US20240068750A1

US20240068750A1 - Closed loop, modular and self-cleaning hvac system

Info

Publication number: US20240068750A1
Application number: US18/455,433
Authority: US
Inventors: James Metropoulos
Original assignee: Blue Box Air LLC
Current assignee: Blue Box Air LLC
Priority date: 2022-08-24
Filing date: 2023-08-24
Publication date: 2024-02-29
Also published as: WO2024044714A2; WO2024044714A3

Abstract

A heat transfer cube includes a housing at least partially bounding a compartment, the housing having a first end with a first opening formed thereat that communicates with the compartment and an opposing second end with a second opening formed thereat that communicates with the compartment. A coil unit is disposed within the compartment between the first opening and the opposing second opening. The coil unit includes a first plate, a last plate, and a plurality of tubes each having a first end connected to the first plate and an opposing second end connected to the second plate. The housing further includes an inlet communicating with the first end of each of the plurality of tubes and an outlet communicating with the second end of each of the plurality of tubes.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No. 63/400,682, filed Aug. 24, 2022, which is incorporated herein by reference in its entirety.

BACKGROUND

Technical Field

This disclosure generally relates to HVAC systems. More specifically, the present disclosure relates to improved modular self-cleaning heat transfer devices and systems.

Related Technology

Heating, ventilation, and air conditioning (HVAC) systems are typically the most capital intensive and energy intensive systems within most building environments, covering everything from homes to high rise buildings. Typical HVAC systems can consume over 50% of a building's total energy. It is estimated that roughly half of this energy is wasted because the heat transfer coils in HVAC systems are operating in a fouled condition. Fouling occurs when the free space within coils through which air would normally flow for thermal energy transfer becomes at least partially blocked so as to limit or restrict the free flow of air. Such fouled coils are the primary source of many operational problems found within HVAC systems, such as excessive equipment wear and tear, decreased human health due to poor indoor air quality, and excessive energy consumption. Hydrocarbon buildup from outside air pollution, pollen, dust, and grease are examples of common materials causing HVAC coil fouling. Another cause of fouling is the formation of bacteria and fungi deep inside the coils.
In addition, not only does coil fouling greatly reduce the efficiency and operational lifetime of the HVAC system, the current design flaws of all conventional HVAC and heat pump systems yield the fundamental problem of fouling within the heat transfer coil. Coil fouling and the inability to penetrate coils so to remove this fouling have driven the HVAC industry to design heat transfer coils to be relatively shallow, which helps prevent heat transfer coils from becoming fouled too quickly over time. This shallow coil design results in HVAC systems being relatively large and bulky. The coil fouling issue also necessitates different coil designs between the evaporative coil and the condenser coil. For example, condenser coils are typically positioned outside so they can expel the heat of the HVAC system directly into the atmosphere. Because such systems are outside, they are typically exposed to greater quantities of fouling particulates, which necessitates that their coils be thin and that the surface area of these units be typically bulky in shape.
In addition, because residential and light commercial systems rely on hydrofluorocarbons (HFCs) as the circulating refrigerant, such systems are pressurized and require welded joints and connections so that the HFCs can evenly flow back and forth between the evaporative and condensing coils. Because of the need to maintain a pressurized system, current HVAC systems and heat pumps must be designed to meet specific capacities in order to cool or heat varying sizes of environment spaces. This fixed designed system requires the industry to design a nearly endless array of varyingly sized HVAC systems to fit differently sized spaces, which greatly increases the complexity and cost of delivering cooling and heating to the built environment.
In addition, because of the need to have shallow designed coils, HVAC systems are typically large and bulky, which is particularly true in larger commercial HVAC systems. This bulky size necessitates that cranes and heavy lifting equipment are required for installation. This also makes replacement of units difficult and costly.
Coil fouling and the failure by the industry to solve this fundamental problem has evolved into a global HVAC industry that manufacturers and installs a highly differentiated and complex array of HVAC systems, which are designed to meet a near endless array of cooling and heat load built spaces.
In addition, 85% of all global HVAC systems are based on using Hydrofluorocarbons (HFC's) as their primary circulating refrigerant. HFCs are known to be a big contributor to climate change as they are in a class of particularly potent greenhouse gases. HFCs are also prone to leakage from HVAC systems, requiring HVAC operators to continually replace the dangerous and expensive refrigerant. This leads to increased costs to maintain a building, and leakages contribute to increases in climate change.
The tubes or loops that circulate the HFCs are a limiting factor for HVAC system design. They provide a constraint on how large the coils can be and provide a point of cleanliness failure. Constraining the size of the coils ultimately puts a restraint on the heat transfer efficiency of the coils. Smaller coils inherently require more thermal energy to be transferred at any given moment in order to arrive at a desired temperature differential/climate-controlled interior. This is because smaller coils have less surface area for the air molecules to interface with the heat transfer coils, meaning the air molecules spend less time absorbing or expelling heat.
Further, replacing and/or upgrading HVAC systems in most buildings (commercial and/or residential) is prohibitively expensive as the entire system must usually be replaced What is needed is a new design for HVAC systems and implementations in commercial and residential buildings that is standardized, modular, and/or greatly reduces the cost and efficiency of HVAC systems.

SUMMARY

The present disclosure is directed toward innovations in heating, ventilation and air conditioning (HVAC) systems and heat transfer coil designs. In some embodiments, the disclosed innovations apply to the air cooling and air heating coils within the HVAC system. Disclosed are self-contained heat transfer cubes and systems that are designed to work as stand-alone systems or be integrated to form larger capacity systems, such as within air handlers.
The disclosed self-contained heat transfer cube systems may include a self-cleaning process for keeping the internal surface areas of the heat transfer cubes free of organic and inorganic fouling so that the system is always operating at its peak thermal efficiency. The disclosed self-contained heat transfer cubes, which can typically be designed in 6″×6″×6″ (15 cm×15 cm×15 cm) or 12″×12″×12″ (30 cm×30× or 30 cm) configurations, are designed so that these cubes can be connected side by side or front and back so as to have a modular system for changing and increasing or even decreasing the total surface area that is comprising of the system so as to deliver a more desired controlled indoor climate. This modularity provides much larger air pathways and surface areas, which greatly increases the time in which the air to be heated or cooled is circulating through and in contact with the heat transfer cube.
In some embodiments, disclosed self-contained heat transfer cubes include a housing and a heat transfer mechanism disposed within the housing. The disclosed self-contained heat transfer cubes may be an air-cooling cube and/or an air heating cube. The air-cooling cube is analogous to an evaporative coil and the air heating cube is analogous to a condenser coil of a typical HVAC/heat pump system.
In one embodiment the heat transfer cube unit includes an inlet, an outlet and a plurality of thermally conductive plates, each plate having a plurality of perforations extending therethrough. The plurality of thermally conductive plates are substantially aligned with each other and are arranged such that the plurality of perforations are in fluid communication with each other and with the inlet and the outlet. A plurality of tubes can extend through the aligned perforations to isolate the heat transfer fluid flowing through the heat transfer cube. The heat transfer cube may also be designed around a collection of tightly spaced tubes with no or limited conductive plates, through which the water or other heat transfer fluid passes through, and the air flows through the tightly spaced bundle of tubes. These tubes can be comprised of highly conductive copper or aluminum, but can also involve lesser conductive materials, such as polycarbonate or other plastic or acrylic-like materials. Either configuration delivers the surface area and heat transfer effect necessary.
In one embodiment, the self-contained heat transfer cubes can also include at least one injection port disposed between a top of the housing and the deep coil. In some embodiments, the at least one injection port receives cleaning solution, via fluid communication lines, from a reservoir tank holding the cleaning solution and periodically injects the cleaning solution into the coil unit, thereby cleaning the coil unit.
Also disclosed are power cubes. In some embodiments, the power cubes include, at least, a control circuit, a thermal loop, a circulation loop and a cleaning loop. The thermal loop may include a compressor, a first heat exchanger in fluid communication with the compressor, a second heat exchanger in fluid communication with the compressor, and an expansion valve in fluid communication with the compressor and the first and second heat exchangers. The circulation loop may include a first pump in fluid communication with the first heat exchanger and a second pump in fluid communication with the second heat exchanger. The first and second pumps may also be in fluid communication with first and second self-contained heat transfer cubes, respectively.
The cleaning loop may include a cleaning solution generator and a reservoir tank in fluid communication with the cleaning solution generator. Fluid communication lines deliver cleaning solution from the reservoir tank to the at least one injection port of each self-contained heat transfer cube. The power cubes may additionally include a control circuit including, at least, a control board, at least one microprocessor unit, and a plurality of sensors.
In some embodiments, a heat transfer cube system includes at least one self-contained heat transfer cube for the evaporative side of the system and at least one self-contained heat transfer cube for the condensing side of the system, resulting in a complete system operating at least one power cube. The at least one self-contained heat transfer cube is capable of providing heated and/or cooled air to a building or other interior space, depending on a direction of air flow through the self-contained heat transfer cube. The power cube provides power, control, logic, and cleaning solutions to the at least one self-contained heat transfer cube. The power cube contains at least two heat exchangers, which enable heating and/or cooling of water (or another heat transfer fluid) where the heated and/or cooled water is circulated through the at least one self-contained heat transfer cube. Such circulation of water (or another heat transfer fluid) through the at least one self-contained heat transfer cube thereby heats and/or cools the air provided to a building or interior space.

Benefits, Advantages and Technical Improvements

The disclosed self-contained heat transfer cubes and systems thereof provide a number of benefits. First, the disclosed self-contained heat transfer cubes eliminate the use of circulating coil loops which is a common feature of all current heat transfer coils. This is where the circulating refrigerant, either water or HFC's enter a central pipe connection and then flow back and forth through the connecting tubes, where the refrigerant will then exit the coil by a primary exit port.
Instead of this circuitous pathway for the refrigerant to move through the heat transfer tubes, the heat transfer cube employs an open faced side baffle system, similar to that seen in tube/shell heat exchangers, whereby the refrigerant (water) enters an open port on one side of the heat transfer cube and the refrigerant passes through all the tubes simultaneously where it then exits the heat transfer tubes and out the exiting port. This flow of refrigerant through all the tubes simultaneously greatly improves the overall heat transfer and dehumidification capabilities of the heat transfer cubes because the same low temperature is found moving through all the tubes simultaneously. This design also enables the water refrigerant to move through the heat transfer cube with much less pressure build up than if this refrigerant was forced to move back and forth through a single coil loop design, as is the case with current heat transfer coil designs. In addition, the heat transfer cubes can have their exterior plates removed so that each cube is able to be connected to other cubes in order to increase the heat transfer capacity of the system without building up pressure of the refrigerant as the water moves from one heat transfer cube to another.
Second, the use of water in the heat transfer cubes as the primary heat transfer fluid through the self-contained heat transfer cubes increases the efficiency of transfers of thermal energy. Specifically, the heat transfer cubes greatly increase the surface area and the path length through the system, meaning smaller temperature differentials between the circulated water and the ultimate temperature of an interior space may be utilized. The increased depth and resulting increase in overall surface area of each cube is possible because of the system's self-cleaning process, which eliminates the fouling effects that all existing HVAC systems currently face during operation, which limit their current heat transfer depth designs. Increasing the surface area and the path length means circulating air spends more time in contact with the heat transfer cube.
In addition, because water is moving through all the tube bundles simultaneously, instead of through a traditional coil loop system, using water as the circulating refrigerant and the movement of this water refrigerant through all the tube bundles simultaneously combines to deliver a system that can generally absorb about 30 times more heat than a traditional hydrofluorocarbon based heat transfer coil utilizing a traditional loop configuration. This means more thermal energy can be transferred at any given moment. These smaller temperature differentials result in reduced energy consumption. For example, a traditional 5 ton residential HVAC system would typically see a 20° F. change in temperature when air is passed through its existing heat transfer coils. In testing of the new heat transfer cube utilizing water as the circulating refrigerant, which passes through the tube bundle evenly, this same system, which was also powered by a 5 ton compressor, is able to deliver a 71° F. change in temperature. In a comparative test, the air was pre-heated and passed through the heat transfer cube at a flow volume of 1,500 cubic feet per minute (CFM) and the exit air temperature was a consistent 44° F. The combination of heat transfer surface area of the cube along with the use of chilled water, which absorbs 30 times more heat than traditional hydrofluorocarbons, combined with even distribution of the circulating water through the entire tube bundle, provided a significant improvement in heat absorption capacity.
Third, the use of water also reduces the need for harmful and expensive hydrofluorocarbons (HFC). This reduction can be as high as 99% compared to existing residential and other HFC-based HVAC systems and heat pumps. This reduction is possible because the refrigerant cycle is encased in the power cube where the HFCs move from the compressor to the condensing and evaporative heat exchangers, where circulating water absorbs the heat generated from the condensing and expanding HFC gases. This very small refrigerant typically requires less than a ½ lb. of HFCs. In contrast, conventional HVAC systems utilize much larger amounts of HFCs, which are prone to leakage and known to be a large contributor to climate change. This is due to the much longer piping required to transfer HFCs between the evaporative coil, the pump and the condensing coil. By reducing the amount of HFCs used, the disclosed self-contained heat transfer cubes and systems substantially reduce the amount of HFCs that can be leaked into the environment, which beneficially decreases their contribution to climate change as a potent greenhouse gas.
Fourth, the use of cleaning cycles and cleaning solutions to maintain a cleanliness of the self-contained heat transfer cubes also increases and maintains the efficiency of any transfers of thermal energy. Specifically, by maintaining a cleanliness of the heat transfer surface areas, whether these are coils or tube bundles contained inside the self-contained heat transfer cubes, air flow is improved and not impeded by, for example, biofilms and other debris. Improved air flow enables improved transfers of thermal energy. Additionally, keeping the heat transfer cube units clean eliminates, for example, insulating biofilms, enabling a greater interaction of air molecules at the surfaces of the coil units which enables a more efficient transfer of thermal energy.
Fifth, the self-cleaning feature of the disclosed heat transfer cubes permits the use of deep coils or tube bundles rather than conventional shallow coils. Without the self-cleaning feature, the deep coils or tube bundles would otherwise be impossible to clean, resulting in build ups of dirt, biofilms and other debris. This build-up or fouling plugs up the coils, ruining the normal functioning of the heat transfer coils and impeding air flow through the coils. Such fouled coils are the primary source of many operational problems found within conventional HVAC systems, such as excessive equipment wear and tear, decreased human health due to poor indoor air quality, and excessive energy consumption. Hydrocarbon buildup from outside air pollution, pollen, dust, and grease are examples of common materials causing HVAC coil fouling. Another cause of fouling is the formation of bacteria and fungi deep inside the coils. The self-cleaning feature solves these problems by keeping the deep coils free of dirt, biofilms and other debris.
Sixth, the disclosed self-contained heat transfer cubes and power cubes are modular in design. This means they can be implemented in existing HVAC and air handler systems, thereby improving the efficiency of existing systems. Additionally, the modular design permits installation of the cubes in any size building, as the cubes may be connected or daisy-chained together to provide the necessary heating and/or cooling capacity. The modular design also permits one power cube to supply power and water to one or more self-contained heat transfer cubes, such as five, seven, ten, fifteen, twenty self-contained heat transfer cubes and so on.
The modular design of, at least, the power cubes also means the power cubes may be connected together into a circuit that makes it easy to size-adjust the system to better meet the heat and cooling loads of a desired building environment. With the power cube, the idea is to establish a fixed capacity design of, say, 1 ton or 2 tons capacity. At this capacity, the compressor can be relatively compact, and the power cube itself can be fixed in size and weight where the objective is to have a system that is easy for 1-2 people to lift, install and fit into small compact spaces. By providing modularity, a space can have its climate controlled more precisely because the system is not centralized. For example, within a typical home, people spend 20% of their time within 80% of the home's spaces. Breaking up both the heat transfer cubes and the power cubes into modular units that integrate allows for far greater control of cooling spaces that are actually being used.
The modular design of the power and self-contained heat transfer cubes also enables individual control of self-contained heat transfer cubes. Thus, if self-contained heat transfer cubes are installed in individual rooms of a commercial or residential building, the self-contained heat transfer cubes can be powered on when and where they are desired. For example, in a residential setting, self-contained heat transfer cubes could be installed in individual bedrooms. When a desired temperature for one room is not the desired temperature for another room, the individual self-contained heat transfer cubes can be powered to provide the desired temperatures for each room. Each user of the disclosed systems now has more control over the desired temperatures of interior spaces. This individualized control may also lead to decreased energy consumption as power can be routed as needed to individual self-contained heat transfer cubes, rather than an all or nothing approach currently used with conventional HVAC systems. These benefits are realized in commercial and residential building spaces.
This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an indication of the scope of the claimed subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

Various objects, features, characteristics, and advantages of the invention will become apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings and the appended claims, all of which form a part of this specification. In the Drawings, like reference numerals may be utilized to designate corresponding or similar parts in the various Figures, and the various elements depicted are not necessarily drawn to scale, wherein:

FIG. 1 illustrates a perspective view a self-contained heat transfer cube;

FIG. 2 illustrates an exploded view of the self-contained heat transfer cube illustrated in FIG. 1 ;

FIG. 3 illustrates an exploded view of a coil unit of a self-contained heat transfer cube;

FIG. 4 illustrates a cross sectional view of a portion of the coil unit shown in FIG. 3 ;

FIG. 5 illustrates a flowchart of an exemplary flow of water through a self-contained air-cooling heat transfer cube;

FIG. 6 illustrates a flowchart of another exemplary flow of water through a self-contained air heating heat transfer cube;

FIG. 7 illustrates a rear perspective view of an alternative embodiment of the heat transfer cube shown in FIG. 1 ;

FIG. 8 illustrates a front perspective view of the heat transfer cube shown in FIG. 7 ;

FIG. 9 illustrates an exploded view of the heat transfer cube illustrated in FIG. 7 ;

FIG. 10 illustrates an exploded view of a coil unit of heat transfer cube shown in FIG. 9 ;

FIG. 11 illustrates a cross sectional view of a portion of the coil unit shown in FIG. 10 ;

FIG. 12A is a front perspective view of a further alternative embodiment of a heat transfer cube;

FIGS. 12B and 12C are exploded perspective views of the heat transfer cube shown in FIG. 12A;

FIG. 13 illustrates an example modular heat transfer cube system;

FIG. 14A illustrates a perspective view of multiple self-contained heat transfer cubes linked together and FIG. 14B illustrates a front view of the linked systems of FIG. 14A;

FIG. 15 illustrates another exemplary system of multiple self-contained heat transfer cubes;

FIG. 16 illustrates a flowchart of an exemplary flow through a thermal loop of a power cube that simultaneously cools and heats water used in the air-cooling and air heating heat transfer cubes, respectively; and

FIG. 17 illustrates a flowchart of an exemplary flow through a cleaning loop of a power cube.

DETAILED DESCRIPTION

Disclosed are devices and systems of modular self-contained heat transfer cubes, including a coil unit with enhanced heat transfer. The self-contained heat transfer cubes are capable of being retrofit into existing HVAC or air handler systems. The disclosed self-contained heat transfer cubes require less energy and less water to operate, as compared to conventional HVAC systems, while still delivering the same amount of cooled and/or heated air to an interior space. Multiple self-contained heat transfer cubes may be fluid coupled together in series (e.g., “daisy-chained” together) to provide heating and/or cooling of air to a building and/or other interior space.
The present disclosure is directed toward innovations in heating, ventilation and air conditioning (HVAC) systems and heat transfer coil designs. In some embodiments, the disclosed innovations apply to the air-cooling and air heating coils within the HVAC system. Disclosed are self-contained heat transfer cubes and systems for integration into existing air handlers and/or HVAC systems. The disclosed self-contained heat transfer cube systems may include self-cleaning HVAC coils, as well as self-cleaning tube bundles where the heat transfer cubes may incorporate traditional materials, such as copper and aluminum, but can also utilize polymer materials such as, but not limited to, polycarbonates, acrylic, and the like.
In some embodiments, disclosed self-contained heat transfer cubes include a housing and a coil unit disposed within the housing. The disclosed self-contained heat transfer cubes may be an air-cooling cube and/or an air heating cube. The coil unit includes an inlet, an outlet and a plurality of thermally conductive plates, each plate having a plurality of perforations extending therethrough. The plurality of thermally conductive plates are substantially aligned with each other and arranged such that the plurality of perforations are in fluid communication with each other and with the inlet and the outlet. A tube can extend through each of the aligned perforations for transferring the heat transfer fluid therethrough. The self-contained heat transfer cubes can also include at least one injection port disposed between a top of the housing and a top surface of the deep coil. In some embodiments, the at least one injection port receives cleaning solution, via fluid communication lines, from a reservoir tank holding the cleaning solution and periodically injects the cleaning solution into the coil unit, thereby cleaning the coil unit. The heat transfer cubes can also employ a tube bundle design that at least partially eliminates the use of the metal plates found in traditional coil designs.
Also disclosed are power cubes. In some embodiments, the power cubes include, at least, a control circuit, a thermal loop, a circulation loop, and a cleaning loop. The thermal loop may include a compressor, a first heat exchanger in fluid communication with the compressor, a second heat exchanger in fluid communication with the compressor, and an expansion valve in fluid communication with the compressor and the first and second heat exchangers. The circulation loop may include a first pump in fluid communication with the first heat exchanger. A second circulation loop can also be provided that includes a second pump in fluid communication with the second heat exchanger. The first and second pumps may also be in fluid communication with first and second self-contained heat transfer cubes, respectively.
The cleaning loop may include a cleaning solution generator and a reservoir tank in fluid communication with the cleaning solution generator. Fluid communication lines deliver cleaning solution from the reservoir tank to the at least one injection port of each self-contained heat transfer cube. The power cubes may additionally include a control circuit including, at least, a control board, at least one microprocessor unit and a plurality of sensors.
In some embodiments, a heat transfer cube system includes at least one self-contained heat transfer cube and at least one power cube. The at least one self-contained heat transfer cube is capable of providing heated and/or cooled air to a building or other interior space, depending on a direction of air flow through the self-contained heat transfer cube. The power cube provides power, control, logic and cleaning solutions to the at least one self-contained heat transfer cube. The power cube contains at least one heat exchanger, which enables heating and/or cooling of water (or another heat transfer fluid) where the heated and/or cooled water is circulated through the at least one self-contained heat transfer cube. Such circulation of water (or another heat transfer fluid) through the at least one self-contained heat transfer cube thereby heats and/or cools air provided to a building or interior space.

Universal Self-Contained Heat Transfer Cubes

FIG. 1 illustrates a perspective view a self-contained heat transfer cube 100 and FIG. 2 illustrates an exploded view of the self-contained heat transfer cube 100 illustrated in FIG. 1 . Referring to FIGS. 1 and 2 , the self-contained heat transfer cube 100 includes a housing 110, a coil unit 120 (described more fully below with respect to FIG. 3 ) and an injection port assembly 108. Housing 110 partially bounds a compartment 111 in which coil unit 120 is disposed.
The housing 110 of the self-contained heat transfer cubes includes a top plate 102, a bottom plate 104, a front plate 106, and a back plate 107. The front plate 106 and back plate 107 of the housing 110 each have an opening 112A and 112B, respectively, passing therethrough and communicating with compartment 111. In some embodiments, the bottom plate 104 includes a drainage pan 105. In some embodiments, the drainage pan 105 is an additional element disposed between the bottom plate 104 and a bottom surface of the coil unit 120. The bottom plate 104 and or drainage pan 105 can include a recess 114 for receiving condensation and a passage 116 that extends from recess 114 through bottom plate 104/drainage pan 105 through which the condensation can be drained out of recess 114. In one embodiment, recess 114 can slope toward passage 116 so as to direct the condensation thereto.
The coil unit 120 includes a front panel 122, a back panel 123, and a coil body 126 disposed therebetween. With reference to FIGS. 2 and 3 , front panel 122 has an outside face 172A and an opposing inside face 174A with an inlet 128 extending therebetween. In one embodiment, a front nozzle 124 communicates with inlet 128. Front nozzle 124 can be coupled with front panel 122 or integrally formed as a unitary body with front panel 122 so as to communicate with inlet 128. During assembly, front plate 106 can be disposed over outside face 172A of front panel 122 and connected to top plate 102 and bottom plate 104. Front nozzle 124 can be configured and positioned so as to pass through opening 112A of front plate 106.
Similarly, back panel 123 has an outside face 172B and an opposing inside face 174B with an outlet 129 extending therebetween. In one embodiment, a rear nozzle 125 communicates with outlet 129. Rear nozzle 125 can be coupled with back panel 123 or integrally formed as a unitary body with back panel 123 so as to communicate with outlet 129. During assembly, back plate 107 can be disposed over outside face 172B of back panel 123 and connect to top plate 102 and bottom plate 104. Rear nozzle 125 can be configured and positioned so as to pass through opening 112B of back plate 107. As discussed further below, the front nozzle 124 and rear nozzle 125 of the coil unit 120, extending through the front plate 106 and back plate 107 of the housing 110, enable delivery of a heat transfer fluid through coil body 126. The front nozzle 124 and rear nozzle 125 also enable multiple self-contained heat transfer cubes 100 to be daisy-chained together, i.e., fluid coupled together in series (see, for example, FIGS. 7A-7B).
In some embodiments, the self-contained heat transfer cubes 100 are approximately 36 inches (91 cm) in length, 12 inches (30 cm) in width and 12 inches (30 cm) in height. In other embodiments, heat transfer cube 100 and the other heat transfer cubes described herein each have a length, width, and height that are each at least 5 cm, 9 cm, 12 cm, 15 cm, 20 cm, 25 cm, 30 cm, 40 cm or 50 cm or are each in a range between any two of the foregoing. Although heat transfer cubes described herein are referenced in their name as a “cube,” they may but need not have the configuration of a “cube.” For example, the heat transfer cubes disclosed herein can have the same or different dimensions for length, width, and height. Likewise, in some embodiments, the disclosed heat transfer cubes can have sloped, curved or irregular configurations. However, having a cubed or elongated cubed configuration can achieve unique benefits in association with stack, coupling, storing and shipping.
In some embodiments, an array of self-contained heat transfer cubes 100 may be linked together, where each self-contained heat transfer cube of the array is approximately 9 inches (23 cm) in length, 3 inches (8 cm) in width and 3 inches (8 cm) in height. Such an array may ultimately give rise to an array that is operationally approximately 36 inches (90 cm) in length, 12 inches (30 cm) in width and 12 inches (30 cm) in height. Individual self-contained heat transfer cubes 100 may be scaled up or down in size, keeping the relative proportions of the length, width and height. These dimensions of the self-contained heat transfer cubes 100 may have a tolerance or margin of error of approximately 4 to 7%.
In one embodiment the inlet 128 and outlet 129 are longitudinally aligned. In other embodiments, they can be laterally and/or vertically offset. In some embodiments, the inlet 128 and outlet 129 each comprise or are coupled with the front nozzle 124 or rear nozzle 125, as discussed above, so that they may extend through the openings 112A of front plate 106 and/or openings 112B of back plate 107. In other embodiments, inlet 128 and outlet 129 can simply be configured for removably coupling with a nozzle or end of tube that deliver or withdraw a heat transfer fluid to coil body 126. In still other embodiments, front plate 106 and back plate 107 can be eliminated and front panel 122 and back panel 123 can extend to and couple directly or indirectly with top plate 102 and bottom plate 104. In this embodiment, front panel 122 and back panel 123 can combine with top plate 102 and bottom plate 104 to form a housing while coil body 126 can be referenced as a coil unit that is disposed within a compartment of the housing. In some embodiments, the inlet 128 and outlet 129 or the nozzles 124 and 125 coupled thereto, respectfully, each have an inside diameter of at least 1, 1.5, 2, 3, 4, 5, 6, 8, 9, 10 or 12 cm or in a range between any two of the foregoing. The diameter size can, in part, depend upon the size of coil body 126.
Continuing with FIG. 3 , in one embodiment the coil body 126 includes a plurality of thermally conductive plates 180, where each plate 180 includes a plurality of spaced apart perforations 184 extending therethrough. Each plate 180 has a front face 186 and an opposing back face 188 with the perforations 184 extending therebetween. Plates 180 are typically disposed so that back face 188 of one plate 180 overlies the front face 186 of the adjacent plate 180 and all plates 180 are disposed in parallel alignment. As such, in the depicted assembled configuration shown in FIG. 3 , coil body 126 comprised of plates 180 has a first side 200A and an opposing second side 200B that both extend between a first end 202A and an opposing second end 202B and that both extend between an upper end 204A and an opposing lower end 204B. Plates 180 are shown as having a square or rectangular configuration but can have other shapes. Although depicted as being an elongated cube in FIG. 3 , coil body 126 can also be in the configuration of a regular cube or have other configurations.
Spacing between each plate 180 of coil body 126/coil unit 120 can be extremely compact, with space measured in millimeters between each thermally conductive plate 180. For example, in one embodiment the spacing between plates 180 can be at least or less than 1, 1.5, 2, 3, 4, 6, 8, or 10 mm or be in a range between any two of the foregoing. Other spacings can be used in other embodiments. One objective of the coil body 126 can be to provide as much surface area as possible within a confined space, making the space between thermally conductive plates 180 only large enough to permit air to pass through.
The number of plates 180 used in coil body 126 can also depend on the intended use for heat transfer cube 100. In one example embodiment, the number of plates 180 can be at least 10, 20, 30, 40, 50, 70, 100, 200, or 300 plates or be in a range between any two of the foregoing. Other numbers can also be used depending on the application. Plates 180 include a first plate 180A having a front face 186 and a last plate 180N have a back face 188 with a plurality of plates 180 disposed therebetween. The plurality of thermally conductive plates 180 can be substantially aligned with each other, such that the plurality of perforations 184 for each plate 180 are at least substantially aligned with the perforations 184 of each of the other plates from first plate 180A to last plate 180N. This alignment of perforations 184 produces a plurality of linear channels 190 that extend from first plate 180A through last plate 180N.
Plates 180 as used in heat transfer cube 100 and the other heat transfer cubes disclosed herein can also be referred to and claimed as “sheets.” The thickness of plates/sheets 180 can vary and depends in part on the intended use. Plates/sheets 180 can be thicker where more structural stability is needed, such as where plates 180A and 180N are needed to support and secure to tubes, as discussed below. However, plates/sheets 180 can be thinner where they are only functioning for radiating or absorbing thermal energy, such as the central plates/sheets 180 between plates/ sheets 180A and 180N. As such, in a plurality of plates/sheets 180 used a heat transfer cube, the plurality of plates/sheets 180 may each have the same thickness or some may have different thicknesses than others. In addition, some plates/sheets 180 may be made of different materials than others to help achieve their intended function. In the alternative embodiments disclosed herein, plates/sheets 180 can have a thickness of at least or less than 0.5 mm, 1 mm, 2 mm, 3 mm, 5 mm, 10 mm, 15 mm, 20 mm or be in a range between any two of the forgoing. For example, in some embodiments, some plates/sheets 180 may have a thickness in a range between 0.5 mm and 3 mm while other plates/sheets 180 have a thickness in a range between 3 mm and 10 mm Other dimensions can also be used.
The channels 190 permit a heat transfer fluid to laterally flow through the coil body 126 from first plate 180A through last plate 180N. In some embodiments, the diameter of each perforation 184 can be at least or less than 0.3, 0.5, 0.7, 1, 1.5, 2 or 2.5 cm or in a range between any two of the foregoing. Spacing between adjacent perforations 184 can also be at least or less than 0.3, 0.5, 0.7, 1, 1.5, 2 or 2.5 cm or in a range between any two of the foregoing. Other dimensions can also be used. The number of perforations per plate 184 depends on the size of plates 180. However, in some embodiments, the number of perforations 180 per plate 180 can be at least 50, 75, 100, 150, 200, 250, 300, 400, 500 or in a range between any two of the foregoing. Other numbers can also be used. In some embodiments, the plurality of thermally conductive plates 180 are constructed from a metal such as copper, aluminum, stainless steel, or an aluminum alloy. Other materials have needed strength and heat transfer properties can also be used.
The plurality of thermally conductive plates 180 may, in some embodiments, be kinked or grooved to increase the surface area of each individual thermally conductive plate 180 of the plurality of thermally conductive plates. Increasing the surface area of each thermally conductive plate 180 increases the capacity of the coil unit 120 to act as a heat sink and store thermal energy. As the heat sink capacity increases, the efficiency of the coil unit 120 to heat and/or cool air molecules passing through the coil body 126 also increases. An increase in efficiency beneficially reduces the energetic needs of the self-contained heat transfer cube 100, thereby reducing both the overall energetic needs of a building and a building's carbon footprint.
The plurality of perforations 184/plurality linear channels 190 are in fluid communication with the inlet 128 and outlet 129 of the coil unit 120. Additionally, and/or alternatively, the plurality of perforations 184/plurality linear channels 190 are in fluid communication with the nozzles 124 and 125 of the coil unit 120. This fluid communication, and alignment of the plurality of thermally conductive plates 180, enables the plurality linear channels 190 to provide a straight-line flow path for a heat transfer fluid to flow through the self-contained heat transfer cube 100. That is, a heat transfer fluid is capable of flowing from the inlet 128, through the coil body 126, and to the outlet 129 of each self-contained heat transfer cube 100 without taking a serpentine route. In some embodiments, the diameter of each perforation of the plurality of perforations is approximately ⅜ inches (1 cm). In some embodiments, the diameter of each perforation of the plurality of perforations is approximately ½ inch (1.3 cm). In some embodiments, the diameter of each perforation of the plurality of perforations is approximately ¼ inch (0.6 cm).
A straight-line path can be beneficial in some embodiments because it decreases or limits the build-up of pressure within the self-contained heat transfer cube 100/coil unit 120. Similarly, the alignment helps decrease changes in pressure within the self-contained heat transfer cube 100/coil unit 120. Pressure build-ups or pressure changes during flow can negatively impact both the efficiency of the heat transfer and the integrity of the heat transfer structure. For example, conventional HVAC systems are generally installed in large spaces to account for the pressure build-up and allow for its release.
The present invention also provides for containment of the heat transfer fluid as it flows along channels 190. Specifically, coil unit 120 can include a tube that extends along each channel 190 from first plate 180A to last plate 180N. For example, FIG. 4 shows a cross sectional side view of a portion of coil unit 120 including thermally conductive plates 180A, 180B, 180C, 180D, 180E, 180F, 180G, and 180N forming a portion of the plurality of thermally conductive plates 180. In this embodiment, discrete tubes 196A-196F, such as in the form of pipes or other conduits, are shown extending laterally through aligned perforations 184, i.e., along channels 190, with each tube 196 bounding a corresponding fluid path 195. In one embodiment, a snug friction fit can be formed between tubes 196 and plates 180. In other embodiments, tubes 196 can be secured to plates 180 such as by welding, adhesive, press fit connection, seals, or the like. In any embodiment, the engagement between tubes 196 and plates 180 is sufficient for an effective heat transfer therebetween.
With continued reference to FIG. 4 , each tube 196 has a first end 197 and an opposing second end 198. First end 197 is secured to first plate 180A so that fluid path 195 communicates with a perforation 184 extending through first plate 180A. Furthermore, first end 197 is secured to first plate 180A so as to form a liquid tight seal therebetween. The liquid tight seal can be formed through a threaded coupling, press fit connection, welded connection, by use of a seal that is disposed between each tube 196 and first plate 180A or through any other conventional sealing technique. Second end 198 is similarly connected to last plate 180N. Front panel 122 is secured to first plate 180A in a liquid tight manner so that a first space gap 199A is formed between front panel 122 and first end 197 of each tube 196. As such, when a heat transfer fluid flows into coil unit 120A through front nozzle 124/inlet 128, the liquid can flow along first space gap 199A and flow into each fluid path 195 of each tube 196. Likewise, back panel 123 is secured to last plate 180N in a liquid tight manner so that a second space gap 199B is formed between back panel 1234 and second end 198 of each tube 196. As such, after the heat transfer fluid passes through each tube 196, the heat transfer fluid can flow along second space gap 199B and exit out through rear nozzle/outlet 129.
In one embodiment front nozzle 124/inlet 128 and rear nozzle/outlet 129 can be horizontally aligned. However, in other embodiments as depicted in FIG. 4 , front nozzle 124/inlet 128 can be spaced at an elevation higher than rear nozzle/outlet 129. Because the heat transfer fluid is being pulled down under the force of gravity, this configuration assists in producing a more uniform flow of the heat transfer fluid throughout all of tubes 196. It is appreciated that the flow rate through tubes 196 can vary based on the needed demand for heating or cooling. That is, a faster flow rate may be required where a greater demand for heating or cooling is needed.
In some embodiments, the inner diameter of each tube 196 can be at least or less than 0.3, 0.5, 0.7, 1, 1.5, 2 or 2.5 cm or in a range between any two of the foregoing. Spacing between adjacent tubes 196 can also be at least or less than 0.3, 0.5, 0.7, 1, 1.5, 2 or 2.5 cm or in a range between any two of the foregoing. Other dimensions can also be used. The number of tubes 196 per coil unit 120 depends on the size of plates 180 and the number of perforations 184 therein. However, in some embodiments, the number of tubes 196 per coil unit 120 can be at least 50, 75, 100, 150, 200, 250, 300, 400, 500 or in a range between any two of the foregoing. Other numbers can also be used. The length of tubes 196 is typically at least 7, 10, 15, 20, 30, 40, 60, 80, 100 or 150 cm or is in a range between any two of the foregoing. Tubes 196 can be made from the same materials as discussed above for plates 180.
During assembly, plates 180 are secured on tubes 196 in adjacent alignment, as shown in FIGS. 3 and 4 , so that coil body 126 is formed with the plurality of isolated fluid paths 195 extending from first plate 180A to last plate 180N, i.e., from first side 200A to second side 200B. However, plates 180 are retained spaced apart so that air can flow therebetween from first end 202A to second end 202B and a cleaning solution can flow therebetween from upper end 204A to lower end 204B. As discussed above, front panel 122 is secured to first side 200A of coil body 126 so that inlet 128 communicates with fluid paths 195 extending through plates 180. For example, this can be done by forming a liquid tight seal between front panel 122 and the outer perimeter edge of first plate 180A and/or the outer perimeter of front face 186 of first plate 180A. Similarly, back panel 123 is secured to second side 200B of coil body 126 so that outlet 129 communicates with fluid paths 195. Again, by way of example, this can be done by forming a liquid tight seal between back panel 123 and the outer perimeter edge of last plate 180N and/or the outer perimeter of back face 188 of last plate 180N.
With reference to FIG. 2 , injection port assembly 108 can be disposed on upper end 204A of coil body 126. Injection port assembly 108 can have a variety of different configurations. In the depicted embodiment, injection port assembly 108 includes a base 206, such as in the form of a flat panel, having a plurality of spaced apart injection ports 208 mounted thereon. Each injection port 208 can comprise any type of nozzle, spray tip, port, or the like through which a cleaning solution can be dispensed. In the depicted embodiment, a supply line 210 is used to deliver cleaning solution to a manifold 212 while the manifold 212, in turn, delivers the cleaning solution to each of the injection ports 208 through transfer lines 214. Injection port assembly 108 is shown as having six injection ports 208. However, depending on the size of injection port 208 and the size of coil body 126, injection port assembly 108 can be formed with other numbers of injection ports 208 including at least 1, 2, 3, 4, 5, 6, 8, 10, or 12 or in a range between any two of the foregoing. Other numbers can also be used.
Injection ports 208 are disposed on base 206 so as to extend therethrough. As such, when injection port assembly 108 is disposed on upper end 204A of coil body 126 and cleaning solution is dispensed through injection ports 208, the cleaning solution is dispensed down between plates 180. In one embodiment, injection port assembly 108 is configured so that the cleaning solution can be dispensed between each adjacent pair of plates 180.
Fouling of coil unit 120 occurs when the area between plates 180 and/or tubes 196 gets at least partially blocked so as to limit or restrict the flow of air through coil unit 120. In turn, the decreased air flow diminishes the thermal energy transfer between the air and the plates 180 and/or tubes 196. In fouling problems faced by coils, the most common problems include bacteria, fungi, and biofilms that grow on the exterior surface of plates 180 and/or tubes 196. Furthermore, coils can also be fouled with grease, hydrocarbons from outside air pollution, dust, grime, and even insect drops. An additional problem with having organic matter growing on a coil is that it can be sticky, thereby retaining a build-up of inorganic matter within the coil.
In view of the foregoing, it is not unusual for a cleaning to involve several types of formulations to address different problems separately. For removing biofilms, there are two primary techniques. The first involves using enzymes, such as those one would find in probiotics, that actively turn the biofilm into a food source and digest the biofilm. In this approach, a wide range of enzymes can be used to address biofilms. Another approach is the use of sodium chloride, which when used in very small volumes, actively works to break down the biofilm matrix into small particles. The advantages of both approaches are that they are pH neutral, non-reactive to metal surfaces, and non-odorous. Other formulations can be introduced to help break down organics, such as traces of hydrogen peroxide.
Further information on compositions and methods for cleaning coils is disclosed in U.S. Provisional Patent Application Nos. 63/316,573 (now U.S. application Ser. No. 18/117,341) and 63/242,340, the entire contents of which are incorporated herein by reference. The cleaning solution disclosed and dispensed by injection port assembly 108 and the other dispensing method disclosed herein can be in the form of a vapor, mist, foam, liquid or in other forms which can be used for removing organic matter, such as biofilms, bacteria, fungi, or the like, and/or inorganic matter. The cleaning solution can include those identified above, incorporated by reference, or otherwise known in the art. Furthermore, the cleaning solution can be applied to clear or clean a partially fouled coil or can be preventively applied to a coil to keep the coil clean and thereby prevent fouling.
Housing 110 is secured over coil unit 120 and injection port assembly 108. Returning to FIG. 1 , housing 110 includes a first end wall 220A having a first opening 222A (see FIG. 9 ) extending therethrough. First opening 222A communicates with compartment 111 and is aligned with and communicates with first end 202A of coil body 126 (FIG. 3 ). Likewise, housing 110 includes a second end wall 220B opposite first end wall 220A having a second opening 222B extending therethrough so as to communicate with compartment 111. Second opening 222B is aligned with and communicates with second end 202B of coil body 126. In view of the foregoing, during operation, air can be blown or otherwise passed through coil body 126 between from first end 202A to second end 202B by blowing or otherwise passing air through compartment 111 of housing 110 from first opening 222A to second opening 222B.
During operation, a heat transfer fluid is pumped or otherwise delivered into front nozzle 124/inlet 128 of coil unit 120. As discussed above, the heat transfer fluid passes through coil body 126 by traveling along fluid paths 195 of tubes 196. The heat transfer fluid exits coil unit 120 by passing out through rear nozzle 125/outlet 129. Depending on the location and intended use of heat transfer cube 100, the heat transfer fluid will typically comprise water or a water-based solution. The use of water minimizes expense and eliminates any environmental concerns should heat transfer cube 100 leak. In one embodiment the heat transfer fluid can comprise a glycol/water mixture to help prevent any unwanted freezing. Examples of glycol that can be used include propylene glycol and ethylene glycol. In any event, the heat transfer fluid is typically not a hydrofluorocarbon or any other compressible refrigerant used in conventional air conditioning units.
As will be discussed below in more detail, the heat transfer fluid is either heated or cool prior to delivering into heat transfer cube 100. As the heat transfer fluid flows through the coil unit 120, the plurality of thermally conductive plates 180 are either heated or cooled by the transfer of thermal energy based on the temperature of the heat transfer fluid. Specifically, when the heat transfer fluid flowing through the coil unit 120 is hot or warm, the plurality of thermally conductive plates 180 are heated. When the heat transfer fluid flowing through the coil unit 120 is cold or cooler, the plurality of thermally conductive plates 180 are cooled. Simultaneously with or subsequent to passing the heat transfer fluid through heat transfer cube 100, air is blown or otherwise passed through heat transfer cube 100 from opening 222A to opening 222B so that the air passes between plates 180 and between tubes 196 so as to either heat or cool the air. The air can then be circulated through an area for heating or cooling the area.
Increasing the surface area coil body 126 allows for more interactions between surfaces of each plate of the plurality of thermally conductive plates 180 and air molecules flowing through the coil unit 120. The interaction of air molecules with the plurality of thermally conductive plates 180 is what heats or cools the air molecules as they move through the coil unit 120 and enables delivery of hot or cold air into an interior space, such as a room in a building.
FIGS. 5 and 6 illustrate flowcharts of exemplary flows of water (or another heat transfer fluid) through a self-contained heat transfer cube. Though the flow will be described with respect to water, it is to be understood that another appropriate heat transfer fluid would follow the same or similar flow path.
With respect to FIG. 5 , warm (or warmer) water enters a cold heat exchanger (incorporated in a power cube, discussed more fully below with respect to FIG. 13 ) and is cooled (410). The cooled water enters a first port, inlet, or nozzle of the self-contained heat transfer cube and flows through the port, inlet, or nozzle into the coil unit (420). The cooled water will flow or be distributed through the plurality of perforations and along the tubes extending across the coil body. As the cooled water flows through the coil unit, the plurality of thermally conductive plates will be cooled (430). Warm air blown through the coil unit will pass through spaces between the plurality of (cooled) thermally conductive plates and thereby be cooled (440).
As the cooled water flows through the coil unit and cools the plurality of thermally conductive plates, the water warms. This warmer water exits the channels via a second port, outlet, or nozzle of the self-contained heat transfer cube (450). The warmer water is passed back into the cold heat exchanger to be cooled again (460).
FIG. 6 illustrates a flowchart of another exemplary flow of water through a self-contained heat transfer cube. Cold (or cooler) water enters a hot heat exchanger (incorporated in a power cube, discussed more fully below with respect to FIG. 13 ) and is heated (510). The heated water enters a first port, inlet, or nozzle of the heat transfer cube and flows through the nozzle into the coil unit (520). The heated water will flow or be distributed through the plurality of perforations and along the tubes extending across the coil body. As the heated water flows through the coil unit, the plurality of thermally conductive plates will be heated (530). Cold air passing through the coil unit will pass through spaces between the plurality of (heated) thermally conductive plates and thereby be heated (540).
As the heated water flows through the coil unit and heats the plurality of thermally conductive plates, the water cools. This cooler water exits the channels via a second port, outlet, or nozzle of the self-contained heat transfer cube (550). The cooler water is passed back into the hot heat exchanger to be heated again (560).
Depending, in part, on the type of cleaning solution being used, in one embodiment the cleaning solution can be dispensed into coil body 126 while the air is being passed through coil unit 120/housing 110. In other embodiments, the air flow can be temporarily halted while the cleaning solution is being dispensed. Typically, the cleaning solution is dispensed at set period intervals. This helps prevent the buildup of any unwanted material within coil unit 120/coil body 126. However, in alternative embodiments, the cleaning solution can be dispensed based upon a measured parameter, such as an increase in air pressure for air flowing through coil unit 120.
It is appreciated that heat transfer cube 100 can also have other configurations. For example, depicted in FIGS. 7 and 8 is a heat transfer cube 100A. Like elements between heat transfer cubes 100 and 100A are identified by like reference characters. Furthermore, for features that are the same between heat transfer cubes 100 and 100A, all of the prior discussion and alternatives for heat transfer cube 100 are also deemed applicable to heat transfer cube 100A. Heat transfer cube 100A includes housing 110 having the first end wall 220A with first opening 222A extending therethrough and communicating with compartment 111 and opposing second end wall 220B having the second opening 222B extending therethrough and communicating with compartment 111. Disposed within compartment 111 is a coil unit 120A. Coil unit 120A is spaced back from first opening 222A so that a recess 228 forming a portion of compartment 111 is openly exposed between first opening 222A and coil unit 120A.
A tubular transfer line 127 couples with an opening extending through top plate 102 so that transfer line 127 communicates with recess 226. As discussed below in greater detail, transfer line 127 can be used to deliver a cleaning solution, as previously discussed, into recess 228 which is subsequently blown through coil unit 120A with the passage of air to help clean and/or to prevent fouling of coil unit 120A. In alternative embodiments, transfer line 127 can be coupled with any one of top plate 102, bottom plate 104, front plate 106, or back plate 107 for delivering the cleaning solution to recess 226. In still other embodiments, the cleaning solution can be delivered directly at first opening 222A or at a location upstream of first opening 222A so that the cleaning solution is blown into compartment 111 for delivery to coil unit 120A. As such, in some embodiments recess 226 is not required.
Turning to FIG. 9 , coil unit 120A includes a coil body 126A bounded between front panel 122 and back panel 123. Front nozzle 124 can outwardly project from front panel 122 while rear nozzle 125 can outwardly project from back panel 123. As with heat transfer cube 100, in one embodiment front plate 106 and back plate 107 can be eliminated and front panel 122 and back panel 123 can extend to and couple directly or indirectly with top plate 102 and bottom plate 104. In this embodiment, front panel 122 and back panel 123 can combine with top plate 102 and bottom plate 104 to form a housing while coil body 126A can be referenced as a coil unit that is disposed within a compartment of the housing. Turing to FIG. 10 , coil body 126A comprises first plate 180A and spaced apart last plate 180N. However, in contrast to coil body 126, the remaining plates 180 between first plate 180A and last plate 180N have been eliminated. Each of plates 180A and 180N have aligned perforations 184, as previously discussed, extending therethrough. In addition, extending between each pair of aligned perforations 184 on plates 180A and 180N is one of tubes 196.
Depicted in FIG. 11 is a cross sectional view of a portion of coil unit 120A. The portion of coil unit 120A shown in FIG. 11 is identical to the portion of coil unit shown in FIG. 4 except that the additional plates 180 have been removed from between first plate 180A and last plate 180N. As such, the prior discussion with regard to FIG. 4 on the parts, assembly, operation and alternatives of coil unit 120 are also applicable to coil unit 120A except for that relating to the additional plates. For example, as shown in FIG. 11 , tubes 196A-F are each shown extending between first plate 180A and last plate 180N with each tube 196 being tubular and bounding a fluid path 195 extending therethrough. Each tube 196 has a first end 197 and an opposing second end 198. First end 197 is secured to first plate 180A so that fluid path 195 communicates with a perforation 184 extending through first plate 180A. Furthermore, first end 197 is secured to first plate 180A so as to form a liquid tight seal therebetween, as previously discussed. Second end 198 is similarly connected to last plate 180N. Front panel 122 is secured to first plate 180A in a liquid tight manner so that first space gap 199A is formed between front panel first end 197 of each tube 196. As such, when a heat transfer fluid flows into coil unit 120A through nozzle 124/inlet 128, the liquid can flow along first space gap 199A and flow into each fluid pathway 195 of each tube 196. Likewise, back panel 123 is secured to last plate 180N in a liquid tight manner so that a second space gap 199B is formed between back panel 123 and second end 198 of each tube 196. As such, after the heat transfer fluid passes through each tube 196, the heat transfer fluid can flow along second space gap 199B and exit out through rear nozzle/outlet 129. The inner diameter, spacing between, number, length, materials, and other properties for tubes 196 in coil unit 120A can be the same as that previously discussed above with regard to coil unit 120.
The elimination of plates 180 from between plates 180A and 180N has been found to achieve a number of benefits in at least some applications. For example, the removal of the plates 180 reduces material costs and simplifies production. In addition, the removal of plates 180 helps to limit fouling within coil unit 120A by providing more space for the cleaning solution to flow and more space to enable debris to flow out of coil unit 120A. Furthermore, the heat transfer can be increased because air is now directly flowing over tubes 196 as opposed to over plates 180 that only connected to tubes 196. In addition, removal of plates 180 enables greater contact between the air and tubes 196 by now allowing the air to more freely flow over, around and along tubes 196. Tubes 196 can now also be moved closer together which enhances the thermal energy transfer with the air. Furthermore, in coil unit 120 it was often more helpful to form tubes 196 and plates 180 from a highly conductive metal, such as copper, because heat or cold needed to be transferred from tubes 196 to plates 180. However, in coil unit 120A, the thermal energy transfer is directly between tubes 196 and the air. As such, tubes 196 for coil unit 120A can be made of less thermally conductive material, such as less conductive metals, like aluminum, or from non-metals, such as a plastic or composite, and still achieve sufficiently high thermal energy transfer. Forming tubes 196 from aluminum or a non-metal can be a substantial cost savings. Other benefits also exist. Heat transfer cube 100A and coil unit 120A operate in the same manner as previously discussed above with regard to heat transfer cube 100 and coil unit 120, respectively. That is, a heat transfer fluid is passed through heat transfer cube 100A/coil unit 120A by flowing between nozzle 124/inlet 128 and rear nozzle/outlet 129. While the heat transfer fluid is passing through tubes 196, the tubes 196 are heated or cooled depending on the temperatures of the heat transfer fluid. Simultaneously with or subsequent to passing the heat transfer fluid through heat transfer cube 100A, air is blown or otherwise passed through heat transfer cube 100A from opening 222A to opening 222B so that the air passes over, around, and between tubes 196 so as to ether heat or cool the air. The air can then be circulated through an area for heating or cooling the area.
During the above operation of heat transfer cube 100A, the cleaning solution can periodically be injected though transfer line 127 and into the air flow upstream of coil unit 120A. For example, the cleaning solution can be injected into recess 226 as previously discussed. The air flow then carries and disperses the cleaning solution over and around each of tubes 196 for cleaning the surface of tubes 196, the area between tubes 196, and/or preventing any build-up or growth on or between tubes 196. Typically, the cleaning solution is dispensed at set time intervals. This helps prevent the build-up of any unwanted material within coil unit 120A/coil body 126. However, in alternative embodiments, the cleaning solution can be dispensed based upon a measured parameter, such as an increase in air pressure for air flowing through coil unit 120A. In combination with or in contrast to dispensing cleaning solution through transfer line 127, heat transfer cube 100A can also incorporate injection port assembly 108 for injecting a cleaning solution direction on top of coil body 126. Injection port assembly 108 can have the same configuration, alternatives, and use as previously discussed above with regard to heat transfer cube 100. In one embodiment, different cleaning solutions can be dispensed through transfer line 127 and injection port assembly 108 to achieve different cleaning objectives.
FIGS. 12A-12C disclose another alternative embodiment of a heat transfer cube 100B. Like elements between heat transfer cubes 100A and 100B are identified by like reference numbers. In general, heat transfer cube 100B comprises a housing 230 having an interior surface that bounds a compartment 232. In general, housing 230 comprises a top plate 234 and an opposing bottom plate 236 and also a front panel 238 and opposing back panel 240 that are disposed between top plate 234 and opposing bottom plate 236. Inlet 128 is formed on front panel 238 while outlet 129 is formed on back panel 240.
Housing 230 extends between a first end 246 and an opposing second end 248. A first opening 250 is formed at first end 246 so as to communicate with compartment 232 while a second opening 252 is formed at second end 248 so as to communicate with compartment 232. Disposed within compartment 232 between first opening 250 and second opening 252 is a coil unit 120B. Coil unit 120B comprises a first plate 256 having the plurality of perforation 184 extending therethrough and a spaced apart last plate 258 having a plurality of perforations 184 extending therethrough. Coil unit 120B also includes a plurality of tubes 196 that extend between first plate 256 and last plate 258. More specifically, as previously discussed with coil unit 120A, the first end of each tube 196 is sealed in a liquid tight fashion with a select one of perforation 184 of first plate 256 while the second end of each tube 196 is sealed in a liquid tight fashion with a select one of perforation 184 of last plate 258. First plate and last plate 258 can be made of the same materials and have the same dimensions and properties as discussed above with regard to plates 180.
During use, front panel 238 is disposed over first plate 256 so that first space gap 199A (FIG. 11 ) is disposed between front panel 238 and the first end of each tube 196. As such, when a heat transfer fluid is passed through inlet 242, the heat transfer fluid can flow to the open first end of each tube 196 and into the fluid path bounded therein. Back panel 240 is disposed over last plate 258 so that second space gap 199B (FIG. 11 ) is disposed between back panel 240 and the second end of each tube 196. Accordingly, as the heat transfer fluid passes out of the second end of each tube 196, the heat transfer fluid can flow to pass out of outlet 129. The inner diameter, spacing between, number, materials, length, and other properties for tubes 196 in coil unit 120B can be the same as that previously discussed above with regard to coil unit 120.
As in the prior embodiments, a heat transfer fluid is passed through heat transfer cube 100B/coil unit 120B by flowing between inlet 128 and outlet 129. While the heat transfer fluid is passing through tubes 196, the tubes 196 are heated or cooled depending on the temperatures of the heat transfer fluid. Simultaneously with or subsequent to passing the heat transfer fluid through heat transfer cube 100B, air is blown or otherwise passed through heat transfer cube 100B from first opening 250 to second opening 252 so that the air passing over and around tubes 196 is either heated or cooled. The air can then be circulated through an area for heating or cooling the area. It is noted that in heat transfer cubes 100 and 100A, all of the perforations 184 and tubes 196 are shown as being in both vertical and horizontal alignment. See FIGS. 3 and 10 . However, in heat transfer cube 100B, as shown in FIGS. 12B and 12C, each adjacent row of perforations 184 and tubes 196 are laterally offset so that not all perforations 184 and tubes 196 are in vertical alignment. This offsetting of tubes 196 assists in further dispersing the air as it flows around tubes 196, thereby further enhancing thermal transfer between tubes 196 and the air. Other offsetting of perforations 184 and tubes 196 can also be used so that not all perforations 184 and tubes 196 are both horizontally and vertically aligned.
Heat transfer cube 100B can also include transfer line 127 mounted on housing 230 or otherwise disposed so as to periodically inject a cleaning solution into the air flow upstream of coil unit 120B. The cleaning solution and application can be the same as previously discussed above with heat transfer cube 100A.

Heat Transfer and Power Cube Systems

FIG. 13 illustrates an example heat transfer cube system 200. Specifically, FIG. 13 illustrates two self-contained heat transfer cubes 100C and 100D (a first and a second self-contained heat transfer cube) flanking a power cube 130. Although heat transfer cubes 100C and 100D are illustrated as being adjacent to power cube 130, during operation transfer cubes 100C and 100D may be spaced apart. For example, one may be located within a building for heating or cooling the building while the other is located outside of the building. One or both of heat transfer cubes 100C and 100D may also be spaced apart from power cube 130. The self-contained heat transfer cubes 100C and 100D may comprise heat transfer cube 100, 100A, 100B or any alternatives thereto, as discussed above. As such, all of the prior discussions with regard heat transfer tubes 100, 100A, and 100B including the elements, operation, and alternatives thereof, are also applicable to heat transfer cubes 100C and 100D and like elements between heat transfer cubes 100/100A/100B and heat transfer cubes 100C and 100D are identified by like reference numbers.
Though not illustrated, in some embodiments, the heat transfer cube system 200 includes thermal storage cubes and/or solar panels. The thermal storage cubes may absorb and store excess thermal energy, for example heat, as it comes off or exits the self-contained heat transfer cubes. As another (non-limiting) example, a thermal storage cube may store “excess cold” by creating ice cubes. The ice cubes can be melted to provide chilled water to be recirculated through a self-contained heat transfer cube. The solar panels may be connected to the power cube to provide power or electricity for the cube. In this way, the heat transfer cube system could potentially be powered by sustainable and renewable energies.
The power cube 130 generally includes a control circuit 132, a thermal loop 140, a first circulation loop 150, a second circulation loop 151, and a cleaning loop 160. The thermal loop 140 includes a compressor 142, a first heat exchanger 144 in fluid communication with the compressor 142, a second heat exchanger 146 in fluid communication with the compressor 142, and an expansion valve 148 in fluid communication with both the first and second heat exchangers 144, 146. A compressible refrigerant, such as hydrofluorocarbons (HFC), is circulated through the thermal loop 140 of the power cube 130.
The refrigerant serves to heat or cool heat transfer fluid circulating through the circulation loop 150/151. For example, power cube 130 can operate in a heating mode or cooling mode. In the heating mode the refrigerant is compressed by compressor 142 so as to be at an elevated temperature and pressure. The heated refrigerant is then passed to heat exchanger where, as discussed below, thermal energy is transferred from the heated refrigerant to the heat transfer fluid that is pumped into heat transfer cube 100C. The now partially cool refrigerant is passed through expansion valve 148 and heat exchanger 146. The refrigerant transitions from a liquid phase to a vapor phase as it passes through the expansion valve 148, thereby cooling the refrigerant. The refrigerant absorbs thermal energy as it passes through heat exchanger 146, thereby causing the refrigerant to partially warm before it returns to compressor to repeat the cycle. In the cooling mode, a reversing valve 147 is activated causing the refrigerant to flow in the opposite direction. Again, the refrigerant is compressed within compressor 142 to an elevated temperature and pressure. The heated refrigerant then passes to heat exchanger 146 where it is partially cooled before passing through expansion valve 148. Again, the refrigerant undergoes a phase change as passes through expansion valve 148 causing it to drop in temperature. The refrigerant absorbs thermal energy from the heat transfer fluid of heat transfer cube 100C as it passes through heat exchanger 144. Finally, the refrigerant returns to compressor 132 where the process is repeated.
In typical embodiments the thermal loop 140 is small, requiring a small amount of HFCs to provide sufficient heating or cooling to the heat transfer fluid that is circulated through heat transfer cube 100A. For example, in some embodiments a maximum of half (½) a pound (0.23 kg) of HFCs may be circulated, in contrast to substantially larger amounts that are circulated in a conventional HVAC system. In some embodiment, the amount of refrigerant, e.g., HFCs, circulating through thermal loop is less than 1, 0.7, 0.5, 0.3, 0.2 kg or is in a range between any two of the foregoing.
The circulation loop 150 includes a first pump 152, a fluid line 266A that extends from first pump 152 to heat exchanger 144, a fluid line 266B that extends from heat exchanger 144 to inlet 128 (FIG. 10 ) of heat transfer cube 100C, and a fluid line 266C that extends from outlet 129 (FIG. 10 ) of heat transfer cube 100C back to pump 152. Pump 152 thus circulates the heat transfer fluid within circulation loop 150 so that it passes through heat exchange 144 where it is heated or cooled, as discussed above, and then passes the heat transfer fluid through heat transfer cube 100C where it passes through and either cools or heats the tubes 196 therein. In turn, the air passing over the tubes heats or cools the air which is then circulated through an area for heating or cooling the area, as previously discussed above with regard to heat transfer cubes 100, 100A, and 100B. The heat transfer fluid then returns to pump 152 where the process is repeated.
The circulation loop 151 includes a second pump 154, a fluid line 268A that extends from first pump 152 to heat exchanger 146, a fluid line 268B that extends from heat exchanger 146 inlet 128 of heat transfer cube 100D, and a fluid line 268C that extends from outlet 129 of heat transfer cube 100D back to pump 154. Pump 154 thus circulates the heat transfer fluid within circulation loop 151 so that it passes through heat exchange 146 where it assists to either warm or cool the refrigerant in thermal loop 140 through thermal energy transfer. The heat transfer fluid which has now either been warmed by absorbing energy from the refrigerant or has been cooled by losing energy to the refrigerant is circulated through heat transfer cube 100D where it passes through tubes 196, as previously discussed above with regard to heat transfer cubes 100, 100A, and 100B, and is either warmed or cooled based on the temperature of the tubes and the ambient temperature of the air about the tubes 196. Depending on the ambient temperature and/or the source for the air that can be passed through heat transfer cube 100D, air may or may not be blown through heat transfer cube 100D as the heat transfer fluid is circulated therethrough. The heat transfer fluid then returns to pump 152 where the process is repeated.
Circulation loops 150 and 151 are closed loops so that little to no heat transfer fluid escapes as waste or is otherwise lost. In one embodiment, approximately 2.5 to 5 gallons per minute (9.5 to 19 liters per minute) of heat transfer fluid is circulated through each circulation loop 150/151 and the respective self-contained heat transfer cubes. In other embodiments, the flow rate can be at least or less than 5, 7, 10, 15, 20, 30, or 40 liters per minute or in a range between any two of the foregoing. This is a beneficial and significant reduction in water usage as compared to conventional HVAC systems, which typically require about 48% of a building's total water consumption.
Additionally, the use of water/heat transfer fluid circulating through the closed-loop self-contained heat transfer cubes increases the efficiency of any heat transfer or transfers of thermal energy. Specifically, water has a relatively high specific heat or heat capacity, meaning water is very efficient at storing and transferring thermal energy. Combined with the increased surface area of the plurality of thermally conductive tubes and/or plates (which can be enhanced by kinks and/or grooves), transfers of thermal energy in the self-contained heat transfer cubes is very efficient. Thus, a smaller temperature differential between water (as a heat transfer fluid) and the desired air temperature may be required. For example, when the desired interior air temperature is approximately 65° F., 62° F., water can be used to achieve the desired temperature.
Contrastingly, to achieve an interior temperature of approximately 65° F., conventional HVAC systems circulate a 45° F. refrigerant. Cooling a refrigerant to 45° F. (and keeping it at that temperature) requires a considerable amount of energy. However, cooling water to 62° F. (and still achieving the same 65° F. interior temperature) requires significantly less energy. Any desired temperature can be achieved through the use of water as the primary heat transfer fluid.
The power cube 130 also includes a cleaning loop 160 which includes a cleaning solution generator 162 and a reservoir tank 164 in fluid communication with the cleaning solution generator 162. The cleaning loop 160 may also include one or more compressors or pumps to circulate a cleaning solution. The cleaning loop 160 may include a plurality of fluid communication lines 166, connecting the cleaning loop 160 (e.g., the reservoir tank 164, the cleaning solution generator 162 and/or pumps) to the self-contained heat transfer cubes 100C and 100D to enable a cleaning cycle. The cleaning solution generator 162 is in fluid communication with each of the first and second self-contained heat transfer cubes 100C and 100D. The cleaning solution generator 162 produces a cleaning solution to be circulated and distributed through the self-contained heat transfer cubes 100C and 100D, thereby cleaning the self-contained heat transfer cubes and the coil units contained inside them. For example, in some embodiments, heat transfer cube 100C and/or 100D can include injection port assembly 108. Cleaning loop 160 can deliver the cleaning solution to injection port assembly 108 so as to periodically inject cleaning solution into the coil unit as previously discussed above with regard to coil unit 120. In other embodiments, heat transfer cube 100C and 100D can include line 127, as previously discussed above with regard to heat transfer cubes 100A and 100B. Cleaning loop 160 can deliver the cleaning solution to line 127 so as to periodically deliver the cleaning solution into the air flow upstream of the coil unit so that the air carries the cleaning solution through the coil unit to facilitate cleaning thereof.
In some embodiments, the coil unit 120 of the self-contained heat transfer cubes 100 may include foaming or self-cleaning coils. Examples of self-cleaning/foaming coils and cleaning solutions and/or foams that may be produced by the cleaning solution generator are outlined and described in U.S. Provisional Patent Application Nos. 63/316,573 (now U.S. application Ser. No. 18/117,341) and 63/242,340, the entire contents of which are incorporated herein by reference.
The power cube 130 also includes a control circuit 132 which includes a control board, at least one microprocessor unit and a plurality of sensors. The control board may be a programmable logic board or other printed circuit board. The control circuit 132 is capable of controlling and implementing a heating cycle, a cooling cycle and/or a cleaning cycle. Additionally, the control circuit 132 is capable of controlling the thermal 140, circulation 150 and cleaning 160 loops of the power cube. The plurality of sensors may include thermistors, infrared (IR) sensors, temperature sensors, timing switches and the like.
In some embodiments, the control board is a programmable logic controller (PLC) board. The PLC board may include one or more microprocessors to control one or more of the loops in the power cube. The one or more microprocessors may also be configured to control other elements of a heat transfer cube system. For example, the one or more microprocessors may be configured to switch on or off an air handler and/or compressor during a cleaning cycle. For example, the one or more microprocessors may switch off the air handler while cleaning solution is being injected (via the at least one injection port) into the self-contained heat transfer cubes. Once an amount of cleaning solution has been injected, the one or more microprocessors may be configured to switch the air handler back on, pulling the cleaning solution throughout the self-contained heat transfer cubes.
The PLC board may include sensors for controlling and monitoring the cleaning solution generator and the ultimate cleaning solution formulation for a cleaning cycle. The PLC may be connected and in communication with various other sensors which automatically activate if a differential pressure within the heat transfer cube system goes above or below a predetermined threshold level. The cleaning solution generator may be automatically activated due to the differential pressure.
FIG. 14A illustrates a perspective view of a plurality of self-contained heat transfer cubes 100 linked together in a system 300 and FIG. 13B illustrates a front view of the linked system 300 of FIG. 14A. In some embodiments, the self-contained heat transfer cubes 100 are linked together via cam lock connectors. Such a connection still allows for the straight-line flow of water (or other heat transfer fluid) through the self-contained heat transfer cubes. In this way, the plurality of self-contained heat transfer cubes can be utilized and implemented to fit and appropriately heat and/or cool any size building or interior space. More specifically, FIGS. 14A and 14B show a plurality of heat transfer cubes fluid coupled together in series, i.e., daisy-chained together. That is, the outlet 129 of each heat transfer cube 100 to fluid coupled to inlet 128 of the adjacent heat transfer cube 100. Thus, a single circulation loop 150 (FIG. 13 ) can circulate a heat transfer fluid through the plurality of interconnected transfer cubes 100 to further optimize the cooling or heating capability. Although FIGS. 14A and 14B show the use of heat transfer cube 100, heat transfer cubes 100A and 100B can also be fluid coupled together in series in the same way.
FIGS. 14A and 14B also show an air mover 272 associated with each heat transfer cube 100 for passing air through each heat transfer cube 100. Air mover can comprise a fan, blower, air handler, or any other device capable of moving air. Air mover 272 can be disposed within the chamber of heat transfer cube 100 or disposed outside of heat transfer cube 100 but in alignment with first opening 250. Air mover 272 is typically disposed upstream of coil unit. Air mover 272 can also be likewise mounted on or associated with heat transfer cubes 100A and 100B.
FIG. 15 illustrates another example of a system 350. The system 350 may be implemented in a commercial building, for example. The system 350 includes a plurality of self-contained heat transfer cubes 100 (which can alternatively be heat transfer cube 100A or 100B) all in communication with a single compressor. The compressor 142 is in communication with a single heat expulsion (or radiative) tower 303. The compressor 142 may be part of a power cube that supplies power, control, logic and cleaning solutions to the plurality of self-contained heat transfer cubes 100. The plurality of self-contained heat transfer cubes 100 may be daisy-chained together, i.e., fluid coupled together in series, as illustrated in FIGS. 14A-14B.
FIG. 16 illustrates a flowchart of an exemplary flow through the thermal loop of a power cube. Hydrofluorocarbons (HFCs) flow through an expansion valve and are expanded, which forms cold HFC gas (910). Cold HFC gas flows through (e.g., is pumped through) a first, cold heat exchanger, thereby cooling water that is also flowing through the first, cold heat exchanger (920) while warming the HFC gas. Warmed HFC gas flows through a compressor and is compressed to hot HFC liquid (930). Hot HFC liquid flows through the second, hot heat exchanger, thereby heating water also flowing through the second, hot heat exchanger (940). Cooled HFC circulates back through the expansion valve and again becomes cold HFC gas (950). The cooled or heated water is circulated through a self-contained heat transfer cube to cool or heat air, thereby cooling or heating a building and/or interior space.
FIG. 17 illustrates a flowchart of an exemplary flow through the cleaning loop of a power cube. First, a cleaning solution is generated (1010). Examples of cleaning solutions and foams are outlined in U.S. Provisional Pat. App. Nos. 63/316,573 (now U.S. application Ser. No. 18/117,341) and 63/242,340, already incorporated herein. The cleaning solution is circulated to respective self-contained heat transfer cubes (such as an air-cooling or air heating cube) (1020). The cleaning solution is passed through the coil unit of each self-contained heat transfer cube (1030). As the cleaning solution is passed through the coil units, the cleaning solution loosens dirt and debris, provides enzymatic breakdown of biofilms and other microorganisms, and flushes the coil units, thereby cleaning the coil units. The cleaning solution exits through the self-contained heat transfer cubes (1040) and dirty/spent solution is drained out of the self-contained heat transfer cubes via, for example, a drainage pan at the bottom of the housing (1050).
As the cleaning cycles ensure biofilms, bacteria, dirt and other debris are removed from the system, clean air leaves the self-contained heat transfer cubes, reducing the need for air purifiers to be incorporated into the disclosed systems. Reducing the need for air purifiers similarly reduces the energetic needs of a building, as air purifiers also require power to operate. As clean air leaves the cubes, the air circulating through the interior spaces of buildings is likewise clean, reducing the effect of circulating air on allergies, sicknesses and other irritating conditions. This is particularly beneficial for hospitals or other medical settings, where immune-comprised individuals and those most susceptible to negative impacts due to breathing dirty air, will be breathing clean air rather than dirty or bacteria-infested air.
In some embodiments, the cleaning solution can be injected or applied to the self-contained heat transfer cubes under sufficiently low pressure so as to not damage the coil units, including so as to not damage the bendable plurality of thermally conductive plates. In some embodiments, the low-pressure cleaning solution is discharged from the at least one injection port at a pressure that is no greater than about 8 psi (55 kpa), preferably no greater than about 5 psi (35 kpa), more preferably no greater than about 3 psi (21 kpa), even more preferably no greater than about 1 psi (7 kpa), such as at a pressure of about 0.5 psi (3 kpa) or less.
In energy savings, improvements may be seen in at least two ways. First, air flow is improved through each self-contained heat transfer cube by removing bacteria, biofilms, dirt, grime and/or other debris. This reduces back pressure, or pressure drops across the coil units (differential of pressure before and after the coil unit). Reducing the pressure drop directly reduces the electricity load on a blower or air handler that is required to push and/or pull air through the coils. In simplistic terms, a 1% reduction in pressure should equate to a 1% reduction in the blower's brake horsepower. This enables using a smaller motor for the blower, which leads to reduction in energy consumption. Reducing the electricity load required also beneficially prolongs a lifespan of the motor.
In addition to reducing back pressure by removing biofilms and/or other fouling residues from the interior surfaces of the coils, heat transfer by the coil units is also improved so that air passing through the coil units gets colder (or hotter) faster. This helps reduce the energy load of the power cubes. Biofilms reduce cooling (or heating) capacity by restricting air flow, reducing contact area between moving air and surfaces of the plurality of thermally conductive plates, and providing a layer of organic matter acting as insulation. Removing biofilms increases air flow and contact area between moving air and surfaces of the plurality of thermally conductive plates, mitigating the insulation effect of biofilms.
As discussed briefly above, the disclosed systems may be implemented with self-cleaning foaming coils, such as those outlined in U.S. Provisional Pat. App. No. 63/316,573 (now U.S. application Ser. No. 18/117,341), already incorporated herein by reference. The foaming coils may be arranged in a vertical, horizontal or top-down arrangement within the coil unit. Foaming coils may be in communication with the at least one injection port of each self-contained heat transfer cube. Inclusion of the foaming coils further enables a self-cleaning process for each self-contained heat transfer cube. The self-cleaning process may be part of a cleaning cycle, which may be controlled by the control circuit of the power cube (discussed more fully above). Such cleaning beneficially prolongs the life of the self-contained heat transfer cubes, increases the efficiency of each heat transfer cube and decreases the energetic needs of the self-contained heat transfer cubes and heat transfer cube systems.
It should be understood that the features described in relation to a specific figure are applicable to the features and embodiments illustrated in all of the figures.

Select Aspects of the Disclosure

One aspect of the present disclosure includes a self-contained heat transfer cube having:

- a housing;
- a coil disposed within the housing, the coil comprising an inlet, an outlet and a plurality of thermally conductive sheets, each sheet having a plurality of perforations, wherein the plurality of thermally conductive sheets are substantially aligned with each other and arranged such that the plurality of the perforations are in fluid communication with the inlet and the outlet; and
- at least one injection port disposed between a top of the housing and the deep coil.

In one embodiment the deep coil further comprises an opposing pair of connection plates, each plate of the opposing pair of connection plates having a nozzle.
Another embodiment includes a cleaning solution generator, wherein the at least one injection port is in fluid communication with the cleaning foam generator.
In another embodiment, the plurality of thermally conductive sheets are kinked and/or grooved.
In another embodiment, at least one foaming coil is in fluid communication with the at least one injection port.
In another embodiment, the self-contained Heat transfer cube is configured to be retrofit installed into an existing HVAC system, such as an existing commercial and/or residential HVAC system.
Another independent aspect of the present disclosure includes a power cube comprising:

- a thermal loop comprising a compressor, a first heat exchanger in fluid communication with the compressor, a second heat exchanger in fluid communication with the compressor and an expansion valve in fluid communication with the first and second heat exchangers;
- a circulation loop comprising a first pump in fluid communication the first heat exchanger, a second pump in fluid communication with the second heat exchanger;
- a cleaning loop comprising a cleaning solution generator and a reservoir tank in fluid communication with the cleaning solution generator; and
- a control circuit comprising a control board, at least one microprocessor unit and a plurality of sensors.

Another independent aspect of the present disclosure includes an HVAC system comprising:

- an air cooling heat transfer cube, the air cooling cube comprising:
- a housing,
- a coil disposed within the housing, the deep coil comprising an inlet, an outlet and a plurality of thermally conductive sheets, each sheet having a plurality of perforations, wherein the plurality of thermally conductive sheets are substantially aligned with each other and arranged such that the plurality of the perforations are in fluid communication with the inlet and the outlet, and
- at least one injection port disposed between a top of the housing and the deep coil;
- an absorption heat transfer cube, the absorption cube comprising:
  - a housing,
  - a deep coil disposed within the housing, the deep coil comprising an inlet, an outlet and a plurality of thermally conductive sheets, each sheet having a plurality of perforations, wherein the plurality of thermally conductive sheets are substantially aligned with each other and arranged such that the plurality of the perforations are in fluid communication with the inlet and the outlet, and
  - at least one injection port disposed between a top of the housing and the deep coil; and
- a power cube, the power cube comprising:
  - a thermal loop comprising a compressor, a first heat exchanger in fluid communication with the compressor, a second heat exchanger in fluid communication with the compressor and an expansion valve in fluid communication with the first and second heat exchangers,
  - a circulation loop comprising a first pump in fluid communication with the absorption cube and the first heat exchanger, a second pump in fluid communication with the air cooling cube and the second heat exchanger,
  - a cleaning loop comprising a cleaning solution generator and a reservoir tank in fluid communication with the cleaning solution generator, the at least one injection port of the absorption cube and the at least one injection port of the air cooling cube, and
  - a control circuit comprising a control board, at least one microprocessor unit and a plurality of sensors.

In one embodiment the heat exchangers of the thermal loop are plate heat exchangers.
In another embodiment, the heat exchangers of the thermal loop are coil heat exchangers.
In another embodiment, the reservoir tank is in fluid communication with the at least one injection port of the air cooling cube via cleaning solution lines.
In another embodiment, the reservoir tank is in fluid communication with the at least one injection port of the absorption cube via cleaning solution lines.
In another embodiment, the first pump of the circulating loop pumps cooled water from the first heat exchanger to the deep coil of the air heating cube via the inlet.
In another embodiment, the second pump of the circulating loop pumps heated water from the second heat exchanger to the deep coil of the absorption cube via the inlet.
In another embodiment, the deep coil further comprises at least one foaming coil in fluid communication with the at least one injection port.
Another embodiment further includes a first air handler in communication with the air heating cube and a second air handler in communication with the absorption cube.
In another embodiment, the control circuit is configured to control one or more of a cleaning schedule, a heating schedule and a cooling schedule.
In another embodiment, the control circuit further comprises a thermostat.
In another embodiment, the HVAC system of further includes:

- a plurality of power cubes;
- a plurality of absorption cubes attached to and in communication with the plurality of power cubes via the inlets; and
- a plurality of air cooling cubes attached to and in communication with the plurality of power cubes via the inlets.

In another embodiment, the plurality of air cooling cubes attach to the plurality of power cubes via cam lock connectors.
In another embodiment, plurality of absorption cubes attach to the plurality of power cubes via cam lock connectors.
In another independent aspect, a heat transfer cube includes a housing at least partially bounding a compartment, the housing having a first end with a first opening formed thereat that communicates with the compartment and an opposing second end with a second opening formed thereat that communicates with the compartment. A coil unit is disposed within the compartment between the first opening and the opposing second opening, the coil unit includes a first plate, a last plate, and a plurality of tubes each having a first end connected to the first plate and an opposing second end connected to the second plate. The housing further includes an inlet communicating with the first end of each of the plurality of tubes and an outlet communicating with the second end of each of the plurality of tubes.

Additional Terms & Definitions

While certain embodiments of the present disclosure have been described in detail, with reference to specific configurations, parameters, components, elements, etcetera, the descriptions are illustrative and are not to be construed as limiting the scope of the claimed invention.
Furthermore, it should be understood that for any given element of component of a described embodiment, any of the possible alternatives listed for that element or component may generally be used individually or in combination with one another, unless implicitly or explicitly stated otherwise.
In addition, unless otherwise indicated, numbers expressing quantities, constituents, distances, or other measurements used in the specification and claims are to be understood as optionally being modified by the term “about” or its synonyms. When the terms “about,” “approximately,” “substantially,” or the like are used in conjunction with a stated amount, value, or condition, it may be taken to mean an amount, value or condition that deviates by less than 20%, less than 10%, less than 5%, less than 1%, less than 0.1%, or less than 0.01% of the stated amount, value, or condition. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.
Any headings and subheadings used herein are for organizational purposes only and are not meant to be used to limit the scope of the description or the claims.
It will also be noted that, as used in this specification and the appended claims, the singular forms “a,” “an” and “the” do not exclude plural referents unless the context clearly dictates otherwise. Thus, for example, an embodiment referencing a singular referent (e.g., “widget”) may also include two or more such referents.
It will also be appreciated that embodiments described herein may also include properties and/or features (e.g., ingredients, components, members, elements, parts, and/or portions) described in one or more separate embodiments and are not necessarily limited strictly to the features expressly described for that particular embodiment. Accordingly, the various features of a given embodiment can be combined with and/or incorporated into other embodiments of the present disclosure. Thus, disclosure of certain features relative to a specific embodiment of the present disclosure should not be construed as limiting application or inclusion of said features to the specific embodiment. Rather, it will be appreciated that other embodiments can also include such features.

Claims

1. A heat transfer cube comprising:

a housing at least partially bounding a compartment, the housing having a first end with a first opening formed thereat that communicates with the compartment and an opposing second end with a second opening formed thereat that communicates with the compartment;

a coil unit disposed within the compartment between the first opening and the opposing second opening, the coil unit comprising:

a first plate having a plurality of perforations extending therethrough;

a last plate having a plurality of perforations extending therethrough, the last plate being spaced apart from the first plate; and

a plurality of tubes each having a first end and an opposing second end with a fluid path extending therebetween, each of the plurality of tubes extending from a select one of the plurality of perforations of the first plate to a select one of the plurality of perforations of the second plate;

wherein the housing further comprises an inlet communicating with the first end of each of the plurality of tubes and an outlet communicating with the second end of each of the plurality of tubes.

2. The heat transfer cube as recited in claim 1, wherein the housing further comprises a front panel at least partially disposed over the first plate so that a first gap space is formed between the front panel and the first end of each of the plurality of tubes.

3. The heat transfer cube as recited in claim 1, wherein each of the plurality of tubes is comprised of a non-metal.

4. The heat transfer cube as recited in claim 1, wherein the plurality of tubes comprises at least 40 separate tubes.

5. The heat transfer cube as recited in claim 1, wherein a spacing between each adjacent pair of the plurality of tubes is in a range between 0.5 cm and 1.5 cm.

6. The heat transfer cube as recited in claim 1, wherein a liquid tight seal is formed between the first plate and the first end of each of the plurality of tubes.

7. The heat transfer cube as recited in claim 1, further comprising an injection port disposed between the housing and the coil unit.

8. The heat transfer cube as recited in claim 7, wherein the injection port is fluid coupled with a reservoir of a cleaning solution.

9. The heat transfer cube as recited in claim 1, further comprising:

the compartment of the housing comprising a recess disposed between the first opening and the coil unit; and

a tubular transfer line coupled with the housing and communicating with recess.

10. The heat transfer cube as recited in claim 1, further comprising a plurality of further plates disposed between the first plate and the last plate so that the plurality of tubes each pass through the plurality of further plates, the plurality of further plates comprising at least 10 further plates that are each spaced apart.

11. The heat transfer cube as recited in claim 1, further comprising an air mover disposed within the compartment of the housing in alignment with the coil unit.

12. The heat transfer cube as recited in claim 1, wherein the heat transfer cube has a height, a width, and a length each in a range between 10 cm and 60 cm.

13. A heat transfer cube system comprising:

a first heat transfer cube as recited in claim 1; and

a second heat transfer cube comprising:

a first plate having a plurality of perforations extending therethrough;

wherein the housing of the second heat transfer cube further comprises an inlet communicating with first end of each of the plurality of tubes and an outlet communicating with second end of each of the plurality of tubes;

wherein the outlet of the first heat transfer cube is fluid coupled to the inlet of the second heat transfer cube.

14. A power cube system comprising:

the heat transfer cube as recited in claim 1; and

a power cube comprising:

a thermal loop comprising a compressor, a first heat exchanger in fluid communication with the compressor, a second heat exchanger in fluid communication with the compressor, and an expansion valve in fluid communication with the first and second heat exchangers;

a first circulation loop comprising a pump, a fluid line extending from the pump to the first heat exchanger, a fluid line extending from the first heat exchanger to the inlet of the heat transfer cube, and a fluid line extending from the outlet of the heat transfer cube back to the pump.

15. The power cube system as recited in claim 14, wherein the power cube further comprises a reservoir of cleaning solution and a transfer line extending from the reservoir to the heat transfer cube.

16. A method for operating the heat transfer cube as recited in claim 1, the method comprising:

passing a heat transfer liquid through each of the plurality of tubes; and

concurrently with passing the heat transfer liquid through each of the plurality of tubes, passing an air stream through the compartment of the housing so that the air stream passes over each of the plurality of tubes.

17. The method as recited in claim 16, the method further comprising injecting a cleaning solution into the air stream so that the air stream carries the cleaning solution over at least a portion of the plurality of tubes.

18. A method for heating or cooling an area using the heat transfer cube as recited in claim 1, the method comprising:

circulating a refrigerant through a thermal loop, the thermal loop comprising a compressor, an expansion valve, a first heat exchanger, a second heat exchanger;

circulating a heat transfer fluid through the first heat exchanger of the thermal loop and through the plurality of tubes of the heat transfer cube; and

passing an air stream through the compartment of the housing of the heat transfer cube so that the air stream passes over each of the plurality of tubes; and

directing the air stream into the area for heating or cooling the area.

19. A power cube system comprising:

a thermal loop comprising a compressor, a first heat exchanger in fluid communication with the compressor, a second heat exchanger in fluid communication with the compressor, and an expansion valve in fluid communication with the first and second heat exchangers, the thermal loop housing a refrigerant;

a first circulation loop comprising a first pump in fluid communication with a first heat transfer cube, the first circulation loop housing a first heat transfer fluid and communicating with the first heat exchanger of the thermal loop so as to enable a thermal energy transfer between the refrigerant and the first heat transfer fluid;

a reservoir housing a cleaning solution, the reservoir being in fluid communication with the first heat transfer cube.

20. The power cube system as recited in claim 19, further comprising a control circuit, the control circuit being programed to periodically deliver the cleaning solution within the reservoir to the first heat transfer cube.