WO2022231804A1 - In-wall and on-wall dehumidifier with integrated bi-polar ion generator - Google Patents

Abstract

A dehumidifier, which in some embodiments is a wall-mounted dehumidifier, comprising a cabinet, a compressor, an evaporator coil, a condenser coil, a fan, and a bi-polar ion generator. In some embodiments, the cabinet is configured to be installed between studs in a wall. The evaporator is installed within the cabinet above the compressor. The condenser, which may include two or more layers of microchannel condenser coils, is installed within the cabinet above the evaporator. The fan is installed between the evaporator and a back surface of the cabinet. The fan is configured to generate airflow that flows into the cabinet through the evaporator coil and out of the cabinet through the condenser coil. The airflow flows through the evaporator and condenser coils in order to dehumidify the air, and the bi-polar generator generates ions that purify the air, in part by reducing particles, including microbial particles.

Description

IN-WALL AND ON- WALL DEHUMIDIFIER WITH INTEGRATED BI POLAR ION GENERATOR

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims the benefit of priority to U.S. Provisional Patent Application No. 63/179,945, filed on April 26, 2021, and U.S. Provisional Patent Application No. 63/180,031, filed on April 26, 2021, the entire contents of each of which are incorporated herein by reference.

FIELD

This invention relates generally to dehumidification and more particularly to an in-wall and/or on-wall dehumidifier.

BACKGROUND

In certain situations, it is desirable to reduce the humidity of air within a structure. For example, homes and apartments may need dehumidification during certain times of the year to reduce the moisture levels within the living spaces. Further, when a home is located near to a source of water, such as an ocean, sea or river, the air is often very humid, and can lead to mold contamination if the air is not dehumidified. To reduce moisture levels, many homes include one or more dehumidifiers. While this approach may lead to less humid air, dehumidifiers are often relatively unsightly, bulky units, and a conventional dehumidifier does not remove airborne contaminants, such as pathogens, volatile organic compounds such as aldehyde, pollen and other allergens, and the like.

One concern associated with people gathering in their homes is the potential for airborne pathogens, such as SARS-CoV2, mold, and bacteria, to circulate inside the air conditioning and ventilations systems and substantially increase the chances of contracting potentially deadly diseases. Another concern is that while a dehumidifier may remove moisture from the air, and minimize the formation of mold, mold may still be present in the air, and cause health concerns.

It would be advantageous to provide a single device for dehumidifying the air, while also removing harmful pathogens, volatile organic compounds, pollen and other allergens, and the like. Some dehumidifiers have included negative ion generators, but these generators typically emit ozone into the air, and this can, over time, cause damage to the lungs. There is little to no difference between ozone in smog outdoors, and ozone produced by negative ion generators. Under certain use conditions, ion generators and other ozone generating air cleaners (see www.epa.gov/indoor-air-quality-iaq/ozone-generators-are-sold-air-cleaners) can produce levels of this lung irritant significantly above levels thought harmful to human health. The Food and Drug Administration has set a limit of 0.05 parts per million of ozone for medical devices.

It would be advantageous to provide a dehumidifier that is able to dehumidify air, while also removing harmful pathogens, volatile organic compounds, pollen and other allergens, and the like from the air, while avoiding significant production of ozone. The present disclosure provides such a dehumidifier.

SUMMARY

In one embodiment, a dehumidifier comprising a bi-polar ion generator is disclosed. In one aspect of this embodiment, the dehumidifier is a wall-mounted dehumidifier, with a cabinet designed to fit within two studs in a wall. In this embodiment, certain disadvantages and limitations associated with previous dehumidification systems may be reduced or eliminated. The dehumidifier can be mounted in the wall, between the studs, or mounted on the wall.

In some aspects of this embodiment, the dehumidifier also includes an air diffuser configured to diffuse an airflow from the dehumidifier along a surface of the wall. The air diffuser includes an inlet, an outlet above or below the inlet, and, optionally, a divider between the inlet and outlet. The divider is configured to prevent the airflow entering the cabinet through the inlet from mixing with the airflow exiting the cabinet from the outlet. This can be important, as air crossing the inlet, and passing across an evaporator coil, will be relatively colder than ambient air, and air crossing a condenser coil as it exits the dehumidifier will be relatively warmer than ambient air. If the relatively cold and relatively warm air mix, the resulting mixed air will have a temperature higher than the air leaving the evaporator, and this may interfere with the condensation of vaporized refrigerant in the condenser coil.

The dehumidifier further includes a compressor, an evaporator, optionally installed within the cabinet above the compressor, and a condenser installed within the cabinet, optionally above the evaporator. In one embodiment, the condenser includes a plurality of microchannel condenser coils, or layers of condenser coils. In one embodiment, two layers of condenser coils are used. In one aspect of this embodiments, refrigerant is circulated from the compressor to the first layer of the condenser coil, to the second layer of the condenser coil, then to the expansion device, then to the evaporator coil, and then to the compressor, in a refrigeration cycle. In another aspect, refrigerant is circulated from the compressor to the second layer of the condenser coil, to the first layer of the condenser coil, then to the expansion device, then to the evaporator coil, and then to the compressor, in a refrigeration cycle.

In various aspects of these embodiments, the first and second layers of the condenser coil can be immediately adjacent to each other, or have up to 2-3 cm of space between them. While air can flow between the layers, the space between the layers is minimized, so as to minimize the depth of the dehumidifier. That is, in certain embodiments, the dehumidifier is intended to fit within the wall, between the wall studs, so as to be minimally intrusive in the space it resides. Ideally, the thickness of the dehumidifier is kept to a minimum as well, so that the dehumidifier does not protrude more than a few inches, for example, from 0 to less than 6 inches, and, more preferably, less than about 4 inches, from the wall when installed between two wall studs, or when mounted on a wall.

The dehumidifier further includes a fan installed between the evaporator and a back surface of the cabinet. The fan is configured to generate the airflow that flows into the cabinet through the inlet of the air diffuser and out of the cabinet through the outlet of the air diffuser. The airflow flows through the evaporator and condenser in order to provide dehumidification to the airflow.

A bi-polar generator is present in the path of the airflow, such that positive and negative ions are released into the room in which the dehumidifier is located as air passes through the condenser to the outside of the dehumidifier, for example, by passing through an air diffuser.

Condensation from the evaporator coils can be collected, for example, in a drain pan. The drain pan can be connected to a hose that drains the water outside of the dehumidifier, or, alternatively, to a reservoir inside of the dehumidifier that can be drained as the reservoir is filled.

Where the dehumidifier includes a drain pan and a hose connected to the drain pan for draining the water as it collects on the evaporator coils, the drain pan can, for example, be installed within the cabinet below the evaporator. The drain pan can be configured to capture water removed from the airflow by the evaporator. The drain pan can alternatively be connected to a condensate hose, which is then connected to existing plumbing fixtures such that the water continuously drains from the dehumidifier, for example, to a sewer or to a septic tank.

In some embodiments where the dehumidifier includes a reservoir, the dehumidifier can include a means for signaling to the user that the reservoir is full and needs to be drained. For example, a reservoir can be provided with a drain valve, float switch and/or vapor barrier. A drain valve can permit the reservoir to be emptied of condensate. A float switch can disengage the dehumidifier when the reservoir becomes full of condensate. A vapor barrier can prevent the condensate in the reservoir from re-evaporating back into the system. In some embodiments, the dehumidifier incorporates one or more safety and/or status features, including an audible alarm which engages when the reservoir is full. These aspects are well-known to those of skill in the art, and are disclosed, for example, in U.S. Patent No. 5,555,732 to Whiticar.

In other embodiments, the drain pan can include a notch and a tab configured to direct an overflow from the drain pan to a front face of the cabinet, thereby causing the overflow to be visible when the dehumidifier is installed in the wall.

In still other embodiments, the dehumidifier can include a sensor installed below the drain pan, where the dehumidifier can be adapted to send ambient air to the sensor that bypasses the rest of the dehumidifier. This can allow the sensor to sense one or more environmental conditions of ambient air as it would flow through the dehumidifier, such as humidity levels.

The fan is ideally installed between the evaporator and a back surface of the cabinet. In those embodiments where the front of the dehumidifier includes an air diffuser that allows incoming air to flow across the evaporator and outgoing air to flow across the condenser, the fan can be configured to generate an airflow that flows into the cabinet through an inlet of the air diffuser and out of the cabinet through an outlet of the air diffuser. The airflow flows through the evaporator and condenser in order to dehumidify the air.

In one embodiment, the dehumidifier includes a cabinet configured to be installed between studs in a wall, an air diffuser configured to diffuse an airflow from the dehumidifier along a surface of the wall into which the dehumidifier is installed, a compressor, an evaporator coil installed within the cabinet above the compressor, a condenser, which condenser comprises two layers of microchannel condenser coils, installed within the cabinet above the evaporator, a bi polar ion generator, a power supply to operate the dehumidifier, and a fan. Certain embodiments of the present disclosure may provide one or more technical advantages. For example, certain embodiments provide an in-wall dehumidifier that may be installed within existing spaces between wall studs, where the dehumidifier reduces or eliminates the amount of living space required for the dehumidifier. The bi-polar ion generator helps remove harmful particles, including microbes such as mold and Covid-19 viruses, and allergens, such as pollen, as well as volatile organic compounds, such as formaldehyde, from the air.

Some embodiments may be blindly installed (i.e., installed while only requiring access from one side of a wall), typically within wall studs, which are typically designed to be 16 inches between centers. One way to install the unit between wall studs is for the cabined to include a flange (i.e., a protruding edge or lip) on two or more sides (i.e., left, right, top, and/or bottom) with holes through which a screw can be passed, so as to screw the unit to one or more wall studs. Where the flange is on the top or bottom, one or more studs can be attached perpendicular or substantially perpendicular to the existing wall studs, and the dehumidifier attached to one or more of these studs. This reduces the installation time, cost, and complexity over dehumidifiers that are not designed with this width in mind.

In another embodiment, the dehumidifier includes a cabinet configured to be wall- mounted. In this embodiment, similar to the embodiment where the cabinet is configured to be inserted between wall studs, the cabinet can include one or more flanges, preferably two or more flanges. The flanges can include holes such that the flanges, and, thus, the dehumidifier, can be attached to wall studs, ideally by screwing through the flange(s), and through the drywall overlying the studs, and into the wall studs, thus securing the dehumidifier to the wall studs.

In some embodiments, the dehumidifier can include air diffusers that provide indirect airflow into the living space of the room in which the dehumidifier is installed, thereby reducing undesirable drafts that might otherwise be caused.

In some embodiments, the dehumidifier includes a controller that allows a user to set a pre determined indoor humidity level unit, and a sensor for determining the humidity level of the ambient air. In these embodiments, once set, the dehumidifier will automatically run until it reaches this humidity level, and will shut off until the ambient air exceeds this humidity level.

Certain embodiments of the present disclosure may include some, all, or none of the above advantages. One or more other technical advantages may be readily apparent to those skilled in the art from the figures, descriptions, and claims included herein. BRIEF DESCRIPTION OF THE DRAWINGS

To provide a more complete understanding of the present invention and the features and advantages thereof, reference is made to the following description taken in conjunction with the accompanying drawings, in which:

FIG. 1 illustrates embodiments of covers for an in-wall dehumidifier installed between typical wall studs, according to certain embodiments;

FIG. 2 illustrates the air flow through a dehumidifier, both mounted in a wall and on a wall, according to certain embodiments;

FIG. 3 illustrates an arrangement of internal components of the in-wall dehumidifier of FIG. 1, namely, the cabinet, compressor, evaporator coil and condenser coil.

FIG. 4 illustrates an arrangement of internal components of the in-wall dehumidifier of FIG. 1, including a cabinet, compressor, evaporator coil, and expansion device, according to certain embodiments;

FIG. 5 illustrates the in-wall dehumidifier of FIG. 1 with its front panel opened, and only the top of the evaporator coil shown, to show the flow of air and refrigerant, namely, where air flows from the evaporator (not shown) to the condenser, and refrigerant flows from the compressor (not shown) to the first layer of a two layer condenser coil (the second layer is not shown, as it is present behind the first layer), then to the first layer of the two layer condenser, then to the expansion device, according to certain embodiments;

FIG. 6 illustrates a condenser with dual layers of condenser coils that may be used by the in-wall dehumidifier of FIG. 1, according to certain embodiments. FIG. 6 is a side view of the in wall dehumidifier of FIG. 1, with the cabinet removed, to show both layers of a two layer condenser, with refrigerant from the compressor flowing to the second layer of a two layer condenser, then to the first layer of a two-layer condenser, then to the expansion device, according to certain embodiments;

FIG. 7 illustrates a bi-polar ion generator, for installation in the dehumidifier of FIG. 1, according to certain embodiments; FIG. 8 illustrates an embodiment of the dehumidifier of FIG. 1, showing flanges for attaching the unit to the wall studs, a compressor, an evaporator coil, and an air filter for removing particulates from the air, according to certain embodiments;

FIG. 9 illustrates an embodiment of the dehumidifier of FIG. 1, showing a bipolar generator above an evaporator coil and an expansion device;

FIG. 10 illustrates a specific embodiment of a dehumidifier disclosed herein, with the front and back covers taken off the dehumidifier to show the internal components; and

FIG. 11 is a schematic illustration of how a bi-polar ion generator can generate ions from a source of oxygen and water.

DETAILED DESCRIPTION

In certain situations, it is desirable to reduce the humidity of air within a structure, and also to remove particulates, such as pollen and microbes, and volatile organic compounds such as formaldehyde. For example, homes and apartments may need dehumidification during certain times of the year to reduce the moisture levels within the living spaces. To accomplish this, one or more dehumidifiers may be placed within the structure to dehumidify the air.

The disclosed embodiments provide an in-wall dehumidifier that includes various features to address some of the issues and inefficiencies and other issues with current dehumidification systems, including dehumidifiers with negative ion generators, which also generate ozone, where the bi-polar ion generator does not generate ozone. Although the dehumidifier can be mounted in the wall, between two studs, in some embodiments, it can also be mounted on the wall.

The dehumidifier with a bi-polar ion generator disclosed herein eliminates excess moisture, and can remove a significant amount of airborne viruses and pathogens. The dehumidifier is integrated with bi-polar ionization, which in some embodiments is capable of producing millions of positive and negative ions every second, to provide relatively cleaner and safer air than dehumidifiers that do not include an ion generator. Further, unlike negative ion generators, which generate ozone, the bi-polar ion generators create both positive and negative ions, without producing significant amounts of ozone.

The presence of the bi-polar ionizer in the dehumidifiers described herein ensures, along with dry air, air that has reduced levels of dust, pollen, microbes such as bacteria, molds and viruses, and volatile organic compounds, some of which can cause odors. In some embodiments, the dehumidifier is tankless, and can include an integrated condensate pump. In one embodiment of the tankless dehumidifier, the dehumidifier is designed for multi-family housing, and automatically condenses excess moisture.

The dehumidifier includes a refrigerant, which travels throughout the dehumidifier in a repeated cycle. The refrigerant in the evaporator coil is evaporated as it cools incoming ambient air, and then passes to a compressor, then to a condenser, then to an expansion device, such as a capillary tube expansion device. In some embodiments, the refrigerant is R134 A. In other embodiments, the refrigerant is "Refrigerant-22," or "R-22" or anhydrous ammonia. If R-22 is used as the refrigerant of choice, the components of the refrigeration system in contact with the R-22 may be made from copper, aluminum, or steel, among other materials. However, as understood by those skilled in the art, if anhydrous ammonia is used as the refrigerant of choice, copper components of the refrigeration system in contact with the anhydrous ammonia may corrode. Alternatively, other refrigerants (including both two-phase and single-phase refrigerants or coolants) may be used with the condenser assembly.

I. Bi-Polar Generators

Bi-polar® ionization is sometimes referred to as cold plasma ionization. In use, two charged poles are used, one positively and one negatively charged, to split water vapor into positively charged hydrogen ions and negatively charged oxygen ions.

Ions have positive or negative charges. To ionize the water and oxygen in the air, plasma discharge can give water a positive charge and oxygen a negative charge. As shown in Figure 11, through plasma discharge, in which voltage is applied to the discharge electrode, positive hydrogen ions (H⁺) and negative oxygen ions (O2 ) are generated from the water and oxygen in the air.

Due to the imbalanced charge effect, these ions are drawn back together to reform as water molecules, their natural state. As this occurs, airborne particles, including dust, pet dander, allergens, mold spores, and even airborne droplets containing viruses, will be drawn together, become too heavy to float and drop from the air. Still, the primary deactivation of these named contaminants is due to a molecular decomposition caused by the reactions of positive oxygen ions interacting with them. When a bi-polar ion generator is used, both positive and negative ions are released into the air. The ions neutralize their bi-polar (positive or negative) charges as they attack and deactivate pollutants in the air. The ions then return to air as water vapor. As the bi-polar ions attack pollutants, OH ions transform into OH radicals, which remove hydrogen from organic compounds, such as proteins or other compounds found on the surface of microbes, and form water.

The positive (H⁺) and negative (O2 ) ions bond on the surface of airborne viruses and other substances and change into OH radicals. With their extremely strong oxidizing power, the OH radicals quickly extract hydrogen (H) from the protein on the surface of viruses and other substances, thus decomposing the protein and suppressing activity. The surface of things like bacteria and allergens consists mainly of protein. Removing the hydrogen atom (H) from this structure inactivates the undesirable substance. Furthermore, the OH radical bonds with the removed hydrogen atom (H) to immediately form water (H2O), which is returned to the air.

The dehumidifier removes excess water in the air, including the moisture resulting from the interaction of OH ions and H⁺ ions with various particles. A dehumidifier with a bi-polar ion generator releases positive and negative ions into the air using one or more fans to spread the ions throughout the room in which the dehumidifier is located. The ions attach to airborne pathogens, such as allergens, bacteria, molds, viruses, and volatile organic compounds (VOCs), breaking down the pathogens/allergens/VOCs. In the process, the ions are converted to water.

The combination of dehumidification, which reduces indoor humidity to proactively prevent mold, and bi-polar ions, which can kill up to 99% of airborne viruses and pathogens, including mold, provides two solutions to the problem of mold in humid environments. This, in turn, can create improved comfort and a healthier living environment.

A filter, such as a HEPA filter, can be used in tandem with the bi-polar ion generator to further clean the air.

In one embodiment, the dehumidifier, filter, and bi-polar ion generator are used to remove microbes, such as coronaviruses, from the air. A coronavims is at the lower end of a HEPA filter’s range, so the filter may not be 100% effective on a single pass. But, if a HEPA system is run over a period of time, it can eventually remove a significant amount of airborne viruses, i.e., somewhere in the high ninetieth percentile (99.94 to 99.97%). Further, in some embodiments, the dehumidifier also comprises a source of UV light, and sufficient exposure to UV light can disable some viruses, including COVID-19. In one embodiment, the bi-polar ion generator uses needlepoint bi-polar ion generating technology.

The dehumidifier described herein, with a bi-polar ion generator, releases positive and negative ions into the air using the units fan to spread ions throughout the room. The ions attach to airborne pathogens including allergens, bacteria, mold, viruses and VOC’s, breaking down the surface proteins, transforming hydrogen molecules into water. The dehumidifiers including bi polar ion generators provide one or more of the following beneficial effects:

Purify the air by emitting both positive and negative ions, similar to those found in nature. Reduce and remove up to 99% of airborne viruses and pathogens Neutralize unwanted odors and toxic gases.

Prevent static electricity

Reduce allergy triggers

Provide cleaner and safer air

Prevents mold

Traps airborne dust particles

Reduce bacteria and viruses in the air

In some embodiments, the dehumidifiers comprise filters that clean the air from dust, odors, microorganisms, and the like. Bi-polar ionizers releases ions, and disinfect and diminish bad smells in a room. They also gather house dust, pollen and other small particles that are responsible for allergies, and help to eliminate harmful volatile organic compounds (VOCs).

In the case of a virus, when contacted with ions from a bi-polar ion generator, a hydrogen is pulled away from the virus’ protein coat, or capsid. The hydrogen is a key component to the actual structure of the viral protein coat. The outer proteins of a virus can be thought of as keys, that must be able to fit the right lock (proteins on the human cell surface) to infect a human.

While not wishing to be bound by a particular theory, it is believed that, with a change in the virus key’s shape resulting from the removal of hydrogen, it can no longer fit in the lock and infect human cells, and in the case of a bacterium or mold, when a hydrogen is removed from the cell surface, the cell is ripped open and the pathogen dies, thus preventing infection.

In some embodiments, the dehumidifiers comprise bipolar ionization and one or both of a high-efficiency particulate air (HEPA) filter and UV-C irradiation. II. Dehumidifiers Comprising the Bi-Polar Ion Generator

In one embodiment, the dehumidifier described herein functions by drawing moist air over a refrigerated evaporator using one or more fans. There are three main types of evaporators, coiled tube, fin and tube, and microchannel technology. While any of these evaporators can be used, because there is an interest in devices which have a relatively small footprint, microchannel coils are preferred.

The cold evaporator coil of the refrigeration device condenses the water in the air crossing the evaporator coil as the refrigerant is evaporated, and the air is cooled. The liquid water is removed, for example, by draining into a reservoir, draining out of the building into a septic tank or a sewer system, and the like. The air is blown by a fan, and passes through a condenser coil, where the air is reheated. The now dehumidified, re-warmed air is released back into the room.

This type of dehumidifier differs from a standard air conditioner in that both the evaporator and the condenser are placed in the same air path. A standard air conditioner transfers heat energy out of the room because its condenser coil releases heat outside. However, since all components of the dehumidifier are in the same room, no heat energy is removed.

In addition, if water is condensed in the room, the amount of heat previously needed to evaporate that water also is re-released in the room (the latent heat of vaporization). The dehumidification process is the inverse of adding water to the room with an evaporative cooler, and instead releases heat. Therefore, an in-room dehumidifier will always warm the room and reduce the relative humidity indirectly, as well as reducing the humidity more directly, by condensing and removing water.

The dehumidifiers described herein include at least the following elements:

Bi-polar ion generator

Evaporator coil

Condenser coil

Compressor

Fan

Expansion device

Cabinet

Cover, optionally equipped with an air diffuser to channel incoming and outgoing air The dehumidifiers can optionally include additional elements, such as a source of UV light to further decontaminate the air passing through the dehumidifier, a filter, such as a HEPA filter, a drain pan, a reservoir, or sufficient piping/tubing to carry the condensed water to the outside of the room, for example, so that there is a connection to pipes that carry water to the sewer or to a septic tank.

In some embodiments, the dehumidifiers include a reservoir equipped with a float sensor that detects when the reservoir is full, to shut off the dehumidifier and prevent an overflow of collected water. In a warm humid environment, these reservoirs may fill with water in 8-12 hours, and may need to be manually emptied and replaced several times per day to ensure continued operation.

In other embodiments, the dehumidifiers are adapted to connect the condensate drip output directly to a drain via a hose. In some aspects of these embodiments, the dehumidifiers can be tied into plumbing drains, or include a built-in water pump, to empty themselves as they collect moisture. Alternatively, a separate condensate pump may be used to move collected water to a disposal location when gravity drainage is not possible.

When the height of the air handler (containing the evaporator) is above the level of the surface drains used for rainwater, the condensate drain lines can often be routed into them. Air handlers located below grade level, e.g. the basement of a house, may need to use a condensate pump to lift the water to a surface drain.

Various microbes, including fungal spores, may accumulate in the water, particularly if the water is stagnant, such as where it is held in a reservoir. However, the tandem use of a dehumidifier and a bi-polar ion generator minimizes the amount of microbial contamination.

Embodiments of the dehumidifier described herein are shown in the various figures.

As shown in Figure 1, the dehumidifier includes a cover (10). As shown, the cover can provide air flow in and out through vents on the right and left side of the cover (the top photo) or from upper and lower vents (the bottom photo). Incoming air either comes in through the lower vent and exits through the top vent, or, as shown in Figure 2, comes in through the vent (air intake, 40) on the right side of the cover (10), and leaves through the vent on the left side of the cover (air discharge, 20). In another embodiment, air can come in through the vent on the left side of the cover, and leave through the vent on the right side of the cover. Figure 2 also shows screw holes (30) for adhering the unit to the studs in the wall (in-wall solution) or behind the wall (on-wall solution), as well as a filter replacement reminder (50).

As shown in Figure 3, which shows one embodiment of the dehumidifier disclosed herein where the front cover is removed. The compressor (80) is shown below the evaporator coil (70), and the condenser coil (60) is shown above the evaporator coil (70).

As shown in Figure 4, within a cabinet (100) housing the components of the dehumidifier, refrigerant passes through the compressor (80), where it passes to the condenser coil (not shown), and then through an expansion device, in this case, a capillary tube (90), before going to the evaporator coil (70).

Air passing through the evaporator coil heats the refrigerant, and the air is cooled. A fan (not shown) passes the cooled air through the condenser coil. The condenser coil re-condenses evaporated refrigerant, and warms the refrigerant. Because the evaporator coil and condenser coil are in the same cabinet, air is cooled, then warmed, after being subjected to compression in the compressor and evaporation in the evaporator. As a result, the air leaving the dehumidifier is typically slightly hotter than the ambient air entering the dehumidifier. This contrasts with an air conditioner, where the condenser column is present outside the building being cooled, so that hot air that has crossed the condenser is vented to the outside of the building being cooled.

Figure 5 shows the inside of one embodiment of the dehumidifier disclosed herein, where not only the cover is removed, but only the top portion of the evaporator coil is visible, and the condenser coil (60) is visible. Refrigerant flows from the compressor (not shown) to the condenser coil, which in this embodiment is a two-layer microchannel condenser coil, along path 120. The second layer of the condenser coil lies behind the first layer of the condenser coil, and refrigerant flows through the second layer to the first layer. From there, refrigerant flows to an expansion device, in this embodiment, a capillary tube (90), and then to the evaporator coil (not shown). In terms of airflow, air flows across the evaporator coil (not shown), where it is cooled, and then across the first layer of the condenser coil (60) along path 130. From there, it flows across the second layer of the condenser coil, and then flows outside the unit.

The flow of refrigerant through the second (150) and first layer (140) of the condenser coil is shown more clearly in Figure 6, which is a side view that shows both layers of the condenser coil. The flow of refrigerant through the dehumidifier is shown, with refrigerant going through a compressor (180), to the second layer of the two layer condenser, then to the first layer of the two layer condenser along path 160, then to an expansion device (90), then to the evaporator coil (70). Air flows in through the evaporator coil (70), gets cooled, passes through the two layers of the condenser coil (140 and 150), and then leaves the dehumidifier through the front cover (not shown). The circulation of refrigerant through the dehumidifier (190) is shown in Figure 6.

Figure 7 shows one embodiment of a bi-polar ion generator (200). The ion generator can be present at any point in the air flow in the dehumidifier, and it typically located in front of the fan, between the evaporator and the condenser coil. As the air passes through the condenser coil, it carries both positive and negative ions with it, which then go into the room in which the dehumidifier is located.

Figure 8 shows an embodiment of the dehumidifier where flanges (210) are shown for attaching the dehumidifier to wall studs (not shown), and an air filter (220) is present, such that when air passes through the condenser coils, it passes through the filter on the way outside the dehumidifier. In this embodiment, the air is filtered, ideally using a HEPA filter, to remove microbial contaminants, dust and/or allergens, and both positive and negative ions leave the dehumidifier in the resulting filtered air stream. Between the dehumidifier dehumidifying the air, the filter capturing particles in the air, and the positive and negative ions produced by the bi-polar ionizer trapping particles in the air, the dehumidifier can significantly improve the air quality in the room in which it is installed. Also shown in this figure are a compressor (80) and an evaporator coil (70).

Figure 9 is a partial view of an embodiment of the dehumidifier disclosed herein, where a bi-polar ion generator (200) is present above the evaporator coil (70) and expansion device (90), and in the path of the airflow from the evaporator coil to the condenser coil (60).

Figure 10 is a view of a specific embodiment of the dehumidifier disclosed herein, where the front and back covers have been removed to show the internal contents of the dehumidifier. The view is from the rear of the dehumidifier. A bi-polar ion generator (200) is present above the evaporator coil (70) and expansion device (90), and in the path of the airflow from the evaporator coil (70) to the condenser coil (60). Holes (230) along the edge of the back side of the dehumidifier are present, which allow the dehumidifier to be mounted on a wall, for example, by screwing through the holes, through the drywall, and, ideally, into a wall stud. The evaporator coil, condenser coil, compressor and expansion device are also shown. In addition to the figures, the following additional description of the dehumidifiers described herein is provided. In certain embodiments, a condenser assembly includes two microchannel condenser coils, both supported by a frame. The frame may be a freestanding structure, or may comprise any number of different designs.

In certain embodiments, the dehumidifier can include a built-in digital humidistat (not shown), can have the ability to automatically restart in the event of power outage, can include an on/off switch, and humidity level controls can be hidden behind the cover.

The advantages and features of certain embodiments are discussed in more detail below. In certain embodiments, the dehumidifier is an in-wall dehumidifier that may be installed between typical wall studs, or can be wall-mounted. There may be various electrical and plumbing knockouts for an in-wall dehumidifier, and an air blower/fan is present. The dehumidifier can be attached between wall studs using a variety of different brackets/flanges. The condenser coils can be attached to the cabinet using brackets. In some embodiments, the dehumidifier includes a drain pan. In other embodiments, the dehumidifier includes a fan outlet diffuser that allows air to diffuse along the wall into which the dehumidifier is installed, rather than blowing out in the direction of the room. While one condenser coil can be used, in some embodiments, the dehumidifier includes a condenser with dual condenser coils, such as a first layer and a second layer.

The dehumidifier includes various components, including a cabinet, an optional air diffuser, a condenser, an evaporator, a compressor, an optional drain pan, and an optional sensor. While a specific arrangement of these and other components of in-wall dehumidifier are illustrated in these figures, other embodiments may have other arrangements and may have more or fewer components than those illustrated.

In general, an in-wall dehumidifier provides dehumidification to an area (e.g., the living areas of a home or apartment) by moving air through the in-wall dehumidifier. To dehumidify air, in-wall dehumidifier generates an airflow that typically enters the cabinet via an air diffuser, travels through the in-wall dehumidifier where it is dried, and then exits the cabinet via the air diffuser. Water removed from the airflow via the in-wall dehumidifier may be captured within a drain pan and directed to an external drain.

An in-wall dehumidifier may be installed between wall studs of any wall of a structure, such as a home or apartment. As such, the dehumidifier may have any appropriate size and shape that permits it to be installed between typical or standard spacing of wall studs (e.g., 16 or 24 inches apart, depending on whether 2X4” or 2X6” studs are used, respectively).

In some embodiments, the in-wall dehumidifier may be able to be blindly installed within walls (i.e., installed while only requiring access from one side of a wall). For example, some embodiments of in-wall dehumidifier have a limited depth (for example, between 4 and 8”, more preferably between 4 and 6”) that allows an installer to remove a portion of drywall from only one side of a wall and install the in-wall dehumidifier between wall studs without having to remove any drywall from the other side of the wall. This saves installation time and costs, relative to where the installation requires access to both sides of the wall.

Furthermore, some embodiments of the in-wall dehumidifier described herein include an air diffuser, which is discussed in more detail below in reference to FIGS. 1 and 2. An air diffuser forces output airflow along the surfaces of the wall in which in-wall dehumidifier is installed parallel to the wall surfaces). This is in contrast to typical systems, which send dehumidified air back into the living space perpendicular to the wall, thereby causing undesirable drafts in the living spaces. By using an air diffuser to diffuse the airflow along the wall surfaces, the dehumidifier reduces or eliminates undesirable drafts in the living spaces.

The cabinet may be any appropriate shape and size. In some embodiments, cabinet has a width that permits in-wall dehumidifier to be installed between wall studs. For example, some embodiments of the cabinet have a width that permits the in-wall dehumidifier to be installed between wall studs that are 16 or 24 inches apart. In some embodiments, the cabinet has a depth that permits in-wall dehumidifier to be blindly installed into a wall without having to remove any portion of drywall from the back side of the wall. For example, cabinet may have a depth that allows it to be installed in walls that use typical 2X4 or 2X6 wall studs without removing any portion of drywall.

The in-wall dehumidifier includes a fan that, when activated, draws airflow into in-wall dehumidifier via air diffuser. Fan causes airflow to flow through evaporator and into condenser 310, and exhausts airflow out of the in-wall dehumidifier via air diffuser. In some embodiments, a fan is located within the cabinet, behind the evaporator, as illustrated in FIG. 4. In such embodiments, the fan is installed between the evaporator and a back surface of cabinet (i.e., the side of cabinet that is opposite air diffuser). The fan may be any type of air mover (e.g., axial fan, forward inclined impeller, backward inclined impeller, etc.) that is configured to generate airflow that flows through the in-wall dehumidifier for dehumidification and exits the in-wall dehumidifier through air diffuser.

An in-wall dehumidifier as described herein includes various components to provide dehumidification to an airflow. The dehumidifier includes a condenser, an evaporator, and a compressor. Particular embodiments of the condenser are described in more detail below with respect to Figure 5. These and other internal components of an in-wall dehumidifier are uniquely arranged so as to minimize the size of the in-wall dehumidifier and allow it to fit between wall studs in a wall, to provide quiet and efficient dehumidification, and to minimize or eliminate unwanted drafts.

As discussed above, a fan may be located within a cabinet behind an evaporator. In some embodiments, a condenser may be located in a top compartment of an in-wall dehumidifier, an evaporator may be installed in a center compartment of an in-wall dehumidifier, and a compressor may be located in a bottom compartment of an in-wall dehumidifier.

In other embodiments, any other appropriate arrangement of these and other components of an in-wall dehumidifier may be used.

In some embodiments, the evaporator is physically isolated from cabinet around the edges/sides of the evaporator. In other words, the evaporator may include gaps on some or all sides of evaporator that allow for bypass air (i.e., air that does not enter the evaporator) to move between the evaporator and the cabinet. This helps to keep conduction to the cabinet to a minimum, thereby reducing or eliminating cold spots on the cabinet which may cause condensation.

In some embodiments, the dehumidifier includes various unit mounting holes for mounting the in-wall dehumidifier to wall studs, and air diffuser mounting holes for mounting the air diffuser to the in-wall dehumidifier. In some embodiments, the unit mounting holes and air diffuser mounting holes have different shapes to aid in the installation of the in-wall dehumidifier. For example, the unit mounting holes may have an oblong shape and the air diffuser mounting holes may be round. This may help the installer to distinguish the purpose for each of the holes. Furthermore, by having an oblong shape, the unit mounting holes may enable the installer to adjust the position of the in-wall dehumidifier so that the sides of the cabinet are not in contact with the wall studs. This may help to lower the amount of noise and vibration caused by the dehumidifier when it is in operation. In some embodiments, the in-wall dehumidifier may include one or more sensors for sensing temperature, humidity, and other environmental conditions needed for proper operation of the in-wall dehumidifier. In some embodiments, the sensor may be installed below the drain pan and proximate to the evaporator, so that it may sense airflow before it enters the evaporator. In this position, the sensor is located away from the evaporator coils in a low, constant bypass airflow, thereby providing for more accurate ambient measurements. In some embodiments, bypass air (i.e., a portion of the airflow that does not enter the evaporator) is present under the drain pan and evaporator. The bypass air flows over the sensor to give an accurate reading of the conditioned space. This helps to keep drain pan dry and allows for the air volume over the condenser to be different greater) than the airflow over evaporator while still only using one fan. This improves moisture removal efficiency. The sensor may be any appropriate sensor such as a thermometer, humidistat, pressure sensor, and the like.

The air diffuser generally sends output airflow along the surfaces of the wall in which the in-wall dehumidifier is installed (i.e., parallel to the wall surfaces). This is in contrast to typical systems which send dehumidified air back into the living space perpendicular to the wall, thereby causing undesirable drafts in the living spaces. In some embodiments, air diffuser includes an outlet, an inlet, and a divider. Airflow may enter the in-wall dehumidifier through the inlet and may exit the in-wall dehumidifier through the outlet. The divider is generally configured to prevent airflow entering cabinet through the inlet from mixing with airflow exiting the cabinet from the outlet. In some embodiments, the divider contacts a foam strip (or any other material) located on the front of cabinet between the condenser and the evaporator in order to further restrict the mixing of airflow.

Various electrical and plumbing knockouts can be present in the in-wall dehumidifier, according to certain embodiments. Electrical knockouts can be included in cabinet to permit electrical cables to enter/exit cabinet. In some embodiments, one or more electrical knockouts may be included in any appropriate location within cabinet (e.g., the bottom, sides, or back). In some embodiments, multiple electrical knockouts are included to accommodate installations with varying wall depths. Drain hose knockouts may be included in the cabinet to permit a drain hose to enter/exit the cabinet. Similar to the electrical knockouts, one or more drain hose knockouts may be included in any appropriate location within cabinet (e.g., the bottom, sides, or back). An optional bezel can be used with the in-wall dehumidifier, according to certain embodiments. In some embodiments, the in-wall dehumidifier may be sized to be blindly installed within walls that utilize 2X6 wall studs and be flush with the surface of the wall. Such embodiments may also be blindly installed in walls with 2X4 wall studs, but will not be flush with the wall. If such embodiments are blindly installed in walls with 2X4 wall studs, a bezel may be added to enhance the appearance of the in-wall dehumidifier and provide for a more professional looking installation.

The fan, in some embodiments, is located between the evaporator and a back panel of the cabinet. In some embodiments, the fan includes a blower scroll that is coupled to the back panel. In some embodiments, the blower scroll includes a molded clamp that securely fastens a rigid wiring conduit against back panel. The molded clamp and rigid wiring conduit helps protect wires within the rigid wiring conduit from being damaged by rotating components of the fan, (e.g., a squirrel cage) while still maintaining the overall depth of cabinet.

Various brackets can be used in connection with the in-wall dehumidifier, according to certain embodiments. In some embodiments, a shipping bracket may be included in order to secure the compressor during shipment. The shipping bracket may be removed during installation of the in-wall dehumidifier. In some embodiments, the in-wall dehumidifier may include a compressor mounting bracket. In general, the compressor mounting bracket may be installed in place of standard washers used to secure the compressor to the cabinet. The compressor mounting bracket may provide a more secure attachment for the compressor during shipping and rough handling of the in-wall dehumidifier. Furthermore, by being secured at two locations, the compressor mounting bracket may be prevented from touching the compressor, thereby mitigating sound and vibration caused by the compressor when in operation.

Condenser brackets may be used to attach the condenser to the in-wall dehumidifier, according to certain embodiments. In some embodiments, the condenser brackets may be used to hard mount the condenser the to cabinet in order to conduct heat out of the condenser and into the cabinet, where it may help reduce or eliminate condensation on the in-wall dehumidifier.

A drain pan may be present in the in-wall dehumidifier, according to certain embodiments. In general, the drain pan collects water that is removed from airflow by the in-wall dehumidifier In some embodiments, the drain pan includes a drain. Any appropriate hose may be coupled to the drain in order to direct water out of the in-wall dehumidifier In some embodiments, the drain pan is sloped as illustrated in order to direct water to the drain.

A fan outlet diffuser can be present in the in-wall dehumidifier, according to certain embodiments. In general, a fan outlet diffuser includes a number of apertures that are configured to evenly distribute airflow as it leaves the fan, and enters the condenser. This helps to reduce any noise caused by the airflow. In some embodiments, the fan outlet diffuser is coupled to the condenser bracket, which is between the outlet of the fan, and the condenser. The apertures of the fan outlet diffuser may have any appropriate shape, including, but not limited to, circular, polygonal (e.g., square, hexagonal, etc.), and the like. Any appropriate number and size of apertures may be included in the fan outlet diffuser.

In certain embodiments, the condenser includes dual layers of condenser coils. The arrangement of components in the various figures are for illustrative purposes only. In some embodiments, the condenser, the evaporator, and the compressor may be arranged as illustrated in the figures, with the condenser at the top of cabinet, the evaporator below the condenser, and the compressor below the evaporator. In some embodiments, a second layer of a condenser coil is connected to the compressor via a line, and the first layer of a condenser coil is connected to the evaporator via a line. In some embodiments, an expansion valve is included on the line between the first layer of the condenser coil and the evaporator. The first layer of the condenser coil and the second layer of the condenser coil can be connected via a condenser connection line the condenser connection line connects an output of the second layer of the condenser coil with an input of the first layer of the condenser coil. In other words, the condenser coils are connected in series, which provides certain advantages as discussed in more detail below.

In some embodiments, the two layers of condenser coils are each microchannel condensers that are made of aluminum. In general, microchannel condensers provide numerous features including a high heat transfer coefficient, a low air- side pressure restriction, and a compact design (compared to finned tub exchangers). In a dehumidifier, the primary air side pressure drop occurs in the evaporator, and reducing the condenser air restriction does not significantly increase airflow. Also, the air temperature upstream of the condenser is typically relatively low, often being below 60°F. The air temperature leaving the condenser is typically over 100° F. The air temperature across the condenser typically increases over 40° F. Using this low temperature air stream efficiently is the key to a good design. In dehumidifier designs, the refrigeration system typically needs to have at least 20° F subcooling when a finned tube condenser is used. Since a normal microchannel condenser does not provide cross counter flow, it is very difficult to get 20°F subcooling. The weakness of a single layer micro-channel condenser (e.g., no cross counter flow) becomes significant when the air temperature rises over 40°F across the condenser. Due to this, a typical single layer microchannel condenser may not be a good condenser for a dehumidifier.

However, in some embodiments, the in-wall dehumidifier includes two layers of condenser coils connected in series as described herein. In this configuration, the pressure drop of two microchannel condenser coils is still lower than that of a single finned tube coil. In addition, since a microchannel coil is thinner than a multi-row finned tube coil, the thickness of two microchannel condenser coils is less than an equivalent single finned tube coil. While not wishing to be bound to a particular theory, it may be that by using two or more microchannel condenser coils in series to make a cross counter flow condenser, more than 20° F of subcooling may be achieved with a reasonable approach temperature when the inlet air temperature is below 60° F. Furthermore, aluminum is typically less costly than copper, so the cost of a dual microchannel aluminum condenser is less than a single finned copper tube condenser.

In embodiments where two microchannel condenser layers are used, each microchannel condenser coil can include an inlet manifold and an outlet manifold, fluidly connected by a plurality of flat tubes. The inlet manifold includes an inlet port for receiving refrigerant, and the outlet manifold includes an outlet port for discharging the refrigerant. One or more baffles may be placed in the inlet manifold and/or the outlet manifold to cause the refrigerant to make multiple passes through the flat tubes for enhanced cooling of the refrigerant.

The flat tubes may be formed to include multiple internal passageways, or microchannels, that are much smaller in size than the internal passageway of the coil in a conventional fin-and- tube condenser coil. The microchannels allow for more efficient heat transfer between the airflow passing over the flat tubes and the refrigerant carried within the microchannels, compared to the airflow passing over the coil of the conventional fin-and-tube condenser coil. The microchannels each can be configured with a rectangular cross-section, although other constructions of the flat tubes may have passageways of other cross-sections. In one embodiment, the flat tubes are separated into about 10 to 15 microchannels, with each microchannel being about 1.5 mm in height and about 1.5 mm in width, compared to a diameter of about 9.5 mm (3/8") to 12.7 mm (1/2") for the internal passageway of a coil in a conventional fin-and-tube condenser coil. However, in other constructions of the flat tubes, the microchannels may be as small as 0.5 mm by 0.5 mm, or as large as 4 mm by 4 mm.

The flat tubes may also be made from extruded aluminum to enhance the heat transfer capabilities of the flat tubes. The flat tubes are typically about 22 mm wide. However, in other constructions, the flat tubes may be as wide as 26 mm, or as narrow as 18 mm. Further, the spacing between adjacent flat tubes may be about 9.5 mm. However, in other constructions, the spacing between adjacent flat tubes may be as much as 16 mm, or as little as 3 mm.

Each microchannel condenser coil includes a plurality of fins coupled to and positioned along the flat tubes. The fins are generally arranged in a zig-zag pattern between adjacent flat tubes. In the illustrated construction, the fin density measured along the length of the flat tubes is between 12 and 24 fins per inch. However, in other constructions of the microchannel condenser coils, the fin density may be slightly less than 12 fins per inch or more than 24 fins per inch. Generally, the fins aid in the heat transfer between the airflow passing through the microchannel condenser coils and the refrigerant carried by the microchannels. The fins may also include a plurality of louvers formed therein to provide additional heat transfer area. The increased efficiency of the microchannel condenser coils is due in part to such a high fin density, compared to the fin density of 2 to 4 fins per inch of a conventional fin-and-tube condenser coil.

The increased efficiency of the microchannel condenser coils, compared to a conventional fin-and-tube condenser coil, allows the microchannel condenser coils to be physically much smaller than the fin-and-tube condenser coil. As a result, the microchannel condenser coils are not nearly as tall, and are not nearly as wide as a conventional fin-and-tube condenser coil.

Since the microchannel condenser coils are much smaller than conventional fin-and-tube condenser coils, the microchannel condenser coils may also contain less refrigerant compared to the conventional fin-and-tube condenser coils. Further, less refrigerant may be required to be contained within the entire refrigeration system, therefore effectively decreasing potential damage to the environment by an accidental atmospheric release. Also, as a result of being able to decrease the amount of refrigerant in the refrigeration system, the retail stores may see an energy savings, since the compressor(s) may expend less energy to compress the decreased amount of refrigerant in the refrigeration system. The condenser assembly can also include one or more fans coupled to the microchannel condenser coils to provide an airflow through the coils. Each layer of the microchannel condenser coils can include two fans mounted thereon. Alternatively, centrifugal blowers may be used in place of the fans or in combination with the fans. The fans can be supported in a fan shroud, which guides the airflow generated by the fans through the microchannel condenser coils, and helps distribute the airflow amongst the face of each layer of the condenser coil. In a preferred construction of the condenser assembly, the fans may be "low-noise" fans, to help decrease noise emissions from the condenser assembly. In other constructions, more or less than two fans may be used for each condenser coil to generate the airflow through the condenser coil, for example, a single fan can be present between the evaporator and the condenser arrangement. Also, the fans and/or the shroud may comprise any number of designs.

A shroud can support an electric motor for driving one of the fans. The electric motor may be configured to operate using either an AC or DC power source. Further, the electric motor 58 may be electrically connected to a controller (not shown) that selectively activates the electric motor to drive the fan, depending on any number of conditions monitored by the controller. For example, the fans may be cycled on and off to either increase or decrease the heat transfer capability of the condenser coils. In one manner of operating the fans, the fans may be turned off during the nighttime, when the ambient temperature around the condenser assembly is typically less than during the daytime. In another manner of operating the fans, the controller may receive a signal from a pressure sensor that is in communication with one or both of the layers of the condenser coils that is proportional to the pressure in the layers. A measured pressure greater than some pre-determined threshold pressure may trigger the controller to activate the electric motors to drive the fans to provide additional heat transfer capability to the layers of coils. Fikewise, a measured pressure less than some pre-determined threshold pressure may trigger the controller to deactivate the electric motors to stop the fans.

Figure 5 illustrates two layers of microchannel condenser coils fluidly connected in a series arrangement. An inlet port of a second layer of the microchannel condenser coil is shown coupled to an inlet header of the first layer of the microchannel condenser, whereby compressed, gaseous refrigerant is pumped to the second layer of the microchannel condenser coil via the inlet header. In one embodiment, the inlet header is coupled to the inlet port by a brazing or welding process. Such a brazing or welding process provides a substantially fluid-tight connection between the inlet header and the inlet port. However, other constructions of the condenser assembly may use some sort of fluid-tight releasable couplings to allow serviceability of the coils.

The outlet port of the second layer of the microchannel condenser coils is shown coupled to an inlet port of a first layer of the microchannel condenser coil via a connecting conduit. In one embodiment, the outlet port of the second layer of the microchannel condenser coil is coupled to the connecting conduit by a brazing or welding process, and the inlet port of the first layer of the microchannel condenser coil is also coupled the connecting conduit by a brazing or welding process. As previously stated, such a brazing or welding process provides a substantially fluid- tight connection between the outlet port of the second layer of the microchannel condenser coil and the inlet port of the first layer of the microchannel condenser coil. However, other constructions of the condenser assembly may use some sort of permanent or releasable fluid-tight couplings.

The outlet port of the first layer of the microchannel condenser coil is shown coupled to an outlet header, whereby compressed, substantially liquefied refrigerant is discharged from the first layer of the microchannel condenser coil to the outlet header for transporting the liquid refrigerant to an expansion device. In one embodiment, the outlet port of the first layer of the microchannel condenser coil is coupled to the outlet header by a brazing or welding process to provide a substantially fluid-tight connection between the outlet port of the first layer of the microchannel condenser coil and the outlet header. However, other constructions of the condenser assembly may use some sort of permanent or releasable fluid-tight couplings.

Since the two layers of condenser coils are connected in a series arrangement, the refrigerant is passed from the second layer of the microchannel condenser coil to the first layer of the microchannel condenser coil.

In operation, refrigerant flows from the evaporator into the compressor, from the compressor into the second condenser coil via a vapor line, and from the second condenser coil into the first condenser coil via a condenser connection line, from the first condenser coil back to the evaporator (through an expansion valve in some embodiments) via a liquid line. The unique configuration of the condenser allows the refrigerant to be managed based on the direction of airflow and temperature. That is, the coldest air (i.e., airflow when it first hits the first layer of the condenser coil) cools the refrigerant within the first condenser coil, and the hottest air (i.e., airflow when it first hits the second layer of the condenser coil after leaving the first layer of the condenser coil) also comes into contact with refrigerant as it passes through the second layer of the condenser coil.

While a particular embodiment of a two-layer condenser has been described as having two condenser coils, other embodiments may have more than two condenser coils. For example, other embodiments of a dehumidification system may have three or four condenser coils. In such embodiments, condenser coils are connected in series using multiple condenser connection lines as described above.

Although a particular implementation of the in-wall dehumidifier is illustrated and primarily described, which can also be mounted on a wall, the present disclosure contemplates any suitable implementation of the in-wall/on-wall dehumidifier, according to particular needs. Moreover, although various components of the in-wall/on-wall dehumidifier have been depicted as being located at particular positions, the present disclosure contemplates those components being positioned at any suitable location, according to particular needs.

Herein, "or" is inclusive and not exclusive, unless expressly indicated otherwise or indicated otherwise by context. Therefore, herein, "A or B" means "A, B, or both," unless expressly indicated otherwise or indicated otherwise by context. Moreover, "and" is both joint and several, unless expressly indicated otherwise or indicated otherwise by context. Therefore, herein, "A and B" means "A and B, jointly or severally," unless expressly indicated otherwise or indicated otherwise by context.

The scope of this disclosure encompasses all changes, substitutions, variations, alterations, and modifications to the example embodiments described or illustrated herein that a person having ordinary skill in the art would comprehend. The scope of this disclosure is not limited to the example embodiments described or illustrated herein. Moreover, although this disclosure describes and illustrates respective embodiments herein as including particular components, elements, feature, functions, operations, or steps, any of these embodiments may include any combination or permutation of any of the components, elements, features, functions, operations, or steps described or illustrated anywhere herein that a person having ordinary skill in the art would comprehend. Furthermore, reference in the appended claims to an apparatus or system or a component of an apparatus or system being adapted to, arranged to, capable of, configured to, enabled to, operable to, or operative to perform a particular function encompasses that apparatus, system, component, whether or not it or that particular function is activated, turned on, or unlocked, as long as that apparatus, system, or component is so adapted, arranged, capable, configured, enabled, operable, or operative. Additionally, although this disclosure describes or illustrates particular embodiments as providing particular advantages, particular embodiments may provide none, some, or all of these advantages.

Claims

Claims

1. A dehumidifier, comprising: a cabinet configured to be installed between studs in a wall, or on a wall; an air diffuser configured to diffuse an airflow from the dehumidifier along a surface of the wall, the air diffuser comprising an inlet, and an outlet above the inlet, a compressor; an evaporator installed within the cabinet above the compressor; a condenser installed within the cabinet above the evaporator; an expansion device; a fan installed between the evaporator and a back surface of the cabinet, the fan configured to generate an airflow that flows into the cabinet through the inlet of the air diffuser and out of the cabinet through the outlet of the air diffuser, the airflow flowing through the evaporator and condenser in order to provide dehumidification to the airflow; and a bi-polar ion generator positioned within the cabinet in such a way that it releases positive and negative ions within the air flow, such that the negative and positive ions leave the dehumidifier when air leaves the cabinet through the outlet of the air diffuser.

2. The dehumidifier of Claim 1, further comprising one or more flanges and/or brackets for attaching the dehumidifier to one or more wall studs.

3. The dehumidifier of Claim 1, wherein the cabinet further comprises two or more screw holes at a rear of the cabinet for mounting the dehumidifier to a wall.

4. The dehumidifier of Claim 1, further comprising a drain pan installed within the cabinet below the evaporator, the drain pan configured to capture water removed from the airflow by the evaporator.

5. The dehumidifier of Claim 1, further comprising one or more sensors for sensing one or more environmental conditions of the ambient air.

6. The dehumidifier of Claim 1, further comprising a fan outlet diffuser installed above the fan, the fan outlet diffuser comprising a plurality of apertures configured to evenly distribute the airflow to the condenser from the fan, thereby reducing noise caused by the airflow.

7. The dehumidifier of Claim 1, wherein the cabinet is further configured to be installed with access from only one side of the wall.

8. The dehumidifier of Claim 1, further comprising a divider between the inlet and outlet, wherein the divider is configured to prevent the airflow entering the cabinet through the inlet from mixing with the airflow exiting the cabinet from the outlet.

9. The dehumidifier of Claim 1, wherein the condenser comprises a plurality of layers of microchannel condenser coils.

10. The dehumidifier of Claim 9, wherein an input of a first layer of a plurality of microchannel condenser coils receives a refrigerant flow from an output of a second layer of a plurality of microchannel condenser coils.

11. The dehumidifier of Claim 9, wherein the plurality of layers of microchannel condenser coils comprises: a first layer of a microchannel condenser coil located so as to receive the airflow after it has passed through the evaporator; and a second layer of a microchannel condenser coil located proximate to the first layer of the microchannel condenser coil, the second layer of the microchannel condenser coil located on a side of the first layer of the microchannel condenser coil so as to receive the airflow after it has passed through the first layer of the microchannel condenser coil.