Note: Descriptions are shown in the official language in which they were submitted.
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SYSTEM, COMPONENTS, AND METHODS FOR AIR, HEAT, AND HUMIDITY
EXCHANGER
DESCRIPTION
Cross-Reference to Related Applications
[001] This application is a divisional of Canadian Patent Application No.
3,089,216, which was filed on January 22, 2019.
Field of the Disclosure
[002] Embodiments of the present disclosure include heat and moisture
transfer systems and components thereof and, more particularly, heat and
moisture
exchangers, membranes for exchangers, methods of manufacturing exchangers,
energy recovery ventilator (ERV) and evaporative cooling systems employing
heat
and moisture exchanges, and gas exchange systems and components thereof.
Background of the Disclosure
[003] Heat and water vapor exchangers (also sometimes referred to as
humidifiers, enthalpy exchangers, or energy recovery wheels) have been
developed
for a variety of applications. These include building ventilation (HVAC),
medical and
respiratory applications, gas drying or separation, automobile ventilation,
airplane
ventilation, and for the humidification of fuel cell reactants for electrical
power
generation. In various devices intended for the exchange of heat and/or water
vapor
between two airstreams, it may be desirable to have a thin, inexpensive heat
or
moisture transfer material. In some devices, it may desirable to transfer
moisture
across the material. In some devices, it may be desirable to transfer heat
across the
material. And, in some devices, it may be desirable to transfer both heat and
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moisture from one stream to the other. In each of these applications, it may
be
desirable that air and contaminants within one stream are not permitted to
migrate to
the other stream.
[004] Planar plate-type heat and water vapor exchangers may use
membrane plates that are constructed using discrete pieces of a planar, water-
permeable membrane (for example, Nafion , natural cellulose, sulfonated
polymers
or other synthetic or natural membranes) supported by a separator material
(which
may or may not be integrated into the membrane) and/or frame. The membrane
plates may typically be stacked, sealed, and configured to accommodate fluid
streams flowing in either cross-flow or counter-flow configurations between
alternate
plate pairs, so that heat and water vapor is transferred via the membrane,
while
limiting the cross-over or cross-contamination of the fluid streams. In some
heat and
water vapor exchanger designs, separate membrane plates may be replaced by a
single membrane core made by folding a continuous strip of membrane in a
concertina, zig-zag, or accordion fashion, with a series of parallel
alternating folds.
Similarly, for heat exchangers, a continuous strip of material may be
patterned with
fold lines and folded along these lines to form a configuration appropriate
for heat
exchange.
[005] Membrane cores may be employed as heat and/or moisture
exchanger(s) for ventilation systems, HVAC systems, air filter systems, energy
recovery ventilator (ERV) systems, and evaporative cooling systems. The
present
disclosure is directed to improvements in existing membranes, methods of
fabricating them, membrane cores, systems, method of fabricating them, and
systems utilizing membrane cores.
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Summary of the Disclosure
[006] In accordance with an embodiment, an air handling module may
comprise a housing and an exchanger contained within the housing. The air
handling module may further comprise a first manifold positioned on a first
side of
the housing and including a first pair of ports arranged on a first end and a
second
pair of ports arranged on a second end and a second manifold positioned on a
second side of the housing and including a first pair of ports arranged on a
first end
and a second pair of ports arranged on a second end. The first pair of ports
of the
first manifold may be in fluid communication with the first pair of ports of
the second
manifold to transfer air through the exchanger and between the first and
second
manifolds, and the second pair of ports of the first manifold may be in fluid
communication with the second pair of ports of the second manifold to transfer
air
through the exchanger and between the first and second manifolds.
[007] In accordance with another embodiment, a method of manufacturing
a membrane material for an enthalpy exchanger may comprise imparting a charge
onto microporous particles, coating a first roller and a second roller with
the charged
microporous particles, feeding a substrate between the first and second
rollers, and
applying heat and pressure to transfer the charged microporous particles from
the
first and second rollers onto the substrate.
[008] In accordance with another embodiment, an air conditioner may
comprise an exchanger including multiple layers of folded membrane material
defining a stack of alternating first and second fluid passageways, wherein
the first
fluid passageways may be configured to receive a first air stream and the
second
fluid passageways are configured to receive a second air stream. The air
conditioner may further comprise a liquid distribution system including a
first header
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including a first distribution channel for delivering a first liquid to the
first fluid
passageways, a second header including a second distribution channel for
delivering
a second liquid to the second fluid passageways, a first plurality of porous
members
in communication with the first distribution channel and in contact with inner
surfaces
of the first fluid passageways, and a second plurality of porous members in
communication with the second distribution channel and in contact with inner
surfaces of the second fluid passageways. The first plurality of porous
members
may be configured to provide a continuous flow of the first liquid onto the
inner
surfaces of the first fluid passageways, and the second plurality of porous
members
may be configured to provide a continuous flow of the second liquid onto the
inner
surfaces of the second fluid passageways.
[009] In accordance with another embodiment, an insulating structure may
comprise a rotationally-molded shell including an interstitial space and an
insulating
material disposed within the interstitial space, wherein the insulating
material may be
one or more of: metal oxide powder; inorganic oxide powder; silica powder;
fumed
silica powder; and aerogel powder.
[010] In yet another embodiment, a method for manufacturing a separator
may comprise delivering a sheet of netting material between a first continuous
belt
having a first corrugated surface and a second continuous belt having a second
corrugated surface, mating together the first and second corrugated surfaces,
applying heat and pressure to the sheet of netting material to form a
corrugated
netted sheet, releasing the corrugated netted sheet from the first and second
continuous belts, cooling the corrugated netted sheet, and applying a constant
tension on the corrugated netted sheet as the corrugated netted sheet is
released
from the first and second continuous belts.
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90178176
[010a] According to another embodiment of the present
invention,
there is provided an air handling module, comprising: a housing; an exchanger
contained within the housing; a first manifold positioned on a first side of
the housing
and comprising first air ports further comprising two or more ports disposed
on a first
end of the first manifold and second air ports further comprising two or more
ports
disposed on a second end of the first manifold, wherein each air port of the
first air ports
and second air ports of the first manifold is configured to interchangeably
attach a
structure to the air handling module; a second manifold positioned on a second
side of
the housing and comprising first air ports further comprising two or more
ports disposed
on a first end of the second manifold and second air ports further comprising
two or
more ports disposed on a second end of the second manifold, wherein each air
port of
the first air ports and the second air ports of the second manifold is
configured to
interchangeably attach a structure to the air handling module; the first air
ports of the
first manifold are in fluid communication with the first air ports of the
second manifold to
transfer air through the exchanger and between the first and second manifolds;
the
second air ports of the first manifold are in fluid communication with the
second air ports
of the second manifold to transfer air through the exchanger and between the
first and
second manifolds; at least one rotary damper disposed in one of the first or
second
manifolds, wherein the rotary damper is configured to rotate to selectively
deliver airflow
within the air handling module; and the air handling module is configured to
be coupled
to one or more additional air handling modules, the air handling module and
the one or
more additional air handling modules configured to operate in parallel with
each other to
achieve a combined conditioning effect greater than a conditioning effect of
the air
handling module.
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Brief Description of the Drawings
[011] Fig. 1 illustrates a perspective view of an exemplary air handling
module having a plurality of modular features, according to an exemplary
disclosed
embodiment;
[012] Fig. 2 illustrates an exploded view of an exemplary air handling
module having a plurality of modular features, according to an exemplary
disclosed
embodiment;
[013] Figs. 3a-3d illustrate cross-sectional perspective views of internal
channel tracks of the air handling module, according to an exemplary disclosed
embodiment;
[014] Figs. 4a-4h illustrate perspective views of a rotary damper, according
to an exemplary disclosed embodiment;
[015] Figs. 5a and 5b illustrate perspective views of access panels,
according to an exemplary disclosed embodiment;
[016] Figs. 6a-6h illustrate cross-sectional views of fan boxes
facilitating air
flow into and out of the air handling module and interchangeable exchanger
dividers
facilitating a crossflow airflow pattern, according to an exemplary disclosed
embodiment;
[017] Figs. 7a and 7b illustrate perspective views of an exemplary air
handling system, according to an exemplary disclosed embodiment;
[018] Figs. 8a and 8b illustrate cross-sectional perspective views of an
exemplary air handling system, according to an exemplary disclosed embodiment;
[019] Fig. 9a illustrates a perspective of an exemplary air handling
system,
according to an exemplary disclosed embodiment;
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[020] Figs. 9b-9g illustrate cross-sectional views of an exemplary air
handling system in exemplary configurations, according to an exemplary
disclosed
embodiment;
[021] Figs. 10a-10e illustrate psychrometric charts corresponding to the
operations of an air handling system, according to an exemplary disclosed
embodiment;
[022] Figs. lla and 11b illustrate perspective views of an exemplary
process for manufacturing a membrane for an exchanger, according to an
exemplary
disclosed embodiment;
[023] Fig. 12 illustrates a perspective view of one layer of a separator,
according to an exemplary disclosed embodiment;
[024] Figs. 13a-13d illustrate perspective views of an exemplary process for
manufacturing a separator, according to an exemplary disclosed embodiment;
[025] Figs. 14a-14c illustrate perspective views of air filters with a
separator, according to an exemplary disclosed embodiment;
[026] Figs. 15a-15c illustrate perspective views of an evaporative cooling
and/or steam regenerating liquid desiccant air conditioner module, according
to an
exemplary disclosed embodiment;
[027] Figs. 15d-15h illustrate perspective views of a liquid distribution
system including first and second distribution headers and related components,
according to an exemplary disclosed embodiment;
[028] Figs. 15i and 15j illustrate perspective views of exemplary
configurations of an evaporative liquid desiccant hex shaped exchange module,
according to an exemplary disclosed embodiment;
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[029] Fig. 15k illustrates a perspective view of a multiple function remote
energy recovery system, according to an exemplary disclosed embodiment;
[030] Fig. 151 illustrates a psychrometric chart corresponding to the
operation of an evaporative cooling and/or steam regenerating liquid desiccant
air
conditioner module, according to an exemplary disclosed embodiment;
[031] Figs. 16a-16d illustrate perspective views of a wall panel formed of a
rotationally molded shell, according to an exemplary disclosed embodiment;
[032] Figs. 16e and 16f illustrate perspective views of interior and exterior
surfaces of a building formed of building panels made of rotationally molded
shells,
according to an exemplary disclosed embodiment;
[033] Fig. 16g illustrates a perspective view of a three-way wall connector
formed of a rotationally molded shell, according to an exemplary disclosed
embodiment;
[034] Fig. 16h illustrates a perspective view of a corner wall connector
formed of a rotationally molded shell, according to an exemplary disclosed
embodiment;
[035] Fig. 16i illustrates a perspective view of a three-way floor connector
formed of a rotationally molded shell, according to an exemplary disclosed
embodiment; and
[036] Fig. 16j illustrates a perspective view of a three-way roof connector
formed of a rotationally molded shell, according to an exemplary disclosed
embodiment.
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Detailed Description
[037] Reference will now be made in detail to the exemplary embodiments
of the present disclosure described above and illustrated in the accompanying
drawings.
Air Handling Module, Air Handling System, and Rotary Damper
[038] Fig. 1 illustrates an air handling module 100 according to the
present
disclosure. In some embodiments, air handling module 100 may be an energy
recovery ventilation (ERV) system and may utilize return air (RA) from a space
or a
building to precondition outside air (OA) for an HVAC system. Air handling
module
100 may include a housing 120 having a top 130, a bottom 140, and sides 110.
Furthermore, air handling module 100 may include a first pair of ports 103,
104
fluidly connected to a second pair of ports 101, 102, and a third pair of
ports 107,
108 fluidly connected to a fourth pair of ports 105, 106.
[039] Fan box 181 may be coupled to port 101 and may contain one or
more fans 189 configured to draw outside air (OA) from ports 103 and/or 104
and
through an exchanger 213. Fan box 186 may be coupled to port 106 and may
contain one or more fans 189 configured to draw return air (RA) from a port
108 and
through a filter 191. An access panel 177 may attach to and detach from port
107 via
panel connectors 107. Connectors 107 may include any suitable connection
mechanisms, such as, for example, latches, screws, and the like. Access panel
177
may be detached from port 107 to provide access for replacing filter 191.
[040] Ports 101-108 may serve as interchangeable attachment points fora
number of additional structures, such as, for example, metal ducts, weather
hoods,
roof curbs, and/or other fluidly connected components of an HVAC system. Ports
101-108 may include any suitable means, including, for example, mechanical
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latches, flanges, friction fit, interference fit, removable fasteners, and the
like, to
readily connect and disconnect components to air handling module 100.
[041] Air handling module 100 may also include a port 109 that may provide
access to electrical, power, and economizer sections of air handling module
100.
Housing 120 may include a plurality of external and internal ports configured
to
facilitate a modular hydronic distribution and collection system. For example,
in some
embodiments, housing 120 may include side drain ports 112, side liquid
desiccant
drain port 118, top drain ports 133, top liquid desiccant port 137, top liquid
desiccant
port 138, and top evaporative port 139. These ports of the hydronic
distribution and
collection system may serve as interchangeable attachment points for a
plurality of
components, including, for example, a condensate drain pipe, an evaporative
water
supply pipe, an evaporative water drain pipe, a liquid desiccant supply pipe,
a liquid
desiccant drain pipe, a refrigerant line conduit, a chilled water conduit, a
steam pipe,
and/or other fluidly connected hydronic components of an HVAC system. In some
embodiments, the ports may be threaded and may incorporate gasketed seals.
[042] Housing 120 may also include a plurality of external and internal ports
configured to facilitate a modular system for components for local
communications
network, electrical distribution, and power distribution. For example, in some
embodiments, housing 120 may include side conduit port 114 and top conduit
port
134. Air handling module 100 may facilitate modular connectivity with
additional air
handling modules 100 via top anchor ports 136 and bottom anchor ports 146.
[043] Fig. 2 illustrates an exploded view of an air handling module 200
according to the present disclosure. As shown in Fig. 2, air handling module
200
may include an exchanger 213 configured to transfer heat and moisture from the
treated air stream. Exchanger 213 may be composed of any number of suitable
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materials to promote various air processing and conditioning objectives
including, but
not limited to, plastic plates, metal plates, enthalpy ceramic porous plates,
cellulous
plates, and various combinations thereof. Exchanger 213 may be contained
within
an exchanger housing 211. Air handling module 200 may also provide for an
integrated electrical cabinet. For example, in some embodiments, air handling
module 200 may include a controller 250 configured to readily attach to and
detach
from housing 211, an electrical disconnect 252, and an actuator 232. An
electrical
access panel 259 may cover the electrical cabinet and may be disconnected from
air
handling module 200 to provide access to the electrical cabinet via latches
256 and a
disconnect handle 254.
[044] As shown in Fig. 2, air handling module 200 may further comprise one
or more exchanger dividers 240. Exchanger divider 240 may be configured to
direct
airflow into and out of exchanger 213. Exchanger divider 240 may facilitate
various
airflow configurations and may be interchangeable with air handling module 200
depending on the application. In some embodiments, for example, exchanger
divider
240 may facilitate cross-over airflow for air handling module 200. In other
embodiments, for example, exchanger divider 240 may facilitate parallel
airflow.
[045] As will be discussed in more detail below, manifolds 220 each
flanking an exchanger divider 240 may include internal air channel tracks and
an air
director 222 to further facilitate air conditioning function modularity. Air
handling
module 200 may also include heat exchangers 292 and filters 291 contained
within
manifolds 220. In some embodiments, heat exchanger 292 may be a suitable coil
heat exchanger, such as, for example, condenser coils, evaporator coils,
chilled
water coils, hot water coils, and steam coils. Filter 291 may be any suitable
particulate filter. It should be appreciated that in other embodiments, filter
291 may
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further include or be substituted for a variety of other components, such as,
for
example, UV lights, drop-stop filters, droplet separators, and gas absorption
filters.
As discussed above, the air handling module of the present disclosure may
facilitate
interchangeably connecting a variety of structures, such as, for example,
metal
ducts, weather hoods, roof curbs, and/or other fluidly connected components of
an
HVAC system.
[046] As shown in Fig. 2, manifolds 220 include plurality of ports which
serve as interchangeable attachment points for a number of structures,
including, for
example, fan box 280 attached via one or more latches 282, a weather hood 260,
a
metal duct 262, and an access panel 270 attached via one or more latches 272.
Manifolds 220 may further include an aperture port to receive a rotary damper
230.
Rotary damper 230 may be controlled by actuator 232.
[047] Figs. 3a-3d illustrate perspective view of a manifold 300 of an air
handling module according to the present disclosure. As discussed above,
manifold
300 may comprise a number of interchangeable attachment points to fluidly
connect
a variety of components of an HVAC system, including, for example, fan boxes,
metal ducts, weather hoods, roof curbs, access panel and/or other. Manifold
300
may include a top channel track 320 and a bottom channel track 322. Channel
track
320 and bottom channel track 322 may be separated by an air director 310 and a
manifold divider 324 positioned between the tracks 320, 322. Manifold 300 may
further include a top slide channel 350, a bottom slide channel 352, and an
economizer track 360. In one embodiment, economizer track 360 may be a bearing
track for a rotary damper.
[048] Top slide channel 350 may receive an exchanger 390. Exchanger 390
may slide into and out of top slide channel 350 as indicated by arrow 390a.
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Exchanger 390 may be composed of any suitable thermal transfer devices, such
as,
for example, condensers, evaporators, fluid heat exchangers, and steam
humidifiers.
In one embodiment, exchanger 390 may be a suitable coil heat exchanger, such
as,
for example, condenser coils, evaporator coils, chilled water coils, hot water
coils,
and steam coils. Manifold 300 includes an inlet 392 and an outlet 394 to
facilitate the
flow of a heat transfer medium to and from exchanger 390.
[049] A heat transfer medium, including, for example, liquid refrigerant,
steam, chilled water, or hot water, may enter exchanger 390 thru inlet 392 and
may
exit exchanger thru outlet 394. Bottom slide channel 350 may receive a filter
391.
Filter 391 may slide into and out of bottom slide channel 352 as indicated by
arrow
391a. Filter 391 may be any suitable particulate filter. It should be
appreciated that in
other embodiments, filter 391 may further include or be substituted for a
variety of
other components, such as, for example, UV lights, drop-stop filters, droplet
separators, and gas absorption filters.
[050] Manifold 300 may also include a top drain port 332, a bottom drain
port 342, and a side drain port 312. Top drain port 332 may facilitate access
to top
slide channel 350 and may provide a modular hydronic collection system for top
slide
channel 350. It should be appreciated that installers at an installation site
may
thereby access top drain port 332 according to site requirements. Top drain
port 332
may be sealed by insulated plug 338. Bottom drain port 342 may facilitate
access to
bottom slide channel 352 and may provide a hydronic collection system for
bottom
slide channel 352. Side drain port 312 may provide an additional access and
hydronic collection point for top channel track 320 in a direction
perpendicular to top
drain port 332. In one embodiment, top drain port 332 may have a threaded
configuration. For example, top drain port 332 may be threaded with type
British
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Standard Parallel Pipe (BSPP) along with an integrated sealing washer. Persons
of
ordinary skill in the art would appreciate that BSPP is compatible with other
international standards including NPT, NPTS, and BSPT, enabling a global
distribution model.
[051] Manifold 300 may further comprise top anchor ports 336 and bottom
anchor ports 346 configured to provide structural connection to an adjacent
manifold
or various structural supports. Manifold 300 also includes a plurality of air
ports 303,
304, 305, and 306. As shown in Fig. 3c, in one embodiment, a duct 362 may be
connected to manifold 300 via port 305, and port 306 may be covered by an
access
panel 376. Access panel 376 may include one or more latches 370 and a seal 371
to
provide an air-tight connection to port 306.
[052] Port 303 and port 304 may be positioned perpendicular relative to
each other. Likewise, port 305 and port 306 may be positioned perpendicular
relative
to each other. Such a configuration may facilitate multi-directional
installation of
components to manifold 300 and adjacent port ready access. Moreover, ports
303,
304, 305, and 306 may provide a readily interchangeable and configurable
manifold
300 for connecting to various HVAC and air handling components. Manifold 300
may
facilitate a number of various on-site installation configuration options.
Persons of
ordinary skill would appreciate that any suitable number of access ports for
manifold
300, oriented in any suitable configuration, and positioned in any suitable
location of
manifold 300, including, for example, the lateral, upper, and lower surfaces,
is
contemplated by the present disclosure.
[053] In some embodiments, a fan box 380 containing one or more fans
389 may be attached to manifold 300 via port 304. Fan box 380 may include one
or
more latches 382 and a seal 381 to provide an air-tight connection to port
304.
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[054] As shown in Fig. 4a-4h, the air handling module 100 may also include
a rotary damper 430. Rotary damper 430 may include a rotatable semi-
cylindrical
member 471. Rotary damper 430 may be configured to permit air flow in
directions
along the rotational axis of the semi-cylindrical member 471. The rotary
damper 430
may also be configured to permit air flow in directions other than along the
rotational
axis of semi-cylindrical member 471. For example, the rotary damper 430 may
permit air flow in directions normal to the rotational axis of semi-
cylindrical member
471. A single rotary damper 430 may eliminate the need for a pair of face and
bypass dampers acting in unison.
[055] Rotary damper 430 may have at least four potential modes within air
handling module 100. The first mode may be to facilitate a complete or partial
economizer bypass around exchanger 213 in order to directly supply outside air
(OA)
as the supply air (SA), thereby providing free cooling to a building or
enclosure. The
second mode may be to facilitate a complete or partial defrost bypass around
exchanger 213 in order to prevent ice buildup from cold outdoor air (e.g.,
below
freezing). The third mode may be to facilitate a complete or partial bypass
around
exchanger 213 in order to modulate the sensible-to-latent ratio of supply air
with a
wrap-around air handling module. The fourth mode may be to facilitate a
regeneration cycle within exchanger 213 to drive off water vapor, carbon
dioxide,
and/or other VOC contaminants. Other uses and modes for rotary damper 430 may
be apparent to those skilled in the art and any such function may be used in
the
practice of the present disclosure.
[056] Rotary damper 430 may comprise semi-cylindrical member 471, shaft
mounting plate 486 (which may be secured by bolts 487), and shaft 484 with
utility
tube 485 disposed within. Shaft 484 may be directly connected to rotary damper
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actuator 432 providing continuous clockwise and/or counterclockwise rotation.
Semi-
cylindrical member 471 may include an end wall 478 with integrated seal
channel
483, an outer surface 476 with integrated seal channel 482, an inner surface
477,
and an end ring 479 with integrated seal channel 481. In some embodiments,
rotary
damper 430 may be made of an insulating material and/or may be a hollow
structure
filled with insulating material, such as, for example, urethane foam, metal
oxide, or
fiberglass, to provide insulating qualities and to avoid condensation or ice
accumulation.
[057] Rotary damper 430 may be structurally positioned between manifold
400 and exchange divider 440. Rotary damper 430 may be fluidly positioned
between two air inlets. The first air inlet to rotary damper 430 may originate
from
exchanger 213 and may be physically located in bottom channel track 422 of
manifold 400, represented by arrow 466. The second air inlet may be located at
exchanger divider 440 and may originate from port 401, represented by arrow
467.
Rotary damper 430 outlet may be fluidly positioned to and face port 404.
[058] For example, rotary damper 430 may be a rotary air damper
configured to selectively control the source of the supply air (SA). In some
embodiments, rotary damper 430 may be positioned in the bottom channel track
422
of the manifold 400, as shown in Figs. 4a-4h. Rotary damper 430 may be
configured
to selectively deliver treated air exiting from the exchanger 213 as supply
air (SA) or
directly deliver outside air (OA) as supply air (SA). Rotary damper 430 may
include a
manifold section 400 and an exchanger divider section 440 rotatably coupled to
the
manifold section 400. The exchanger divider section 440 may include semi-
cylindrical member 471 having a first opening 473 in fluid connection to the
manifold
section 400 and a second opening 472 on the side surface of the semi-
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member 471. In some embodiments, rotary damper 430 may be disposed within
conventional ductwork or HVAC systems.
[059] Rotary damper 430 may permit air flow in a direction along the X-
rotational axis of the semi-cylindrical member 471. Rotary damper 430 may also
permit airflow in a direction other than along the X-rotational axis of the
semi-
cylindrical member 471. The side surface of the semi-cylindrical member 471
opposite the second opening may block airflow.
[060] Fig. 4c is a perspective view of rotary damper 430 according to the
present disclosure. Rotary damper 430 may facilitate fluid inlet 472 along the
X-axis
shaft 484, as well as fluid inlet 473 perpendicular to the X-axis shaft 484.
Fluid outlet
474 may pass through end ring 479 with integrated end sealed channel 481
containing end ring seal 490.
[061] Fig. 4d is another perspective view of rotary damper 430 according to
the present disclosure. Fluid inlet 472 may pass through end ring 479 with
integrated
end sealed channel 481 containing end ring seal 490. Rotary damper 430 may
facilitate fluid outlet 475 along the X-axis shaft 484, as well as fluid inlet
474
perpendicular to the X axis shaft 484.
[062] As shown in Fig. 4e, the semi-cylindrical member 471 may be rotated
about X-axis shaft 484 to a first position to adjust the direction of fluid
flowing through
the first opening 422 represented by fluid inlet 473 and second openings 404
represented by fluid outlet 468. For example, the semi-cylindrical member 471
may
be rotated to a first position, wherein the second fluid outlet 468 faces the
outlet port
404 for the supply air (SA) stream. In the first position, treated air exiting
from the
exchanger 213 may be directed through the manifold 400 and the first and
second
openings 422, then through 404 of the semi-cylindrical member 471, and may
then
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exit the air handling module 100 as supply air (SA). The outside air (OA)
entering the
air handling module 100 may be blocked by the end wall 478 of the semi-
cylindrical
member 471 opposite the second opening 404 and facing the direction of the
outside
air (OA) flow. End wall seal 489 may prevent or restrain fluid flow 473 from
leaking
thru to port opening 401.
[063] As shown in Fig. 4f, the semi-cylindrical member 471 may be rotated
about X-axis shaft 484 to a second position to adjust the direction of fluid
flowing
through the third opening 401 represented by fluid inlet 473 and second
openings
404 represented by fluid outlet 468. Semi-cylindrical member 471 may seal off
passage 422, and thus block fluid flow thru exchanger 213. Outside air (OA)
flow
entering the air handling module 100 may enter the semi-cylindrical member 471
and
may be directly delivered as supply air (SA). The rotation of the semi-
cylindrical
member 471 may be controlled by any suitable power source, such as, for
example,
a rotary motor 432. End wall seal 489 may prevent or restrain fluid flow 473
from
leaking thru to port opening 401.
[064] As shown in Fig. 4g, the semi-cylindrical member 471 may also be
rotated about X-axis shaft 484 to a third position to facilitate the
installation or
removal of air filter or coil 390. Filter or coil 390 may slide in or out
along bottom slide
channel 452 as depicted by arrow 391a. In this embodiment, end wall seal 489
may
be positioned parallel to the bottom slide channel 452. Rotary damper actuator
432
may include a manual override so that semi-cylindrical member 471 may be
manually positioned to minimize any risk of injury or damage during operation.
[065] Fig. 4h is a side view of rotary damper 430 according to the present
disclosure. Rotary damper 430 may facilitate fluid inlet 472 along the X-axis
shaft
484 as well as fluid inlet 473 in a direction other than along the X-axis
shaft 484.
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Fluid outlet 474 may pass through end ring 479 with integrated end sealed
channel
481 containing end ring seal 490.
[066] Existing HVAC or ERV systems may employ multiple air dampers to
control the direction of air flow. Each damper may be dedicated to controlling
the
direction of a single source of air flow. Typically, conventional air dampers
may be
rectangular or square shaped frames with movable louvers to permit and block
the
flow of air. Rotary damper 430 of the present disclosure may be positioned at
the
intersection of two different air flows and may regulate the direction of both
air flows
by rotating the semi-cylindrical member 471. As a result, rotary damper 430 of
the
present disclosure obviates the need for multiple or separate air dampers.
Semi-
cylindrical member 471 of rotary damper 430 may be rotated by any desired
amount
to proportionally control and vary the mixing ratio of air streams and/or the
volume of
air passed through rotary damper 430.
[067] Figs. 5a and 5b illustrate perspective views of an access panel 570
according to the present disclosure. As discussed above, access panel 570 may
readily attach to, and detach from, air ports of an air handling module 500.
Access
panel 570 may include one or more latches 572 to engage and hold access panel
570 onto an inner surface 577 of air handling module 500. In one embodiment,
latches 572 may include a screw and thread configuration to engage and
disengage
latches 572 by tightening or loosening the screw. Access panel 570 may also
include
a seal 573 disposed on an access panel seal channel. Seal 573 may engage with
an
outer surface 576 of air handling module 500 to provide an air-tight
connection
between the access panel 570 and the port. In other embodiments, a single
twist
handle (not shown) may actuate latches 572 in a linear or semi-circular
fashion.
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Access panel 570 may operate in any orientation and may provide for complete,
interchangeable access to internal components of the air handling module.
[068] Figs. 6a-6h illustrate the modularity of the air handling module of
the
present disclosure by illustrating exemplary configurations of the air
handling
module. Fig. 6a illustrates a cross-sectional view along the dashed line shown
in Fig.
1 of an air handling module 600 in a first configuration according to the
present
disclosure. Air handling module 600 may include a fan box 686 coupled to port
606
and a fan box 681 coupled to port 601. Fan box 686 and fan box 681 may be
configured to pull air flow into and out of a housing 620. Air handling module
600
may include an air-to-air heat exchanger 612 contained within housing 620. Air
handling module 600 may also include a first pair of ports 601-602 fluidly
connected
to a second pair of ports 603-604. One or both of the second pair of ports 603-
604
may receive outside air (OA). Air may flow through housing 620 and may be
discharged from air handing module 600 through one or both of the first pair
of ports
601-602 as supply air (SA). Air handling module 600 may further include a
third pair
of ports 605-606 fluidly connected to a fourth pair of ports 607-608. One or
both of
the fourth pair of ports 607-608 may receive return air (RA). Exhaust air (EA)
may be
discharged from air handing module 600 through one or both of the third pair
of ports
605-606.
[069] Outside air (OA) may enter housing 620, which may comprise sides
610, through port 603 and may flow through opening 613, while paired port 604
may
be sealed by an access panel 674. An air director 622 and an exchanger divider
640
may direct outside air (OA) through filter 691a, exchanger 612, and supply air
coil
692a. Exchanger 612 may be any suitable exchanger for promoting a variety of
air
processing and conditioning objectives, including, but not limited to,
sensible plate
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type, enthalpy plate type, wheel type, heat pipe, indirect evaporation type,
direct
evaporation type, liquid desiccant type, carbon dioxide scrubbing, VOC
scrubbing,
and various other types of exchangers know to those skilled in the art. One or
more
fans 689 may be positioned inside fan box 681 and may pull supply air (SA)
from
exchanger 612, through an opening 611, and out of port 601, while paired port
602
may be sealed by an access panel 672. One or more fans 689 may be positioned
inside fan box 686 and may pull exhaust air (EA) from exchanger 612 and out of
port
606, while paired port 605 may be sealed by access panel 675. A rotary damper
631
may seal bypass openings 623, and a port 609 may be sealed by an access panel
679.
[070] Return air (RA) may enter air handling module 600 through port 608,
while paired port 607 may be sealed by an access panel 677. An air director
622 and
an exchange divider 640 may direct return air (RA) through a filter 691b,
exchanger
612, and an exhaust air coil 692b. Supply air coil 692a and exhaust air coil
692b may
be any suitable thermal transfer device for promoting a variety of air
processing and
conditioning objectives, including, but not limited to, a condenser coil, an
evaporator
coil, a chilled water coil, a hot water coil, a steam coil, a carbon dioxide
scrubber,
and/or a VOC scrubber.
[071] Fig. 6b illustrates a cross-sectional view of air handling module 600
in
a second configuration according to the present disclosure. As shown in Fig.
6b, fan
box 686 may be coupled to port 606 and fan box 681 may be coupled to port 601.
Fan box 686 and fan box 681 may be configured to push air flow into and out of
housing 620. One or both of third pair of ports 605-606 may receive outside
air (OA).
Air may flow through housing 620 and may be discharged from air handing module
600 through one or both of fourth pair of ports 607-608 as supply air (SA).
One or
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both of first pair of ports 601-602 may receive return air (RA). Exhaust air
(EA) may
flow through housing 620 and may be discharged from air handing module 600
through one or more of second pair of ports 603-604.
[072] One or more fans 689 of fan box 686 may push outside air (OA)
entering at port 606 through housing 620 and exchanger 612, while paired port
605
may be sealed by access panel 675. Air director 622 and exchanger divider 640
may
direct outside air (OA) through filter 691a, exchanger 612, and supply air
coil 692b.
One or more fans 689 of fan box 681 may push return air (RA) entering at port
601
through opening 611, housing 620, and exchanger 612, while paired port 602 may
be sealed by access panel 672. Air director 622 and exchange divider 640 may
direct return air (RA) through filter 691b, exchanger 612, and exhaust air
coil 692c.
Supply air (SA) may exit port 608, while paired port 607 may sealed by access
panel
677. Exhaust air (EA) may flow through opening 613 and exit port 603, while
paired
port 604 may be sealed by access panel 674. Rotary damper 631 may seals bypass
openings 623, and port 609 may be sealed by access panel 679.
[073] Fig. 6c illustrates a cross-sectional view of air handling module 600
in
a third configuration according to the present disclosure. As shown in Fig.
6c, a fan
box 688 may be coupled to port 608 and fan box 681 may be coupled to port 601.
Fan box 688 and fan box 681 may be configured to push and pull air flow into
and
out of housing 620. One or both of second pair of ports 603-604 may receive
outside
air (OA). Air may flow through housing 620 and may be discharged from air
handing
module 600 through one or both of first pair of ports 601-602 as supply air
(SA). One
or both of fourth pair of ports 607-608 may receive return air (RA). Exhaust
air (EA)
may flow through housing 620 and may be discharged from air handing module 600
through one or both of third pair of ports 605-606.
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[074] Outside air (OA) may enter housing 620 through port 604 and may
flow through opening 613, while paired port 603 may be sealed by access panel
673.
Air director 622 and exchanger divider 640 may direct outside air (OA) through
filter
691a, exchanger 612, and supply air coil 692a. One or more fans 689 of fan box
681
may pull supply air (SA) from exchanger 612, through opening 611, and out of
port
601, while paired port 602 may be sealed by an access panel 672. Rotary damper
631 and optional rotary damper 634 may seal bypass openings 623, and access
panel may 679 may seal port 609. One or more fans 689 may be positioned inside
of
fan box 688 and may push return air (RA) entering at port 608 through housing
620
and exchanger 612, while paired port 607 may be sealed by access panel 677.
Air
director 622 and exchange divider 640 may direct return air (RA) through
filter 691b,
exchanger 612, and exhaust air coil 692b. Exhaust air (EA) may exit port 605,
while
paired port 606 may be sealed by an access panel 676.
[075] Fig. 6d illustrates a cross-sectional view of air handling module 600
in
a fourth configuration according to the present disclosure. The embodiment of
Fig.
6d provides a configuration of air handling module 600, wherein one air flow
may
bypass exchanger 612 to facilitate an economizer, a defrost, and/or a carbon
dioxide
scrubbing regeneration function. An economizer function may be an energy
efficiency measure that may increase ventilation rates due to a lower pressure
drop
when bypassing exchanger 612. The economizer function may be implemented
during mild weather to reduce the need for mechanical cooling. Further, the
economizer function may decrease respiratory issues by supplying a higher
percentage of outside air.
[076] As shown in Fig. 6d, fan box 688 may be coupled to port 608 and fan
box 681 may be coupled to port 601. Fan box 688 and fan box 681 may be
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configured to push and pull air flow into and out of housing 620. One or both
of
second pair of ports 603-604 may receive outside air (OA). Air may flow
through
housing 620 and may be discharged from air handing module 600 through one or
both of first pair of ports 601-602 as supply air (SA). One or both of fourth
pair of
ports 607-608 may receive return air (RA). Exhaust air (EA) may flow through
housing 620 and may be discharged from air handing module 600 through one or
both of third pair of ports 605-606.
[077] Outside air (OA) may enter housing 620 through port 604 and may
flow through an opening 613, while paired port 603 may be sealed by an access
panel 673. Rotary damper 631 and optional rotary damper 634 may be actuated to
block air path to exchanger 612 and redirect outside air (OA) through bypass
openings 623. One or more fans 689 of fan box 681 may pull supply air (SA)
through
bypass openings 623 and out of port 601, while paired port 602 may be sealed
by
access panel 672. One or more fans 689 of fan box 688 and may push return air
(RA) entering at port 608 through housing 620 and exchanger 612, while paired
port
607 may be sealed by access panel 677. Air director 622 and exchange divider
640
may direct return air (RA) through filter 691b, exchanger 612, and exhaust air
coil
692b. Exhaust air (EA) may exit port 605, while paired port 606 may be sealed
by
access panel 676.
[078] One of the main challenges facing fixed plate air-to-air exchangers
may be frost generation inside the exchanger during cold temperature
conditions.
Enthalpy exchangers may have a lower frost threshold temperature than sensible
exchangers because enthalpy exchangers may transfer moisture between two
airstreams. The rotary damper of the present disclosure may permit air bypass
in the
air handling module to prevent frost build-up in the exchanger. The rotary
damper
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may modulate the amount of outside air volume by reducing or eliminating cold
air
flow through the exchanger. As a result, rotary damper may improve the
performance of exchanger, resulting in higher temperatures of air supplied
inside a
room or building. In one exemplary embodiment, as the temperature of the
exhaust
air (EA) falls below an adjustable frost control set point (e.g., 28 F),
rotary damper
631 may be actuated to maintain the temperature at or above the frost control
set
point. By keeping the exhaust air (EA) at or above the frost control set point
above
(e.g., 28 F), frost may be prevented from forming in exchanger 612.
[079] Fig. 6e illustrates a cross-sectional view of air handling module 600 in
a fifth configuration according to the present disclosure. As shown in Fig.
6e, fan box
682 may be coupled to port 602 and fan box 686 may be coupled to port 606. Fan
box 686 and fan box 682 may be configured to pull air flow into and out of
housing
620. One or both of second pair of ports 603-604 may receive outside air (OA).
Air
director 622 and exchanger divider 640 may direct outside air (OA) through
filter
691a, exchanger 612, and supply air coil 692a. Air may flow through housing
620
and may be discharged from air handing module 600 through one or both of first
pair
of ports 601-602 as supply air (SA). One or both of fourth pair of ports 607-
608 may
receive return air (RA). Exhaust air (EA) may flow through housing 620 and may
be
discharged from air handing module 600 through one or both of third pair of
ports
605-606.
[080] One or more fans 689 may be positioned inside fan box 682 and may
pull supply air (SA) from exchanger 612, through opening 611, and out of port
602,
while paired port 601 may be sealed by an access panel 671. Return air (RA)
may
enter housing 620 through port 607, while paired port 608 may be sealed by an
access panel 678. Air director 622 and exchange divider 640 may direct return
air
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(RA) through filter 691b, exchanger 612, and exhaust air coil 692b. One or
more fans
of fan box 686 may pull exhaust air (EA) from exchanger 612 and out of port
606,
while paired port 605 may be sealed by access panel 675.
[081] Fig. 6f illustrates a cross-sectional view of air handling module 600
in
a sixth configuration according to the present disclosure. The embodiment of
Fig. 6f
provides a configuration of air handling module 600, wherein interchangeable
exchanger 612 may facilitate a cross-flow air pattern within air handling
module 600.
Fan box 686 may be coupled to port 606 and may be configured to push air flow
into
and out of housing 620. Fan box 682 may be coupled to port 602 and may be
configured to pull air flow into and out of housing 620 in series with fan box
686.
Return air (RA) may enter housing 620 through one or both of fourth pair of
ports
607-608 and may be conveyed through housing 620 and exit though one or both of
second pair of ports 603-604 as exhaust air (EA). Return air (RA) may be
conveyed
through and exit housing 620 as exhaust air (EA) by a remote HVAC system fan
or
building pressure differential. One or both of third pair of ports 605-606 may
receive
outside air (OA). Air may flow through housing 620 and may be discharged from
air
handing module 600 through one or both of first pair of ports 601-602 as
supply air
(SA).
[082] Outside air (OA) may enter housing 620 through port 606, while
paired port 605 may be sealed by an access panel 675. Air director 622 and
exchanger divider 640 may direct outside air (OA) through filter 691a,
exchanger
612, and supply air coil 692a. One or more fans 689 of fan box 686 may push
outside air (OA) through exchanger 612 and out of port 602 as supply air (SA),
while
paired port 601 may be sealed by access panel 671. One or more fans 689 of fan
box 682 may pull supply air (SA) out of port 602 in series with fan box 686.
Return
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air (RA) may enter housing 620 through port 607, while paired port 608 may be
sealed by access panel 678. Air director 622 and exchange divider 640 may
direct
return air (RA) thru filter 691b, exchanger 612, and exhaust air coil 692b.
Exhaust air
(EA) may exit port 603, while paired port 604 may be sealed by access panel
674.
[083] Fig. 6g illustrates a cross-sectional view of air handling module 600
in
a seventh configuration according to the present disclosure. As shown in Fig.
6g, the
interchangeable exchanger 612 may facilitate a cross-flow air pattern within
air
handling module 600. Fan box 681 may be coupled to port 601 and may be
configured to pull air flow into and out of housing 620. A fan box 684 may be
coupled
to port 604 and may be configured to pull air flow into and out of housing
620. One or
both of third pair of ports 605-606 may receive outside air (OA). Air may flow
through
housing 620 and may be discharged from air handing module 600 through one or
both of first pair of ports 601-602 as supply air (SA).Retum air (RA) may
enter
housing 620 through one or both of fourth pair of ports 607-608 and may be
conveyed through housing 620 and exit though one or both of second pair of
ports
603-604 as exhaust air (EA).
[084] Outside air (OA) may enter housing 620 through port 605, while
paired port 606 may be sealed by access panel 676. Air director 622 and
exchanger
divider 640 may direct outside air (OA) through filter 691a, exchanger 612,
and
supply air coil 692a. One or more fans 689 of fan box 681 may push outside air
(OA)
through exchanger 612 and out of port 601 as supply air (SA), while paired
port 602
may be sealed by access panel 672. Return air (RA) may enter housing 620
through
port 608, while paired port 607 may be sealed by access panel 677. Air
director 622
and exchange divider 640 may direct return air (RA) thru filter 691b,
exchanger 612,
and exhaust air coil 692b. One or more fans 689 positioned inside fan box 684
may
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pull exhaust air (EA) out of port 604, while paired port 603 may be sealed by
access
panel 673.
[085] Fig. 6h illustrates a cross-sectional view of air handling module 600
in
an eighth configuration according to the present disclosure. As shown in Fig.
6h,
interchangeable exchanger 612 may facilitate a cross-flow air pattern within
air
handling module 600. Fan box 681 may be coupled to port 601 and may be
configured to pull air flow into and out of housing 620. Fan box 688 may be
coupled
to port 608 and may be configured to push air flow into and out of housing
620. One
or both of third pair of ports 605-606 may receive outside air (OA). Air may
flow
through housing 620 and may be discharged from air handing module 600 through
one or both of first pair of ports 601-602 as supply air (SA). Return air (RA)
may
enter housing 620 through one or both of fourth pair of ports 607-608 and may
be
conveyed through housing 620 and exit though one or both of second pair of
ports
603-604 as exhaust air (EA).
[086] Outside air (OA) may enter housing 620 through port 606, while
paired port 605 may be sealed by access panel 675. Air director 622 and
exchanger
divider 640 may direct outside air (OA) through filter 691a, exchanger 612,
and
supply air coil 692a. One or more fans 689 of fan box 681 may pull outside air
(OA)
through exchanger 612 and out of port 601 as supply air (SA), while paired
port 602
may be sealed by access panel 672. Return air (RA) may enter housing 620
through
port 608, while paired port 607 may be sealed by access panel 677. Air
director 622
and exchange divider 640 may direct return air (RA) thru filter 691b,
exchanger 612,
and exhaust air coil 692b. One or more fans 689 of fan box 688 push return air
(RA)
into port 608, while paired port 607 may be sealed by access panel 677. Return
air
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(RA) may be pushed through exchanger 612 by fan box 688 and may exit out of
port
604 as exhaust air (EA), while paired port 603 may be sealed by access panel
673.
[087] Fig. 7a illustrates a perspective view of a plurality of air handling
modules coupled together to form an air handling system according to the
present
disclosure. As shown in Fig. 7a, an air handling system 700 may comprise a
plurality
of air handling modules 710 stacked together. Air handling modules 710 may
operate in parallel with each other to achieve a combined conditioning effect
greater
than, or equal to, a conditioning effect of a single air handling unit with a
desired
level of redundancy. Air handling module 710 may comprise lightweight plastic
construction which may facilitate hand transport by one or more installation
personnel 799 without employing cranes and other heavy machinery. Air handling
module 710 may preferably weigh under 100 pounds.
[088] A bottom 740 of air handling module 710 may be stacked on a top
730 of adjoining air handling module 710. As discussed above, ports of air
handling
module 710 may serve as interchangeable attachment points for a variety of
structures, such as, for example, fan boxes, metal ducts, weather hoods, roof
curbs,
access panels, and/or other fluidly connected components of an HVAC system.
Components may readily attach and detach from the ports to accommodate
multiple
combinations for air handling module 710 customizable per installation site
requirements.
[089] One or more ports 706 of air handling module 710 may serve as
interchangeable attachment points for fan boxes 786 containing one or more
fans
789, and one or more ports 701 of air handling module 710 may serve as
interchangeable attachment points for fan boxes 781 containing one or more
fans
789. Fan boxes 781 and fan boxes 786 may direct air flow into and out of air
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handling module 710 through attached ports 701 and ports 706, respectively.
Fan
boxes 781 and 786 may readily attach and detach from ports 701 and ports 706
using standard screw drivers or wrenches. Fan boxes 781 and 786 may also
include
integrated power and communication bus wire harnesses to connect into any of
the
ports to provide a "plug-and-play" arrangement.
[090] Each paired port 707-708 may include an access panel 778 that may
readily attach and detach using standard screw drivers or wrenches. This port
duality
may facilitate numerous airflow directions and may be customized at the site
location. In some embodiments, a plurality of ports may be aligned to
facilitate the
attachment of a single, four-sided rectangular duct. As shown in Fig. 7a,
extension
flanges outlining ports (e.g., ports 707) may be flush along top 730 and
bottom sides
740.
[091] Fig. 7b illustrates a perspective view of a plurality of air handling
modules coupled together to form an air handling system according to the
present
disclosure. As shown in Fig. 7a, air handling system 700 may comprise a
plurality of
air handling modules 710, vertically positioned and adjacently stacked. Air
handling
modules 710 may operate in parallel with each other to achieve a combined
conditioning effect greater than, or equal to, a conditioning effect of a
single air
handling unit with a desired level of redundancy. Air handling modules 710 of
air
handling system 700 may be in a vertical orientation to facilitate fluid flow
in
evaporative cooling and/or steam regeneration liquid desiccant conditioning
applications and carbon dioxide scrubbing systems.
[092] Fans 789 in fan housing 786 may pull recirculating return air (RA) to
be conditioned through a single common duct 757 coupled to ports 707 of air
handling modules 710. Return air (RA) may pass through the exchangers in air
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handling modules 710 and may exit air handling modules 710 as supply air (SA)
through a single common duct 756 coupled to ports 706 of air handling modules
710.
Fans 789 in fan housing 781 may pull outside air (OA) into air handling
modules 710
through one or more weather hoods 764 coupled to ports 704 of air handling
modules 710. Outside air (OA) may pass through the exchangers in air handling
modules 710 and may exit air handling modules 710 as exhaust air (EA) through
one
or more weather hoods 761 coupled to ports 701 of air handling modules 710.
[093] Fig. 8a illustrates a cross-sectional perspective view as indicated
by
the dashed line shown in Fig. 7b of an air handling system 800 according to
the
present disclosure. As shown in Fig. 8a, air handling system 800 may comprise
a
plurality of air handling modules 812a-812c stacked in a vertical
configuration. Each
of air handling modules 812a-812c may contain a plurality of internal and
external
ports facilitating a multi-functional hydronic distribution and collection
system.
[094] Port(s) 839 may be connected to an evaporative water pipe 853 with
sealed threads and may facilitate entry, distribution, and discharge of supply
water
through a plurality of housings 820a-820c via evaporative water pipe 853. An
exchanger 213 may be contained within each housing 820a-820c and may include a
plurality of plates arranged in a successively stacked configuration with
portions
thereof having a spaced apart arrangement. A first and second series of
discrete
alternating passages may be defined at the spaced apart portions.
[095] Evaporative water 825 may be delivered into exchanger 213. The
evaporative water 825 may gravitationally flow down the first series of
discrete
alternating passages until reaching a first drain conduit 832 for collecting
the flowing
evaporative water 825 from the first series of passages. The first drain
conduit 832
may be entirely outside of the exchanger 213 and adjacent to first and second
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of the plurality of plates. The first drain conduit port 832 may be connected
to an
evaporative water drain pipe 859 with sealed threads and may facilitate entry,
distribution, and discharge of water through the plurality of housings 820a-
820c.
[096] Port(s) 837 may be connected to a liquid desiccant pipe 851 with
sealed threads and may facilitate entry, distribution, and exit of liquid
desiccant 826
through a plurality of housings 820a-820c via liquid desiccant pipe 851.
Liquid
desiccant 826 may be delivered into exchanger 213. The liquid desiccant 826
may
gravitationally flow down the second series of discrete alternating passages
until
reaching a second drain conduit 838 for collecting the flowing liquid
desiccant 826
from the second series of passages. The second drain conduit 838 may be
entirely
outside of the exchanger 213 and adjacent to first and second ends of
plurality of
plates. Second drain conduit 838 may be connected to a liquid desiccant drain
pipe
855 with sealed threads and may facilitate entry, distribution, and exit of
liquid
desiccant through the plurality of housings 820a-820c.
[097] In some embodiments, side liquid desiccant drain port(s) 818a-818c
and 819a-819c may be connected to drain pipe(s) 819a-819c with sealed threads
and may provide an additional or alternate exit for liquid desiccant through
drain
pipe(s) 819a-819c. In some embodiments, aqueous solutions of alkylamines,
other
reversibly binding aqueous solutions, lithium chloride, or combinations
thereof may
flow through the exchangers 213.
[098] In some embodiments, the ports of air handling modules 812a-812c
facilitating the multi-functional hydronic distribution and collection system
may be
threaded. It should be appreciated that the ports may serve as interchangeable
attachment points for a plurality of components including a condensate drain
pipe, an
evaporative water supply pipe, an evaporative water drain pipe, a liquid
desiccant
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supply pipe, a liquid desiccant drain pipe, a refrigerant line conduit, a
chilled water
conduit, a steam pipe, reversibly binding aqueous scrubbing pipe, and/or other
fluidly
connected hydronic components of an HVAC system. The components may readily
attach and detach from the ports and may allow customized configuration at the
installation site. Gasketed seals may be incorporated between the components
and
the ports. In some embodiments, the ports may be threaded in accordance with
British Standard Parallel Pipe (BSPP) standards with integrated sealing
washers to
ensure international compatibility with National Taper Pipe (NPT), American
Standard Straight Pipe for Mechanical Joints (NPSM), American Standard
Straight
Pipe (NPS), and British Standard Tapered Pipe (BSTP) standards. In some
embodiments, bottom conduit port(s) 844a-844c may be attached to supply coil
pipe
858 and return coil pipe 869 to distribute liquids between a plurality of
housings
820a-820c. Supply coil port 861a-861c and return coil port 863a-863c may form
access points between conduit port(s) 844a-844c.
[099] Fig. 8b
illustrates a cross-sectional perspective view of an air handling
system along the dashed line "813" of Fig. 7a. As shown in Fig. 8b, air
handling
system 800 may comprise a plurality of adjacently stacked air handling modules
812a-812c. Air handling modules 812a-812c may contain a plurality of internal
and
external ports, which may facilitate: (a) multi-functional structural
connectivity; (b)
"plug-and-play" electrical power distribution; and (c) "plug-and-play"
communication
bus. The communications bus and power distribution of the air handling system
may
provide a single point of control connection to synchronously operate the
plurality of
air handling modules.
[0100] Air handling modules 812a-812c may be structurally connected via
anchor bolts 865 mating with anchor port(s) 846. Anchor port(s) 846 may also
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provide a multi-functional structural connection to the ground or support base
867. In
some embodiments, anchor port(s) 846 that may not be utilized may be sealed
and
secured with insulated threaded plug(s) 864. In some embodiments, anchor
port(s)
846 may be threaded. Anchor port(s) 846 may serve as interchangeable
attachment
points for a plurality of attachment structures, such as, for example,
structural anchor
bolts, module interconnectivity clamps, module seals, and insulated plug
seals.
These attachment structures may readily attach and detach from anchor port(s)
846,
which may allow for customized configuration at the installation site.
[0101] Power wire 827 may be connected to a power conduit fitting 833 at
threaded port(s) 834, which may facilitate a "plug-and-play" electrical power
distribution. A power harnesses 843 may transfer power between top conduit
ports
834 and bottom conduit ports 844. Electrical and economizer bypass enclosures
857a-857c may contain a plurality of devices and accommodate multiple
combinations of orientations and various numbers of modules per installation
site
requirements.
[0102] Electrical enclosure 857a may provide a single point electrical
disconnect 852 for air handling system 800. Electrical enclosure 857b may
provide a
single point electrical distribution 848 for powering a central controller
849. Electrical
enclosure 857c may be empty. In some embodiments, anchor port(s) 844c that may
not be utilized in the electrical power distribution may be sealed and secured
with
insulated threaded plug(s) 864. Power distribution includes electrical power
conduit,
electrical disconnect handle, module grounding point, and electrical wire
harness
connectors.
[0103] Signal wire 835 may be connected to a signal conduit fitting 841 at
threaded port(s) 834, which may facilitate a "plug-and-play" communications
bus. A
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signal harness 831 may transfer signals between top conduit ports 834 and
bottom
conduit ports 844. Electrical enclosure 857b may contain a central controller
849 to
which all other air handling modules 812 of air handling module system 800 may
be
slaves. In some embodiments, a plurality of components, including, for
example, fan
boxes, may be linked to the "plug-and-play" communications bus and electrical
power distribution via an AHU power and signal harness 881 and a fan power and
signal harness 880. Interchangeable attachment points may be compatible for a
plurality of components, including, for example, a communication bus wire
conduit,
sensor probes, and communication bus harness connectors.
[0104] Gasketed seals may be incorporated between the anchor and
threaded ports and their mated components. In some embodiments, the anchor and
threaded ports may be threaded in accordance with British Standard Parallel
Pipe
(BSPP) standards with integrated sealing washers to ensure international
compatibility with National Taper Pipe (NPT), American Standard Straight Pipe
for
Mechanical Joints (NPSM), American Standard Straight Pipe (NPS), and British
Standard Tapered Pipe (BSTP) standards.
[0105] Fig. 9a illustrates a perspective view of air handling system 900
according to the present disclosure. As shown in Fig. 9a, energy recovery
module
912a may be fluidly coupled in series to a wrap-around dehumidification module
914a to form dual plate air handling module 900a. Ports 904a and 905a of
energy
recovery module 912a may be respectively joined to ports 901a and 908a of 904b
of
dehumidification module 914a. A dual plate air handling module 900b may
comprise
energy recovery module 912b fluidly coupled in series to wrap-around
dehumidification module 914b, and dual plate air handling module 900c may
comprise energy recovery module 912c fluidly coupled in series to a wrap-
around
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dehumidification module 914c. The plurality of dual plate air handling modules
900a-
900c may be stacked in a vertical configuration to form a dual plate air
handling
system 900. Air handling modules 900a-900c may be configured to operate in
parallel with each other to achieve a combined conditioning effect greater
than, or
equal to, a conditioning effect of a single air handling unit with a desired
level of
redundancy.
[0106] Fan(s) 989 in fan housing 986 may pull outside air (OA) through
weather hood 964, and outside air (OA) may enter energy recovery module 912a
at
port 904a. Outside air (OA) may exit as supply air (SA) through port 906. A
single
common supply air (SA) duct 956 may be connected to a plurality of ports 906.
A
single common rectangular return duct 957 may be connected to a plurality of
ports
907, and fan(s) 989 in fan housing 985 may pull return air (RA) through the
single
common return duct 957. Return air (RA) may exit as exhaust air (EA) through
weather hood 965 at port 905.
[0107] Air handling module 914 may comprise lightweight plastic
construction which may facilitate hand transport by one or more installation
personnel 999 without employing cranes and other heavy machinery. Air handling
module 914 may preferably weigh under 100 pounds.
[0108] Figs. 9b-9g illustrate the modularity of the air handling system of the
present disclosure by illustrating exemplary configurations of the air
handling system.
Fig. 9b illustrates a cross-sectional view of dual plate air handling system
900
according to the present disclosure. As shown in Fig. 9b, air handling system
900
may comprise a sensible heat exchanger 916 in series with an enthalpy
exchanger
915 to facilitate lower temperature, frost-free operation of air handling
module 900.
Air handling system 900 may include fan box 981 coupled to port 901 and fan
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988 coupled to port 908. Fan box 981 and fan box 988 may be configured to pull
and
push air flow into and out of a housing 920 of air handling system 900.
[0109] Air handling system 900 may include a series of air-to-air exchangers
916 and 915 contained within housing 920. Air handling system 900 may also
include a first pair of ports 901-902 fluidly connected to second pair of
ports 903-904.
One or both of second pair of ports 903-904 may receive outside air (OA). Air
may
flow through housing 920 and may be discharged from air handling system 900
through one or both of first pair of ports 901-902 as supply air (SA). Air
handling
system 900 may further include third pair of ports 905-906 fluidly connected
to fourth
pair of ports 907-908. One or both of fourth pair of ports 607-608 may receive
return
air (RA). Exhaust air (EA) may be discharged from air handling system 900
through
one or both of third pair of ports 905-906.
[0110] Outside air (OA) may enter housing 920, which may comprise sides
910, through port 904, while paired port 903 may be sealed by access panel
973. Air
director 922 and exchanger divider 940 may direct outside air (OA) through
filter
991a, heat exchanger 916, enthalpy exchanger 915, and supply air coil 992a.
One or
more fans 989 may be positioned inside fan box 981 and may pull supply air
(SA)
through exchangers 916, 915 and out of port 901, while paired port 902 may be
sealed by access panel 672. Rotary damper 941 may seal bypass openings 923a,
and access panel 679 may seal port 909. One or more fans 989 may be positioned
inside fan box 988 and may push return air (RA) entering at port 908 through
exchangers 916, 915 and out port 606, while paired port 907 may be sealed by
access panel 977. Air director 922 and exchanger divider 940 may direct return
air
(RA) through filter 991b, enthalpy exchanger 915, heat exchanger 916, and
exhaust
air coil 992b. Supply air coil 992a and exhaust air coil 992b may be any
suitable
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thermal transfer device for promoting a variety of air processing and
conditioning
objectives, including, but not limited to, a condenser coil, an evaporator
coil, a chilled
water coil, a hot water coil, and/or a steam coil. Exhaust air (EA) may exit
port 905,
while paired port 906 may be sealed by access panel 976.
[0111] Fig. 9c illustrates a cross-sectional view of another dual plate air
handling system 900 according to the present disclosure. As shown in Fig. 9c,
air
handling system 900 may comprise of energy recovery module 912a serially
coupled
to wrap-around dehumidification module 914b. Ports 901a and 908a of energy
recovery module 912a may be fluidly connected to ports 904b and 905b of
dehumidification module 914b, respectively. The dual plate air handling system
of
Fig. 9c may provide energy savings and load reduction of enthalpy recovery for
dedicated outdoor air. Furthermore, the sensible/latent ratio control of wrap-
around
dehumidification may deliver low dewpoint to an application at neutral
temperature;
which may eliminate space reheat.
[0112] The dual plate air handling system of Fig. 9c may include exchanger
915 housed in housing 920a of energy recovery module 912a fluidly connected in
series to exchanger 916 housed in housing 920b of dehumidification module
914b.
Paired ports 903a-904a of energy recovery module 912a may be fluidly connected
to
paired ports 905b-906b of dehumidification module 914b. One or both of paired
ports
903a-904a may receive outside air (OA). Air may flow through energy recovery
module 912a and dehumidification module 914b (and exchangers 915, 916) and
may be discharged from one or both of paired ports 905b-906b as supply air
(SA).
Paired ports 907a-908a of energy recovery module 912a may be fluidly connected
to
paired ports 905a-906a of energy recovery module 912a. One or both of paired
ports
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907a-908a may receive return air (RA). Exhaust air (EA) may be discharged from
one or both of paired ports 905a-906a.
[0113] Outside air (OA) may enter housing 920a of energy recovery module
912a, which may comprise sides 910a, through port 904a, while paired port 903a
may be sealed by an access panel 973. Air director 922a and exchanger divider
940a may direct outside air (OA) through energy recovery exchanger 915.
Outside
air (OA) may exit housing 920a through port 901a and may enter housing 920b of
dehumidification module 914b, which may comprise sides 910b, through port
904b.
An air director 922b, an exchanger divider 940b, and sealed ports 908b, 901b
may
direct a first pass of outside air (OA) through sensible exchanger 916 and
coil 922a.
One or more fans 989 of fan box 986 may pull outside air (OA) through coil
922b,
which may be arranged in series with coil 922a, and back through sensible
exchanger 916 for a second pass. The air may then exit as supply air (SA)
through
port 906b. A fan box 985 may be fluidly coupled to port 905a. One or more fans
989
positioned inside fan box 985 may pull return air (RA) through port 907a,
while
paired port 908a may be sealed. Air director 922a and exchange divider 940a
may
direct return air (RA) through exchanger 915 and exhaust air coil 992c.
[0114] In some embodiments, exhaust air coil 992c may be a condenser type
coil configured to reject heat from evaporator coils 992a and 992b. A rotary
damper
934a may seal bypass openings 923a and a rotary damper 934b may seal bypass
openings 923b. The air pulled by fan box 985 may exit port 905a as exhaust air
(EA),
while paired port 906a may be sealed.
[0115] Fig. 9d illustrates a cross-sectional view of another configuration of
the dual plate air handling system of Fig. 9c according to the present
disclosure. As
shown in Fig. 9d, dual-plate air handling module 900 may be arranged to
provide
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energy savings and load reduction through enthalpy exchanger 915. It may also
provide bypass 923b around wrap-around heat exchanger 916 to change the
sensible/latent ratio depending upon changing site requirements. Rotary damper
934b may be opened to permit airflow through bypass opening(s) 923b, while
blocking airflow through the path directed by air director 922b and exchange
divider
940b for the first pass of the outside air (OA) through exchanger 916 as shown
in
Fig. 9c. As such, rotary damper 934b may facilitate outside air (OA) bypassing
sensible exchanger 916. Sealed ports 908b-901b may direct outside air (OA) to
pass
through coils 992b and then sensible exchanger 916. One or more fans 989 of
fan
box 986 may pull this outside air (OA) through sensible exchanger 916 for a
single
pass. The air may then exit as supply air (SA) through port 906b. In some
embodiments, coils 992a may be closed or turned off to prevent freezing due to
the
lack of airflow.
[0116] Fig. 9e illustrates a cross-sectional view of another dual plate air
handling system according to the present disclosure. As shown in Fig. 9e, dual
plate
air handling system 900 may comprise energy recovery module 912a serially
coupled to wrap-around dehumidification module 914b and arranged to facilitate
recirculated return air (RA) optionally entering through a port 938. This
arrangement
may provide the energy savings and load reduction of enthalpy recovery,
sensible/latent ratio control, low dewpoint air delivered at room neutral
temperature,
and recirculating air conditioning during unoccupied periods. The dual plate
air
handling system of Fig. 9e may include port 938 and return air (RA) port
rotary
damper 936. Rotary damper 936 may be actuated to open and seal port 938. When
rotary damper 936 is opened, port 938 may be fluidly connected to paired ports
905b-906b of dehumidification module 914b.
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[0117] Fig. 9f illustrates a cross-sectional view of another configuration of
the
dual plate air handling system of Fig. 9e according to the present disclosure.
As
shown in Fig. 9f, rotary damper 936 may be actuated to facilitate a variable
percentage of recirculated return air (RA) entering through port 938 and
mixing with
outside air (OA). This arrangement may provide the energy savings and load
reduction of enthalpy recovery for dedicated outdoor air. Furthermore, the
sensible/latent ratio control of wrap-around dehumidification may deliver low
dewpoint to an application at neutral temperature; which may eliminate space
reheat.
Incorporating a variable percentage of recirculating air conditioning may
reduce
energy during unoccupied periods and/or increase space comfort levels. Rotary
damper 936 may be at least partially opened to permit return air (RA) to enter
through port 938. When rotary damper 936 is at least partially opened, port
938 may
be fluidly connected to ports 901a and 904b and return air (RA) entering
through port
938 may mix with outside air (OA). The mixture of outside air (OA) and return
air
(RA) then may be supplied to dehumidification arrangement 914b through port
904b.
The amount of return air (RA) mixing with outside air (OA) may be modulated by
rotary damper 936.
[0118] Air director 922b, exchanger divider 940b, and sealed ports 908b-
901b may direct the mixture of outside air (OA) and return air (RA) through
sensible
exchanger 916 and coil 992a for a first pass. One or more fans 989 of fan box
986
may pull this mixed air through coil 922b and back through sensible exchanger
916
for a second pass. The air may then exit as supply air (SA) through port 906b.
Rotary dampers 934a and 931a may seal bypass openings 923a, and rotary
dampers 934b and 931b may seal bypass openings 923b.
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[0119] Fig. 9g illustrates a cross-sectional view of another configuration of
the dual plate air handling system of Fig. 9e according to the present
disclosure. As
shown in Fig. 9e, rotary damper 936 may be actuated to facilitate recirculated
return
air (RA) entering through port 938. This arrangement may provide
sensible/latent
ratio control of wrap-around dehumidification and may deliver low dewpoint to
an
application at neutral temperature, which may eliminate space reheat.
Incorporating
a variable percentage of recirculating air conditioning may reduce energy
during
unoccupied periods and/or increase space comfort levels. For example, many
winter
vacation homes sit empty during the humid summer months and controlling dew
point may be more important than controlling temperature for reduction of mold
and
elimination of odors. As shown in Fig. 9g, rotary damper 936 may be opened to
permit return air (RA) to enter through port 938 and into housing 920b. Rotary
damper 934h may be opened to permit airflow through bypass opening(s) 923b and
facilitate return air (RA) bypassing sensible exchanger 916. Air director
922b,
exchanger divider 940b, and sealed ports 908b-901b may direct return air (RA)
through coils 992b and sensible exchanger 916. One or more fans 989 of fan box
986 may pull this return air (RA) through sensible exchanger 916. The air may
then
exit as supply air (SA) through port 906b. One or more fans 989 of fan box 985
may
pull outside air (OA) through port 907 and through exchanger 915 and exhaust
air
coil 992b. Air director 922a and exchange divider 940a may direct the outside
air
(OA) through exchanger 915 and exhaust air coil 992b. The air pulled by fan
box 985
may then exit port 905a as exhaust air (EA), while paired port 906a may be
sealed.
Rotary damper 934a may be closed to seal bypass opening(s) 923a.
[0120] Fig. 10a illustrates a psychrometric chart corresponding to the
operation of air handling system of Fig. 9b according to the present
disclosure. Figs.
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9b and 10a depict a first airstream of outside air (OA) to supply air (SA) and
a
second airstream of return air (RA) to exhaust air (EA). As shown in Fig 10a,
the first
airstream may traverse points A, B, C, and D, and the second airstream may
traverse points E, F, and G. Fig 10a charts the estimated temperatures and
humidity
levels for the first and second airstreams as they traverse these points.
[0121] The first airstream and the second airstream may pass through heat
exchanger 916 and enthalpy exchanger 915 in a counterflow orientation. Point E
may represent a typical winter return air condition from a conditioned space.
The
second airstream may enter an entry port of enthalpy exchanger 915 at point E
on
Fig. 10a and may flow through enthalpy exchanger 915 to point F. The first
airstream
may flow simultaneously through enthalpy exchanger 915 from point B to point C
in a
counterflow orientation in relation to the second airstream flowing through
enthalpy
exchanger 915 from point E to point F. As the second airstream flows through
enthalpy exchanger 915 from point E to point F and the first airstream flows
through
enthalpy exchanger 915 from point B to C, moisture and heat content may
transfer
from the second airstream to the first airstream.
[0122] The second airstream may also enter an entry port of heat exchanger
916 at point F on Fig. 10a and flow through heat exchanger 916 to point G. The
first
airstream may flow simultaneously through heat exchanger 916 from point A to
point
B in a counterflow orientation in relation to the second airstream. As the
second
airstream flows through heat exchanger 916 from point F to point G and the
first
airstream flows through heat exchanger 916 from point A to point B, heat
content
may transfer from the second airstream to the first airstream. The first
airstream may
exit enthalpy exchanger 915 at point C and may enter exhaust air coil 922a.
The first
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airstream may receive heat from the exhaust air coil 992c and be heated to a
point
D.
[0123] Fig. 10b illustrates a psychrometric chart corresponding to the
operation of air handling system of Fig. 9c according to the present
disclosure. Figs.
9c and 10b depict a first airstream of outside air (OA) to supply air (SA) and
a
second airstream of return air (RA) to exhaust air (EA). As shown in Fig. 10b,
the
first airstream may traverse points A, B, C, D, E, and F, and the second
airstream
may traverse points G, H, and I. Fig. 10b charts the estimated temperatures
and
humidity levels for the first and second airstreams as they traverse these
points.
[0124] The first airstream and the second airstream may pass through
enthalpy exchanger 915 in a counterflow orientation. Point G may represent a
typical
summer return air condition from a conditioned space. The second airstream may
enter an entry port of enthalpy exchanger 915 at point G on Fig. 10b and may
flow
through enthalpy exchanger 915 to point H. The first airstream may flow
simultaneously through enthalpy exchanger 915 from point A to point B in a
counterflow orientation in relation to the second airstream flowing through
enthalpy
exchanger 915 from point G to point H. As the second airstream flows through
enthalpy exchanger 915 from point G to point H and the first airstream flows
through
enthalpy exchanger 915 from point A to point B, moisture and heat content may
transfer from the first airstream to the second airstream. The second
airstream may
exit enthalpy exchanger 915 at point H and may flow through exhaust air coil
992c.
The second airstream may receive heat from exhaust air coil 992c and may be
heated to point I.
[0125] The first airstream may also enter an entry port of heat exchanger 916
and may flow through heat exchanger 916 being sensibly cooled to point C. The
first
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airstream may exit enthalpy exchanger 915 at point C and may flow through
evaporator coil 992a. The first airstream may be cooled and dehumidified by
evaporator coil 992 to point D. The first airstream may then be directed
through
another evaporator coil 992b. The first airstream may be cooled and
dehumidified by
evaporator coil 99b to point E. The first airstream may again be directed
through
heat exchanger 916 and may be sensibly heated to point F.
[0126] Fig. 10c illustrates a psychrometric chart corresponding to the
operation of the air handling system of Fig. 9d according to the present
disclosure.
Figs. 9d and 10c depict a first airstream of outside air (OA) to supply air
(SA) and a
second airstream of return air (RA) to exhaust air (EA). As shown in Fig. 10c,
the first
airstream may traverse points A, B, and E, and the second airstream may
traverse
points G, H, and I. Fig. 10c charts the estimated temperatures and humidity
levels for
the first and second airstreams as they traverse these points.
[0127] The first airstream and the second airstream may pass through
enthalpy exchanger 915 in a counterflow orientation. Point A may represent a
typical
summer outside air condition. The first airstream may enter an entry port of
enthalpy
exchanger 915 at point A of Fig. 10c and may flow through enthalpy exchanger
915
to point B. The second airstream may enter an entry port of enthalpy exchanger
915
at point G of Fig. 10c and may flow simultaneously from point G to point H in
a
counterflow orientation in relation to the first airstream. As the first
airstream flows
through enthalpy exchanger 915 from point A to point B and the second
airstream
flows through enthalpy exchanger 915 from point G to point H, moisture and
heat
content may transfer from the first airstream to the second airstream. The
first
airstream may then flow through evaporator coil 992b and may be cooled and
dehumidified to point E. The second airstream may exit enthalpy exchanger 915
at
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point H and may flow through exhaust air coil 992c. The second airstream may
receive heat from exhaust air coil 992c and may be heated to point I.
[0128] Fig. 10d illustrates a psychrometric chart corresponding to the
operation of the air handling system of Fig. 9f according to the present
disclosure.
Figs. 9f and 10d depict a first airstream of outside air (OA) to supply air
(SA), a
second airstream of return air (RA) to exhaust air (EA), and a third airstream
of
supply air (SA). As shown in Fig. 10d, the first airstream may traverse points
A and
B, the second airstream may traverse points H, I, and J, and the third
airstream may
traverse points C, D, E, F, and G. Fig. 10d charts the estimated temperatures
and
humidity levels for the first, second, and third airstreams as they traverse
these
points.
[0129] The first airstream and the second airstream may pass through
enthalpy exchanger 915 in a counterflow orientation. Point A may represent a
typical
summer outside air condition. The first airstream may enter entry port of
enthalpy
exchanger 915 at point A of Fig. 10d and may flow through enthalpy exchanger
915
to point B. The second airstream may enter entry port of enthalpy exchanger
915 at
point H of Fig. 10d and may flow simultaneously from point H to point I in a
counterflow orientation in relation to the first airstream. As the first
airstream flows
through enthalpy exchanger 915 from point A to point B and the second
airstream
flows through enthalpy exchanger 915 from point H to point I, moisture and
heat
content may transfer from the first airstream to the second airstream. The
second
airstream may exit enthalpy exchanger 915 at point I and may flow through
exhaust
air coil 992c. The second airstream may receive heat from the exhaust air coil
992c
and may be heated to a point J.
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[0130] The outside air (OA) of the first airstream and a partial volume flow
of
the return air (RA) of the second airstream may mix to form the third
airstream in the
form of supply air (SA) at point C. The third airstream may enter entry port
of heat
exchanger 916 at point C of Fig. 10d and may flow through heat exchanger 916
and
may be sensibly cooled to point D. The third airstream may then flow through
evaporator coil 992a and may be cooled and dehumidified to point E. The third
airstream may then flow through another evaporator coil 992b and may be cooled
and dehumidified to point F. The third airstream may then encounter may again
enter
heat exchanger 916 at point F and may flow through heat exchanger 916 and may
be sensibly heated to point G.
[0131] Fig. be illustrates a psychrometric chart corresponding to the
operation of air handling system of Fig. 9g according to the present
disclosure. Figs.
9g and 10e depict a first airstream of outside air (OA) to exhaust air (RA)
and a
second airstream of return air (RA) to supply air (SA). As shown in Fig. 10e,
the first
airstream may traverse points H though J, and the second airstream may
traverse
points A through D. Fig. 10e charts the estimated temperatures and humidity
levels
for the first and second airstreams as they traverse these points.
[0132] The first airstream and the second airstream may flow through
enthalpy exchanger 915 and heat exchanger 916, respectively, but may not
experience a state change as no opposing airstream may flow in a counterflow
orientation. Point A may represent a typical summer return-air condition. The
second
airstream may flow through evaporator coil 992b, heat exchanger 916, and
evaporator coil 992c, and may be cooled and dehumidified to point D. The first
airstream may enter enthalpy exchanger 915 at point H, flow through enthalpy
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exchanger 915, and flow through exhaust air coil 992c, receiving heat from
exhaust
air coil 992c and may be heated to point J.
[0133] Persons of ordinary skill in the art would appreciate that the air
handling system of the present disclosure may be modular with respect to the
power
and velocity of the air flows delivered and supplied by the system. For
example, and
as shown in Figs. 7a-7b, multiple air handling modules may be stacked together
(horizontally or vertically) to increase the power, velocity, and capacity of
the air
flows associated with the system. The power, velocity, and noise of the air
flows may
be increased or decreased by adjusting the fan speed of the fan boxes. In
certain
embodiments, the air handling system may be coupled to an existing HVAC unit.
One or more air handling modules may be coupled to an HVAC unit to increase
the
capacity of the HVAC unit. In such an embodiment, the air handling system may
act
as a pre-treatment stage to remove heat and humidity from air that is supplied
to an
HVAC unit.
Membranes for Exchanger and Related Methods of Manufacture
[0134] Enthalpy exchangers of the present disclosure may embody a variety
of configurations depending on, among other factors, the desired application.
For
example, an enthalpy exchanger may be a planar heat and moisture plate-type
exchanger. The enthalpy exchanger may comprise of membrane plates each
constructed of a planar, water-permeable membrane. Membrane plates may be
stacked and sealed and may be configured to accommodate air streams flowing in
counter-flow configurations between alternate plate pairs. This may facilitate
heat-
and water vapor-transfer via the membrane, while preventing the air streams
from
mixing, or otherwise contacting one another. In other embodiments, the
enthalpy
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exchanger may include membrane plates arranged to accommodate air streams
flowing in crossflow configurations between alternate plate pairs.
[0135] In some embodiments, the membrane may permit heat and not
moisture to be transferred across the material from one air stream to the
other. The
membrane of the enthalpy exchanger may, in addition or as an alternative to
the
membrane plates, comprise a single membrane core made by folding a continuous
strip of membrane in a concertina, zig-zag or accordion fashion, with a series
of
parallel alternating folds.
[0136] The present disclosure also contemplates an enthalpy exchanger
which may have a rotating wheel arrangement. The enthalpy exchanger may
comprise a membrane constructed to include a number of parallel pores or
opening,
such as a honeycomb structure, through which air passes. The enthalpy
exchanger
may be formed by winding or stacking the membrane into a wheel shape to
provide
air passageways parallel to the axis of the wheel.
[0137] The membrane or transfer medium of the present disclosure may be
used to form heat and moisture transfer bodies, such as enthalpy exchangers,
and
may comprise a substrate embedded with microporous particles. The substrate
may
comprise fibrous materials, including, for example, natural cellulose fibers,
as well as
synthetic thermoplastic fibers, such as polyvinyl alcohol polymer fibers,
bicomponent
fibers and microfibers. The substrate may comprise any type of fibrous
materials that
may hold substantial amounts of liquids and microporous particles. The
substrate
may be formed by conventional paper making processes into adsorbent paper or
desiccant paper having adsorbent or desiccant contained therein. In some
embodiments, additives, such as reinforcement fibers, may be added to the
substrate.
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[0138] Examples of fibrous materials suitable for use as substrate may
include: wood pulp; cellulose fiber; synthetic thermoplastic organic fiber;
and
mixtures thereof. Inorganic fiber, such as glass or metal fibers and rock
wool, may
also be used in conjunction with fibrillated organic fiber. The substrate may
also
comprise synthetic organic thermoplastic fiber including: polymeric fiber,
such as
polyethylene, polypropylene, polystyrene, polyvinyl chloride, polyester, rayon
(cellulose acetate), acrylic, acrylonitrile homopolymer, copolymer with
halogenated
monomer, styrene copolymer, and mixtures of such polymers. Suitable synthetic
thermoplastic organic fiber may be in staple form (chopped yarn), fabricated
form
(staple form that has been refined), or extruded/precipitated form. In certain
embodiments, substrate may comprise one or more of: soft wood fiber, such as
Rayonier Poroganier; fiberglass; biocomponent fiber, such as T-201
bicomponent;
acrylic fiber, such as Vonnel microfiber, and PVA fiber, such as KuraIon.
[0139] Microporous particles may be embedded into the substrate and may
comprise any material capable of efficiently holding liquids through capillary
action,
surface tension, or other mechanisms. Microporous particles may be activated
for
adsorption by removing water from their hydrated precursors. Microporous
material
may be capable of efficiently adsorbing/desorbing said moisture to a counter-
flowing
air stream. Microporous material may also be capable of efficiently
adsorbing/desorbing said moisture to a crossflowing air stream.
[0140] Substrate embedded with microporous particles may have liquid
sorption capacity for liquids, such as, for example, lithium chloride, water,
lithium
bromide, tri-ethylene glycol, calcium chloride, potassium formate, zinc-
carbon, zinc-
chloride, alkaline, nickel oxyhydroxide, lithium-copper oxide, lithium-iron
disulfide,
lithium-manganese dioxide, lithium-chromium oxide, lithium-silicone, mercury
oxide,
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zinc-air, silver-oxide, magnesium, NiCd, lead-acid, NiMH, NiZn, AgZn, LiFePO4,
lithium ion, and mixtures thereof. In some embodiments, the liquid may be a
lithium
chloride with an amount of lithium chloride in the solution being 8.3% wt. or
less.
[0141] Microporous particles may include activated aluminas, silica gels,
molecular sieves, porous titania, or zeolites, activated carbon, and the like,
and
mixtures of these compounds. In certain embodiments, microporous particles may
include transition alumina, such as gamma alumina, due to their inert
properties,
lower cost, and wide market availability. An example of commercially available
gamma alumina is VGL 15 produced by U.O.P. Corporation.
[0142] An exemplary system and process for manufacturing substrate for
use as a membrane or transfer medium according to the present disclosure will
now
be described with reference to Figs. 11a and 11b. As shown in Figs. lla and
11b, a
roll of substrate 1201 may be continuously fed to coating chamber 1200. As
substrate 1201 is fed through coating chamber 1200, substrate 1201 may be
embedded with microporous particles and may exit coating chamber 1200 as
membrane or transfer medium 1206. Membrane 1206 may be continuously collected
and rolled up into a roll of membrane 1260.
[0143] Substrate 1201 may be a thermoplastic sheet formed of thermoplastic
fibers, such as polypropylene. In some embodiments, additives, such as
reinforcement fibers, may be added to the thermoplastic sheet. Alternatively,
substrate 1201 may comprise paper formed of natural fibers, such as wood pulp
or
cellulose.
[0144] Microporous particles embedded into substrate 1201 may include
transition alumina, such as gamma alumina. In some embodiments, membrane 1206
may comprise a thermoplastic sheet containing gamma alumina, and in other
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embodiments, membrane 1206 may comprise paper containing gamma alumina.
The present disclosure contemplates that membrane 1206 may be manufactured by
coating or embedding any suitable substrate with any suitable microporous
particles,
as described above.
[0145] Coating chamber 1200 may include housing 1210 enclosing first
calender roller 1212 and second calender roller 1214. First coating apparatus
1216
may be positioned proximate first calender roller 1212, and second coating
apparatus 1218 may be positioned proximate second calender roller 1214. Each
of
first coating apparatus 1216 and second coating apparatus 1218 may be
configured
to spray microporous particles (e.g., gamma alumina) in powdered form onto its
respective calender roller 1212, 1214. First and second coating apparatuses
1216,
1218 may be connected to source 1220 of powdered microporous particles via
suitable supply lines 1222. Powdered microporous particles may be delivered
from
source 1220, through supply lines 1222, and sprayed from first and second
coating
apparatuses 1216, 1218 by any appropriate means, including, for example,
compressed air.
[0146] First and second coating apparatuses 1216, 1218 may impart a
positive charge onto microporous particles 1222 as they are sprayed out of
first and
second coating apparatuses 1216, 1218 and onto first and second calender
rollers
1212, 1214. Each of first and second calender rollers 1212, 1214 may be
electrically
grounded. As such, powdered microporous particles may be electrostatically
coated
onto first and second calender rollers 1212, 1214.
[0147] Persons of ordinary skill in the art would appreciate that first and
second coating apparatuses 1216, 1218 may be configured to control the rate at
which charged microporous particles are sprayed and may be configured to
control
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the electrical charge rate of powdered microporous particles as they exit the
apparatuses 1216, 1218. First and second coating apparatuses 1216, 1218 may
include any suitable device for use in electrostatic coating. For example, in
some
embodiments, first and second coating apparatuses 1216, 1218 may include
powder
coating spray guns. A high degree of uniformity may be achieved as a monolayer
of
microporous particles 1222 may adhere to rollers 1212, 1214. This uniformity
may be
achieved because the high electrical potential between microporous particles
1222
and rollers 1212, 1214 may diminish exponentially after a first monolayer is
deposited. An electrostatic cloud of sprayed microporous particles 1222 may
create
nearly complete coverage of these monolayer microporous particles 1222 on the
top
and bottom rollers 1212, 1214. In some embodiments, the microporous particles
1222 loading to the thermoplastic substrate sheet 1201 may be as high as 90%
by
weight. It should be appreciated that in other embodiments, the loading of the
microporous particles 1222 to the substrate 1201 may be 50% to 90% by weight,
and in certain embodiments, the loading of the microporous particles 1222 to
the
substrate 1201 may be 50% to 60% by weight.
[0148] Each of first and second calender rollers 1212, 1214 may be
configured to embed powdered microporous particles into substrate 1201.
Substrate
1201 may be fed between rollers 1212, 1214, and rollers 1212, 1214 may rotate
in a
direction toward the feed direction of substrate 1226. Rollers 1212, 1214 may
comprise hard, anti-stick material and may be configured to be heated to a
suitable
temperature. In some embodiments, rollers 1212, 1214 may be formed of hardened
steel. Persons of ordinary skill in the art would appreciate that rollers
1212, 1214
may be diamond coated. As rollers 1212, 1214 rotate, rollers 1212, 1214 may
press
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onto the top and bottom surfaces of the substrate 1230 and embed the surfaces
of
substrate 1201 with powdered microporous particles from rollers 1212, 1214.
[0149] The heat and pressure between rollers 1230 may transfer the
powdered microporous particles from rollers 1212, 1214 onto substrate 1201 by
impregnating the substrate 1201 with microporous particles. In some
embodiments,
rollers 1212, 1214 may be heated to at or near the melting point of the
thermoplastic
fibers forming a thermoplastic substrate to embed microporous particles with
thermoplastic fibers and improve the bond and concentration of the microporous
particles on the substrate. For example, when coating a polypropylene
substrate with
microporous particles, rollers 1212, 1214 may be heated up to, but not
exceeding,
the melting point of polypropylene (160 C). Line speeds greater than 10 meters
per
minute may be achieved. In some embodiments, hydraulic pressure at the nip of
an
8-inch-wide membrane may be between 2,000 psi and 5,000 psi, and preferably
4,000 psi. A metering-type calender may be advantageous in controlling the
thickness of the membrane.
[0150] Rollers 1212, 1214 may be straight rollers. Persons of ordinary skill
in
the art would appreciate that in other embodiments, the rollers 1212, 1214 may
have
an arch-shaped configuration to, for example, accommodate flexing of the
rollers
under pressure particularly in impregnating wider substrates. Rollers 1212,
1214
may be arched to accommodate pressure while maintaining a straight contact
surface. Rollers 1212, 1214 may be meter rollers configured to meter the
amount of
powdered microporous particles transferred onto sheeting structure 1201.
Rollers
1212, 1214 may comprise wells or cups etched onto the coating surface of
rollers
1212, 1214 that carry a certain amount of powdered microporous particles. The
wells
or cups of rollers 1212, 1214 may meter the certain amount of powdered
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microporous particles transferred onto sheeting structure 1201 with an even
and
uniform thickness of microporous particles. In other embodiments, rollers
1212, 1214
may have a substantially smooth coating surface.
[0151] Coating chamber 1200 may also include one or more doctor blades
1232 in contact with the coating surfaces of first and second calender rollers
1212,
1214. Doctor blades 1232 may be configured to remove excess microporous
particles 1234 that are coated on first and second calender rollers 1212, 1214
by
wiping first and second calender rollers 1212, 1214 as they rotate relative to
doctor
blades 1232. By removing excess microporous particles on first and second
calender
rollers 1212, 1214, doctor blades 1232 may also even out the distribution of
microporous particles coated on rollers 1212, 1214 and reduce splotching of
microporous particles.
[0152] Doctor blades 1232 may be formed of any suitable material, including,
for example, steel or plastic. It should also be appreciated that doctor
blades 1232
may be adjusted depending on the conditions of the coating process. For
example,
the radial positions of doctor blades 1232 relative to rollers 1212, 1214, the
positions
of doctor blades 1232 relative to the longitudinal axis of rollers 1212, 1214,
the angle
at which doctor blades 1232 contact rollers 1212, 1214, and the pressure
applied by
doctor blades 1230 may be adjusted to address the locations and degree of
excess
microporous particles to be removed.
[0153] In some embodiments, shrouds 1236 may be coupled to the edges of
each of first and second calender rollers 1212, 1214. Shrouds 1236 may extend
along the longitudinal axis of each of rollers, 1212, 1214 and cover portions
of the
coating surfaces of rollers 1212, 1214 adjacent to their edges. The shrouds
1236
may block microporous particles from coating portions of the coating surfaces
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covered by shrouds 1236. Accordingly, shrouds 1236 may frame the coating
surface
of rollers 1212, 1214 to match a given width of substrate 1201 to be deposited
with
microporous particles. Shrouds 1236 may therefore reduce the amount of wasted
microporous particles that may be coated on the edge of rollers 1212, 1214 but
do
not contact and transfer to substrate 1201. Shrouds 1236 may be adjustable in
length relative to the longitudinal axes of the rollers 1212, 1214 to
accommodate
various widths of substrate 1201. Persons of ordinary skill in the art would
also
appreciate that shrouds 1236 may be formed of any suitable material that is
electrically insulated and anti-stick to avoid microporous particles coating
shrouds
1236.
[0154] First and second coating apparatuses 1216, 1218 may be arranged
relative to first and second calender rollers 1212, 1214 to regulate the
coating
properties of microporous particles onto substrate 1201. For example, the
position of
first coating apparatus 1216 may be angled relative to first calender roller
1212 and
the position of second coating apparatus 1218 may be angled relative to second
calender roller 1214 depending on the desired direction the powdered
microporous
particles are to be sprayed onto first and second calender rollers 1212, 1214.
In
some embodiments, first coating apparatus 1216 may be angled upwards such that
a spray end of first coating apparatus 1224 may be pointed towards an upper
portion
of first calender roller 1212, and second coating apparatus 1218 may be angled
downwards such that a spray end of second coating apparatus 1218 may be
pointed
towards a lower portion of second calender roller 1214. The angle between
first
coating apparatus 1216 and the longitudinal axis of the feed direction of
substrate
1201 may be approximately 450, and the angle between second coating apparatus
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1218 and the longitudinal axis of the feed direction of substrate 1201 may be
approximately negative 45 .
[0155] First and second coating apparatuses 1216, 1218 may be adjusted to
any suitable angle relative to first and second calender rollers 1212, 1214,
respectively. In other embodiments, for example, first coating apparatus 1216
may
be angled downwards such that a spray end of first coating apparatus 1224 may
be
pointed towards a lower portion of first calender roller 1212, and second
coating
apparatus 1218 may be angled upwards such that a spray end of second coating
apparatus 1225 may be pointed towards an upper portion of second calender
roller
1214.
[0156] Angling the position of first and second coating apparatuses 1216,
1218 relative to first and second calender rollers 1212, 1214 may improve the
uniformity of powdered microporous particles spray coated onto first and
second
calender rollers 1212, 1214, which in turn may provide a more uniform
distribution of
microporous particles embedded into substrate 1202 and 1204. In contrast,
first and
second coating apparatuses 1216, 1218 horizontally positioned relative to
first and
second calender rollers 1212, 1214, respectively (i.e., substantially parallel
to the
longitudinal axis of the feed direction of the substrate 1201), may result in
uneven
accumulation and coating of the powdered microporous particles on first and
second
calender rollers 1212, 1214. This, in turn, may result in an uneven
distribution and
splotching of microporous particles embedded into substrate 1201. Uneven
distribution and splotching of microporous particles that may be caused by
horizontally positioning first and second coating apparatuses 1216, 1218 may
be
avoided by adjusting the proximity of first and second coating apparatuses
1212,
1214 relative to first and second calender rollers 1212, 1214, the rate at
which
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powdered microporous particles are sprayed, and the electrical charge rate of
powdered microporous particles as they exit the apparatuses.
[0157] X-axis (horizontal) adjustments of first and second coating
apparatuses 1212, 1214 may be made via a micrometer 1241, 1243. Y-axis
adjustments (vertical) of first and second coating apparatuses 1212, 1214 may
be
made via micrometer 1242, 1244. Angular adjustments of first and second
coating
apparatuses 1212, 1214 may be made via micrometer 1245, 1246.
[0158] In other embodiments, first and second coating apparatuses 1216,
1218 may be vertically positioned relative to first and second calender
rollers 1212,
1214, respectively (i.e., substantially perpendicular to the longitudinal axis
of the feed
direction of the substrate 1201). This configuration may avoid excess
accumulation
of powdered microporous particles on substrate 1201.
[0159] The proximity of first and second coating apparatuses 1216, 1218
relative to first and second calender rollers 1212, 1214 may also affect the
density
and distribution of powdered microporous particles spray coated onto first and
second calender rollers 1212, 1214. In some embodiments, first coating
apparatus
1216 may be positioned three (3) to twelve (12) inches on an eight (8) inch
wide
roller from first calender roller 1212, and second coating apparatus 1218 may
be
positioned three (3) to twelve (12) inches on an eight (8) inch wide roller
from second
calender roller 1214. The widths of the rollers and spray patterns may be
adjusted to
accommodate different distances between the rollers and the coating
apparatuses.
Positioning first and second coating apparatuses 1216, 1218 closer to first
and
second calender rollers 1212, 1214 may focus a spray profile of powdered
microporous particles and concentrate the amount of powdered microporous
particles coated on particular surface areas of first and second calender
rollers 1212,
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1214. Positioning the first and second coating apparatuses 1216, 1218 further
away
from first and second calender rollers 1212, 1214 may expand a spray profile
of
powdered microporous particles and coat more of the surface areas of first and
second calender rollers 1212, 1214 with powdered microporous particles. The
expanded spray profile may also increase the amount of powdered microporous
particles that may pass and not be electrostatically picked up by first and
second
calender rollers 1212, 1214.
[0160] Coating chamber 1210 may also include reclamation system 1264
configured to return powdered microporous particles that are not impregnated
into
substrate 1201 from coating chamber 1210 to source 1220. Reclamation system
1264 enables the process to recycle and reuse unimpregnated coating material.
Reclamation system 1264 may include one or more outlet ports 1265 disposed in
coating chamber 1200 connected to source 1220 via suitable conduits 1264. As
the
powdered microporous particles are sprayed from first and second coating
apparatuses 1212, 1214, any powdered microporous particles that may not have
been coated on first and second calender rollers 1212, 1214 or deposited onto
substrate 1201 may be collected from coating chamber 1200 and returned to
source
1220. Microporous particles may exit through outlet ports 1265 and be
delivered
through conduits 1264 and to source 1220 by any appropriate means, including,
for
example, a vacuum source.
[0161] Persons of ordinary skill in the art would appreciate that the process
for manufacturing the membrane of the present disclosure may obviate the use
of
additives, such as retention aids and binders (e.g., polyvinyl alcohol,
hydrophilic
latex, and starch) to embed and retain microporous particles within the fiber
matrix of
substrate 1201. The process of the present disclosure may manufacture the
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membrane 1206 by embedding the microporous particles into the substrate 1201
without using or by reducing the amount of additives on substrate 1201,
rollers 1212,
or microporous particles. Accordingly, unspent microporous particles in the
coating
chamber 1222 that have not been deposited onto substrate 1201 may be reclaimed
and reused via reclamation system 1264 without the need for any additional
conditioning or other processing of redaimed microporous particles. In some
embodiments, for example, approximately 20-30% of the powdered microporous
particles sprayed from first and second coating apparatuses 1216, 1218 may be
electrostatically coated on rollers 1212, 1214. Of this amount of material
deposited
on the rollers, approximately 30-40% of microporous particles coated on the
rollers
1212, 1214 may be deposited onto substrate 1201. The remaining microporous
particles 1234 that were deposited on rollers 1212, 1214 but not applied to
the
substrate 1201 may be wiped off rollers 1212, 1214 by doctor blades. This
material
along with the material that was not deposited on rollers 1212, 1214 may be
continuously recycled and reused in preparing membrane 1206.
[0162] As shown in Fig. 11b, membrane 1206 exiting coating chamber 1200
may be delivered through cooling stage 1268. Cooling stage 1268 may include
any
suitable cooling mechanisms to cool membrane 1201 as it is fed from heated
calender rollers 1212, 1214 of coating chamber 1200. Cooling stage 1268 may
include one or more apparatuses to direct ambient or chilled air, such as, for
example, air knives, onto the top and bottom surfaces of the membrane 1201. In
other embodiments, cooling stage 1268 may include one or more ouffeed rollers
on
or between which membrane 1206 may be calendered. The ouffeed rollers may be
chilled to ambient or cooler temperatures. By cooling the membrane 1206
immediately after it exits coating chamber 1200, cooling stage 1268 may set
warm
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membrane 1206, control shrinkage, and preventing crinkles and other surface
defects on membrane 1206.
[0163] Following cooling stage 1268, membrane 1206 enters rewinding
stage 1270. Rewinding stage 1270 may include a number of rollers or a festoon
that
may deliver membrane sheet 1206 to rewinder 1272 configured to wind membrane
sheet 1206 into a roll. Rollers and rewinder 1272 of rewinding stage 1270 may
be
configured to apply a constant tension on membrane sheet 1206 as membrane
sheet 1206 is wound into the roll of membrane 1260. The tension applied on
membrane sheet 1206 may be approximately two pounds per linear foot in a warm
state. A tension significantly higher than 10 pounds per linear foot applied
on
membrane sheet 1206 in a warm state may create surface defects in membrane
sheet 1206, such as microfractures, that may result in an undesired increase
in the
permeability of membrane sheet 1206. No tension or a tension significantly
lower
than one pound per linear foot applied on membrane sheet 1206 may disrupt
deposition of the microporous particles on membrane sheet 1206, such as the
uniformity and distribution of the microporous particles on the sheet 1206
surfaces.
[0164] Membrane 1206 manufactured by the manufacturing process of the
present disclosure may include a number of advantageous properties when
applied
as a substrate for heat and/or moisture transfer applications, such as
enthalpy
exchangers. The coating surface of first calender roller 1212 may contact the
entire
top surface of substrate 1202, and the coating surface of 1204 second calender
roller 1214 may contact the entire bottom surface of substrate 1201. In this
configuration, the entire surface area of substrate 1201 may be impregnated
with
microporous particles. Rollers 1212, 1214 may promote complete coverage of
membrane 1206 with microporous particles. Rollers 1212, 1214, in combination
with
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doctor blades 1232 and shrouds 1236, may also promote a homogenous and
uniform embedding of the microporous particles into the surfaces of substrate
1201.
In some embodiments, microporous particles may form a thin layer on the
surfaces
of membrane 1206, such as, for example, approximately 1 mil thick on each side
of
substrate 1201, and microporous particles may comprise 80-90 weight percent of
the
impregnated substrate material.
[0165] As a substrate material for heat and/or moisture transfer applications,
it may be desirable for membrane 1206 to be impermeable to air. In some
embodiments of the present disclosure, membrane 1206 may be formed of a paper
coated with gamma alumina. In other embodiments, membrane 1206 may be formed
of thermoplastic sheet coated with gamma alumina. Alumina may act as a natural
release agent while any voids or areas of non-uniform coating will result in
immediate adhesion of membrane material.
[0166] Membrane 1206 formed of a paper coated with gamma alumina may
have a wide pore size distribution. An example of commercially available gamma
alumina is VGL 15 produced by U.O.P. Corporation. The porosity selected of the
gamma alumina-coated paper may permit the flow of moisture across membrane
1206 but block the flow of air. Accordingly, the gamma alumina-coated paper
may
accommodate both heat and moisture transfer across membrane 1206.
[0167] Preferred microporous particles may be a transition alumina, such as
gamma alumina, due to their inert properties, electrical charge properties,
lower cost,
and wide market availability. These materials may be activated for adsorption
by
removing water from their hydrated precursors. Preferred surface area ranges
may
be between 100 m2/gm and 250 m2/gm. Preferred pore volume ranges may be 1.30
cc/g to 1.40 cc/g. Preferred loose bulk density optimized for spraying and
imparting
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electrostatic charges may be between 150 kg/m3 to 200 kg/m3. Friability index
values
of 9-10 may be preferred. The higher the friability index, the more easily the
product
may be deagglomerated and may accept a charge more rapidly upon entrance into
coating apparatuses. The friability index may be a function of calcination
conditions.
The friability index is the relative loss of >20-micron particles in a nominal
5 wt%
slurry of caused by ultrasonification.
[0168] Membrane 1206 formed of a thermoplastic sheet coated with gamma
alumina of the present disclosure may have a pore volume of approximately 1.36
wig. The porosity of the gamma alumina-coated thermoplastic sheet may restrict
the
flow of both air and moisture across the membrane 1206. Accordingly, the gamma
alumina-coated thermoplastic sheet may accommodate only heat transfer across
membrane 1206. The microporous particles may be any material capable of
efficiently holding liquids through capillary action and surface tension while
allowing
for imparting a charge. The microporous material may also be capable of
efficiently
adsorbing/desorbing said moisture to a counterflowing air stream. Examples of
such
microporous particles, include, for example, activated aluminas, silica gels,
molecular sieves, porous titania, or zeolites, activated carbon, and mixtures
thereof.
[0169] A single monolayer of microporous particle on the top side and a
monolayer of microporous particle on the bottom side with greater than 99%
roller
coating coverage may be achievable. Coefficient of heat transfers may meet or
exceed that of aluminum foils of equivalent thicknesses due to the high
surface
areas disrupting the boundary layer for fluid flow. Preferable heat transfer
coefficients may exceed 59-64 w/m2.K at air velocity of 3 m/s. Preferable
membrane
thickness may range between 3 and 7 mils. A high tear resistance may be
achievable utilizing polyethylene or polypropylene reinforced with various
fiber types.
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Porous particles may be physically embedded onto the surface of a
thermoplastic
and held in place due to the physical porosity structure of the particle.
Preferable
weight ranges of a substrate before application of microporous particles may
be 15
to 35 grams per square meter. Preferable weight ranges after application of
microporous particles may be 60 to 130 grams per square meter.
[0170] The surfaces of the gamma alumina-coated paper and the gamma
alumina-coated thermoplastic sheet may be highly wettable because the gamma
alumina may adsorb large quantities of moisture. Moreover, the thermoplastic
fibers
of the gamma alumina-coated thermoplastic sheet may have low surface tension
and
promote sheet flow of moisture, including water and a liquid desiccant, such
as
lithium chloride, along the surfaces of the membrane 1206. By promoting the
flow of
a liquid desiccant along the surfaces of the membrane 1206, the thermoplastic
fibers
may promote air-to-liquid surface interaction resulting in a higher transfer
efficiency
from membrane 1206. In some embodiments, the thermoplastic sheet may be
corona treated prior to being coated with the gamma alumina. Corona treating
the
surfaces of the thermoplastic sheet may further promote bonding of the gamma
alumina to the sheet and may increase the wettable properties of membrane
1206.
[0171] While membrane 1206 of the present disclosure has been described
in applications as a substrate for heat and moisture transfer applications,
such as
enthalpy exchangers, it would be apparent to persons of ordinary skill in the
art that
membrane 1206 may be used in other applications. For example, in some
applications, membrane 1206 may be used as a battery separator material in an
electrochemical cell.
[0172] Membrane 1206 may be processed under suitable post-
manufacturing treatments. In some embodiments, membrane 1206 may be treated
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with a desiccant to increase the adsorption properties of membrane 1206 and
further
reduce its permeability. For example, membrane 1206 may be exposed to a brine
solution including a liquid hydroscopic salt desiccant, such as lithium
chloride, and
dried so that desiccant is absorbed and maintained by membrane 1206.
[0173] Membrane 1206 may be folded and joined at certain edge locations to
form multiple opening exchangers for various applications, including heat
and/or
water vapor exchangers. The exchangers may be suitable for use as exchangers
in
energy recovery ventilators (ERV) applications. The exchangers may also be
used in
heat and/or moisture applications, air filter applications, gas dryer
applications, flue
gas energy recovery applications, sequestering applications, gas/liquid
separator
applications, automobile outside air treatment applications, carbon dioxide
scrubbing
applications, airplane outside air treatment applications, and fuel cell
applications.
The exchangers typically may be disposed within a housing.
[0174] For example, in heat and/or moisture transfer applications, such as
enthalpy exchangers membrane 1206 may be folded, layered, and sealed at
certain
edge locations to form an exchanger having multiple membrane layers with a
plurality of inlet and outlet passageways in an alternating arrangement, as
described
in U.S. Application No. 13/426,565; U.S. Patent No. 9,562,726; and U.S. Patent
No.
7,824,766.
[0175] Membrane 1206 may be coated with a bonding material. In a
preferred embodiment, a thermoplastic material may be extruded onto the edges
of
membrane 1206. The thermoplastic material may act as a bonding agent. The
membrane 1206 may be folded and sealed at select portions of the edges by
welding (e.g., ultrasonic, vibration, or heat) the thermoplastic-coated
portions of the
edges.
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[0176] In some embodiments, the thermoplastic may be extruded on the
edges of both the top surface and the bottom surface of membrane 1206, and the
extruded thermoplastic material on the top surface and the extruded
thermoplastic
material on the bottom surface may extend laterally and join together. In
other
embodiments, the thermoplastic material may be extruded on the edges of only
one
of the top surface and the bottom surface of membrane 1206, and the extruded
thermoplastic material may extend laterally and wrap around the edges of the
membrane 1206 and bond to the other of the top surface and the bottom surface.
[0177] The thermoplastic material may be any suitable thermoplastic,
including, for example, polyethylene. The width of the thermoplastic material
extruded on membrane 1206 may be approximately 0.125-0.25 inches but may be
adjusted to any other width appropriate to achieve a suitable bonding area
between
folds of membrane 1206. The microporous particles, such as gamma alumina,
impregnated into the surface of substrate 1201 may protect membrane 1206 from
potential damage that may otherwise result from the high heat of the edge
coating
process. For example, the gamma alumina deposited on substrate 1201 may
insulate substrate 1201 from the high heat of the extruded polyethylene.
Separators for Exchanger and Related Methods of Manufacture
[0178] The enthalpy exchanger of the present disclosure may comprise
membrane 1206 and separator. Separator may be positioned between layers of
membrane 1206. Separator may be disposed in some or all the passageways
between adjacent membrane layers and may assist with fluid flow distribution
and/or
to help maintain separation of the membrane layers. In some embodiments,
separator may be a corrugated netting formed of thermoplastic material.
Separator
may be formed of any suitable material, including, for example, corrugated
aluminum
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inserts, plastic molded inserts, and mesh inserts. In some embodiments, the
separator may include porous materials, such as a porous felt, to facilitate
wicking
and wetting of membrane 1206. As discussed in more detail below, separator may
be inserted during the folding and joining process of membrane 1206 in forming
the
enthalpy exchanger. Alternatively, separator may be inserted between membrane
layers after the enthalpy exchanger has been formed. In particular, separator
may be
inserted between adjacent membrane layers after membrane 1206 has been folded
but before the select edges of membrane 1206 have been joined together.
[0179] Fig. 12 illustrates a perspective view of one layer 1302 of separator
1300. Separator 1302 may be a corrugated netting 1304 formed of a
thermoplastic
material, such as, for example, polypropylene or polyethylene. Persons of
ordinary
skill in the art would appreciate that corrugated netting 1304 may be formed
of any
other suitable thermoplastic material. Corrugated netting 1304 preferably has
a
weight of less than 3 lbs/1,000 ft2 and, more preferably, less than 1.5
lbs/1,000 ft2.
Utilizing a thermoplastic material to form corrugated netting 1304 may be
advantageous because thermoplastic materials may be resistant to most forms of
corrosion, which may allow for operation in air streams containing corrosive
chemicals. Further, thermoplastic materials may be compatible with most forms
of
heat and vapor membranes.
[0180] Corrugated netting 1304 may include a first plurality of filament
members 1306 extending along a first plane (the X-plane) in a sinusoidal
pattern.
Corrugated netting 1304 may also include a second plurality of filament
members
1308 that may extend along a second plane transverse or at an angle to the
first
plane (the Y-plane) and connect to the first plurality of filament members
1306. The
second plurality of filament members 1308 preferably may be substantially
straight
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and connect to the first plurality of filament members 1306 at 90 angles
relative to
the X-plane. Separator structure 1300 provides appropriate spacing between
membrane 1206 layers.
[0181] Sinusoidal filament members 1306 may include an amplitude Z.
Amplitude Z may define a discrete fluid flow channel within the passageways of
the
exchanger. In some embodiments, amplitude Z may be 0.8 mm for a type "F" flute
at
125 flutes per foot. In other embodiments, amplitude Z may be 1.6mm fora type
of
"E" flute at 95 flutes per foot. Additionally, amplitude Z may be 3.2mm for a
type of
"B" flute at 49 flutes per foot. Further, amplitude Z may be 4.0mm for a type
of "C"
flute at 41 flutes per foot. The size of apertures 1310 of corrugated netting
1304
formed between the filament members 1306, 1308 may be selected depending on
the desired vapor transmission, pressure drop, and separator strength.
[0182] For example, decreasing the distance between adjacent sinusoidal
filament members 1306 and/or the distance between adjacent connector filament
members 1308 may reduce the size of the apertures 1310 and increase the
structural strength of the separator 1300. The reduced size of the apertures
1310
may, however, restrict a desired vapor transmission across membrane 1206 and
may contribute to a higher pressure drop of fluid, such as air, flowing
through the
passageways of the exchanger. Increasing the distance between adjacent
sinusoidal
filament members 1306 and/or the distance between adjacent connector filament
members 1308 may increase the size of apertures 1310. The increased size of
apertures 1310 may accommodate a desired vapor transmission across membrane
1206 and may result in a lower pressure drop of fluid flowing through the
passageways of exchanger. The increased size of apertures 1310 may, however,
decrease the structural strength of separator 1300.
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[0183] In a preferred embodiment, Y-axis filament members 1308 may be of
similar distance and strength as X-axis filaments 1306. Filament connections
may
occur at the apex of each curve. Strand thickness may range between 4-20 mil.
Separator 1300 may withstand 12 inches of wg pressure differential at 72 F.
[0184] Separator 1300 may be used in any appropriate heat and moisture
exchanger design. Corrugated netting 1304 of separator 1300 may be produced
through an extrusion process. Corrugated netting 1304 of thermoplastic
material may
be preferably biaxial oriented, which may be lighter in weight and more
flexible than
extruded square mesh. Orientation "stretches" extruded square mesh in X and Y
directions under controlled conditions, which may produce strong, flexible,
and light
weight netting. Biaxial-oriented corrugated netting 1304 may have improved
performance over known heat and water vapor separator materials and
techniques.
[0185] Apertures 1310 of corrugated netting 1304 may provide more
membrane surface area to the air stream, and in some applications, may
facilitate
faster vapor transfer over separators formed of corrugated sheet materials,
such as
foils, plastics, or paper. In addition, water vapor within an air stream
flowing through
a passageway of exchanger separated with corrugated netting 1304 may on
average
travel a shorter distance to interact with membrane 1206 compared to a
passageway
with a corrugated sheet separator. Further, biaxial-oriented corrugated
netting 1304
may facilitate fluid movement in both the X and Y plane directions. Airflow
entering a
corrugated sheet separator, however, may travel only in a straight-line path.
Bi-
directional airflow provided by biaxial-oriented corrugated netting 1304 may
allow for
a broader range of geometric shapes within the context of heat and moisture
exchangers. Corrugated netting 1304 may also utilize less material than
corrugated
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sheet separators, which may achieve both cost reduction and better performance
in
smoke/fire testing.
[0186] An exemplary process for manufacturing separator 1400 according to
the present disclosure will now be described with reference to Figs. 13a-13d.
A roll of
thermoplastic netting material 1402 may be continuously delivered to
corrugation
chamber 1404. Corrugation chamber 1404 may include housing 1406 enclosing
first
continuous belt 1408 and second continuous belt 1410. First continuous belt
1408
includes first corrugated surface 1412 having corrugation crests and valleys,
and
second continuous belt 1410 includes second corrugated surface 1414 having
corrugation crests and valleys. The corrugation crests of first corrugated
surface
1412 may mate with the corrugation valleys of second corrugated surface 1414,
and
corrugations crests of the second corrugated surface 1414 may mate with the
corrugation valleys of first corrugated surface 1412. Corrugation chamber 1404
may
further include first drive unit 1416 configured to drive first continuous
belt 1408 and
second drive unit 1418 configured to drive second continuous belt 1410 in
synchronous operation. Each of drive units 1416, 1418 may include one or more
pulleys or rollers 1426, 1428 rotatably driven by a suitable power source,
such as, for
example, a motor. Continuous belts 1408, 1410 may be trained over pulleys
1426,
1428, and pulleys 1426, 1428 and may rotate and drive continuous belts 1408,
1410,
mating together first and second corrugated surfaces 1412, 1414.
[0187] In some embodiments, rollers 1426, 1428 may be at least 0.5 meters
in diameter. Corrugated belts 1408, 1410 may have amplitudes of between 1.5mnn
and 6mm and widths between 250mm and 1000mm. Continuous belts 1408, 1410
may first be formed with the sinusoidal profile and then precisely cut to
length at the
apex of a flute.
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[0188] Continuous belts 1408, 1410 may be welded end-to-end to form a
continuous loop using micro-laser welding techniques. In certain embodiments,
the
alignment and corrugation intervals may be maintained through the micro-laser
weld
utilizing fixturing to maintain tolerances while micro-welding. Maintaining an
acceptable interval pattern and tolerances may prevent cutting or breaking of
the
biaxial netting. In other embodiments, welding methods may include WIG,
plasma,
electron beam or laser welding. Continuous belts 1408, 1410 may be made from a
17-7 or 17-4 stainless steel with a high tolerance to repeated flexural and
fatigue
resistance. lnfeed web tension may be maintained between 5 and 20 pounds per
linear foot. Higher web tensions may result in a thinner sinusoidal strand.
Residence
time between inlet and outlet nips is between 5 and 30 seconds depending on
thickness of strands.
[0189] As netting material 1420 is fed through first and second continuous
belts 1408, 1410 netting material 1420 may be pressed between first and second
corrugated surfaces 1412, 1414 of continuous belts 1408, 1410. Heat and
pressure
from continuous belts 1408, 1410 may corrugate netting material 1420 and form
sinusoidal members 1306 of separator 1300. Heat may be applied on portions of
continuous belts 1408, 1410 where netting material 1420 enters. For example, a
heat source, such as heat lamps 1422, may be positioned proximate an entry
portion
1424 of continuous belts 1408, 1410 to heat corrugated surfaces 1412, 1414 as
they
initially contact and press the sheeting structure 1420. Additionally, or
alternatively,
pulleys 1426, 1428 proximate the entry potion 1424 of continuous belts 1408,
1410
may be heated, via, for example, heating element within the core of pulleys
1426,
1428, and may transfer heat to corrugated surfaces 1412, 1414 of continuous
belts
1408, 1410. In some embodiments, corrugated surfaces 1412, 1414 may be heated
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to approximately 240 F to 260 F for polypropylene and 180 F to 220 F for
polyethylene.
[0190] Persons of ordinary skill would understand that other combinations of
time, pressure, temperature, and line speed may also be used to form the
netting of
the present disclosure. Any such combinations of parameters are appropriate
which
may enable separator 1430 to be formed into the desired shape and
substantially to
hold this shape through subsequent processing, assembly, and use.
[0191] Corrugated netting material 1432 may be released and collected as
material 1432 exits output potion 1434 of continuous belts 1408, 1410.
Corrugated
netting material 1432 may be cooled proximate output portion 1434 of
continuous
belts 1408, 1410 to set the corrugations. In some embodiments, cooling source
1438, such as, for example, one or more air knives, may be positioned
proximate
output portion 1434 of continuous belts 1408, 1410 to cool corrugated netting
material 1432. One or more air knives may direct air at the top and bottom
surfaces
of corrugated netting material 1432 at an ambient temperature or cooler, such
as, for
example, 80 F to 120 F. Additionally, or alternatively, pulleys 1426, 1428
proximate
output potion 1434 of continuous belts 1408, 1410 may be cooled, via, for
example,
a cooling element within the core of pulleys 1426, 1428, and may remove heat
from
the corrugated netting material 1432.
[0192] As corrugated netting material 1432 is cooled and released from
continuous belts 1408, 1410, corrugated netting material 1432 may be collected
by
collector 1442. Collector 1442 may include a number of rollers or festoon 1448
that
may deliver corrugated netting material 1432 to rewinder 1446 configured to
wind
corrugated netting material 1432 into roll 1444. Rollers 1448 and rewinder
1446 of
collector 1442 may be configured to apply a constant tension on corrugated
netting
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material 1432 as corrugated netting material 1432 is wound into roll 1444. The
tension applied on the corrugated netting material 1432 may be approximately
less
than 0.5 pounds per linear foot. Collector 1442 may apply tension on
corrugated
netting material 1432 to prevent surface irregularities, such as, for example,
crinkles,
and to maintain the alignment of the sinusoidal members 1306 along a
longitudinal
axis of corrugated netting material 1432.
[0193] The process for manufacturing separator 1432 according to the
present disclosure may provide numerous advantageous and improvements over
known processes for manufacturing corrugated netting materials. Known
processes
may employ corrugated rollers to form a corrugated profile on a material fed
between
the rollers. These known processes, however, may have limitations associated
with
the surface area provided by the corrugated rollers for corrugating a netting
material.
Continuous belts 1408, 1410 of the present disclosure may provide a larger
corrugation surface compared to known corrugated rollers. The larger
corrugation
surface area of continuous belts 1408, 1410 may accommodate a greater output
rate
of corrugated netting material and may improve the uniformity and alignment of
the
corrugated profile of the corrugated netting. Continuous belts 1408, 1410 may
also
accommodate a larger heating surface area for forming the corrugations on the
netting material. The larger heating surface area may allow continuous belts
1408,
1410 to heat a greater area of netting material and at a wider range of
temperatures.
[0194] For example, a higher temperature profile and area may improve the
setting of corrugations on netting material, permit a higher amplitude of
corrugations,
and strengthen corrugations against deformation (i.e., increase the shape
memory of
the corrugations). Moreover, continuous belts 1408, 1410 may provide a dwell
section between the heating portion and the cooling portion that may
facilitate setting
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corrugated netting material. Continuous belts 1408, 1410 may also produce
corrugated netting material 1432 with thicker sinusoidal and connection
members
1306, 1308 compared to a corrugated netting material 1432 manufactured by
known
corrugated rollers. The disclosed process may afford a much longer dwell time
in
which the filaments can be fully heated and then fully cooled before being
released,
unlike a conventional corrugation roller system. Furthermore, the tension
applied to
corrugated netting material by collector 1442 may maintain the alignment of
sinusoidal members 1306 and may improve the uniformity of corrugated netting
material 1432.
[0195] While separator 1432 of the present disclosure has been described in
applications as a separation structure for membrane layers of heat and
moisture
transfer bodies, such as enthalpy exchangers, persons of ordinary skill in the
art
would appreciate that separator 1432 may be utilized as a separation structure
in
various other applications. For example, in some applications, the separator
1432
may serve as a separation structure for air filters known in the art. As shown
in Figs.
14a-14c, air filter 1500 may include filter material 1504, such as, for
example, any
suitable fibrous material that may remove solid particulates, including, dust,
pollen,
mold, and bacteria, from the air. In some embodiments, filter material 1504
may
include membrane 1206 discussed above. Air filter 1500 may include input side
1514
for receiving air to be filtered and output side 1516 from which filtered air
may exit air
filter 1500. The filter material 1504 may be folded to form a plurality of
pleats 1508.
As shown in Figs. 14a-14c, air filter 1500 may also include separator 1300
positioned on output side 1516 of air filter 1500 and folded with pleats 1508
of filter
material 1504.
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[0196] Air filters with separator 1300 according to the present may provide
numerous advantageous and improvements over known air filters. Existing air
filters
may employ a plurality of bridge structures that may space out and connect
adjacent
pleats of the filter material via an adhesive or weld. The bridge structures
generally
may be positioned on the input side of the air filter. This configuration may
restrict air
flow through the air filter and reduce the filtering performance of the air
filter.
Separator 1300 of the present disclosure, may provide improved air flow
through the
air filter. Corrugated netting material 1304 of separator 1300 may be more
open than
existing bridge structures, which may accommodate more air flow through the
filter
material. For example, 97-98% of the surface area of corrugated netting
material
1304 may be open and provide unrestricted airflow. Moreover, the sinusoidal
and
connecting members 1306, 1308 of corrugated netting material 1304 may be
thinner
than existing bridge structures to further minimize restrictions to airflow.
In some
embodiments, for example, the sinusoidal and connecting members 1306, 1308 may
be approximately 1/16 of an inch thick. Separator 1300 may also be less dense
than
existing bridging structures and may provide a spacing structure that may be
lighter
in weight and smaller in size.
[0197] The compressible property of separator 1300 may also improve the
performance of the air filter. As the input side of the air filter receives
air, the pleats
of the filter material may fan out or open to increase the capacity of the
filter material
to filter particulates from the input air. Separator 1300 disposed on the
output side of
the air filter may receive the load from the pleats opening up on the input
side and
compress.
[0198] As discussed above, an enthalpy exchanger may be formed of
membrane 1206 and separator 1300. For example, membrane 1206 and separator
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1300 may form enthalpy exchangers as described in U.S. Application No.
13/426,565.
Air Conditioner Modules and Systems
[0199] Figs. 15a-15h illustrate perspective views of an evaporative cooling
and/or steam regenerating liquid desiccant air conditioner module 1600 and its
related components according to the present embodiment. The present disclosure
may be directed to an air conditioning module and system configured to perform
various air treatment operations. Such air treatment operations may include,
but are
not limited to: (1) changing the moisture and/or heat content of the air being
processed; (2) absorbing carbon dioxide (CO2), formaldehyde, and other
volatile
organic compounds (VOC) from the air being processed; (3) regeneration of weak
solutions of the liquid desiccant being processed; (4) regeneration of spent
liquid
sorbents of the reversibly binding aqueous solution being processed; (5)
recovery of
moisture and/or heat content between two remote air streams; and (6) changing
the
heat content of a working liquid using indirect/direct evaporative cooling.
[0200] Air conditioner module 1600 may comprise exchanger housing 211
and exchanger 213. The entirety of exchanger 213 may be contained inside
exchanger housing 211. Exchanger 213 may be formed of membrane 1206
comprising a thermoplastic sheet embedded with gamma alumina. Exchanger 213
may comprise a plurality of plates 1615 with a plurality of intermittently
sealed plate
edges 1620 arranged in a successively stacked configuration. Portions of
plates
1615 may be spaced apart to provide a first series of discrete alternating
passages
1613 and a second series of discrete alternating passages 1614.
[0201] A first air stream 1680 may be passed through first series of passages
1613 and a second air stream 1681 may be passed through second series of
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passages 1614 in a counterflow configuration with respect to first air stream
1680.
First and second air streams 1680, 1681 may be maintained physically separate
from one another, while maintaining thermal contact between them to allow heat
to
freely pass therebetween. Air conditioner module 1600 may include first liquid
supply
conduit 1622 secured in first liquid threaded inlet 1636 and second liquid
supply
conduit 1624 secured in second threaded inlet 1638. First liquid 1626 and
second
liquid 1628 may be feed into first liquid supply conduit 1622 and second
liquid supply
conduit 1624, respectively. First liquid 1626 and second liquid 1628 may pass
through to adjoining air conditioner module 1600 via first liquid return
conduit 1623
and second liquid return conduit 1625, respectively.
[0202] First liquid 1626 may exit air conditioner module 1600 through first
liquid threaded outlet 1640, and second liquid 1628 may exit air conditioner
module
1600 through second liquid threaded outlet 1642. These return conduits may
facilitate a plurality of air conditioning modules being supplied with first
liquid 1626
and second liquid 1628 and may be used to flush module 1600 of impurities that
may
build up. With appropriate modifications such as the, The air conditioner of
the
present disclosure may be adapted by, for example, selecting first and second
air
stream and type of delivered liquids, for using the air conditioner in various
applications, including, but not limited to, indirect evaporative cooling,
direct
evaporative cooling, liquid desiccant dehumidification, carbon dioxide
scrubbing,
VOC scrubbing, hot water liquid desiccant regeneration, indirect steam liquid
desiccant regeneration, hot water regeneration of scrubbing reversibly binding
aqueous solutions, indirect steam regeneration of scrubbing reversibly binding
aqueous solutions, and the like.
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[0203] Conduits 1622, 1623, 1624, and 1625 may extend through a liquid
distribution system comprising a stacked configuration of plates including
first
distribution headers 1632 and second distribution headers 1634. Figs. 15d-15h
illustrate perspective views of first and second distribution headers 1632,
1634 and
their related components according to the present disclosure. In some
embodiments,
the distribution headers 1632 and 1634 may be made of silicone, urethane,
thermoplastics, vital, Teflon, or other non-corroding sealing material.
Headers 1632
and 1634 may include silicone leaves having porous members 1630. First and
second distribution headers 1632 and 1634 may be sealed together by
compression
plates 1645 tied together by compression rods 1644 passing through headers
1632
and 1634.
[0204] As illustrated in Fig. 15g, for example, membrane 1206 of exchanger
213 may be positioned between first distribution headers 1632 and second
distribution headers 1634. Membrane 1206 may also include a plurality of
membrane
conduit holes 1672 aligning with conduits 1622, 1623, 1624, and 1625. First
liquid
1626 may be delivered into first distribution headers 1632 and may be
discharged
through conduit 1622 or 1623 and onto membrane 1206 through membrane conduit
holes 1672 aligned with conduit 1622 or 1623. Second liquid 1628 may be
delivered
into second distribution headers 1634 and may be discharged through conduit
1624
or 1625 and onto membrane 1206 through membrane conduit holes 1672 aligned
with conduit 1624 or 1625. A suitable alignment mechanism, for example, a
tine,
may be coupled to headers 1632 and 1634, membrane conduit holes 1672, and
exchanger housing 211 holes 1640 and 1638 to maintain the alignment and
registration of the components of the liquid distribution system.
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[0205] First distribution header 1632 may comprise first liquid feeder channel
1648 and a plurality of feeder holes 1652. Porous members 1630 may be inserted
into feeder holes 1652 by, for example, a press-fit. Porous members 1630 may
be,
for example, porous wicks or pipette-shaped porous inserts for delivering
liquids to
membrane 1206 of exchanger 213. Porous members 1630 may be in direct contact
with the inside membrane surfaces of the first series of fluid passages 1613.
Second
distribution header 1634 may comprise second liquid feeder channel 1650 and a
plurality of feeder holes 1652. Porous members 1630 may also be inserted into
feeder holes 1652 of second distribution header 1634. First and second liquids
1626,
1628 may be dispensed directly to membrane surfaces of first and second
passages
1613, 1614 via porous members 1630 with the liquids maintaining intimate
contact in
the transition from feeder holes 1652 to membrane surfaces.
[0206] Liquids may be dispersed without creating microdroplets which may
become entrained within the air streams. Microdroplet entrainment may occur
through unrestrained transition between feeder holes 1652 and membrane
surfaces
without porous members 1630. Porous members 1630 may provide protection from
the aerodynamic forces posed by flowing airstreams at the exit of liquids from
feeder
holes 1652. These porous members 1630 may be advantageous for strong
hygroscopic liquid desiccants and strong carbon dioxide absorbing alkylamine
solutions. Strong liquid desiccants may be highly polar by nature, which may
make
then even more susceptible to entrainment absent porous members 1630 to
maintain fluid flow at the transition to the membrane surfaces. Small amounts
of
alkylamine solutions entrained into an air stream may create an unpleasant
amine
smell inside building enclosures.
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[0207] Dispensing liquids via porous members 1630 may be accomplished
without spanning or bridging of liquids across the respective airstreams along
the
inside surfaces of first and second fluid passages 1613, 1614. Spanning or
bridging
may occur through unrestrained transition between feeder holes 1652 and
membrane surfaces absent porous members 1630. Porous members 1630 may
provide protection from the aerodynamic forces posed by flowing airstreams.
Aerodynamic forces may arbitrarily focus the flow into various concentrated
streams
upon wetting of membrane surfaces. Absent porous members 1630, aerodynamic
forces from flowing airstreams may favor one of the two inside surfaces of
fluid
passages 1613,1614 causing uneven flow and reducing performance. The strong
polarity of many liquids may further exacerbate the spanning and bridging
phenomena.
[0208] Dispensing liquids via porous members 1630 may also be
accomplished, without variance in flow rates, through a plurality of feeder
holes
1652. Flow variance may occur through unrestrained transition inside feeder
holes
1652 because of variability in entrance/exit effects, diameter, length, or
wall friction.
Porous members 1630 may deliver liquids to the membrane surface in a uniform
manner across a plurality of feeder holes 1652. This uniform resistance may
ensure
that each feeder hole 1652 has the same volume of liquid flowing through it.
Porous
members 1630 may reduce distribution header pressure and related pump energy.
Distribution headers 1632, 1634 may operate below 1 psi while still affording
full
control of variable flow rates. Furthermore, precise dispensing of liquids via
porous
members 1630 may promote uniform wetting characteristics on the inside
membrane
surfaces of passages 1613, 1614. Distribution headers 1632 and 1634 and porous
members 1630 may be fluidly connected to one of the six sides of exchanger
213.
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Liquid dispensing may be accomplished without blocking or interfering with
first or
second air streams 1680, 1681.
[0209] Porous members 1630 may include inlet 1654 passing through the
walls of first distribution header 1632 and into first liquid feeder channel
1648.
Porous members 1630 may also include outlet 1656 passing through the walls of
first distribution header 1632 and positioned outside first distribution
header 1632.
First liquid 1626 may enter the pores of porous members 1630 at inlet 1654.
First
liquid 1626 may pass through the porous members 1630 and exit the pores of
porous members 1630 at outlet 1656 in direct contact with the inside membrane
surfaces of first passages 1613. Porous members 1630 may provide a continuous
flow of first fluid 1626 from first end to second end of the first passages
1613 while
the first fluid 1626 is in contact with the first air stream 1680.
[0210] Second liquid 1628 may enter the pores of porous members 1630 at
inlet 1654. Second liquid 1628 may pass through porous members 1630 and exit
the
pores of porous members 1630 at outlet 1656 in direct contact with the inside
membrane surfaces of second passages 1614. Porous members 1630 may provide
a continuous flow of second liquid 1628 from first end to a second end of
second
passages 1614 while second liquid 1628 is in contact with second air stream
1681.
[0211] Porous members 1630 may include any suitable material capable of
capillary action, including, for example ceramic, metal, or plastic such as
polypropylene or polyethylene. Porous members 1630 may have an average
controlled pore size of between 25 and 60 microns, and preferably 30 microns.
Porous members 1630 may comprise microporous particles selected from: porous
titania; transition alumina; silica gel; molecular sieve; zeolite; activated
carbon;
porous polypropylene; or porous polyethylene. Porous members 1630 may also
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include a width substantially equal to the spacing between the plates 1615 to
facilitate direct contact and capillary action on the inside walls of plates
1615. The
motion of liquid flow may be controlled by the porous link between headers
1632,
1634 and membrane walls 1206, whereby the continuous flow of liquid may avoid
the formation of droplets by blowing air currents that may be entrained in
passing air
streams 1680, 1681.
[0212] Headers 1632, 1634 of the present disclosure may provide
continuous liquid flow through porous members 1630 by a combination of
capillary
action, surface tension, adhesion, and little to no additional head pressure
beyond
given fluid column height and with the porous members 1630 being in intimate
contact with the membrane walls 1206. Liquid may pass through porous members
1630 via a tortuous path, which may result in a uniform deposition of flow
characteristics regardless of where an individual porous member 1630 is
located
within the system.
[0213] As shown in Fig. 15h, headers 1632 and 1634 may be formed of
silicone leaves. Porous members 1630 may be pressed into the silicone leaves
and
may provide controlled delivery of liquid onto membrane walls 1206. The
components of first and second distribution headers 1632, 1634 may provide for
a
low flow of liquids under low pressure. First and second distribution headers
1632,
1634 may deliver continuous flow 1658 of liquid at a time onto the membrane
walls
1206 of first and second passages 1613 and 1614, thereby affording an ultra-
low
flow conditioner. Continuous flow 1658 of liquid may flow down membrane walls
1206 of first and second passages 1613 and 1614 in a direction perpendicular
to first
and second air streams 1680 and 1681. The headers 1632 and 1634 may be
integrated into the exchanger 213 during the folding or layering process of
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membrane 1206. In one embodiment, for example, header 1632 may be positioned
on a layer of membrane 1206 after each folding or layering step of membrane
1206.
Headers 1632 and 1634 may be positioned on the layers of membrane 1206
manually or by an automated process, such as, for example, a 3D printing step
between folding steps.
[0214] Membrane 1206 of exchanger 213 may be formed of a thermoplastic
sheet comprising porous material, such as, for example, gamma alumina,
disposed
along at least a portion of the inside surfaces of the first and/or second
series of
passages 1613 and 1614. The thermoplastic sheet comprising porous material on
both sides may be about 4 to 7 mils thick. The porous material of membrane
1260
may draw up liquid from the porous members 1630 via capillary action and may
provide uniform flow of first and second liquids 1626 and 1628 via gravity
from first
and second distribution headers 1632 and 1634 to first and second ends of
plurality
of plates 1615. As discussed above, the surfaces of the thermoplastic sheet
coated
with porous material, such as, for example, gamma alumina, may form membrane
1206 and may be highly wettable because the porous material, like gamma
alumina,
may facilitate large quantities of liquid to flow within its pore structure
and adsorb
large quantities of moisture. This may also provide a greater surface area for
heat
transfer within first and second plurality of passageways 1613 and 1614 and
improved cooling of first and second air streams 1680 and 1681. Furthermore,
wettable membrane 1206 and the delivery of liquid provided by alternating
first and
second header array 1632 and 1634 may promote hugging of the liquid to
membrane walls and inhibit entrainment of undesired liquids into airstreams
1680
and 1681.
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[0215] Air conditioner module 1600 may also comprise a liquid collection
system for collecting first liquid 1626 and second liquid 1628 flowing out of
the
plurality of first passages 1613 and plurality of second passages 1614. The
liquid
collection system may include first liquid drain conduit 1616 for collecting
the flowing
first liquid 1626 from first passages 1613 and second liquid drain conduit
1618 for
collecting the flowing second liquid 1628 from second passages 1614.
[0216] First and second liquid drain conduits 1616, 1618 may be located
entirely outside of the exchanger 213 and may be adjacent to the second ends
of the
plurality of plates 1615. By being wholly outside the exchanger 213, first and
second
liquid drain conduits 1616, 1618 may facilitate lower manufacturing costs and
a
compact form factor and may be readily and efficiently inspectable. External
liquid
drain conduits 1616, 1618 may be optimized (e.g., by size and/or number) given
the
desired number of air conditioner modules 1600 implemented and the anticipated
fluid flows corresponding to given building design conditions. The reservoir-
less
design may also reduce costs and weight, may require less sealing, and may
reduce
potential mold growth.
[0217] Although not depicted, a suitable system may be coupled to
exchanger 213 to collect, treat, and recycle the cooling medium and liquid
desiccant
delivered through exchanger 213. For example, water or water vapor from first
passageways 1612 may be collected and recycled through suitable outlet ducts.
In
some embodiments, the collected water may be further cooled via a refrigerant
or
the like before being delivered to exchanger 213. In addition, the cool weak
liquid
desiccant from second plurality of passageways 1614 may be collected and
passed
through suitable outlet ducts to regenerator, such as, for example, a boiler.
Strong
liquid desiccant from regenerator may then be recycled back to exchanger 213.
In
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some embodiments, exchanger 213 may be used as the regenerator, rather than a
conventional boiler.
[0218] Exchanger 213 may comprise at least one separator 1300 disposed
on each of the inside surfaces of first and second passages 1613 and 1614 for
maintaining the space therebetween. Separator 1300 may be formed of a high
temperature thermoplastic able to withstand high temperatures (e.g., between
212 F
and 300 F) in applications where the exchanger 213 is used in a steam
regenerating
liquid desiccant module. In some embodiments, separator 1300 height may be
0.062
inches to ensure no bridging of fluids and optimize heat transfer. First and
second
distribution headers 1632 and 1634 may deliver an interchangeable plurality of
first
and second liquids 1626 and 1628, such as, for example, strong liquid
desiccant,
weak liquid desiccant, directly evaporating water, indirectly evaporating
water, hot
water, cooling tower water, steam condensate, antimicrobial cleaner, or
combinations thereof. Delivered liquids may also include those that absorb or
adsorb
certain air contaminants, such as, for example, carbon dioxide scavengers,
formalydyde absorbers, materials that absorb other contaminants, and
combinations
thereof.
[0219] Air conditioner module 1600 may provide an interchangeable plurality
of air conditioning effects to first and second air streams 1680 and 1681. The
air
streams may be conditioned by air conditioner module 1600 to provide, for
example:
(1) dehumidified or humidified process air; (2) sensibly cooled or heated
process air;
(3) indirectly and/or directly evaporatively cooled process air; (4)
indirectly and/or
directly evaporatively cooled working liquid using outside air; (5) remote
heat and/or
moisture recovery between exhaust air and outside air; (6) steam and/or hot
water
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regeneration of a weak desiccant; and (7) direct and/or indirect fired air
regeneration
of a weak desiccant.
[0220] In some embodiments, exchanger 213 may be utilized in evaporative
liquid desiccant air conditioning applications. For example, exchanger 213 may
be
used in air handling modules described in Fig. 8a and air conditioner module
described in the Fig. 15a-15h. In such applications, exchanger 213 may be used
in
the modules that may provide an evaporative cooling and steam heating air
conditioner.
[0221] Membrane 1206 of the exchanger 213 may be formed of a
thermoplastic sheet embedded with gamma alumina. First air stream 1680 may
pass
through first plurality of passageways 1613 of exchanger 213. First air stream
1680
may be, for example, outside air, and may undergo direct evaporative cooling
within
first plurality of passageways 1613. To that end, a cooling medium, such as,
for
example, water, may flow on membrane walls defining first plurality of
passageways
1613. The cooling medium may cool outside air 1680. The outside air 1680 may
evaporate the cooling medium and may be released from the first plurality of
passageways 1613 as cool moist air.
[0222] Second air stream 1681 may pass through second plurality of
passageways 1614 of exchanger 213. Second air stream 1681 may be supply air
and may be dehumidified as it passes through second plurality of passageways
1614.
[0223] In some embodiments, fresh supply air stream 1681 may be super dry
air exiting the second plurality of passageways 1614 and may be directed
through a
direct evaporation device to bring it to supply conditions using vapor
cornpression-
based cooling of 55 F and 100% humidity. In other embodiments, supply air
stream
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1681 may be cooled, moist air exiting first plurality of passageways 1613 and
redirected through second plurality of passageways 1614. In further
embodiments,
supply air stream 1681 may be a separate stream of air, such as, for example,
recirculated air from the system, such as from a building. In such
embodiments, cool
moist air from first plurality of passageways 1613 may indirectly cool the
recirculation
supply air stream 1681, whereby cool moist air may remove heat from
recirculation
supply air stream 1681 through membrane walls 1206. To remove moisture from
supply air stream 1681, liquid desiccant, such as, for example, lithium
chloride, may
flow onto membrane walls 1206 defining second plurality of passageways 1614.
Lithium chloride flowing wholly within the porosity of the gamma alumina
embedded
in membrane 1206, may dehumidify the supply air stream 1681 by adsorbing
moisture from supply air stream 1681.
[0224] As discussed above and described in Figs. 15d-15h, exchanger 213
may also include first and second liquid distribution headers 1632 and 1634
configured to deliver cooling medium and liquid desiccant onto internal
membrane
walls 1206 forming first and second plurality of passageways 1613, 1614 of
exchanger 213. First liquid distribution headers 1632 may deliver cooling
medium,
such as, for example, water, along first plurality of passageways 1613. Porous
members 1630 may deliver a continuous flow of water onto internal membrane
walls
1206 forming first plurality of passageways 1613, and the water may flow down
membrane walls 1206 in a direction perpendicular to outside air flow 1680.
[0225] Second liquid distribution headers 1634 may deliver liquid desiccant,
such as, for example, lithium chloride, along second plurality of passageways
1614.
Porous members 1630 may deliver a continuous flow of lithium chloride onto the
internal membrane walls 1206 forming second plurality of passageways 1614, and
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the lithium chloride may flow down membrane walls 1206 in a direction
perpendicular
to supply air flow 1681. In some embodiments, flow of water delivered by the
headers 1632 may be 1/16 of an inch, and flow of lithium chloride delivered by
headers 1634 may be 1/16 of an inch.
[0226] Air conditioner module 1600 with exchanger 213 and first and second
liquid distribution headers 1632, 1634 may also be configured to provide
indirect
evaporative cooling. In such a configuration, a liquid cooling medium, such as
water,
may be delivered onto internal membrane walls 1206 of both first and second
plurality of passageways 1612, 1614. As a result, supply air stream 1681 may
be
cooled but relatively humid.
[0227] In some embodiments, air conditioner module 1600 may function as a
highly-efficient liquid desiccant regenerator. First liquid 1626 delivered to
air
conditioner module 1600 may be a weak liquid desiccant, such as, for example,
lithium chloride. The lithium chloride may contact first air stream 1680,
which may be
atmospheric air. Second air stream 1681 may be directly heated and physically
separate from first air stream, while maintaining thermal contact to allow
heat to
freely pass therebetween and directly warm the lithium chloride through
membrane
walls 1206. Heating the lithium chloride may drive off part of the water vapor
previously absorbed in the evaporatively cooled module, thus regenerating it.
The
regenerated liquid desiccant may be returned to conditioner module 1600 to
again
remove moisture. Water vapor may be discharged from the regenerator module
1600 to the atmosphere.
[0228] Regenerator module 1600 may implement one or more sources of
energy to heat second air stream 1681. In one embodiment, steam from a boiler
may
be applied directly to second air stream 1681 in a closed loop to provide
uniform
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heat (e.g., 212 F) across membrane walls 1206. Steam condensate forming and
flowing down the membrane walls may be collected and reheated. Steam may
provide a uniform thermal heating across the entire membrane surface, thereby
creating ideal regeneration conditions for driving water molecules out of the
lithium
chloride.
[0229] In another embodiment, hot water between 160 F and 210 F, may be
employed within regenerator module 1600 to regenerate lithium chloride. Hot
water
may be distributed via second distribution header 1634 directly warming the
lithium
chloride through membrane walls 1206. In some embodiments, hot water may be
used in conjunction with steam heat depending upon the available energy
available
at a given time period. In other embodiments, second air stream is heated via
direct
fire combustion to between 200 F and 300 F, thereby regenerating the lithium
chloride.
[0230] The previously described desiccant regenerator module 1600 may
present a substantial surface area flowing with weak lithium chloride to the
rejecting
atmospheric air stream. This large surface area serves to lower required
thermal
temperatures and reduce energy use compared to existing regeneration boilers.
Furthermore, exchanger 213 comprises the same materials and components and,
therefore, allows the regenerator module 1600 to change modes of operation and
provide a different function for the building altogether (e.g., during a
different
season).
[0231] In a preferred embodiment of an air handling system, a further air
handling module comprised of a sensible air-to-air plate exchanger (not
depicted)
may preheat the first air stream to further enhance the rejection of water
molecules
out of the liquid desiccant and may also pass back through the said sensible
air-to-
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air plate exchanger. This embodiment advantageously reduces the amount of
thermal energy lost to the atmosphere from first air stream 1680.
[0232] Although not depicted, a suitable system may be coupled to
exchanger 213 to collect, treat, and recycle the cooling medium and liquid
desiccant
delivered through exchanger 213. For example, water or water vapor from first
passageways 1613 may be collected and recycled through suitable threaded
ports.
In some embodiments, the collected water may be further cooled via a
refrigerant or
the like before being delivered to exchanger 213. In addition, the cool weak
liquid
desiccant from second plurality of passageways 1614 may be collected and
passed
through suitable threaded ports to a regenerator, such as, for example, a
boiler. The
strong liquid desiccant from the regenerator may then be recycled back to the
exchanger.
[0233] Multiple functions and multiple modes may be alternated between,
depending on the driving requirements of the conditioned building space.
Exchanger
213 with alternating header arrays 1632 and 1634 and supply system may be
instantly configured to provide indirect evaporative cooling. In such a
configuration, a
liquid cooling medium, such as water, may be delivered onto membrane walls of
both first and second plurality of passageways 1613 and 1614.
[0234] Evaporative liquid desiccant air conditioner modules 1600 may be
adjacently stacked in a vertical orientation to form an evaporative liquid
desiccant air
conditioner system. With reference to Fig. 8a, for example, each module 812a,
812b,
and 812c may air conditioner modules 1600 may contain the components of air
conditioner module 1600 described in Figs. 15a-15h.
[0235] Fig. 15i illustrates a perspective view of an evaporative liquid
desiccant hex shaped exchange module 1660 according to the present disclosure.
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Exchange module 1660 may accommodate airflows in a counterflow configuration.
Exchange module 1660 may comprise a plurality of plates 1615 having a
plurality of
intermittently sealed plate edges 1620 and arranged in a successively stacked
configuration. Portions of plates 1615 may be spaced apart to provide first
series of
discrete alternating passages 1613 and second series of discrete alternating
passages 1614. A first air stream 1680 may be passed through first series of
passages 1613 and a second air stream 1681 may be passed through second series
of passages 1614 in a counterflow configuration with respect to the first air
stream
1680. Exchange module 1660 may include an air stream divider 1662 to separate
the first and second air streams 1680, 1681.
[0236] Exchange module 1660 may include first liquid supply conduit 1622
secured in first liquid threaded inlet 1636 and second liquid supply conduit
1624
secured in second threaded inlet 1638. First liquid 1626 and second liquid
1628 may
be fed into first liquid supply conduit 1622 and second liquid supply conduit
1624,
respectively. First liquid distribution headers 1632 may deliver first liquid
1626 from
first liquid supply conduit 1622 to first series of passages 1613. Second
liquid
distribution headers 1634 may deliver second liquid 1628 from second liquid
supply
conduit 1624 to second series of passages 1614. First and second liquid
distribution
headers 1632, 1634 may be positioned within first and second passages 1613,
1614
of plates 1615. Positioning first and second liquid distribution headers 1632,
1634
within first and second passages 1613, 1614 may provide a compact shape and
may
maintain a hexagonal shape compatible with applications utilizing existing hex
counterflow plate-type exchangers.
[0237] Exchange module 1660 may also include a liquid collection system for
collecting first liquid 1626 and second liquid 1628 flowing out of the
plurality of first
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passages 1613 and plurality of second passages 1614. The liquid collection
system
may include first liquid drain conduit 1616 for collecting flowing first
liquid 1626 from
first passages 1613 and second liquid drain conduit 1618 for collecting
flowing
second liquid 1628 from second passages 1614. First and second liquid drain
conduits 1616, 1618 may be located entirely outside of exchanger 213 and may
be
adjacent to the second ends of the plurality of plates 1615.
[0238] Fig. 15j illustrates a perspective view of another configuration of
evaporative liquid desiccant hex shaped exchange module 1660 according to the
present disclosure. As shown in Fig. 15j, first and second liquid distribution
headers
1632, 1634 may be positioned outside of first and second passages 1613, 1614
of
plates 1615. Positioning first and second liquid distribution headers 1632,
1634
outside of first and second passages 1613, 1614 may provide an obstruction-
free
pathway for counterflowing first and second air streams 1680 and 1681.
[0239] The present disclosure contemplates a multiple function remote
energy recovery system. With reference to Fig. 15k, in some embodiments, a
system
1690 may be implemented for multiple function remote energy recovery. System
1690 may be configured to recover heat and moisture between two or more
detached airstreams. System 1690 may comprise first liquid desiccant recovery
exchange module 1691 and second liquid desiccant recovery exchange module
1692. First and second liquid desiccant recovery exchange modules 1691, 1692
may
embody exchange module 1660 described in Figs. 15i and 15j.
[0240] First air stream 1680, which may be, for example, process supply air
to a building, may pass through first liquid desiccant recovery exchange
module
1691 and may be dehumidified and cooled by first liquid 1626, which may be,
for
example, a strong desiccant, and may be cooled by second liquid 1628, which
may
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be, for example, water evaporating into a second air stream 1681, such as, for
example, atmospheric air, passed through first liquid desiccant recovery
exchange
module 1691.
[0241] With respect to the second liquid desiccant recovery exchange
module 1692, first air stream 1680, which may be, for example, exhaust air
from the
building, may pass through module 1692. First liquid 1626, which may be a weak
desiccant, may remotely extract energy from the exhaust air, while second
liquid
1628, which may be, for example, water evaporating into second air stream
1681,
such as, for example, atmospheric air, passed through second liquid desiccant
recovery exchange module 1692, may simultaneously cool the exhaust air.
[0242] First liquid desiccant recovery exchange module 1691 may be
connected to second liquid desiccant recovery exchange module 1692 via conduit
pipes and an enthalpy pump may facilitate flow of liquid desiccant between
modules
1691, 1692. First liquid drain conduit 1616 on first exchange module 1691 may
collect weak desiccant. The weak desiccant may be pumped to second exchange
module 1692 via weak desiccant pump 1664 powered by motor 1665. Weak
desiccant may be delivered to second exchange module 1692 via weak desiccant
conduit 1668.
[0243] First liquid drain conduit 1616 on second exchange module 1692 may
collect strong desiccant. Strong desiccant may be pumped to first exchange
module
1691 via strong desiccant pump 1666 powered by motor 1667. Strong desiccant
may
be delivered to first exchange module 1691 via strong desiccant conduit 1670.
Second liquid drain conduits 1618 connected to each of first and second
exchange
modules 1691, 1692 may collect excess water that may not be evaporated, and
the
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excess water may be returned back to liquid distribution headers 1632, 1634 of
modules 1691, 1692.
[0244] In some embodiments, an evaporatively cooled liquid desiccant air
handling unit of the present disclosure may process outdoor air at a
temperature of
about 86 F and a humidity ratio of 135 grains. The liquid desiccant used may
be a
45% lithium chloride solution. Six hundred cfm may be passed through air
handling
unit having 0.063" gaps between plates. The resulting supply air exiting the
unit may
have a temperature of 80 F and a humidity ratio of 35 grains.
[0245] Water or salt water, such as lithium chloride, may be the most
common solvent used to remove inorganic contaminants, such as formaldehyde and
other VOCs. In some embodiments, the disclosed evaporative cooling and steam
regenerating module 1600, may, independently or concurrently, function as a
regenerable scrubber system.
[0246] In some embodiments, and with reference to Fig. 15k, air handling
system 1690 may be implemented for controlling carbon dioxide (CO2),
formaldehyde, and volatile organic compound (VOC) emissions from a building
enclosure. CO2 liquid sorbent may flow within the exchanger and may be
regenerated by thermal means to release and capture the absorbed CO2. Amines
are well-known for their reversible reactions with 002, which may make them
ideal
for CO2 capture from several gas streams, including flue gas. Systems for
controlling
and eliminating the CO2 from a breathable air supply may be utilized in
submarines,
space vehicles, space suits, and various types of building enclosures. In this
respect,
selective CO2 absorption by aqueous alkanolamines may be energy intensive and
the absorbant may be corrosive.
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[0247] Physical absorption of pollutant molecules may depend on properties
of the gas stream and liquid solvent, such as density and viscosity, as well
as
specific characteristics of the pollutant(s) in the gas and the liquid stream,
including
diffusivity and equilibrium solubility. For most regenerative sorbents, these
properties
may be temperature dependent. Lower temperatures may generally favor
absorption
of gases by the solvent. Absorption may be enhanced by greater contact surface
area, higher liquid gas ratios, and higher concentrations in the gas stream.
Chemical
absorption may be limited by the rate of reaction, although the rate-limiting
step may
be typically the physical absorption rate, not the chemical reaction rate.
Cold
solutions of alkylamines may bind CO2, but the binding may be reversed at
higher
temperatures. The integrated, indirect evaporation of the present disclosed
may cool
the amines solution, while the integrated secondary air flow path filled with
steam
indirectly may heat the amines solution. This may create a large enough
temperature
differential to remove the majority of carbon dioxide continuously from a
process air
stream. This may be done in concert with the lithium chloride water vapor
removal,
reducing the need for outside air.
[0248] Carbon dioxide from a process air stream may be absorbed by a
solution of an amine, with the amine solution subsequently being regenerated
by
heating, and the resulting desorbed carbon dioxide may be rejected to a second
gas
stream. The concentrated gas stream may subsequently be discharged to the
atmosphere or solidified by a combination of compression and low temperature
condensation.
[0249] Amines and other organics may be frequently coated in thin layers but
may be found subject to physical losses by carry over or entrainment as vapor
or
liquid. The dispensing of amines may be accomplished without the creation of
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microdroplets which may become entrained within the air streams. During an
absorption cycle, a parallel portion of excess water vapor of the air may in
turn be
absorbed by a mixture of aqueous solutions of alkylamines and lithium
chloride. It
may be advantageous to perform the absorption portion of the cycle at the wet
bulb
temperature of the atmosphere. Indirect evaporation in summer conditions and
indirect free airside cooling in winter conditions may bring a low energy
utilization to
carbon dioxide scrubbing. Air passing through the absorber may then be
returned or
supplied to the building, with only a small amount of its original carbon
dioxide and
water vapor content.
[0250] For the purposes of regeneration for reuse, the exchanger may be in-
directly heated to a temperature at or slightly above 200 F via hot water or
steam.
The carbon dioxide, formaldehydes, VOC compounds, and chemically absorbed
water contained in the reversibly binding aqueous solutions may be driven off.
The
warm aqueous solutions of alkylamines may be subsequently cooled by indirect
evaporation and process air. A liquid-to-liquid heat exchanger (not depicted)
may be
used to pre-heat solution contained within conduit 1668 and pre-cool solution
contained within conduit 1670. The liquid-to-liquid heat exchanger may be made
of a
material compatible with corrosive salts and strong alkylarnine solutions,
including,
for example, polymers, stainless steel, nickel, titanium, or carbon.
[0251] System 1690 of the present disclosure may be used to absorb the
carbon dioxide and to desorb into a separate gas stream in a higher
concentrated
form. By this application, carbon dioxide may be rejected from an enclosed
environment to the atmosphere, but the resulting concentrated air stream may
afford
other opportunities and uses. The system 1690 of the present disclosure may
help
occupants improve their wellness, productivity, and comfort, improve
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mental and/or physical tasks, increase their alertness, quality of life and
pleasure,
reduce their drowsiness, and aid in curing and preventing disease by
decreasing the
percentage of carbon dioxide in the enclosed space to a beneficial and safe
level.
[0252] Formaldehyde is a common indoor pollutant that is an irritant and has
been classified as a carcinogen. Adsorption technology may be safe and stable
and
may remove formaldehyde efficiently but its short life span and low adsorption
capacity may limit its indoor application. The system 1690 of the present
disclosure
may remove unwanted air pollutant molecules via absorption into liquid
solvent,
reaction with a sorbent or reagent solution, or by inertial or diffusional
impaction.
[0253] System 1690 of the present disclosure may remove inorganic fumes,
vapors, and gases (e.g., chromic acid, hydrogen sulfide, ammonia, chlorides,
fluorides, and S02); volatile organic compounds (VOC); and particulate matter
(PM),
including PM less than or equal to 10 micrometers (pm) in aerodynamic diameter
(PM10), PM less than or equal to 2.5 ion in aerodynamic diameter (PM2.5), and
hazardous air pollutants (HAP) in particulate form (PMHAp).
[0254] Absorption may be used as a raw material and/or product recovery
technique in separation and purification of gaseous streams containing high
concentrations of VOC, especially water-soluble compounds, such as methanol,
ethanol, isopropanol, butanol, acetone, and formaldehyde. Hydrophobic VOC can
be
absorbed using an anwhiphilic block copolymer dissolved in water. However, as
an
emission control technique, it may be more commonly employed for controlling
inorganic gases than for VOC. When using absorption as the primary control
technique for organic vapors, the spent solvent must be easily regenerated or
disposed of in an environmentally acceptable manner per Environmental
Protection
Agency regulations.
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[0255] The suitability of gas absorption as a pollution control method may
generally be dependent on the following factors: (1) availability of suitable
solvent;
(2) required removal efficiency; (3) pollutant concentration in the inlet
vapor; (4)
capacity required for handling waste gas; and (5) recovery value of the
pollutant(s) or
the disposal cost of the unrecoverable solvent.
[0256] Air handling and scrubbing system 1690 may maintain the indoor air
quality at an acceptable level within various enclosed spaces by providing
comfortable and healthy conditions and cleanliness. HVAC systems may
constitute a
significant part of a building's energy budget, particularly in extreme
climates.
System 1690 of the present disclosure may provide a practical, modular, and
scalable system for removing contaminants from the circulating air in an HVAC
system, utilizing regenerable absorbent materials and a continuous absorption-
desorption cycle being isothermally cooled and isothermally heated,
respectively.
[0257] Treating large volumes of indoor air having low concentrations of
organic and inorganic contaminants may require bringing large volumes of
absorbent
materials into intimate contact with large volumes of circulating indoor air.
It may also
be advantageous to use air treatment systems, such as air handling unit 100,
that
are scalable and relatively compact in size so as to be readily installed in
existing
buildings by human operators. Furthermore, different buildings may have
different air
flow requirements and contaminant levels. To efficiently and practically
manufacture
and deploy air treatment systems adaptable to a wide variety of buildings, it
may be
advantageous to provide a modular air treatment system design, based on one
size
that is easily manufactured and combined to provide scalable solutions for
different
building sizes and air quality requirements. It may also be advantageous to
make air
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treatment systems that are easily integrated with existing HVAC systems rather
than
replacing existing infrastructure.
[0258] A building according to the present disclosure may include, without
limitation, an office building, residential building, store, mall, hotel,
hospital,
restaurant, airport, train station and/or school. A vehicle according to the
present
disclosure may include, without limitation, an automobile, ship, train, plane,
or
submarine.
[0259] Scrubbing system 1690 of the present disclosure may be configured
to remove unwanted gases, vapors, and contamination, including, without
limitation,
volatile organic compounds (VOC) and CO2 produced within human-occupied space
by human occupants. Other contaminants that may be removed include without
limitation carbon monoxide, sulfur oxides and/or nitrous oxides.
[0260] With reference to Fig. 15k, multiple function air handling and
scrubbing system 1690 may be configured to remove carbon dioxide. System 1690
may comprise first carbon dioxide scrubbing module 1691 and second
regeneration
module 1692. First and second modules 1691, 1692 may embody exchange module
1660 described in Figs. 15i and 15j.
[0261] First air stream 1680, which may be, for example, process supply air
to a building, may pass through first carbon dioxide scrubbing module 1691 and
carbon dioxide may be removed and cooled by first liquid 1626, which may be,
for
example, an aqueous solution of alkylamines, and may, in turn, be cooled by
second
liquid 1628, which may be, for example, water evaporating into a second air
stream
1681, such as, for example, atmospheric air, passed through first carbon
dioxide
scrubbing module 1691.
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[0262] With respect to the second regeneration module 1692, first air stream
1680, which may be, for example, atmospheric air, may pass through module
1692.
First liquid 1626, which may be a carbon dioxide saturated alkylamine, may
release
carbon dioxide, while air stream 1681 may be, for example, steam saturated
running
in a closed loop (not shown), and may simultaneously heat the saturated
alkylamine.
[0263] First carbon dioxide scrubbing module 1691 may be connected to
second regeneration module 1692 via conduit pipes and a liquid pump may
facilitate
flow of alkylamine between the modules 1691, 1692. First liquid drain conduit
1616
on first exchange module 1691 may collect saturated alkylamine. The saturated
alkylamine may be pumped to second regeneration module 1692 via saturated
alkylamine pump 1664 powered by motor 1665. Saturated alkylamine may be
delivered to second regeneration module 1692 via saturated alkylamine conduit
1668.
[0264] First liquid drain conduit 1616 on second exchange module 1692 may
collect regenerated alkylamine. The regenerated alkylamine may be pumped to
first
exchange module 1691 via regenerated alkylamine pump 1666 powered by motor
1667. The regenerated alkylamine may be delivered to first exchange module
1691
via a regenerated alkylamine conduit 1670. Second liquid drain conduits 1618
connected to each of the first and second exchange modules 1691, 1692 may
collect
excess water that may not be evaporated, and the excess water may be returned
back to liquid distribution headers 1632, 1634 of modules 1691, 1692.
[0265] Fig. 151 illustrates a psychrometric chart corresponding to the
operation of the evaporative cooling and/or steam regenerating liquid
desiccant air
conditioner module of the present disclosure. Fig. 151 depicts a first
airstream of
outside air (OA) to supply air (SA), a second airstream of return air (RA) to
exhaust
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air (EA), and a third regeneration airstream. The first airstream may traverse
points
C and D, the second airstream may traverse points A and B, and the third
airstream
may traverse points C, E, and F. Fig 15a charts the estimated temperatures and
humidity levels for the first, second, and third airstreams as they traverse
these
points.
[0266] The first airstream and the second airstream may flow through the
heat exchanger in a counterflow orientation. Point A may represent a summer
return
air condition from a conditioned space. The second airstream may enter an
entry
port of the heat exchanger at point A of Fig. 15L and may flow through the
heat
exchanger to point B. The second airstream may be exposed to a liquid
desiccant
solution which may flows along the membrane surfaces of the heat exchanger.
The
liquid desiccant may act to dehumidify the second airstream. The first
airstream may
flow simultaneously through the heat exchanger from point C to point D in a
counterflow orientation in relation to the second airstream. As the second
airstream
flows through the heat exchanger from point A to point B and the first
airstream flows
through the heat exchanger from point C to point D, heat content may transfer
from
the second airstream to the first airstream. The third regeneration airstream
may be
heated by a heat source from point C to point E and may draw moisture from
liquid
desiccant solution from point E to point F which may flow along the membrane
surfaces of the heat exchanger. Drawing moisture from the liquid desiccant
solution
from point E to point F may re-concentrate the liquid desiccant solution.
[0267] The exchanger 213 of the present disclosure may be used in various
types of heat and water vapor exchangers. For example, as mentioned above,
exchanger 213 can be used in energy recovery ventilators for transferring heat
and
water vapor between air streams entering and exiting a building. This may be
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90178176
accomplished by flowing the streams on opposite sides of the counter-pleated
exchanger 213. Membrane 1206 of exchanger 213 may allow the heat and moisture
to transfer from one stream to the other while substantially preventing the
air streams
from mixing or crossing over. Other potential applications for exchanger 213
may
include, but are not limited to, the applications described in U.S.
Application No.
13/426,565.
Rotationally-Molded Hollow Shells
[0268] Figs. 16a-16d illustrates a perspective view of a rotationally molded
shell 1700 according to the present disclosure. Shell 1700 may comprise
interstitial
space 1701 filled with insulating material 1702. Insulating material 1702 may
include
powdered metal oxides, powdered inorganic oxides, silica powder, fumed silica
powder, and/or aerogel powder. Powdered ceramic may be superior to
conventional
urethane foams, as foams degrade in their thermal performance as the inert
gases
trapped inside their pore structure leak out over time. Powdered ceramic may
provide insulation and prevent heat build-up.
[0269] Walls of shell 1700 may be rotationally molded (rotomolded). Shell
1700 may be formed of cross-linked or non-cross-linked polyolefins, including,
for
example, polyethylene (PE), polypropylene, filled polypropylene, polybutylene
(PB),
cross-linked polyethyene (PEX), polyamides, polysuphones, poly-ether ketones,
polyethylene terephthalate (PET), and mixtures thereof. Walls of rotationally-
molded
shell 1700 may be furthermore modified with additives, fillers, and
reinforcements,
including, for example, boron fibers, carbon fibers, glass fibers, Kevlar
fibers, silanes,
titanates, chlorides, bromines, phosphorous, metallic salts, calcium
carbonate,
silicas, clays, chromates, carbon black, pigments, or combinations thereof. In
certain
embodiments, the outer and inner walls of shell 1700 may be formed of a non-
brittle
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thermoplastic, such as polypropylene. The polypropylene may also be carbon-
impregnated to provide UV protection and heat deflection.
[0270] In some embodiments, interstitial space 1701 of shell 1700 may be
under a vacuum to provide further insulation and may be filled with unmolded,
loose,
powdery insulating material 1702. Thermal conductivity of less than 0.010
W/(m*K)
may be measured, and preferably less than 0.004 W/(m*K), under vacuum.
[0271] In certain embodiments, filled shell 1700 may be used to make
building components, such as, for example, wall panel 1703. A typical wall
using
two-by-four wall studs may be 3.5 inches thick, with an inside of 1/2 inch
thick drywall
and 1/2 inch thick exterior plywood and/or siding, for a total wall thickness
of 4.5
inches. Assuming four inches of modest vacuum insulation, wall panel 1703
formed
from filled shell 1700 may provide an R value of 100 or greater.
[0272] In other embodiments, the air handling module, the energy recovery
module, and the dehumidification module of the present disclosure may be
insulated
by forming the components of the modules with the filled rotationally molded
shell
1700. Components of the modules, including, for example, the exchanger
housing,
the air director, manifolds, fan boxes, access panels, and electrical access
panels,
may be rotationally molded (rotonnolded). The rotationally-molded components
may
include outer wall, inner wall, and hollow interstitial space between the
outer and
inner walls. The hollow interstitial space may be filled with appropriate
insulation
material including, for example, a powdered ceramic, such as fumed silica or
preferably aerogel powder. The rotomolded components of the modules may be
lighter than existing components of air handling and conditioning systems. As
a
result, the modules of the present disclosure may readily be moved and
transported
by an operator without employing heavy machinery and the like.
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[0273] Shells 1700 may also be useful in construction of building walls,
building basements, building roofs, airplane shells, automobile enclosures,
HVAC air
handling modules, energy recovery ventilators, and air ducts. It may be
advantageous to have molded features allowing for a plurality of
interconnected
hollow shells to snap or otherwise structurally seal in these applications.
[0274] As shown in Figs. 16a-16d, wall panel 1703 may be formed of
rotationally molded shell 1700 having interstitial space 1701 filled with
insulating
material 1702. Wall panel 1703 may include an electrical wire conduit, a
communication bus conduit, electrical outlets, water piping, hot water piping,
window
wells, skylight wells, shelves, structural supports, and wall hangers.
[0275] Wall panel 1703 may comprise inside surface 1704, outside surface
1705, interconnecting left side 1706, interconnecting right side 1707,
interconnecting
top side 1708, and interconnecting bottom side 1709. In some embodiments,
interstitial space 1701 may be under a vacuum while insulating material 1702
may
provide the compressive structure necessary to keep inside surface 1704 and
outside surface 1705 from collapsing inward. Wall panel 1703 may be
manufactured
under a vacuum, whereby shell 1700 may be free of all defects and manufactured
from thermoplastics that inhibit molecules to pass or leak in. The
interstitial space
1701 of wall panel 1703 may be linked, through a plurality of sealed,
interconnected
ports to a centralized vacuum generator. Furthermore, a partial vacuum may be
maintained throughout the lifetime of the building structure during which age,
wear,
and tear may generate microfractures or penetrations into wall panel 1703
reducing
or eliminating the original partial vacuum.
[0276] A partial vacuum, controlled by the centralized vacuum generator,
may be adjusted given the temperature gradient between the inside and outside
of
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the building. During times of extreme cold or extreme heat, a greater vacuum
may be
desirable while during times of more moderator environmental temperatures a
lesser
vacuum or no vacuum may be desirable. The ability to maintain and/or change
the
thermal resistance of structure's wall may be advantageous by optimizing the
energy
characteristics at a specific site with specific environmental conditions.
[0277] In certain embodiments, wall panel 1703 may include hydronic
distribution and collection system 1710. The hydronic distribution and
collection
system 1710 may employ a plurality of interconnecting ports on horizontal,
vertical,
and sides of wall panel 1703. The ports may serve as interchangeable
attachment
points for a plurality of structures, including, for example, a hot water
pipe, a potable
water pipe, a refrigerant line pipe, a sewer/septic pipe, a liquid desiccant
pipe, a
chilled water conduit, a steam pipe, vacuum lines, and/or other fluidly
connected
hydronic components found within a commercial, residential, or industrial
building.
Furthermore, the port may be threaded and/or incorporate gasketed seals. The
ports
may also readily attach and detach to a plurality of appliances, including,
for
example, sinks, bathtubs, toilets, washers, dishwashers, boilers, condensers,
and
evaporators.
[0278] Hydronic distribution and collection system 1710 may be positioned
along a bottom portion of wall panel 1703 and may include a sewer conduit with
at
least two ports disposed on each end and at least one port therebetween. For
example, first sewer water edge port 1717 may be positioned on left side 1706,
second sewer water edge port 1717 may be positioned on the right side 1707,
and
third inside port 1719 may be positioned on inside surface 1704. A sewer water
pipe
1718 may be freely disposed of within sewer conduit and may allow for the
proper
pipe angle to facilitate gravitational draining.
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[0279] Wall panel 1703 may include hot water pipe 1713 comprising
interconnecting first and second edge ports 1712 and inside port Wall panel
1703
may also include potable water pipe 1715 including interconnecting first and
second
edge ports 1714 and inside port 1716. These ports may be threaded and/or may
incorporate gasketed seals between a plurality of wall panels 1703 to maintain
seals
between liquids, pressure, and vacuum conditions. In some embodiments, the
ports
may be threaded in accordance with British Standard Parallel Pipe (BSPP)
standards with integrated sealing washers to ensure international
compatibility with
National Taper Pipe (NPT), American Standard Straight Pipe for Mechanical
Joints
(NPSM), American Standard Straight Pipe (NPS), and British Standard Tapered
Pipe
(BSTP) standards.
[0280] The present disclosure contemplates any suitable number of pipes
and ports for wall panel 1703, and ports may be arranged on any suitable
location of
the wall panel 1703, including, for example, lateral, upper, and lower
surfaces. The
conduit and hermetically sealed port connections of the hydronic distribution
and
collection system 1710 may additionally serve as the means of evacuating the
interstitial space 1701 of wall panel 1703 linked to a centralized vacuum
generator.
[0281] In certain embodiments, wall panel 1703 may include communication
bus 1720. Communication bus 1720 may employ a plurality of interconnecting
ports
on horizontal, vertical, and sides of wall panel 1703. Interconnecting ports
may serve
as attachment points for a plurality of communication wire types, including,
for
example, electrical wire, communication bus wire, sensor probe wire, wire
harness
connectors, TV cable, DSUintemet cable, telephone cable, security/camera wire,
and combinations thereof. Communication bus 1720 may include communication
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bus conduit 1723 including interconnecting first and second edge ports 1722
and
inside port 1724.
[0282] The present disclosure contemplates any suitable number of bus bars
and bus ports for wall panel 1703, and ports may be arranged on any suitable
location of wall panel 1703, including, for example, lateral, upper, and lower
surfaces. The conduit and hermetically sealed port connections of
communication
bus 1720 may additionally serve as the means of evacuating interstitial space
1701
of wall panel 1703 linked to a centralized vacuum generator.
[0283] In some embodiments, wall panel 1703 may include electrical power
distribution 1730. Electrical power distribution 1730 may employ a plurality
of
interconnecting ports on horizontal, vertical, and sides of wall panel 1703.
Interconnecting ports may serve as attachment points for a plurality of
electrical wire
types, including, for example, AC power wires, DC power wires, grounding
wires,
light switches, appliance outlets, and electrical wire harness connectors.
Electrical
power distribution 1730 may include a receptacle conduit 1733 including
interconnecting first and second edge ports 1732 and inside port 1734.
Electrical
power distribution 1730 may also include lighting conduit 1736 comprising
interconnecting first and second edge ports 1735 and inside port 1737.
[0284] The present disclosure contemplates any suitable number of power
conduits and ports for wall panel 1703, and ports may be arranged on any
suitable
location of wall panel 1703, including, for example, lateral, upper, and lower
surfaces. The conduit and hermetically sealed port connections of electrical
power
distribution system 1730 may additionally serve as the means of evacuating the
interstitial space 1701 of wall panel 1703 linked to a centralized vacuum
generator.
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[0285] In certain embodiments, wall panel 1703 may include an air
distribution system 1740. Air distribution system 1740 may employ a plurality
of
interconnecting ports having ducts. The interconnecting ports of air
distribution
system 1740 may be positioned on horizontal, vertical, and sides of wall panel
1703.
The interconnecting ports serve as attachment points for a plurality of
structures,
including, for example, diffuser vents, return vents, supply and exhaust fans,
metal
ducts, access panels, and/or other fluidly connected components of an HVAC
system. A first air duct 1761 may have at least two duct ports 1742 disposed
on each
end of air duct 1761 and at least one inside port 1743 therebetween. Second
air duct
1762 may have at least two duct ports 1744 disposed on each end of air duct
1762
and at least one inside port 1745 therebetween. A third air duct 1763 may have
at
least two duct ports 1746 disposed on each end of air duct 1763 and at least
one
inside port 1747 therebetween.
[0286] An evaporative liquid desiccant air conditioner module 1600, 1660
may be positioned between first and second air ducts 1761, 1762 and may
connect
first air duct 1761 with second air duct 1762 to provide sensible cooling,
dehumidification, heating, humidification, and ventilation to an enclosure,
such as a
building. Air conditioner module 1600, 1660 may be connected to and powered
via
first fluid port 1748 and second fluid port 1749.
[0287] By way of example, a first portion of air duct 1761 may carry outside
air through air conditioner module 1600, 1660, and first portion of air duct
1762 may
deliver conditioned outside air to a space through inside air duct port 1745.
A second
portion of air duct 1761 may draw return air through inside air duct port 1743
and
through air conditioner module 1600, and stale air may be exhausted through
second portion of air duct 1762. First fluid port 1748 may flow a strong
lithium
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chloride salt to dry outside air while second fluid port 1749 may flow water
for indirect
evaporative cooling of the outside air using return air.
[0288] Although not shown, one or more air moving systems may be coupled
via the hermetically sealed ducts to a centralized system. Additionally,
natural
ventilation and natural buoyancy of air may provide the means of delivering
conditioned outside air into a building or enclosure. In some embodiments, the
size
of air conditioner module 1600, 1660 may encompass most, if not all, of the
interstitial space of wall panel 1703 depending on specific site requirements.
The
present disclosure contemplates any suitable number of air ducts and ports for
wall
panel 1703, and ports may be arranged on any suitable location of wall panel
1703,
including, for example, lateral, upper, and lower surfaces. The ducts and
hermetically
sealed port connections of air distribution system 1741 may additionally serve
as the
means of evacuating interstitial space 1701 of wall panel 1703 linked to a
centralized
vacuum generator.
[0289] In certain embodiments, wall panel 1703 may comprise structural
connector 1750 including a plurality of interconnecting ports and tabs on
horizontal
and vertical sides of said wall panel. The interconnecting ports and tabs may
align
and attach a plurality of adjacent wall panels 1703 and may include, for
example,
structural anchor bolts, module interconnectivity clamps, module seals, tongue-
and-
groove hermetic seals, and combinations thereof. For example, male
interconnecting
tabs 1752 on interconnecting left side 1706 may be structurally and
hermetically
sealed to female interconnecting tabs 1753 on right side 1707. A plurality of
structural pin holes 1754 may structurally lock wall panels 1703 in place and
may
keep the panels 1703 from coming loose. These structural pin holes 1754 may be
slotted to facilitate expansion and contraction of the panels 1703 given
changing
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environmental conditions. The interconnecting ports and structural tabs of
structural
connector 1750 may additionally serve as the means of evacuating the
interstitial
space 1701 of wall panel 1703 linked to a centralized vacuum generator.
[0290] The present disclosure contemplates any suitable types of interior
textures or colors 1771 applied to inside surface 1704 during the molding
process.
Drywall found in typical building wall construction may be eliminated.
Furthermore,
surfaces of wall panel 1703, molded out of polypropylene, for example, may
have
their surface color changed after manufacturing/installation by using primers
specific
for low surface energy plastics.
[0291] As shown in Fig. 16c, a number of components may be installed on
wall panel 1703 to create a finished interior look and function. For example,
sewer
cover plate 1781 may attach over sewer water inside port 1719. Communications
cover plate 1782 may attach over communication bus inside port 1724.
Receptacle
cover plate 1783 may attach over receptacle inside port 1734. Lighting cover
plate
1784 may attach over lighting inside port 1737. First HVAC grill 1785 may
attach
over first air duct inside port 1743. Second HVAC grill 1786 may attach over
second
air duct inside port 1745. Third HVAC grill 1787 may attach over third air
duct inside
port 1747.
[0292] As shown in Fig. 16d, the present disclosure contemplates any
suitable types of exterior textures or colors 1772 to outside surface 1705 of
wall
panel 1703. Exterior siding, trim, stucco, and various other elements
typically found
in exterior building wall construction may be eliminated. Furthermore,
surfaces of
wall panel 1703, molded out of polypropylene, for example, may have their
surface
color changed after manufacturing/installation by using primers specific for
low
surface energy plastics.
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PCT/US2019/014622
[0293] A first air duct outside port 1764 may connect to first air duct 1761
with first air duct port 1742 on ends of first air duct 1761. A second air
duct outside
port 1765 may connect to second air duct 1762 with second air duct port 1744
on
ends of second air duct 1744. The present disclosure contemplates any suitable
number of exterior components to facilitate the purpose and intent of specific
building
types or enclosures.
[0294] As shown in Fig. 16e, the present disclosure contemplates the use of
rotationally molded hollow shells 1700 on all interior and exterior surfaces
of building
enclosures using interlocking structural tabs and a plurality of
interconnecting ports.
For example, a plurality of basement wall panels 1797 may attach horizontally
to a
plurality of three-way wall connectors 1790. Wall panel 1703 may be positioned
in a
substantially horizontal orientation to form a roof of a commercial,
residential, or
industrial building. In such a configuration the roof may be formed of the
lightweight
and durable panel 1703 and may accommodate all types of weather conditions,
including hail. Textures, colors, and port locations may be selected to
provide
underfloor air distribution and underfloor utility distribution.
[0295] A plurality of floor panels 1794 may attach horizontally to a plurality
of
three-way floor connectors 1792. A plurality of wall panels 1703 may attach
vertically
to a plurality of three-way roof connectors 1793. A plurality of interior wall
panels
1795 may attach to a plurality of three-way wall connectors 1790. A plurality
of roof
panels 1796 may connect vertically to a plurality of three-way roof connectors
1793.
All interconnecting ports may be preserved through the transition between
various
types of rotationally molded hollow shells 1700. Structural additives, such
as, for
example, carbon fiber, may be added to subterranean basement panels 1797 or
roof
panels 1796 to accommodate high structural loading. Numerous modifications and
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variations in the combination of these wall panel types may be readily
apparent to
persons skilled in the art and may be combined to form a wide range of
building
shapes and sizes.
[0296] Fig. 16f illustrates an exterior perspective view of building system
1725 comprising a plurality of rotationally molded hollow shells 1700 having
interstitial space 1701 filled with insulating material 1702. As shown in Fig.
16f, a
ground line 1799 provides reference to molded hollow shells 1700 being
particularly
advantageous in their use in subterranean environments. A corner wall
connector
1791 may attach to a plurality of wall panels 1703 to form an exterior corner.
The
present disclosure contemplates any suitable types of exterior structures,
such as,
for example, windows, doors, intake vents, basement window wells, and exhaust
vents. A window panel 1798 may attach to a plurality of wall panels 1703.
Numerous
modifications and variations in the combination of these wall panel types may
be
readily apparent to persons skilled in the art and may be combined to form a
wide
range of building shapes and sizes.
[0297] As shown in Fig. 16g, three-way wall connector 1790 may be formed
from a rotationally molded hollow shell 1700 having interstitial space 1701
filled with
insulating material 1702. Three-way wall connector 1790 may include
interconnecting inside surface 1704, outside surface 1705, interconnecting
left side
1706, interconnecting right side 1707, interconnecting top side 1708, and
interconnecting bottom side 1709. All interconnecting ports may be preserved
through the transition between various types of rotationally molded hollow
shells
1700 facilitated by three-way wall connector 1790.
[0298] As shown in Fig. 16h, corner wall connector 1791 may be formed
from a rotationally molded hollow shell 1700 having interstitial space 1701
filled with
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insulating material 1702. Corner wall connector 1791 may include two outside
surfaces 1705, interconnecting left side 1706, interconnecting right side
1707,
interconnecting top side 1708, and interconnecting bottom side 1709. All
interconnecting ports may be preserved through the transition between various
types
of rotationally molded hollow shells 1700 facilitated by corner wall connector
1791.
[0299] As shown in Fig. 16i, three-way floor connector 1792 may be formed
from a rotationally molded hollow shell 1700 having interstitial space 1701
filled with
insulating material 1702. Three-way floor connector 1792 may include outside
surfaces 1705, interconnecting inside surface 1704, interconnecting left side
1706,
interconnecting right side 1707, interconnecting top side 1708, and
interconnecting
bottom side 1709. All interconnecting ports may be preserved through the
transition
between various types of rotationally molded hollow shells 1700 facilitated by
three-
way floor connector 1792.
[0300] As shown in Fig. 16j, three-way roof connector 1793 be formed from a
rotationally molded hollow shell 1700 having interstitial space 1701 filled
with
insulating material 1702. Three-way roof connector 1793 may include extended
outside surfaces 1705, interconnecting inside surface 1704, interconnecting
left side
1706, interconnecting right side 1707, interconnecting top side 1708, and
interconnecting bottom side 1709. All interconnecting ports may be preserved
through the transition between various types of rotationally molded hollow
shells
1700 facilitated by three-way roof connector 1793.
[0301] Numerous modifications and variations will readily occur to persons
skilled in the art. The present disclosure is not limited to the exact
construction and
operation illustrated and described. All suitable modifications and
equivalents may
be resorted to, falling within the scope of the present disclosure.
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