US2783982A - Evaporative cooler with tower air flow - Google Patents

Description

March 5, 1957 c. H. w. KAHL EVPORTIVE COOLER WITH TOWER AIR FLOW Filed Jan. 27, 19.55

2 Sheets-Sheet l March 5, 1957 c. H. w. KAHL EVAPORATIVE COOLER WITH TOWER AIR FLOW Filed Jan. 27, 1955 2 Sheets-Sheet 2 WMA/me United States Patent 2,783,982 EVAPORATIVE COOLER WITH TOWER All? FLQ'W Carl H. Wiliiam Kahl, Phoenix, Ariz. Application January 27, 1955, Serial No. 484,435 3 Claims. (Cl. 261-24) This application is a continuation in part of my two prior applications, Ser. No. 392,348, tiled Nov, i6, i953, and Ser. No. 448,096, filed Aug. 5, 1954, both for Evaporative Cooler With Tower Air Flow, and both now abandoned.

This invention relates to a type of air-treating apparatus generally known as an evaporative cooler.

Most present-day evaporative coolers are equipped with three moistened lilter packs through which air is drawn by a blower. Some fifty cubic feet of air per second pass through these filter packs, the thickness of which is not more than a mans wrist. There is a possibility that some of the air may sweep through these thin packs without making satisfactory wiping contact.

Wood shavings are chosen as the cheapest and best suited material for a tightly packed lter panel. However, wood shavings disintegrate in one season; mineral sediment, dust, and a form of algae, clogging up the pores. The packing has to be torn out and replaced with fresh material. Packs of metal shavings will also clog up.

Wood shaving material in filter packs is bound to sag as the water drips on it, and then weak spots develop. The suction of the blower, responding to the line of least resistance, exerts its drawing power primarily upon the thinnest section of a panel, favoring the centers of the two side panels. It is possible that the third iilter pack, in the rear, may not get its full quota of air intake.

In View of the foregoing, one objective of my invention is to provide an evaporative cooler affording a longerdrawn-out travel of the air over moistened surfaces.

Another object is to obtain cooling by forcing the air to wipe over moistened surfaces that cannot sag.

Another objective is to construct an all-metal device which will be operable through the years without requiring the seasonal tear-downs and replacements of the filter packs.

Another objective is to add a device which will precool the intake water before the intake air touches it.

Still another objective is to avoid drawing into this cooler the excessively hot air of the outside and, instead, provide a duct connection to the dwelling for the intake air, resulting in the circulation of the house air.

Briefly stated, this device consists of a square top casing, open at the bottom, having an air outlet and a duct leading therefrom into a dwelling to be cooled; a blower and a motor positioned inside; a tower unit shaped like the top casing, attached to the open bottom of the top casing.

Corrugated metal sheets, their furrows positioned horizontally, are hung upon anges in the tower unit. V- trough humidifers are used to moisten the rondures of the corrugated metal sheets over which the intake air is drawn up through the open bottom of the tower unit.

To obtain circulation of the house air, an elbow duct is connected to the open bottom of the tower unit, then a duct connection through a hole in the dwelling.

I attain the aforementioned objectives by means of the devices and constructions illustrated in the accompanying drawings, in which- Fig. l is a plain view in side elevation of the cooler installed on the side of a dwelling.

Fig. 2 is a plain view in side elevation of the cooler installed at ceiling height of a dwelling. It shows elbow duct connection to a house duct for the circulation of the house air.

Fig. 3 gives a plain view of an emergency water outlet valve.

Fig. 4 is a plain view of a metal disk with slots and gable rooets used for the precooling of the intake water.

Fig. 5 is a perspective view of the rectangular trough of the water distribution section. Perforated V-troughs are attached, leading off at right angles from the main trough.

Fig. 6 gives a perspective view of the tower unit, open at the rear, with one corrugated metal sheet hung upon the flanges.

Fig. 7 isa perspective top view of the cut edges on top of each corrugated sheet..

Fig. 8 presents a perspective view of a spacer metal clip.

Fig. 9 gives a perspective view in side elevation of three corrugated metal sheets with spacers.

Referring to the drawings, Fig. 1 presents the apparatus asembled of sheet metal, consisting of a top casingk A and a tower unit B. The tower unit B is attached to the open bottom of the top casing A.

The apparatus is installed `and connected to a dwelling C, by means of bracket 24 and by duct 2 at the air outlet opening.

Top casing A is square in shape, closed on the top and onall four sides, except for air outlet 2. A blower 1 and a motor 3 are positioned within the` casing. The tower unit B, of similar shape, is connected to the open bottom of top casing A. The rear side of tower unit E and Gis removable.

Arrows 34 are inserted in Fig. 1 to indicate the direction of the air flow.

Fig. 2 shows the apparatus installed at ceiling height of a dwelling D. The cooler is supported by air outlet duct 4 and by air intakev duct 25. Top casing F is square in shape, closed on all sides and on top, except for the outlet duct 4. A blower 45 and a motor 56 are installed within the casing. Tower unit G, of similar shape, is connected to the open bottom of top casing F. Arrows 47 indicate the direction of the air ow.

In tower unit G, as in tower unit B (Fig. l), angle-iron flanges 37 are fastened within, one near the top and one near the bottom of each side, for the insertion of corrugated metal sheets 5.l Slots 35 are cut in the sides of these sheets 5, one near the top and one near the bottom of each side, to fit upon the flanges 37.

Spacers 3S, fastened to top and bottom side edges of the corrugated sheets 5, are metal clips with ends protruding at right angles. These spacers 38 are installed to create narrow passageways for the air wiping between the sheets 5, yet these passageways are by no means so narrow as to hold danger of getting clogged up by sedimentary deposits. The sheets 5 which lill the tower unit B or G, are not to be serviced every season or every second season; they are designed for continual functioning during the life of the apparatus.

It is imperative, for best results, that the corrugated metal ysheets 5 be uniformly moistened. For that reason, the top edge of each sheet 5 Ihas been altered in order to expose a greater area of each sheet to the falling drops of water. Vertical incisions, about a ingers width apart, are made on the top edge of each sheet 5. Then the spaces between the incisions are bent slightly downward, alternately to the front and to the rear, but not deep enough that the prongs would hinder the air ow. It will be noted that prongs 39 are leaning backwards, while prongs 40 are leaning forward. Prongs 39 and 4% stand adjacent, on the same sheet 5, but when drops of water hit them, a prong 39 will shed it to the front side, while a prong 4t) will shed it to the rear side of the sheet 5, thus assuring a uniform moistening of the sheets 5.

These corrugated metal sheets 5, however, are water repellent; they must be processed to tit them for effective air wiping over their furrows. Aluminum or galvanized sheet metal, fresh from the mills, has .an almost oily surface. Water rolls off the metalas olf a ducks back. The drops that cling, do not spread out. By Sandblasting the sheets 5 and then applying a porous scale by a dip in lime, cement, or similar solutions, the surface becomes more amenable. A sediment of calcium, as found in every water kettle, makes an ideal surface for a sheet rIhe intrusion of such sediments are destructive in the present day evaporative coolers filter pads, because suoh sediments clog up their pores and, in short time, require the pad to be torn out and replaced, but in a cooler of the character described, such sediments prove an laid in spreading the 'drip of water on the corrugated metal sheets 5; there is no danger of clogging up any pores. That is why recirculation of the water by a pump may be safely recommended for this type of cooler.

In Fig. l is shown a cooler installed at a small dwelling C, of one or two rooms. No attempt is made to circulate the house air. But precooling of the intake water has been provided.

Atop casing A is positioned a panl 7. Specially prepared metal disks, Fig. 4, are stackedupon this pan 7 and strapped thereto. These disks have parallel slots cut in them, the ensuing strips being bent into little gable roofs 8. Drops of water falling on them, are spread into thin films. A marginal border 9 holds the strips together.

lt will be noted in Fig. 4 that the cutting of the slots in these disks, is by design. The H-side varies from the K-side. By this method it is easy to ensure the placing of the eaves over the ridges of the rooflets 8.

A V-trough 49 with perforations is levelled and fastened upon the stack of prepared disks. An inlet pipe 10 is overhead, bringing water which the V-trough 49 spills in drops upon the stacked disks. The drops of water, split and resplit over the rooflets 8, are turned into thin films. spread out and cooled readily by evaporation.

The shallow pan 7 has an outlet in its bottom, with an outlet tube 11. This tube 11 is extended downward through a hole drilled into casing A. Here a hose 12 is attached to the outlet 11, for conveying the precooled water to a water distribution section positioned above the assembled corrugated metal sheets 5.

The water distribution section consists of a rectangular trough 13, into which the hose 12 with the precooled water is led. Attached to and inserted into the rectangular trough 13. are nine or more sl-troughs 14, leading of? at right tangles from the main trough 13.

The V-troughs 14, being positioned over the assembled corrugated sheets 5, spill drops of water upon the prongs 39 and 40, willich are designed to shed water to both sides of their sheet 5. See Fig. 7.

The rear edges on the sides of the tower units B or G are provided with anges 36 (Fig. 6) for a removable door 46 or 48 respectively.

There are openings cut at each side of the top casing A or F, also an opening at the rear, and removable doors provided to close upon these openings. They are needed for possible removal of the blowers pulley or shaft, or for the removal of the motor, also to give 4 access to the water distribution section, and to the lubricating system.

In Fig. 2 is [demonstrated a cooler assembled from top casing F and a tower unit G, connected and attached to dwelling D by the outlet duct 4 of the blower 45 and by elbow duct 25 through which air is to be drawn from dwelling D into the tower unit G. The latter is filled with moistened corrugated metal sheets 5.

'llhe suction created by the blower 45 forces the air in the tower unit G to surge upward, past the rounded furrows of the sheets 5. Elbow duct 25, being tightly connected to the open bottom of tower unit G and to the sump pan 21, is bound to have its air content follow the upward draft, and so the house air is drawn upon for circulation.

The intake air ot' the cooler illustrated in Fig. l is draw-n in through openings 20, near the bottom of tower unit B. Below the air intake 2t), a sump 42 is suspended from the bottom of tower unit B by rods 23. Sump pan 42 gathers the water dripping from the corrugated metal sheets 5 and passes it out through an opening having an outlet tube 22.

The cooler illustrated in Fig. 2 has a sump pan 21 at the bottom of the tower unit G. However, the structure of this cooler, Fig. 2, involves the elbow duct 25, installed to draw air from dwelling D. This necessitates airtight connections of the tower unit G to both the air duct 25 and to the sump pan 21.

There is a remote danger that the sump Water inpan 21 of Fig. 2 might get clogged up in outlet 44, because the sump pan 21 is tightly attached to the elbow duct 25. In coolers requiring pads of wood shavngs, such stoppages :are not rare. However, if for some reason, outlet 44 of Fig. 2 should clog up, the water in sump pan 21 would rise and spill through duct 25 into the dwelling D. i

Therefore, a simple emergency water outlet flap valve 27 has been installed on the side of sump pan 21. An opening 30 is cut into the side of sump pan 21. Over this opening 30 is placed valve 27, a strip of sheet rubber, the lower part of which is fastened to the outside of pan 21 by two stove bolts 28. The part of sheet rubber which covers the outlet hole 30, is backed by and cemented to a metal plate 29. Attached to this piece of metal 29 and thrust through the opening 30, is a curved metal arm 31 bearing a wooden tloat 32. The weight of lloat 32 holds the valve 27 airtight against the outside of sump pan 21 until the Wlater should happen to rise in sump pan 21, causing tloat 32 to raise the curved metal arm 31, which opens the valve 27.

Precooling of the water is omitted in the cooler illustrated in Fig. 2. An inlet water tube 17 leads directly to a tube and hose connection 18, affixed to an opening through top casing F. A ihose 19, attached to the connection 18, leads down to trough 43 with consequent spilling of drops of water from the V-troughs 14, as in the cooler illustrated in Fig. l.

A bracket 24 in Fig. l is a structural support fastened to tower unit B and to dwelling C.

Since the cooling obtained in this type of cooler does not require tightly packed filter panels, there is no expense for tear-downs and replacements each season. The material used for the wiping of the intake air will give service through the years. It will not clog up. lt will not disintegrate, and it will not sag. v

The intake air is made to travel a long-drawn-out course without encountering any treacherous leak holes which let hot air slip through.

The shaping of the corrugated metal sheets 5 with their.

rounded furrows falls in line with the direction and sweep of the air ow. Enough opposition is presented by the deep rondures of the furrows for adequate wiping of the air, yet it is not severe enough to obstruct the air ow. Y

A threefold adjustment of the corrugated sheets 5 is available: the rondures of the furrows may be altered; the spacing may be changed, and the height of the sheets 5, as well as the height of the tower units B or G may be adjusted.

The advantages of circulating the house air are twofold: A dwelling can be cooled more rapidly by this method, and at a saving; humidity is held down, because the problem of cooling the excessively h'ot outside air has been avoided.

I claim:

l. In an apparatus of the character described, comprising a top casing of sheet metal, open at the bottom, having an air outlet and a duct leading therefrom into a dwelling to be cooled; a blower and a motor positioned within the said casing; a tower unit, its back side removable, its shape like the said top casing, forming an extension thereof downward, being fitted and attached to the open bottom of the said top casing; thin, corrugated metal sheets, less in height and width than the said tower unit, their rounded furrows positioned horizontally in the said tower unit; four angle-iron ianges fastened horizontally on the inner sides of the said tower unit, one of the said flanges being positioned at the upper left side, another at the upper right side, within the said tower unit, a third ange being positioned at the lower left side, a fourth ange being positioned at the lower right side, within the said tower unit; slots cut in the sides of the said corrugated metal sheets, one near the bottom and one near the top of each side; spacersa in the form of metal clips, with an end protruding at a right angle, fastened at top and bottom sides of the said corrugated sheets to obtain uniform spacing for them; the said corrugated sheets, by means of the said slots, being slid upon the said anges into the said tower unit; means for distributing drops of water upon the corrugated metal sheets assembled in the said tower unit; the said blower producing air movement upwards through the said tower unit and past the moistened furrows of the said corrugated sheets which form closely spaced passageways moistened for the wiping and the cooling of the intake air, the said spacers holding the assembled sheets far enough apart to eliminate clogging up by sedimentary scale and to eliminate seasonal replacements; vertical cuts, a ngers width apart, along the top edge of each corrugated metal sheet, the spaces between the incisions being slightly bent downward, alternately forward and backward, so that a greater area of each corrugated metal sheet be exposed to the drip of the water, and so that uniform moistening be afforded both sides of each corrugated sheet; a liange bent outward from the edges at the rear of each side of the said tower unit; a sheet metal door aligned to the said two flanges and closed upon the rear of the said tower unit after the assembly of the said corrugated metal sheets; a sump pan, suspended by rods from the bottom of the said tower unit; an outlet opening in the bottom of the said sump pan, with a water outlet pipe; and a space between the open bottom of the said tower unit and the said sump pan, the intake air being swept upwards through the said space against an opposing shower of drops of water falling from the sheets in the said tower unit; air and water striking with head-'on force, resulting in a primary cooling of the intake air, before its Contact with the moistened metal sheets in the said tower unit.

2. ln an apparatus of the character described, comprising a top casing, open at the bottom, having an air outlet and a duct leading therefrom into a dwelling to be cooled; a blower and a motor positioned within the said casing; a tower unit, its back side removable, its shape like the said top casing, forming an extension thereof downward, being fitted and attached to the open bottom of the said top casing; corrugated metal sheets, their furrows positioned horizontally within the said tower unit; four angle-iron anges fastened horizontally on the inner sides of the said tower unit, one of the said anges being positioned at the upper left side, another at the upper right side, a third liange being positioned at the lower left side, a fourth at the lower right side, within the said tower unit; slots `cut in the sides of the said corrugated sheets to fit upon the said flanges; spacers, in the form of metal clips, upon the side edges of the said metal sheets; means for distributing drops of water upon the sheets assembled in the said tower unit; the said blower producing air movement upwards, through the said tower unit and past the moistened corrugated sheets; vertical incisions along the top edge of each corrugated sheet, the spaces between the incisions being bent alternately forward and backward to obtain uniform moistening for each side of the said sheets; a flange formed at the rear edge Iof each side of the said tower unit; a door to fit and to fasten upon the said flanges; an elbow duct connected to the open bottom of the said tower unit; an air duct connected to the said elbow duct, leading through an opening in the wall, to draw air from a dwelling to be cooled, thus adapting this evaporative cooler for the circulation of the house air, effecting lower humidity in the said dwelling by avoiding the intake of excessively hot outside air; an opening at the bottom of the said elbow duct; a sump pan built into the said opening, with airtight connections on all four sides; an opening in the bottom of the said sump pan; a water outlet pipe afhxed therein; and an emergency water outlet valve aixed at one side of the said sump pan, to forestall a possible clogging up and a ooding of the said elbow duct leading into the dwelling.

3. In an apparatus of the character described, comprising a top casing, open at the bottom, having an air outlet and a duct leading therefrom into a dwelling to be cooled; a blower and a motor positioned within the said casing; a tower unit, its back side removable, its shape like the said top casing, forming an extension thereof downward, being fitted and attached to the open bottom of the said top casing; corrugated metal sheets, their furrows positioned horizontaliy within the said tower unit; four angle-iron flanges fastened horizontally on the inner sides of the said tower unit, one of the said anges being positioned at the upper left side, another at the upper right side, a third frange being positioned at the lower left side, a fourth at the lower right side, within the said tower unit; slots in the sides of the said corrugated sheets to fit upon the said flanges; spacers, in the form of metal clips, upon the side edges of the Said corrugated sheets; means for distributing drops of water upon the corrugated sheets assembled in the said tower unit; the said blower producing air movement upwards, through the said tower unit and past the moistened sheets; vertical incisions along the top edge of each corrugated sheet, the spaces between the incisions being bent slightly downward, alternately forward and backward, to obtain uniform moistening for each side of the said sheets; a flange formed at the rear edge of each side of the said tower unit; a door to fit and to fasten upon the said ilanges; an elbow duct connected to the open bottom of the said tower unit; an air duct connected to the said elbow duct, leadinff through an opening in the wall, to draw air from. a dwelling to be cooled; an opening at the bottom of the said elbow duct; a sump pan built into the said opening, with airtight connections; an opening at the bottom of the said sump pan; a water outlet pipe aiixed therein; an emergency water outlet valve aliixed at one side of the said sump pan; a water inlet pipe atop the said top casing, and water running therefrom to be precooled for the moistening of the said corrugated metal sheets; a shallow pan positioned atop the said top casing; metal disks having slots cut into them, the ensuing strips of metal being bent into little gable roofs, over which the intake water is to be spread out; said rooet disks being stacked horizontally upon the said shallow pan and strapped thereto; a rectangular trough leveled and fastened upon the said stack of rooflet disks, beneath the said water inlet pipe; six or more "7 perforated V-troughs attached to and leading off at right angles from the said rectangular main trough; said V-troughs t0 spill drops of water upon the said stack of rooflet disks; the said stack being designed to effect an arrangement of eaves over ridges of the rooets, thus splitting and resplitting the ow of the intake water, creating thin films of water, cooled readily by evapora tion; an outlet in the said shallow pan atop the top casing; an outlet tube attached to the said outlet; a hose attached to the said tube for conveying the precooled water; an opening in the said top casing to lead the said hose down through the said top casing to a water distribution section positioned above the said corrugated metal sheets assembled within the said tower unit; said distribution section consisting of a rectangular trough into which the said hose with the precooled Water is led; and nine vor more perforated V-troughs attached to and leading off at right angles from the said main trough;

` 8 said V-troughs being positioned close over the assembled corrugated metal sheets, drops of water from the said perforated V-troughs providing moisture for the rounded furrows of the said metal sheets over which the intake air is being swept.

References Cited in the le of this patent UNITED STATES PATENTS 586,766 Haslam July 20, 1897 1,334,515 Brown Mar. 23, 1920 2,161,834 Seeley June 13, 1939 2,231,088 Richardson Feb. 11, 1941 2,241,493 van Thiel May 13, 1941 2,462,763 Nichtingall Feb. 22, 1949 FOREIGN PATENTS 464,433 Great Britain Apr. 19, 1937 571,510 Great Britain Aug. 28, 1945

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