fan 120. Motor 130 is mounted within the interior region of cooler housing 102. As illustrated in FIG. 6, motor 130 is coupled to fan 120 in order to rotate fan 120 about the axis of rotation 122. In an exemplary embodiment, motor 130 is positioned along the axis of rotation 122 of fan 120, and is configured to rotate fan 120. Motor may include a shaft 132 For example, motor 130 may be positioned below fan 120, and may rotate fan 120 about the vertical axis.
Motor 130 may be an electric motor. Suitable motors 130 for use with evaporative cooler 100 include permanent split capacitor motors. Other suitable motors 130 will be known to one of ordinary skill in the art from the description herein.
Evaporative cooler 100 may further include a motor housing 134. Motor housing 134 may surround motor 130. Motor housing 134 may protect motor 130 from contacting the water received in cooler housing 102. Motor housing 134 may be formed integrally with cooler housing 102. Alternatively, motor housing 134 may be formed separately and affixed to cooler housing 102. Motor housing 134 may be formed from the same materials as cooler housing 102. Other suitable materials for forming motor housing 134 will be known to one of ordinary skill in the art from the description herein.
FIG. 5 show an embodiment of a pump system 140 in accordance with an aspect of the present invention. Pump system 140 circulates the water received in cooler housing 102 to enable evaporative cooling. Pump system 140 includes a pump 142, tubing 148, and pump controller 150. Additional details of pump system 140 are provided below.
Pump 142 pumps the water received in cooler housing 102. As illustrated in FIG. 11, pump 142 has a water inlet 144 in communication with the water received in cooler housing 102. In an exemplary embodiment, pump 142 is disposed at least partially within the receptacle defined by cooler housing 102, and water inlet 144 of pump 142 is configured to contact water that is received in, the receptacle. Pump 142 may be partially or completely submerged when water is received in the receptacle. Pump 142 is operable to pump water from water inlet 144 to a water outlet 146 of pump 142. Suitable pumps will be understood by one of ordinary skill in the art from the description herein.
Tube 148 receives water pumped by pump 142. Tube 148 is coupled to receive water from water outlet 146 of pump 142. Water pumped by pump 142 may travel out water outlet 146 and through tube 148. In an exemplary embodiment, tube 148 releases the water pumped by pump 142 at a top portion of evaporative media 113 when media 113 is coupled to inlet grating 112. The pumped water may then flow downward over evaporative media 113. Tube 148 may be formed from any suitable waterproof material.
Pump controller 150 controls the operation of pump 142. Pump controller 150 is electrically coupled to pump 142 in order to activate and deactivate pump 142. For example, controller 150 may be configured to activate pump 142 to pump water upon receipt of a signal. Additionally, controller 150 may be configured to deactivate pump 142 from pumping water upon receipt of another signal. A suitable pump controller 150 for controlling the operation of pump 142 will be understood by one of ordinary skill in the art from the description herein.
FIGS. 7-10 show an embodiment of a float 160 for use with evaporative cooler 100 in accordance with an aspect of the present invention. As illustrated in FIGS. 12-16, float 160 is disposed within cooler housing 102 and is positioned to float on the water received in cooler housing 102. Thus, float 160 may move in a substantially vertical direction within cooler housing 102 responsive to changes in the water level of the water received in cooler housing 102.
In an exemplary embodiment, float 160 includes a floating portion 162 and an elongated portion 164. The floating portion 162 of float 160 contacts the surface of the water received in cooler housing 102. The elongated portion 164 is coupled to and extends from floating portion 162. Elongated portion 164 of float 160 is received in a float guide 166 formed on the front wall 108 of cooler housing 102. Float guide 166 confines the movement of float 160 such that float 160 moves only in a substantially vertical direction. For example, as illustrated in FIG. 7, float guide 166 may form a gap or recess in which the elongated portion 164 of float 160 may be inserted. Thus, float 160 may move up and down in the substantially vertical direction within the gap defined by float guide 166 responsive to changes in the water level of the water received in cooler housing 102.
Float 160 may include further include a water level indicator 168 for visually indicating the level of water received in the receptacle defined by the cooler housing 102. Water level indicator 168 is formed on the elongated portion 164 of float 160. Water level indicator 168 may indicate the level of the water based on the height of floating portion 162 within cooler housing 102. In an exemplary embodiment, cooler housing 102 includes a port 118 for enabling a user to view water level indicator 168. Port 118 may be located near float guide 166 such that the water level indicator 168 of float 160 is visible through port 118, as shown in FIGS. 1 and 2.
For example, as illustrated in FIG. 8, when a large amount of water is received in the receptacle, floating portion 162 is located at a high point within cooler housing 102, and a lower portion of water level indicator 168 is visible through port 118. As illustrated in FIG. 9, when a low amount of water is received in the receptacle, floating portion 162 is located a low point within cooler housing 102, and an upper portion of water level indicator 168 is visible through port 118. Thus, a user of evaporative cooler 100 may visually determine the level of water received in cooler housing 102 based on the portion of water level indicator 168 that is visible through port 118.
Floating portion 162 of float 160 may be formed from any buoyant material or a substantially hollow body suitable for floatation. Suitable materials for forming floating portion 162 include, for example, acrylonitrile butadiene styrene (ABS), high-impact polystyrene (HIPS), polypropylene, polystyrene, and other suitable polymers or plastics. Other suitable materials for forming floating portion 162 will be known to one of ordinary skill in the art from the description herein. Elongate portion 164 of float 164 may be formed from any suitable materials, which will be known to one of ordinary skill in the art from the description herein. Elongate portion 164 and floating portion 162 may be formed from the same or different materials and may be integrally formed. While float 160 is illustrated having a floating portion 162 and an elongate portion 164, it will be understood that the shape and orientation of float 160 illustrated in FIGS. 7-10 is illustrative and not limiting.
FIGS. 11-13 show an alternative embodiment of a float 260 for use with an evaporative cooler in accordance with an aspect of the present invention. As illustrated in FIGS. 11-13, float 260 is disposed within a cooler housing 202 and is positioned to float on the water received in cooler housing 202. In an exemplary embodiment, float 260 includes a floating portion 262 and an elongated portion 264. The floating portion 262 of float 260 contacts the surface of the water received in cooler housing 202. The elongated portion 264 is coupled to and extends from floating portion 262.
Elongated portion 264 of float 260 is rotatably mounted to the front wall of cooler housing 202 at a float pivot 266. Float pivot 266 confines the movement of float 260 such that float 260 rotates relative to float pivot 266. Thus, floating portion 262 may move up and down in elevation but along a generally arcuate path defined by elongated portion 264 responsive to changes in the water level of the water received in cooler housing 202.
Float 260 may further include a water level indicator 268 for visually indicating the level of water received in the receptacle defined by the cooler housing 202. Water level indicator 268 is coupled to the elongated portion 264 of float 260. Water level indicator 268 may indicate the level of the water based on the height of floating portion 262 within cooler housing 202. In an exemplary embodiment, cooler housing 202 includes a port for enabling a user to view water level indicator 268, similar to the port 118 disclosed with respect to evaporative cooler 100. The port may be located near float pivot 266 such that the water level indicator 268 of float 260 is visible through the port.
For example, as illustrated in FIG. 11, when a high level of water is received in the receptacle, floating portion 262 is located a high point within cooler housing 202, and a lower portion of water level indicator 268 is visible through port 218. As illustrated in FIG. 12, when a low amount of water is received in the receptacle, floating portion 262 is located at a low point within cooler housing 202, and an upper portion of water level indicator 268 is visible through port 218. Thus, a user of evaporative cooler 200 may visually determine the level of water received in cooler housing 202 based on the portion of water level indicator 268 that is visible through the port in cooler housing 202.
Floating portion 262 and elongated portion 264 of float 260 may be formed from the same materials as floating portion 162 and elongated portion 164 of float 160, respectively. While float 260 is illustrated having a floating portion 262 and an elongate portion 264, it will be understood that the shape and orientation of float 260 illustrated in FIGS. 11-13 is illustrative and not limiting.
Returning to evaporative cooler 100, it may be desirable for float 160 to operate in conjunction with pump system 140. For example, it may be desirable that pump 142 not run when there is insufficient water in cooler housing 102 to pump, in order to avoid damage to pump 142. Accordingly, float 160 may operate such that pump controller 150 deactivates pump 142 when float 160 indicates a low level of water in cooler housing 102. Operation of float 160 in conjunction with pump system 140 will be described below. While the aspects of the invention will be discussed below with reference to float 160, it will be understood that the same aspects could be employed with the use of float 260.
Float 160 may include a magnet 170. Magnet 170 may be coupled to the elongated portion 164 of float 160, as illustrated in FIGS. 7-10. Magnet 170 may be any type of permanent magnet.
Evaporative cooler 100 may further include a magnetic switch 172, as illustrated in FIGS. 8 and 9. Magnetic switch 172 may be mounted on cooler housing 102. Magnetic switch 172 is configured for activation by magnet 170 when magnet 170 is proximal to magnetic switch 172. Magnetic switch 172 may be, for example, a hall effect switch. Suitable magnetic switches for use with the present invention will be understood by one of ordinary skill in the art from the description herein.
Magnetic switch 172 may be configured for activation by magnet 170 when a water level in the receptacle of cooler housing 102 is low. Accordingly, magnet 170 of float 160 may be positioned proximal to magnetic switch 172 when the water level is low within cooler housing 102. In an exemplary embodiment, as illustrated in FIGS. 8 and 9, magnetic switch 172 is mounted adjacent float guide 166. Float 160 may be positioned within float guide 166 such that, when a large amount of water is received in the receptacle, floating portion 162 is located at a high point within cooler housing 102, and magnet 170 is not proximal to magnetic switch 172, as illustrated in FIG. 8. Conversely, when a low amount of water is received in the receptacle, floating portion 162 is located a low point within cooler housing 102, and magnet 170 is proximal to magnetic switch 172, as illustrated in FIG. 9. Thus, magnetic switch 172 may be activated only when there is a low water level in cooler housing 102. The level of water in cooler housing 102 may be defined as low when pump 142 is less than completely submerged in the water received the receptacle defined by cooler housing 102.
As described above, it may be desirable that pump 142 not run when there is insufficient water in cooler housing 102 to pump, in order to avoid damage to pump 142. Accordingly, magnetic switch 172 may be electrically coupled to pump 142. When magnetic switch 172 is activated by magnet 170, e.g., when there is a low level of water in cooler housing 102, magnetic switch 172 may deactivate pump 142.
Further, magnetic switch 172 may be electrically coupled to controller 150. When magnetic switch 172 is activated by magnet 170, e.g., when there is a low level of water in cooler housing 102, magnetic switch 172 may send a signal to controller 150, and controller 150 may deactivate pump 142.
Still further, magnetic switch 172 may be electrically coupled to an alarm 174 for alerting a user of evaporative cooler 100. When magnetic switch 172 is activated by magnet 170, e.g., when there is a low level of water in cooler housing 102, magnetic switch 172 may send a signal to alarm 174, and alarm 174 may alert a user that there is a low level of water in cooler housing 102. Alarm 174 may be a visual or audible alarm. In an exemplary embodiment, alarm 174 is a visible alarm located on the display 176 of evaporative cooler 100, as illustrated in FIG. 14.
Operation of evaporative cooler 100 will now be described. Generally, the principles of air cooling are described below. Background information regarding evaporative coolers is available in U.S. patent application Ser. No. 12/037,348, which is incorporated herein by reference in its entirety.
In an exemplary embodiment, a user of evaporative cooler 100 may turn on fan 120. Fan 120 may rotate about the axis of rotation 122, thereby blowing air in the interior region of cooler housing 102 outwards and out of air outlet 110. As blown air flows out of air outlet 110 through outlet grating 114, other air flows into the interior region of cooler housing 102 through air inlet 106. Air flowing into cooler housing 102 may pass through inlet grating 112 and evaporative media 113. A user may adjust the speed of fan 120 and the direction of outlet grating 114 to generate a desired flow of air from evaporative cooler 100.
Pump system 140 may be employed to cool the air blown by evaporative cooler 100. As described above, pump system 140 may pump water received in cooler housing 102 up to a top portion of media 113. The pumped water may then flow downwards over evaporative media 113 by the force of gravity, and fall back down into the receptacle of cooler housing 102, to be recirculated. Evaporative media 113 may promote the evaporation of water flowing over evaporative media. This evaporating water may cool the air flowing into cooler housing 102 through evaporative media 113. This cooled air may then be blown out of cooler housing 102. Evaporative media 113 may be specially designed to promote the evaporation of water. Suitable materials for forming evaporative media 113 may include paper or cellulose, for example. Suitable evaporative media will be known to one of ordinary skill in the art from the description herein.
As described above, water level indicator 168 of float 160 may be used to determine the amount of water in cooler housing 102 to be circulated. As water evaporates during evaporative cooling, the water level in cooler housing 102 may lower. When a low water level is reached, magnet 170 may be configured to activate magnetic switch 172. Activation of magnetic switch 172 may cause alarm 174 to alert a user that the water level in cooler housing 102 is low, and needs to be refilled via water access port 116. Further, when a low water level is reached, magnetic switch 172 may deactivate pump 142, in order to prevent damage to pump 142 that may arise from operating pump 142 without water in cooler housing 102.
Accordingly, as set forth above, evaporative cooler 100 may be configured to deactivate pump 142 when a level of the water received in cooler housing 102 is low. A method for so configuring evaporative cooler 100 is disclosed in accordance with an aspect of the present invention. Float 160 is positioned in cooler housing 102 to float on water received in cooler housing 102. Optionally, float 160 may be positioned in float guide 166 such that float guide 166 confines the movement of float 160 in the substantially vertical direction. Magnetic switch 172 is mounted on cooler housing 102. Magnetic switch 172 is configured for activation when magnet 170 is proximal to magnetic switch 172. Further, magnetic switch 172 is electrically coupled to pump 142 such that pump 142 is deactivated when magnetic switch 172 is activated by magnet 170 of float 160.
Optionally, magnetic switch 172 may be electrically coupled to controller 150, and controller 150 may be electrically coupled to pump 142, such that controller 150 deactivates pump 142 when magnetic switch 172 is activated by magnet 170. Magnetic switch 172 may also be coupled to alarm 174 such that alarm 174 is activated when magnetic switch 172 is activated by magnet 170.
While preferred embodiments of the invention have been shown and described herein, it will be understood that such embodiments are provided by way of example only. Numerous variations, changes and substitutions will occur to those skilled in the art without departing from the spirit of the invention. Accordingly, it is intended that the appended claims cover all such variations as fall within the spirit and scope of the invention.

Claims

1. An evaporative cooler comprising:

a cooler housing defining an interior region, a single air inlet positioned to permit air flow into the interior region of the cooler housing generally along an inlet axis, and an air outlet positioned to permit air flow from the interior region of the cooler housing generally along an outlet axis, the inlet axis and outlet axis being angled with respect to one another such that the general direction of air flow into the interior region of the cooler housing through the single air inlet differs from the general direction of air flow from the interior region of the cooler housing through the air outlet;

a centrifugal fan mounted within the interior region of the cooler housing, the centrifugal fan being oriented to rotate about a vertical axis that is substantially orthogonal to the inlet and outlet axes; and

a motor mounted within the interior region of the cooler housing and coupled to the centrifugal fan, the motor being configured to rotate the centrifugal fan about the vertical axis.

2. The evaporative cooler of claim 1, wherein the general direction of air flow into the interior region is toward the centrifugal fan.

3. The evaporative cooler of claim 1, wherein the centrifugal fan is configured to receive air that flows through the single air inlet and to urge air through the air outlet.

4. The evaporative cooler of claim 1, further comprising a fan housing disposed around a portion of the centrifugal fan such that the fan housing forms a fan scroll.

5. The evaporative cooler of claim 1, wherein the fan housing is an integral portion of the cooler housing, and the cooler housing forms the fan scroll.

6. The evaporative cooler of claim 1, wherein the centrifugal fan has a height extending substantially in the direction of the vertical axis and a diameter extending substantially orthogonal to the vertical axis, and wherein the height of the centrifugal fan is larger than the diameter of the centrifugal fan.

7. The evaporative cooler of claim 1, wherein the single air inlet has a height extending substantially in the direction of the vertical axis and a width extending substantially orthogonal to the vertical axis, and wherein the height of the single air inlet is larger than the width of the single air inlet.

8. The evaporative cooler of claim 1, wherein the air outlet has a height extending substantially in the direction of the vertical axis and a width extending substantially orthogonal to the vertical axis, and wherein the height of the air outlet is larger than the width of the single air inlet.

9. The evaporative cooler of claim 1, wherein the cooler housing has a front wall defining the air outlet and a side wall adjacent the front wall and defining the single air inlet.

10. The evaporative cooler of claim 1, wherein the inlet axis and the outlet axis form an angle of between approximately 45° and 135°.

11. The evaporative cooler of claim 10, wherein the inlet axis and the outlet axis form an angle of approximately 90°.

12. The evaporative cooler of claim 1, further comprising a media component extending across the single air inlet, wherein at least some of the air flowing into the interior region of the cooler housing through the single air inlet flows through the media.

13. A method for configuring an evaporative cooler to move air from a single air inlet defined in a cooler housing to an air outlet defined in the cooler housing, the method comprising:

mounting a centrifugal fan within an interior region of the cooler housing such that the centrifugal fan is oriented to rotate about a vertical axis that is substantially orthogonal to an inlet axis along which air flows through the single air inlet and an outlet axis along which air flows through the air outlet, the inlet axis and outlet axis being angled with respect to one another such that the general direction of air flow into the interior region of the cooler housing through the single air inlet differs from the general direction of air flow from the interior region of the cooler housing through the air outlet; and

mounting a motor within the interior region of the cooler housing such that the motor is configured to rotate the centrifugal fan about the vertical axis.

14. The method of claim 13, wherein the step of mounting the centrifugal fan comprises mounting the centrifugal fan such that the general direction of air flow into the interior region of the cooler housing through the single air inlet is toward the centrifugal fan.

15. The method of claim 13, wherein the step of mounting the centrifugal fan comprises mounting the centrifugal fan such that the centrifugal fan receives air that flows through the single air inlet and blows air through the air outlet.

16. The method of claim 13, further comprising:

positioning a media component across the single air inlet such that at least some air flowing into the interior region of the cooler housing through the single air inlet flows through the media.

17. The method of claim 13, wherein the inlet axis and the outlet axis form an angle of between approximately 45° and 135°.

18. The method of claim 17, wherein the inlet axis and the outlet axis form an angle of approximately 90°.