Note: Descriptions are shown in the official language in which they were submitted.
Docket No: GEM100-2CA
1
AIR-HANDLER MODULE AND EVAPORATOR-EXPANSION MODULE FOR
BUILDING STRUCTURE
TECHNICAL FIELD
[0001] This document relates to the technical field of (and is not limited to)
(A) an apparatus
including an evaporator-expansion module and an air-handler module (and method
therefor),
and/or (B) an apparatus including an evaporator-expansion module configured to
cooperate
with an air-handler module (and method therefor).
BACKGROUND
[0002] Standalone heating equipment (deployed in or for a building structure)
is configured
to operate by utilizing a fuel (such as, natural gas, propane, oil,
electricity, etc.).
[0003] Standalone power generation equipment (deployed in or for a building
structure) is
configured to operate by utilizing a fuel (such as, natural gas, propane, oil,
solar, wind, etc.).
SUMMARY
[0004] It will be appreciated that there exists a need to mitigate (at least
in part) at least one
problem associated with the existing heating equipment (also called the
existing technology)
for a building structure. After much study of the known systems and methods
with
experimentation, an understanding of the problem and its solution has been
identified and is
articulated as follows:
[0005] Known heating assemblies or appliances (for utilization with building
structures),
such as a gas-fired furnace, an electric-driven heat pump, etc., are
configured to produce heat
while consuming electrical power.
[0006] Known electrical power generators (for utilization with building
structures), such as
an internal combustion engine, a solar photovoltaic system, etc., are
configured to provide
electrical power (and do not provide thermal energy usable for heating
building structures).
[0007] Known European and Japanese manufacturers provide heating equipment
configured
to provide heat and electrical power (also called CHP equipment, or
Cogeneration or
Combined Heat and Power equipment). Known CHP equipment is configured to
utilize
internal combustion engines, Stirling engines, combustion turbines and fuel
cells, etc. Known
CHP equipment are also known to: (A) be relatively higher in cost to
manufacture, (B) need
excessive maintenance, (C) be relatively overly complex, (D) be relatively
difficult to install
or service, and/or (E) emit a relatively higher noise level and/or relatively
higher combustion
emission (chemical pollution, etc.). In addition, known CHP equipment are not
configured to
switch between different types of fuel sources (such as, between cheaper fuel
sources and/or
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cleaner fuel sources, etc.). Moreover, some known CHP equipment is configured
to use a
building hydronic distribution loop (also called a hydronic system) as a heat
sink. A majority
of North American residential building structures (such as homes) utilize air
ducts (conduits)
and, therefore, are not typically (and conveniently) compatible with known
hydronic systems.
[0008] What may be needed, for at least some embodiments, is an apparatus
configured to
provide (at least in part) a combination of (A) heat (thermal energy) to the
building structure
(such as, residential buildings, commercial buildings, etc.) and (B)
electrical power to the
building structure. In this manner, electrical-power consumption savings may
be realized for
the case where the building structure (such as for the case where the building
structure does
not receive electric power from an electrical utility grid). In this manner,
energy security or
independence may be provided.
[0009] What may be needed, for at least some embodiments, is an apparatus
configured to
(A) deliver relatively higher electrical utility (cost) savings, (B) provide
heat (thermal energy),
and/or (C) electric power usable to offset an electrical load (electrical
consumption demand)
associated with the building structure.
[0010] What may be needed, for at least some embodiments, is an apparatus
configured to
provide (at least in part) lower manufactured cost, a lower installation cost,
a lower
maintenance cost, and/or a lower operating cost, etc.
[0011] What may be needed, for at least some embodiments, is an apparatus
configured to
utilize, at least in part, solar thermal energy and/or higher-temperature
geothermal energy
(instead of fuel combustion or in combination with fuel combustion) to drive a
vapor
expansion cycle process.
[0012] What may be needed, for at least some embodiments, is an apparatus
configured to
utilize (at least in part) a building air duct system as the heat sink.
[0013] What may be needed, for at least some embodiments, is an apparatus
configured to be
installable in building structures (that may have basements) located in
northern climates.
[0014] What may be needed, for at least some embodiments, is an apparatus
configured to
deliver (provide), at least in part, relatively higher electrical utility
savings during winter
season operation as well as provide heat and electric power for a building
structure. The
delivered heat (thermal energy) offsets a heating load that the building
structure may normally
experience during the winter season. The delivered electric power offsets (at
least in part) the
electric power normally consumed by components (motors and electronics, etc.)
of the heating
equipment, along with other electrical loads in the building structure.
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[0015] What may be needed, for at least some embodiments, is an apparatus
configured to
have (at least in part) a relatively lower manufactured cost, installation
and/or maintenance
requirement. In accordance with a preferred embodiment, the apparatus includes
(for instance)
a premix-fuel burner assembly with a modulating gas valve configured to
deliver an
appropriate amount of heat to an evaporator coil without the need for dilution
of combustion
exhaust gases.
[0016] What may be needed, for at least some embodiments, is an apparatus
configured to be
equipped with an optional evaporator heat exchanger configured to cooperate
with a suitable
source of renewable energy (such as, solar thermal, geothermal, waste heat,
etc., and any
equivalent thereof).
[0017] What may be needed, for at least for some embodiments, is an apparatus
configured
to operate in a North American building structure (such as, a residential
building and/or a
commercial building, etc.) that has an air duct system. For instance, a
combustion and vapor
expansion process may be located in a module configured to be utilized with
(mounted either
outside or inside) the building structure. An air handler module may be is
configured to be
utilized with (mounted in a basement, attic or closet of) the building
structure (preferably, in
any given orientation).
[0018] What may be needed, for at least some embodiments, is an apparatus
configured to
(A) include (at least in part) improved ability to obtain government approval
or certification,
and/or (B) be relatively easier to install.
[0019] What may be needed, for at least some embodiments, is an apparatus
configured to
provide a safety and interlock system for the case where a vapor expansion
module is located
outside of a building structure.
[0020] What may be needed, for at least some embodiments, is an apparatus
configured to
include an indoor air handler module and an outdoor vapor expansion module, in
which case
space in a building structure may be preserved for other uses.
[0021] To mitigate, at least in part, at least one problem associated with the
existing
technology, there is provided (in accordance with a first major aspect) an
apparatus. The
apparatus includes and is not limited to (comprises) an air-handler module and
an evaporator-
expansion module. The air-handler module is configured to provide thermal
energy to a
building structure. The evaporator-expansion module is configured to provide
electric energy
to the building structure. The evaporator-expansion module is also configured
to cooperate
with the air-handler module. The evaporator-expansion module includes (and is
not limited to)
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an evaporator assembly. The evaporator assembly includes (and is not limited
to) a heated
fluid conduit and a refrigerant conduit. The heated fluid conduit is
configured to convey, in
use, a heated fluid. The refrigerant conduit is configured to convey, in use,
an evaporator
refrigerant. The heated fluid conduit is positioned relative to (proximate to)
the refrigerant
conduit. This is done in such a way that the heated fluid conduit, in use,
transfers thermal
energy from the heated fluid that is positioned in the heated fluid conduit to
the evaporator
refrigerant that is positioned in the refrigerant conduit.
[0022] To mitigate, at least in part, at least one problem associated with the
existing
technology, there is provided (in accordance with a second major aspect) an
apparatus. The
apparatus includes and is not limited to (comprises) an evaporator-expansion
module. The
evaporator-expansion module is configured to provide electric energy to a
building structure.
The evaporator-expansion module is also configured to cooperate with an air-
handler module.
The air-handler module is configured to provide thermal energy to a building
structure. The
evaporator-expansion module includes (and is not limited to) an evaporator
assembly. The
evaporator assembly includes (and is not limited to) a heated fluid conduit
and a refrigerant
conduit. The heated fluid conduit is configured to convey, in use, a heated
fluid. The
refrigerant conduit is configured to convey, in use, an evaporator
refrigerant. The heated fluid
conduit is positioned relative to (proximate to) the refrigerant conduit. This
is done in such a
way that the heated fluid conduit, in use, transfers thermal energy from the
heated fluid that is
positioned in the heated fluid conduit to the evaporator refrigerant that is
positioned in the
refrigerant conduit.
[0023] Embodiments of the apparatus may be configured to provide relatively
constant heat
and power to a building structure while providing a source of electrical power
to the building
structure, thereby providing utility savings (electrical utility savings)
and/or energy security
(self-sufficiency for the case where the building structure does not rely on
the electrical grid
for receiving electrical power).
[0024] For the case where a heat source for the apparatus is provided by a
renewable energy
source (such as, solar thermal, geothermal, hydrogen fuel, etc., and any
equivalent thereof),
the heat and electrical power that are produced by the apparatus may result in
relatively lower
(preferably zero) greenhouse gas emissions. Having access to affordable and/or
reliable heat
and electrical power may be a requirement for the building structure (such as,
a residential
home, detached home, a town home, an apartment building, a commercial
building, etc., and
any equivalent thereof).
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[0025] Other aspects are identified in the claims. Other aspects and features
of the non-
limiting embodiments may now become apparent to those skilled in the art upon
review of the
following detailed description of the non-limiting embodiments with the
accompanying
drawings. This Summary is provided to introduce concepts in simplified form
that are further
described below in the Detailed Description. This Summary is not intended to
identify key
features or essential features of the disclosed subject matter, and is not
intended to describe
each disclosed embodiment or every implementation of the disclosed subject
matter. Many
other novel advantages, features, and relationships will become apparent as
this description
proceeds. The figures and the description that follow more particularly
exemplify illustrative
embodiments.
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DETAILED DESCRIPTION OF THE DRAWINGS
[0026] The non-limiting embodiments may be more fully appreciated by reference
to the
following detailed description of the non-limiting embodiments when taken in
conjunction
with the accompanying drawings, in which:
[0027] FIG. 1 depicts a schematic view of an apparatus including an evaporator-
expansion
module configured to cooperate with an air-handler module; and
[0028] FIGS. 2-11 depict schematic views of the evaporator-expansion module of
FIG. 1.
[0029] The drawings are not necessarily to scale and may be illustrated by
phantom lines,
diagrammatic representations and fragmentary views. In certain instances,
details unnecessary
for an understanding of the embodiments (and/or details that render other
details difficult to
perceive) may have been omitted. Corresponding reference characters indicate
corresponding
components throughout the several figures of the drawings. Elements in the
several figures are
illustrated for simplicity and clarity and have not been drawn to scale. The
dimensions of some
of the elements in the figures may be emphasized relative to other elements
for facilitating an
understanding of the various disclosed embodiments. In addition, common, but
well-
understood, elements that are useful or necessary in commercially feasible
embodiments are
often not depicted to provide a less obstructed view of the embodiments of the
present
disclosure.
[0030] LISTING OF REFERENCE NUMERALS USED IN THE DRAWINGS
100 air-handler module
101 evaporator-expansion module
102 supply air assembly
104 return air assembly
106 supply-fan controller
108 supply-fan assembly
109 supply-fan motor assembly
110 condenser assembly
111 pump-condenser module
112 filter assembly
113 refrigerant flow circuit
114 pump assembly
115 pump motor
116 expander assembly
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117 generator assembly
118 pump controller
119 fan-and-burner controller
120 evaporator assembly
121 refrigerant conduit
122 evaporator fan
123 evaporator fan motor
124 expander controller
125 evaporator refrigerant
126 battery assembly
127 electric heating element
128 pipe structure
129 electric heating controller
132 evaporator heat exchanger
133 first three-way valve
134 second three-way valve
135 third three-way valve
136 fourth three-way valve
138 condenser heat exchanger
140 battery controller
142 automatic-disconnect assembly
144 electrical-distribution panel
146 supply-fan controller
148 battery assembly
150 power generation system
199 apparatus
322 mixture
324 heat-generating assembly
325 heated fluid
326 inlet manifold
328 heated fluid conduit
330 thermal buffer
332 inlet
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334 outlet
336 outlet manifold
338 water-vapor drain
340 pressure vent
344 tank assembly
346 combustion exhaust-gas vent
801 supply air
802 exhaust gas
803 return air
804 fuel
806 combustion air
808 solar thermal return
810 solar thermal supply
812 hydronic return
814 hydronic supply
816 electric utility grid
900 building structure
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DETAILED DESCRIPTION OF THE NON-LIMITING EMBODIMENT(S)
[0031] The following detailed description is merely exemplary and is not
intended to limit
the described embodiments or the application and uses of the described
embodiments. As
used, the word "exemplary" or "illustrative" means "serving as an example,
instance, or
illustration." Any implementation described as "exemplary" or "illustrative"
is not necessarily
to be construed as preferred or advantageous over other implementations. All
of the
implementations described below are exemplary implementations provided to
enable persons
skilled in the art to make or use the embodiments of the disclosure and are
not intended to
limit the scope of the disclosure. The scope of the claim is defined by the
claims (in which the
claims may be amended during patent examination after filing of this
application). For the
description, the terms "upper," "lower," "left," "rear," "right," "front,"
"vertical,"
"horizontal," and derivatives thereof shall relate to the examples as oriented
in the drawings.
There is no intention to be bound by any expressed or implied theory in the
preceding
Technical Field, Background, Summary or the following detailed description. It
is also to be
understood that the devices and processes illustrated in the attached
drawings, and described in
the following specification, are exemplary embodiments (examples), aspects
and/or concepts
defined in the appended claims. Hence, dimensions and other physical
characteristics relating
to the embodiments disclosed are not to be considered as limiting, unless the
claims expressly
state otherwise. It is understood that the phrase "at least one" is equivalent
to "a". The aspects
(examples, alterations, modifications, options, variations, embodiments and
any equivalent
thereof) are described regarding the drawings. It should be understood that
the invention is
limited to the subject matter provided by the claims, and that the invention
is not limited to the
particular aspects depicted and described. It will be appreciated that the
scope of the meaning
of ta device configured to be coupled to an item (that is, to be connected to,
to interact with the
item, etc.) is to be interpreted as the device being configured to be coupled
to the item, either
directly or indirectly. Therefore, "configured to" may include the meaning
"either directly or
indirectly" unless specifically stated otherwise.
[0032] FIG. 1 depicts a schematic view of an apparatus 199 including an
evaporator-
expansion module 101 configured to cooperate with an air-handler module 100.
[0033] Referring to an embodiment (in accordance with a first major
embodiment) as
depicted in FIG. 1, there is provided the apparatus 199. The apparatus 199
includes and is not
limited to (comprises) a synergistic combination of an air-handler module 100
and an
evaporator-expansion module 101.
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[0034] The air-handler module 100 is configured to provide thermal energy to a
building
structure 900 (such as, a residential home). More specifically, the air-
handler module 100 is
configured to provide (generate) thermal energy (such as heated air), and to
move the thermal
energy through the building structure 900.
[0035] The evaporator-expansion module 101 is configured to provide (generate
and supply)
electric power (electric energy) to the building structure 900 (that is, to
either provide some of
the electric energy or all of the electric energy to be consumed by the
building structure 900).
The evaporator-expansion module 101 is also configured to cooperate with the
air-handler
module 100.
[0036] The evaporator-expansion module 101 includes (and is not limited to) an
evaporator
assembly 120. The evaporator assembly 120 includes (and is not limited to) a
heated fluid
conduit 328 and a refrigerant conduit 121. The heated fluid conduit 328 is
positioned relative
to (proximate to) the refrigerant conduit 121. The heated fluid conduit 328 is
configured to
convey, in use, a heated fluid 325. For instance, the heated fluid conduit 328
is configured to
receive the heated fluid 325 from the air-handler module 100. The refrigerant
conduit 121 is
configured to convey, in use, an evaporator refrigerant 125. This is done in
such a way that the
heated fluid conduit 328, in use, transfers thermal energy (that is positioned
in the heated fluid
conduit 328) from the heated fluid 325 to the evaporator refrigerant 125 (that
is positioned in
the refrigerant conduit 121). For instance, the evaporator refrigerant 125 is
usable in an
electrical-generating process for generating electrical energy (which may be
utilized by the
building structure 900), as depicted in the embodiments of FIG. 6 to FIG. 9.
[0037] Referring to the embodiment (in accordance with a preferred embodiment)
as
depicted in FIG. 1, the evaporator assembly 120 further includes a thermal
buffer 330. The
thermal buffer 330 is configured to be positioned relative to (proximate to or
between) the
heated fluid conduit 328 and the refrigerant conduit 121. This is done in such
a way that the
thermal buffer 330, in use, transfers, at least in part, thermal energy from
the heated fluid 325
(that is positioned in the heated fluid conduit 328) to the evaporator
refrigerant 125 (that is
positioned in the refrigerant conduit 121).
[0038] Referring to an embodiment (in accordance with a second major
embodiment) as
depicted in FIG. 1, there is provided the apparatus 199. The apparatus 199
includes and is not
limited to (comprises) an evaporator-expansion module 101 (for this case, the
evaporator-
expansion module 101 is configured to be retrofitted to the air-handler module
100). For
instance, the evaporator-expansion module 101 is manufactured by a first
company, and the
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air-handler module 100 is manufactured by a second company. The evaporator-
expansion
module 101 is configured to provide, at least in part, electric energy to a
building structure
900. The evaporator-expansion module 101 is also configured to cooperate with
(to be
retrofitted to) the air-handler module 100. The air-handler module 100 is
configured to provide
thermal energy to a building structure 900. The evaporator-expansion module
101 includes
(and is not limited to) an evaporator assembly 120. The evaporator assembly
120 includes (and
is not limited to) a heated fluid conduit 328 and a refrigerant conduit 121.
The heated fluid
conduit 328 is configured to convey, in use, a heated fluid 325. The
refrigerant conduit 121 is
configured to convey, in use, an evaporator refrigerant 125. The heated fluid
conduit 328 is
positioned relative to (proximate to) the refrigerant conduit 121. This is
done in such a way
that the heated fluid conduit 328, in use, transfers thermal energy from the
heated fluid 325
(that is positioned in the heated fluid conduit 328) to the evaporator
refrigerant 125 (that is
positioned in the refrigerant conduit 121). In accordance with a preferred
embodiment, the
evaporator assembly 120 further includes a thermal buffer 330. The thermal
buffer 330 is
configured to be positioned relative to (proximate to or between) the heated
fluid conduit 328
and the refrigerant conduit 121. This is done in such a way that the thermal
buffer 330, in use,
transfers, at least in part, thermal energy from the heated fluid 325 (that is
positioned in the
heated fluid conduit 328) to the evaporator refrigerant 125 (that is
positioned in the refrigerant
conduit 121).
[0039] The thermal buffer 330 is configured to (A) receive (either directly or
indirectly)
thermal energy (from the heated fluid conduit 328), and (B) release thermal
energy (to the
refrigerant conduit 121). Preferably, the thermal buffer 330 is configured to
limit (A) the
amount of heat transferred (provided) to the evaporator refrigerant 125, and
(B) the
temperature of the evaporator refrigerant 125 positioned in the refrigerant
conduit 121. The
thermal buffer 330 is configured to physically isolate the heated fluid
conduit 328 from the
refrigerant conduit 121 (this is done in such a way that the fluids from the
heated fluid conduit
328 and the refrigerant conduit 121 do not make contact with each other).
Advantageously, for
instance, the thermal buffer 330 improves, at least in part, overall safety
regarding potential
fire hazards. Advantageously, for the case where there is an uncontrolled fire
in the heated
fluid conduit 328, the thermal buffer 330 is configured to block the passage
of the fire from
the heated fluid conduit 328 the refrigerant conduit 121. In addition
(advantageously), for
instance, the thermal buffer 330, in use, prevents thermal degradation of the
evaporator
refrigerant 125 and the lubrication oil utilized in the evaporator assembly
120.
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[0040] In accordance with a preferred embodiment, the thermal buffer 330 is
configured to
have a predetermined thermal capacity. For instance, the thermal buffer 330
includes,
preferably, a thermal heat transfer fluid, such as the DYNALENE (TRADEMARK)
Model
Number MT synthetic heat transfer fluid. Preferably, the refrigerant conduit
121 includes an
evaporator coil (evaporator conduit) and any equivalent thereof (with
reference to the
embodiment as depicted in FIG. 1). Preferably, the refrigerant conduit 121 is
wrapped around
(coiled around) the heated fluid conduit 328. The heated fluid 325 is provided
by a heat-
generating assembly 324 (which is preferably a part of the air-handler module
100) and any
equivalent thereof (with reference to the embodiments as depicted in FIGS. 1
to 5). The heat-
generating assembly 324 is any type of assembly configured to generate and/or
provide
thermal energy, heat energy, heat, etc., and any equivalent thereof.
[0041] In accordance with an embodiment as depicted in FIG. 1, the heat-
generating
assembly 324 includes a premix-fuel burner assembly with a modulating gas
valve that is
coupled to the evaporator assembly 120 (also called a direct-fired evaporator)
without dilution
of an air-and-gas mixture (to be consumed by the premix-fuel burner assembly).
For instance,
the heat-generating assembly 324 includes a premix burner assembly, a
catalytic converter,
any type of burner, etc., and any equivalent thereof. The heated fluid 325
includes a
combusted gas (also called a burner exhaust) and any equivalent thereof.
Preferably, the
heated fluid conduit 328 is aligned along a linear direction. Preferably, the
heated fluid conduit
328 includes a plurality of spaced-apart combustion exhaust-gas tubes aligned
along a linear
direction (aligned along a longitudinal axis), and any equivalent thereof. In
accordance with an
alternative, the evaporator assembly 120 includes an indirect fired evaporator
assembly, an
indirect fired evaporator, etc., and any equivalent thereof.
[0042] In accordance with a preferred embodiment, an evaporator fan 122 is
configured to
receive a mixture 322 of pre-mixed fuel and air (also called a fuel-and-air
pre-mixture). The
evaporator fan 122 is fluidly coupled to an inlet manifold 326 (also called a
combustion
exhaust-gas inlet manifold). The heated fluid conduit 328 is fluidly connected
to the inlet
manifold 326. Preferably, the heated fluid conduit 328 includes spaced-apart
tubes (also called
combustion exhaust-gas tubes). Preferably, the heat-generating assembly 324
includes a
burner assembly or a pre-mix burner assembly. The refrigerant conduit 121
includes an inlet
334 (also called a refrigerant evaporator coil inlet), and an outlet 332 (also
called a refrigerant
evaporator coil outlet). The heated fluid conduit 328 is fluidly connected to
an outlet manifold
336 (also called a combustion exhaust -as outlet manifold). A water-vapor
drain 338 (also
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called a combustion exhaust condensate drain) extends downwardly from the
outlet manifold
336. A combustion exhaust-gas vent 346 is fluidly connected to the outlet
manifold 336. The
interior of the evaporator assembly 120 is configured to receive the thermal
buffer 330. A
pressure vent 340 is coupled to the interior of the evaporator assembly 120.
The pressure vent
340 is configured to relieve excessive interior pressure generated in the
interior of the
evaporator assembly 120. The evaporator assembly 120 includes a tank assembly
344 (also
called a heat exchanger tank shell).
[0043] In accordance with an embodiment as depicted in FIG. 1, the heated
fluid 325, in use,
transfers thermal energy (indirectly such as via the thermal buffer 330) to
the refrigerant
conduit 121. More specifically, the heated fluid 325 positioned in the heated
fluid conduit 328,
in use, transfers thermal energy (directly) to the thermal buffer 330, and the
thermal buffer
330, in use, transfers thermal energy (directly) to the evaporator refrigerant
125 positioned in
the refrigerant conduit 121. The thermal buffer 330 may be called an
intermediate thermal
fluid or thermal fluid. The thermal buffer 330 is configured to physically
separate (isolate) the
heated fluid conduit 328 and the refrigerant conduit 121.
[0044] OPERATION
[0045] With reference to FIG. 1 and FIGS. 6 to 9, for the case where a control
system
(known and not depicted) receives a call signal (also called a request signal)
indicating that
heat (thermal energy) is to be provided to (or may be required by) the
building structure 900,
the control system transmits a turn-on signal to the heat-generating assembly
324. This is done
in such a way that the heat-generating assembly 324 is activated to provide
thermal energy to
the heated fluid 325. An amount of thermal energy is transferred from the
heated fluid 325
(such as, the exhaust gas from the burner assembly) to the evaporator
refrigerant 125 located
in the refrigerant conduit 121 (such as, the evaporator coil) via the thermal
buffer 330.
[0046] For the case where the temperature of the heated fluid 325 (such as,
the exhaust gas),
in use, drops (falls) below its dew point, the formation of water vapor within
the heated fluid
325 may condense (within the heated fluid conduit 328) and may liberate
additional thermal
heat energy.
[0047] The evaporator refrigerant 125, in use, enters the refrigerant conduit
121 in a liquid
state and at a relatively higher pressure. The heat (an amount of thermal
energy) from the
heated fluid 325, in use, is transferred to the evaporator refrigerant 125 and
thereby causes a
change of state from liquid to vapor (for the evaporator refrigerant 125). The
evaporator
refrigerant 125, in use, that departs from the refrigerant conduit 121 is in a
vapor state and at a
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relatively higher pressure. The evaporator refrigerant 125 exits (departs) the
evaporator
assembly 120 and enters an expander assembly 116 (as depicted in FIGS. 6 to 9)
at a relatively
higher pressure, in which the evaporator refrigerant 125, in use, imparts
mechanical energy to
the expander assembly 116 (thereby causing a decrease in pressure in the
evaporator
refrigerant 125). Through rotation, the expander assembly 116, in use, turns a
generator
assembly 117 to produce (generate) electricity (electrical power or electrical
energy).
[0048] The evaporator refrigerant 125, in use, leaves (departs from) the
expander assembly
116 in a vapor state and at a relatively lower pressure. The evaporator
refrigerant 125, in use,
enters the condenser assembly 110 (also called a condenser coil) in a vapor
state and at a
relatively lower pressure. The thermal heat energy from the evaporator
refrigerant 125 is
transferred to the building air (via the supply air assembly 102), thereby
causing a change of
state of the evaporator refrigerant 125 from a vapor state to a liquid state.
The evaporator
refrigerant 125, in use, leaves (departs from) the condenser assembly 110 in a
liquid state and
at a relatively lower pressure. The evaporator refrigerant 125, in use, enters
the pump
assembly 114 at a relatively lower pressure. A pump motor 115 is configured to
consume
electricity to turn the pump assembly 114 through rotation. The pump assembly
114, in use,
imparts mechanical energy to the evaporator refrigerant 125 and thereby causes
an increase in
pressure of the evaporator refrigerant 125. The evaporator refrigerant 125, in
use, leaves
(departs from) the pump assembly 114 in a liquid state and at relatively
higher pressure. The
evaporator refrigerant 125 exits (departs) from the pump assembly 114 and
enters the
evaporator assembly 120 (and into the refrigerant conduit 121, as depicted in
FIG. 1) to repeat
the operating cycle. The supply-fan assembly 108 in the air-handler module 100
induces a
building air flow through a side of the condenser assembly 110.
[0049] THERMAL BREAKDOWN
[0050] A potential concern with deployment of the evaporator refrigerant 125
in the
evaporator assembly 120 is that the thermal breakdown temperature of the
evaporator
refrigerant 125 and/or a lubrication oil may be exceeded (if not properly
addressed and
mitigated). To mitigate such a possibility, a thermal-control device (known
and not depicted)
is provided, in which the thermal-control device is configured to control the
temperature of the
heated fluid 325 impinging on the evaporator assembly 120. Preferably, the
thermal-control
device (for protecting against the overheating of the heated fluid 325)
includes a temperature
switch configured to open in response to a predetermined temperature to shut-
off the heat-
generating assembly 324 (such as, a burner circuit). The temperature switch
includes the
CA 2997502 2018-03-06
Docket No: GEM100-2CA
THERMODISC (TRADEMARK) Model 49T temperature switch. THERMODISC is
headquartered in Ohio, U.S.A.
[0051] For instance, an option for mitigating the thermal breakdown
temperature of the
evaporator refrigerant 125 is to utilize an indirect heating process
configured to transfer energy
from the heated fluid conduit 328 (having the heated fluid 325, such as to be
provided by a
combustion process, etc.) to the refrigerant conduit 121 having the evaporator
refrigerant 125.
The combustion gases are utilized to heat a fluid (such as steam, pressurized
water, thermal
oil, etc.) within a closed piping loop. With an internal pump, the heated
fluid is transferred
from the fluid to the evaporator assembly 120 (also called a refrigerant heat
exchanger), which
may then evaporate the evaporator refrigerant 125. The advantage is that the
fluid
temperatures in contact with the evaporator assembly 120 are limited. The
disadvantage is that
the system may be more complex with an additional pump assembly, piping and/or
fluid.
[0052] Another option for mitigating the thermal breakdown temperature of the
evaporator
refrigerant 125 is to utilize a catalytic burner to evaporate the evaporator
refrigerant 125. A
catalytic burner relies on the use of an exotic metal to enable a flameless
chemical reaction
between the fuel and oxygen to liberate heat energy. The advantage of the
catalytic burner is
that the exhaust-gas temperatures are relatively lower to the point where
recirculated dilution
gases may not be needed (and thus may be expelled). A disadvantage of the
catalytic burner
may be that the catalytic burner takes up a very large surface area.
[0053] Referring to an option of the embodiment as depicted in FIG. 1, the
evaporator fan
122 in the external module is located either upstream or downstream from the
refrigerant
conduit 121 (also called the evaporator coil). The thermal buffer 330 within
the tank of the
evaporator assembly 120 (the indirect-fired evaporator) may be stationary or
may be agitated
by a mechanical means (also called a mixer device) to increase the rate of
heat transfer.
[0054] Referring to an option of the embodiment as depicted in FIG. 1, the
evaporator
assembly 120 is configured to be direct fired, with a premix-fuel burner
assembly and a
modulating gas valve. For instance, the evaporator assembly 120 is configured
to be indirect
fired with a tank assembly 344 (also called a thermal fluid tank or tank
shell) and a premix-
fuel burner assembly with a modulating gas valve.
[0055] FIG. 2 and FIG. 3 depict schematic views (side views) of the evaporator-
expansion
module 101 of FIG. 1.
[0056] Referring to the embodiments as depicted in FIG. 2 and FIG. 3, the air-
handler
module 100 and the evaporator-expansion module 101 are both positioned
(located) within the
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interior of the building structure 900. Referring to the embodiment as
depicted in FIG. 2, the
evaporator-expansion module 101 has a left-hand return air (return air
assembly 104).
Referring to the embodiment as depicted in FIG. 3, the evaporator-expansion
module 101 has
a right-hand return air (return air assembly 104). The air-handler module 100
includes a
supply-fan controller 106 configured to control the operation of a heating
assembly (such as a
natural-gas burner), which is known and not depicted. The heating assembly is
configured to
generate heat to be fluidly provided to the interior of the building structure
900. A supply-fan
assembly 108 is configured to move air (fresh cooler air) from a return air
assembly 104 (such
as an air intake or return air 801 either from an interior or exterior (or
both) of the building
structure 900) to the heating assembly that is positioned in the air-handler
module 100. The
heating assembly is configured to provide heat to the return air received from
the return air
assembly 104 (as a result of the operation of the supply-fan assembly 108).
The supply-fan
assembly 108 is also configured to move air (heated air) from the heating
assembly of the
evaporator-expansion module 101 towards the air-handler module 100, and then
towards a
supply air assembly 102 (such as the air outtake or supply air 803 to the
interior of the
building structure 900); in this manner, heated air is provided to the
interior of the building
structure 900 and also to the air-handler module 100.
[0057] The evaporator-expansion module 101 includes (and is not limited to) a
condenser
assembly 110 (also called the condenser coil), a filter assembly 112, a pump
assembly 114, an
expander assembly 116, a pump controller 118, an evaporator assembly 120 (also
called an
indirect fired evaporator section), an evaporator fan 122, and an expander
controller 124. As
an option, a battery assembly 126 is provided. The details for the evaporator-
expansion
module 101 are depicted in FIGS. 6 to 9.
[0058] FIG. 4 and FIG. 5 depict schematic views of the evaporator-expansion
module 101 of
FIG. I.
[0059] Referring to the embodiments as depicted in FIG. 4 and FIG. 5, the
evaporator-
expansion module 101 is configured to be deployed (positioned) outside (the
exterior of) the
building structure 900, and the air-handler module 100 is configured to be
deployed
(positioned) inside (the interior of) the building structure 900. Referring to
the embodiment as
depicted in FIG. 4, the air-handler module 100 has a left-hand return air.
Referring to the
embodiment as depicted in FIG. 5, the air-handler module 100 has a right-hand
return air. A
pipe structure 128 (field-installed pipes) is configured to fluidly connect
the air-handler
module 100 with the evaporator-expansion module 101.
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[0060] FIG. 6 depicts a schematic view of the evaporator-expansion module 101
of FIG. 1.
[0061] Referring to the embodiment as depicted in FIG. 6, and for the case
where the
combination of the air-handler module 100 and the evaporator-expansion module
101 is
installed (positioned) inside the building structure 900, the evaporator-
expansion module 101
includes a refrigerant flow circuit 113. The refrigerant flow circuit 113
includes an evaporator
assembly 120 (that is fluidly connected to the pump assembly 114), an expander
assembly 116
(that is fluidly connected to the evaporator assembly 120), a condenser
assembly 110 (that is
fluidly connected to the expander assembly 116), and a pump assembly 114 (that
is fluidly
connected to the condenser assembly 110). The evaporator refrigerant 125 (as
depicted in FIG.
1) is made to flow through the refrigerant flow circuit 113 (as depicted in
FIG. 6). A pump-
condenser module 111 includes the pump assembly 114 and the condenser assembly
110. A
pump motor 115 is configured to operate the pump assembly 114. The expander
assembly 116
is configured to rotate a generator assembly 117. A supply-fan motor assembly
109 is
configured to operate the supply-fan assembly 108. An evaporator fan motor 123
is configured
to operate the evaporator fan 122. A heat-generating assembly 324 is fluidly
coupled to the
evaporator assembly 120. The evaporator assembly 120 is fluidly coupled to the
exhaust gas
802. A fuel 804 is configured to be fluidly connected to the heat-generating
assembly 324. A
combustion air 806 is configured to be fluidly connected to the heat-
generating assembly 324.
[0062] Referring to a variation of the embodiment as depicted in FIG. 6, and
for the case
where the evaporator-expansion module 101 is to be installed (positioned)
outside of the
building structure 900, the evaporator assembly 120 and the expander assembly
116 are
located within the evaporator-expansion module 101, while the condenser
assembly 110 and
the pump assembly 114 are located (positioned) within the air-handler module
100 (which is
located in the building structure 900).
[0063] The evaporator-expansion module 101 includes a refrigerant flow circuit
113
configured to circulate the evaporator refrigerant 125. The evaporator
assembly 120 is
configured to be indirect fired. The condenser assembly 110 is configured to
be air cooled.
The evaporator-expansion module 101 may be located inside or outside the
building structure
900. The pump-condenser module 111 may be located within the air-handler
module 100, in
which the air-handler module 100 is positioned or located inside the building
structure 900.
The supply-fan assembly 108 may be located downstream of the condenser
assembly 110.
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[0064] Referring to the embodiment as depicted in FIG. 6, the supply-fan
assembly 108 in
the internal module may be located either upstream or downstream from the
condenser coil of
the condenser assembly 110.
[0065] FIG. 7 depicts a schematic view of the evaporator-expansion module 101
of FIG. 1.
[0066] Referring to the embodiment as depicted in FIG. 7, an evaporator heat
exchanger 132
is configured to utilize solar thermal and/or or geothermal energy in
conjunction with the
evaporator assembly 120 (direct-fired evaporator using fuel combustion). The
evaporator heat
exchanger 132 (also called a liquid-to-refrigerant heat exchanger) may be
provided in parallel
with the evaporator assembly 120 (such as an indirect fired evaporator) to
take advantage of
solar thermal and/or geothermal energy. The evaporator heat exchanger 132 is
configured to
be fluidly coupled to a renewable thermal energy source. The evaporator heat
exchanger 132 is
fluidly connected to a solar thermal return 808 and a solar thermal supply
810. The evaporator
heat exchanger 132 is configured to operate in cooperation with the evaporator
assembly 120.
A second three-way valve 134 and a fourth three-way valve 136 are configured
to fluidly
interface the evaporator heat exchanger 132 with the evaporator assembly 120.
[0067] The evaporator assembly 120 is configured to be indirect fired. The
condenser
assembly 110 is configured to be air cooled. The evaporator heat exchanger 132
is solar
thermal heated. The evaporator-expansion module 101 may be located inside or
outside the
building structure 900. The pump-condenser module 111 may be located within
the air-handler
module 100, in which the air-handler module 100 is positioned or located
inside the building
structure 900. The supply-fan assembly 108 may be located downstream of the
condenser
assembly 110.
[0068] FIG. 8 depicts a schematic view of the evaporator-expansion module 101
of FIG. 1.
[0069] Referring to the embodiment as depicted in FIG. 8, a condenser heat
exchanger 138 is
configured to utilize hydronic water, domestic water or pool water. The
condenser heat
exchanger 138 (also called a liquid-to-refrigerant heat exchanger) may be
provided in parallel
with the condenser assembly 110 (configured to be air cooled) to take
advantage of a hydronic
loop, a domestic water loop and/or a pool water loop. The condenser heat
exchanger 138 is
configured to fluidly cooperate with the condenser assembly 110. The condenser
heat
exchanger 138 is configured to fluidly connect with a hydronic return 812 and
a hydronic
supply 814. A first three-way valve 133 and a third three-way valve 135 are
configured to
fluidly interface the condenser assembly 110 with the condenser heat exchanger
138.
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[0070] The evaporator assembly 120 is configured to be indirect fired. The
condenser
assembly 110 is configured to be air cooled. The condenser heat exchanger 138
is configured
to be hydronic cooled. The evaporator-expansion module 101 may be located
inside or outside
the building structure 900. The pump-condenser module 111 includes the pump
assembly 114
and the condenser assembly 110. Alternatively, the pump-condenser module 111
may be
located within the air-handler module 100, in which the air-handler module 100
is positioned
or located inside the building structure 900. Alternatively, the supply-fan
assembly 108 may
be located downstream of the condenser assembly 110.
[0071] FIG. 9 depicts a schematic view of the evaporator-expansion module 101
of FIG. 1.
[0072] Referring to the embodiment as depicted in FIG. 9, the condenser heat
exchanger 138
and the evaporator heat exchanger 132 are deployed with the evaporator
assembly 120. The
evaporator assembly 120 is configured to be indirect fired. The evaporator
heat exchanger 132
is solar thermal heated. The condenser assembly 110 is configured to be air
cooled. The
condenser heat exchanger 138 is configured to be hydronic cooled. The
evaporator-expansion
module 101 may be located inside or outside the building structure 900. The
pump-condenser
module 111 includes the pump assembly 114 and the condenser assembly 110. The
pump-
condenser module 111 may be located within the air-handler module 100, in
which the air-
handler module 100 is positioned or located inside the building structure 900.
The supply-fan
assembly 108 may be located downstream of the condenser assembly 110.
[0073] FIG. 10 depicts a schematic view of the evaporator-expansion module 101
of FIG. 1.
[0074] In accordance with an embodiment as depicted in FIG. 10, a battery
assembly 148
(also called an on-board battery, or a battery storage system) and the
expander controller 124
(also called a grid-independent expander controller or an inverter-and-
charging assembly) is
configured to allow the apparatus 199 to operate in the event of outage of the
electric utility
grid 816.
[0075] A battery controller 140 is electrically connected to an electrical-
distribution panel
144 (also called a breaker panel). An automatic-disconnect assembly 142
electrically connects
the electrical-distribution panel 144 (breaker panel) to the electric utility
grid 816. A supply-
fan controller 146 is electrically connected to the electrical-distribution
panel 144.
[0076] The generator assembly 117 is configured to output AC (Alternating
Current) power
(preferably, three-phase AC power) that may be rectified to DC (Direct
Current) power. The
DC power may be converted to single phase AC power through an inverter that is
compatible
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with the electric grid. Alternatively, the DC power can also be left as is to
charge a battery that
may operate independently of the electric grid.
[0077] The pump motor 115 of the pump assembly 114 may utilize AC power from
the
electric utility grid 816 through a controller that rectifies AC power
(provided by the electric
utility grid 816) to DC power before inverting to AC power (or three-phase AC
power) that is
input to the pump motor 115.
[0078] For the case where the evaporator-expansion module 101 is to be
deployed as a grid-
connected system, the power output from the generator assembly 117 is exported
to the
building structure 900 or to the electric utility grid 816 via an expander
controller 124.
[0079] Power input for the internal loads of the apparatus 199 may be imported
from the
building structure 900 or from the electric utility grid 816 (through other
controllers). The
building structure 900 has the option to install a battery storage system that
has the ability to
run the apparatus 199 along with other electrical loads in the event of an
electric utility grid
816 outage. A main disconnect switch may be required to be activated in order
to prevent the
electric utility grid 816 from being energized in an outage situation.
[0080] The generator assembly 117 is configured to provide electrical output
to the
electrical-distribution panel 144 (breaker panel or utility grid connection)
via the expander
controller 124.
[0081] The battery assembly 126 (the on-board battery) is not provided (in
accordance with
an option). The expander controller 124 is a utility grid-connected unit, and
includes an anti-
islanding unit (known). The automatic-disconnect assembly 142 is optional
(known and may
be provided by a third party). The automatic-disconnect assembly 142 may be
required for the
case where a battery assembly 148 is present, in which the battery assembly
148 is configured
to prevent the electric utility grid 816 from being energized in the event of
the electric utility
grid 816 is not operational (also called a grid outage condition). The battery
assembly 126
(also called a battery storage system) is optional. The battery assembly 126
may be configured
to charge and/or discharge depending on a control and management algorithm,
etc.
[0082] In accordance with a preferred embodiment, the evaporator fan motor 123
and/or the
heat-generating assembly 324 (also called the burner assembly) are configured
to be controlled
by a fan-and-burner controller 119.
[0083] In accordance with an embodiment, the air-handler module 100 also
includes an
electric heating element 127, and an electric heating controller 129
configured to operate the
electric heating element 127.
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[0084] The electric heating element 127 is configured to selectively not
provide thermal
energy (heat) for heating the building structure 900 for the case where
natural gas rates (fuel
costs) are relatively less expensive than electric rates (electrical costs)
associated with the
electric utility grid 816. For this case, heating of the building structure
900 is provided by
utilizing (consuming) natural gas, and the generation of electric power may be
provided by the
generator assembly 117.
[0085] The electric heating element 127 is also configured to selectively
provide, in use,
thermal energy (heat) for heating the building structure 900 (by consuming
electric power
provided by the electric utility grid 816) for the case where the electric
rates (costs) are
relatively less expensive than the natural gas rates (fuel costs). For this
case, electric power is
not produced by the generator assembly 117.
[0086] The selection between the two heating modes (the operation of the
electric heating
element 127) may occur by operation of a thermostat (not shown and known), a
controller (not
shown and known), and any equivalent thereof.
[0087] FIG. 11 depicts a schematic view of the evaporator-expansion module 101
of FIG. 1.
[0088] Referring to the embodiment as depicted in FIG. 11, a battery assembly
148 is
configured to operate independently of the electric utility grid 816 (the
electric grid), in which
case the battery may be used to provide the DC power that is inverted to three-
phase AC
power for usage by the pump motor 115 of the pump assembly 114. The battery
assembly 148
(also called an on-board battery bank) is configured to allow for grid
independent operation
for the evaporator-expansion module 101 (that is, for the vapor expansion
cycle utilized in the
evaporator assembly 120, as depicted in FIG. 1). For the case where the
evaporator-expansion
module 101 is deployed as a grid-independent system, the power output from the
generator
assembly 117 is utilized to either (A) charge the battery assembly 148 via a
battery controller
140, and/or (13) power other electrical loads directly connected to the
evaporator-expansion
module 101. Power input for the internal loads may always be obtained from the
battery
assembly 148 through the battery controller 140 (upon start-up, etc.). The
generator assembly
117 is provided with no output to the electrical-distribution panel 144
(breaker panel or utility
grid connection). The power generation system 150 is utility grid independent
(that is, the
power generation system 150 is not electrically connected to the electric
utility grid 816). The
evaporator-expansion module 101 and the air-handler module 100 may initialize
operations
from (and obtain electrical power from) the battery assembly 148.
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[0089] The following is offered as further description of the embodiments, in
which any one
or more of any technical feature (described in the detailed description, the
summary and the
claims) may be combinable with any another one or more of any technical
feature (described
in the detailed description, the summary and the claims). It is understood
that each claim in the
claims section is an open ended claim unless stated otherwise. Unless
otherwise specified,
relational terms used in these specifications should be construed to include
certain tolerances
that the person skilled in the art would recognize as providing equivalent
functionality. By
way of example, the term perpendicular is not necessarily limited to 90.0
degrees, and may
include a variation thereof that the person skilled in the art would recognize
as providing
equivalent functionality for the purposes described for the relevant member or
element. Terms
such as "about" and "substantially", in the context of configuration, relate
generally to
disposition, location, or configuration that are either exact or sufficiently
close to the location,
disposition, or configuration of the relevant element to preserve operability
of the element
within the invention which does not materially modify the invention.
Similarly, unless
specifically made clear from its context, numerical values should be construed
to include
certain tolerances that the person skilled in the art would recognize as
having negligible
importance as they do not materially change the operability of the invention.
It will be
appreciated that the description and/or drawings identify and describe
embodiments of the
apparatus 199 (either explicitly or inherently). The apparatus 199 may include
any suitable
combination and/or permutation of the technical features as identified in the
detailed
description, as may be required and/or desired to suit a particular technical
purpose and/or
technical function. It will be appreciated that, where possible and suitable,
any one or more of
the technical features of the apparatus 199 may be combined with any other one
or more of the
technical features of the apparatus 199 (in any combination and/or
permutation). It will be
appreciated that persons skilled in the art would know that the technical
features of each
embodiment may be deployed (where possible) in other embodiments even if not
expressly
stated as such above. It will be appreciated that persons skilled in the art
would know that
other options may be possible for the configuration of the components of the
apparatus 199 to
adjust to manufacturing requirements and still remain within the scope as
described in at least
one or more of the claims. This written description provides embodiments,
including the best
mode, and also enables the person skilled in the art to make and use the
embodiments. The
patentable scope may be defined by the claims. The written description and/or
drawings may
help to understand the scope of the claims. It is believed that all the
crucial aspects of the
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disclosed subject matter have been provided in this document. It is
understood, for this
document, that the word "includes" is equivalent to the word "comprising" in
that both words
are used to signify an open-ended listing of assemblies, components, parts,
etc. The term
"comprising", which is synonymous with the terms "including," "containing," or
"characterized by," is inclusive or open-ended and does not exclude
additional, unrecited
elements or method steps. Comprising (comprised of) is an "open" phrase and
allows coverage
of technologies that employ additional, unrecited elements. When used in a
claim, the word
"comprising" is the transitory verb (transitional term) that separates the
preamble of the claim
from the technical features of the invention. The foregoing has outlined the
non-limiting
embodiments (examples). The description is made for particular non-limiting
embodiments
(examples). It is understood that the non-limiting embodiments are merely
illustrative as
examples.
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