This application is generally related to air conditioning systems and devices, and more particularly related to an air conditioning and fan system that may be easily and safely mounted.
Air conditioning systems are in widespread use in homes, offices, and other buildings to cool the space in warm weather, circulate air, and control humidity. Existing air conditioning systems range from large central air conditioning systems with the capacity for cooling an entire building or home, to split or ductless air conditioning systems mounted through a wall in a home or hotel, to more portable and less permanent solutions such as standalone portable air conditioners in a mobile unit having a hose vent, and window air conditioners that are mounted in a window and removed during the cooler months of the year. Portable air conditioners, especially window air conditioners, are very popular for apartments and other rental properties, temporary or student housing, older homes without a central air conditioning system, as well as buildings in cooler climates that only require cooling occasionally, as such air conditioning units are generally cost-effective, can be installed, removed, and stored when not in use, and can be moved based on the owner's needs.
Despite the popularity of window air conditioners and the large market for them, there exist a number of disadvantages in existing window air conditioning units. These disadvantages including the significant size and weight of current window air conditioners, which makes installation difficult and potentially dangerous, especially for users attempting to install a unit by themselves. Existing window air conditioners often weigh between 50 to 120 pounds, range between 14″-48″ in width, range between 18″-34″ in height, and range between 18″-36″ in depth. Accordingly, these existing units are often too large and heavy for an individual to carry and move safely and comfortably. In addition, installation of a window air conditioner typically requires lifting the unit and aligning it in a window opening, and then holding the unit in place until it is sufficiently secured, which can be made significantly more difficult by the size and weight of existing units. Removing a window air conditioner from a window is similarly demanding, causing many users to keep their window air conditioners installed even during colder weather such as the winter months, which leads to a significant loss of heat from the home and higher energy bills. The large dimensions of existing window air conditioners may not fit smaller windows, and large interior space with only one or a few windows that require particularly high levels of cooling capacity relative to the available window area are not well served by existing units. Furthermore, the large form factor of existing window air conditioners blocks much of the view and light from the window, and is commonly regarded as an eye sore from both inside and outside of the building. The visual property of the frontal, visible area of the window air conditioner is a significant driver of consumer perception of the product. Existing window air conditioners also produce a large amount of noise during operation, and do not offer an efficient air circulation option to bring in fresh air from outside without utilizing all of the fans in the unit, which increases power consumption and noise.
In addition to the limitation discussed above, energy efficiency has become a primary goal for air conditioning systems, driven by government regulation and consumer demand for lower operating costs. A significant contributor to high energy efficiency is the performance of the condenser heat exchanger. The condenser heat exchanger takes superheated refrigerant from the compressor, and uses air, generally driven by a fan to remove heat from the refrigerant until said refrigerant condenses to a liquid, transferring the latent enthalpy of the fluid to the air source. A suitable heat exchanger will allow the refrigerant to dense at a temperature very near the temperature of the source air as it leaves the heat exchanger. A suitable heat exchanger will also allow a significant amount of air to flow over the heat exchanger surfaces, which reduces the exit temperature of the air. The lower temperature correspondingly reduces the pressure that the compressor must overcome to achieve complete condensing of the working refrigerant.
In the case of a typical air conditioning system, the evaporator from the indoor air source is also a source of condensed water resulting from the dehumidifying action of the cold evaporator heat exchanger. This condensate water contains a significant source of enthalpy due to the energy required to vaporized water and may be the result of approximately 20% of the total capacity of the system. This enthalpy, in addition to the condenser source air, can be used to further reduce the temperature of the condenser heat exchanger. These two sources of refrigeration cooling must be leveraged to achieve the modern energy efficiency standards demanded by governments and consumers alike.
A low-profile window air conditioner.
Given the disadvantages discussed above and the prevalence of window air conditioners worldwide, a need exists for an air conditioning system that has an aesthetically pleasing form that make efficient use of the available space within the housing and has high efficiency, low noise, yet an effective cooling system, and, when desired, can be easily installed, uninstalled, moved, and stored. A need further exists for a compact low profile window air conditioner that is visually less obtrusive, and allows for a better view out of the window, a significant factor in homes where the natural light entering the room is a factor in the quality of life of the room's inhabitants. A need further exists for an air conditioning system that allows for a compact low profile window air conditioner where the frontal, visible area of the air conditioner is reduced, while achieving increased efficiency of its heat exchangers without merely increasing the front face area of the heat exchanger, as doing so would similarly increase the visual front area of the heat exchanger and prevent the air conditioner from having a slim profile with a reduced visual frontal area.
The present solution to the prior art provides an air conditioner having components in a space efficient assembly, a housing that facilitates that space efficient assembly, and a uniquely shaped condenser that increases efficiency without sacrificing the compact visual profile of the air conditioner. The condenser is non-linear and positioned within the housing of the air conditioner behind an evaporator and at least one evaporator air mover, and arranged such that a body of the condenser is substantially perpendicular to a body of the evaporator. The body of the condenser may be formed to be C-shaped to conform to the shape of at least one condenser air mover, and to approximate the perimeter of the air conditioner.
The present solution also provides a non-linear condenser for an air conditioner, the condenser having a housing with a major axis, a plurality of coils positioned in the denser housing for guiding a flow of refrigerant. The housing of the condenser is at least partially curved along the major axis.
The present solution also provides a method of dissipating heat in a condenser of an air conditioner. The method includes the steps of providing an air conditioner having an evaporator, at least one fan, and a condenser positioned downstream of the fan between the fan and evaporator. The method further includes the steps of forming a water condensate via the evaporator, directing the water condensate to the at least one fan, and dispersing the water condensate onto the condenser via the fan.
The following detailed description of the preferred embodiments of the present application will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there is shown in the drawings embodiments that are presently preferred. It should be understood, however, that the inventions are not limited to the precise arrangements shown in the drawings.
Certain terminology is used in the following description for convenience only and is not limiting. The words “front,” “back,” “top,” “bottom,” “inner,” “outer,” “upper,” “lower,” “internal,” and “external” designate directions in the drawings to which reference is made. The words “upward,” “downward,” “above,” and “below” refer to directions towards a higher or lower position from the parts referenced in the drawings. The words “inward” and “outward” refer to directions towards an inner or outer portion of the element referenced in the drawings. The words “clockwise” and “counterclockwise” are used to indicate opposite relative directions of rotation, and may be used to specifically refer to directions of rotation about an axis in accordance with the well-known right hand rule. Additionally, the terms “a” and “one” are defined as including one or more of the referenced item unless specifically noted otherwise. A reference to a list of items that are cited as “at least one of a, b, or c” (where a, b, and c represent the items being listed) means any single one of the items a, b, or c, or combinations thereof. The terminology includes the words specifically noted above, derivatives thereof, and words of similar import.
The present application includes a description of a compact low profile air conditioner which more efficiently utilizes given space by including a pair of air movers and a centrally-located compressor, and further addresses the issues faced by traditional heat exchangers and efficiency limitations of known air conditioner units by utilizing a unique C-shaped condenser heat exchanger design. The C-shaped condenser is arranged so that its body is substantially perpendicular to the body of the evaporator heat exchanger, such that the condenser in conjunction with the rest of the air conditioner components and body forms an enclosed volume in which air driven through the back axial fans can more effectively be used to cool the heat exchanger and achieve higher flowrates and energy efficiency.
One of ordinary skill in the art will appreciate that there are many different types of compressors, including without limitation rotary compressors, piston compressors, and electrolytic compressors, any of which may be used with the present air conditioner. Furthermore, a variety of coolants having the requisite heat transfer characteristics may be used in the present air conditioner, including without limitation coolants that undergo phase transitions as it circulates throughout the system, which are common known as refrigerants. In an embodiment of the present air conditioner where a thermoelectric heat pump is used in place of the compressor, the coolant does not circulate between the evaporator and the condenser, but rather is separately contained in the evaporator and the condenser individually, as will be described in detail below. For purposes of the present application, the reference to a “refrigerant” is used for convenience only, and does not limit the specific coolant that may be used to a known AC refrigerant or a coolant that undergoes phase transitions, and instead may refer broadly to any coolant or heat transfer fluid that is capable of being circulated to transfer heat between components of the present air conditioner 10, including coolants that keep its phase or the use of solid materials as coolants.
As will be described, the housing 20 includes a face plate 30 which may be located adjacent to and/or form part of a room air intake grate 34 through which air from inside of the room or building to be cooled may be drawn into the internal cavity of the housing. The room air intake grate 34 may also be referred to as the “evaporator fan air intake” in the present application, as the air flowing through the room air intake grate is being drawn into the internal cavity of the housing 20 by the evaporator fans. The housing 20 may further include a cold air exit vent 44 through which cooled air is expelled back into the interior of the space to be cooled. The cold air exit vent 44 may also be referred to as the “evaporator fan air outlet” in the present application, as the air (whether cooled interior air or fresh external air) flowing through the cold air exist vent is being expelled out from the internal cavity of the housing by the evaporator fans. The cold air exit vent may be located at the front portion of the housing 20, such as, for example and without limitation, on a top portion of the outer surface of the housing. The housing 20 may also include one or more external air intake grates 33, which may also be referred to as “condenser fan air intakes.” The external air intake grates 33 are located at the back portion of the housing, and may further be arranged on at least one of the top portion, the bottom portion, or the sides of the outer surface of the housing. Air from an exterior of the room or building to be cooled is drawn into the internal cavity of the housing through the external air intake grates to cool the condenser 16, and then the heated external air is expelled back out to the exterior atmosphere through a hot air exit vent (also known as the “condenser fan air outlet”) located in a back plate of the housing 20.
As shown in
If a thermoelectric heat pump is used in place of a traditional compressor 12, each of the evaporator 18 and condenser 16 may include a heat pipe containing a suitable coolant, and be thermally associated with the thermoelectric heat pump, such that the coolant within the heat pipes of the evaporator 18 and condenser 16 is being heated or cooled by the thermoelectric heat pump to transfer heat out of the interior of the room to be cooled.
The air conditioner 10 includes air movers in the form of a pair of condenser fans 24 and a pair of evaporator fans 26 which are arranged on opposing sides of the compressor 12. The condenser fans 24 are preferably axial fans or crossflow fans and the evaporator fans 26 are preferably centrifugal fans or crossflow fans. The condenser fans 24 and the evaporator fans 26 may be driven by a common motor 42 positioned respectively between each set of fans (as shown in
Although centrifugal fans are known in air conditioners, known window air conditioners usually are driven by a single motor in the prior art fan assembly. By way of contrast, the present air conditioner 10 utilizes two separate sets of evaporator fans 26 and condenser fans 24, each driven by a separate motor 42 along a rotational axis that is aligned with the longitudinal direction Y along the length (i.e. the depth) of the housing, thus allowing the compressor 12 to be uniquely positioned between the two sets of fans.
The evaporator fans 26 need high pressure but less overall airflow, as the goal of the evaporator fans 26 is to pull air through the face plate 30 and/or room air intake grate 34, possibly through a filter in the air filter slot. The backward curved or inclined blades of the evaporator fans 26 are well suited to this need, and provide more energy efficient than straight radial blades, which extend straight out from the center of the fan axis. On the other hand, the condenser fans 24 do not need as high of pressure but does require greater overall airflow, as the goal of the condenser fans 24 is to move as much external atmosphere air as possible along the surface of the condenser 16 in order to cool the refrigerant in the condenser 16. The figures illustrate preferred fan blade configurations in the presently preferred air conditioner. One of ordinary skill would understand that the desired performance characteristics of the blades will inform how they are curved and inclined.
The condenser 16 may include a non-rectangular shape in order to match a shape of the housing 20 and achieve higher efficiency. The non-rectangular shape may maximize cross-sectional area within the slot external shape of the air conditioner 10 and take advantage of the full diameters of the condenser fans 26 so that there is no wasted surface area on the condenser 16. In known air conditioners, the condenser is rectangular in shape while the fans have a circular cross-sectional area, resulting in areas of the condenser that does not receive direct airflow from the fans. In addition to being formed with a non-rectangular shape, the present condenser 16 is unique in its arrangement with respect to the condenser fans 24, which are generally located in front of the condenser so that cold outside air is drawn through the condenser in order to cool the refrigerant, but the rectangular profile of such prior art condensers would result in the wasted surface area discussed above. Furthermore, in such an arrangement the dimension of the condenser that has the most significant effect on the efficiency of the condenser as a heat exchanger is the frontal, cross-sectional area measured by the area of the condenser normal to the direction of airflow over the condenser, called face area. Air pressure, caused by the viscous losses of air as it passes through the condenser, is approximately proportional to the square of the velocity of the air over the condenser face area. Therefore, the face area of the condenser has a significant effect on the amount of air a fan may deliver through a heat exchanger. Furthermore, additional face area adds more surface area between the condenser heat exchanger and the air working fluid, which the largest source of thermal resistance in the heat exchanger system. In a larger condenser, each unit volume of air becomes more effective at reducing the condensing temperature of the fluid inside. Regardless of the shape of condenser 16, the major axis 25 of the condenser 16 is in the direction of air intake via condenser fans 24; in other words, the major axis 25 is substantially perpendicular to the evaporator 18.
Accordingly, in known air conditioners in order to increase efficiency of the condenser the face area of the condenser must be increased. However, increasing the face area of a traditional heat exchanger in a window air conditioner is at odds with the goal of reducing the visual frontal area of the air conditioner for a more compact, low profile design that allows the air conditioner to be less obtrusive and easier to handle, install, and uninstall. Instead of reducing the face area of the heat exchanger, such as the condenser or evaporator to satisfy a visual requirement at the expense of the energy efficiency requirements of the air conditioner, the present air conditioner 10 utilizes a unique configuration to create a significant face area of the condenser 16 without merely increasing its dimensions and therefore the dimensions of the entire air conditioner. The present condenser 16 is designed with a slot-shape that is volumetrically optimal, especially when using twin condenser fans 24 to further reduce the overall profile of the air conditioner 10. Furthermore, the C-shape of the condenser 16 allows it to be arranged in a unique arrangement such that the body of the condenser 16 extends substantially perpendicular to the body of the evaporator 18, while wrapping around the sides of the condenser fans 24 to maximize the airflow through the entire face area of the condenser 16. The condenser 16 in conjunction with the other air conditioner 10 components and the body form an enclosed volume in which air driven through the condenser fans 24 can be more effectively used to cool the condenser 16 and achieve higher flowrates and energy efficiency. Further advantages and details relating to the present condenser 16 design and configuration will be discussed in detail below.
The compressor 12, condenser fans 24, and evaporator fans 26 may be at least partially surrounded and/or positioned by the retainer strap 28. The retainer strap 28 may also be the point at which the air conditioner 10 is divided between the portion indoors and the portion outdoors when positioned in a window.
The evaporator 18 preferably includes evaporator piping or tubing 22 that coils through the body, preferably in a serpentine path so as to maximize the path of the refrigerant that flows through the tubing and the evaporator. The body of the evaporator 18 is a heat exchanger, which includes a plurality of fins that may be formed out of a material having good heat transfer properties, such as a highly thermally conductive metal such as aluminum or copper. One of ordinary skill in the art would appreciate that there are a variety of shapes, such as pins, straight fins, or flared fins suitable for heat sink fins. The body of the evaporator 18 may be further configured to include what is commonly known as “offset interrupted fins” or “louvered fins.” In the offset interrupted fins configuration, each “fin” or “plate” of the evaporator body includes a plurality of slits (the “interruptions”) that are generally placed close together at regular intervals. As airflows along the longitudinal direction Y between two fins of the evaporator body, the air enters and exits the plurality of slits/interruptions formed in the fins, which increases heat transfer and causes the airflow to become turbulent, thus ensuring that the cooled air immediately mixes with the surrounding air. To further optimize performance of the evaporator 18 and increase heat transfer, the material between adjacent slits/interruptions in the fins may be stamped to create an “offset,” adjacent offsets being stamped in opposite directions. The offsets interrupt the boundary condition of the airflow and further increase air turbulence, which improves the heat transfer capabilities of the evaporator 18. In the louvered fins configuration, the offsets are at an angle, and adjacent offsets are formed with opposing angles, so that air flowing through one offset out through a slot is forced to change angles before entering an adjacent slot to flow through the next offset, once again increasing turbulence and improving heat transfer.
The fins of the evaporator 18 and condenser 16 heat exchangers are preferably formed from a material having good heat transfer properties, and may be arranged vertically such that air may flow between adjacent fins. The fins are very thin and are arranged vertically along the body of the condenser 16 to maximize the surface area of the fins as external air is blown through the body of the condenser 16 to cool down the refrigerant or other coolant circulating through the condenser tubing.
In existing window air conditioners, positioning the evaporator behind the fan results in “wasted” areas of the evaporator (usually at the four corners) that do not receive direct airflow from the evaporator fan. By taking full advantage of the non-rectangular surface area of the evaporator, the present evaporator assembly configuration is able to utilize a relative smaller evaporator 18, which also contributes to the overall smaller size of the air conditioner 10.
Further advantages of the present evaporator assembly include a reduction in noise. Since there is no direct line of sight from the faceplate of the housing 20 and room air intake grate 34 into the evaporator fans due to their orientation, the sound of the evaporator fans during operation is decreased.
The refrigerant that exits the compressor 12 is in a high-pressure hot gaseous state, and flows through the condenser 16 within the condenser tubing. Like the evaporator 18, the condenser 16 includes a substantially rectangular body that extends and is arranged along the vertical direction, and condenser piping or tubing that coils through the body, preferably in a serpentine path. The body of the condenser 16 is a heat sink having a plurality of fins, which may be arranged like the fins in the evaporator body and configured as “offset interrupted fins” or “louvered fins.” Although the condenser body has a substantially straight profile without any curvature along the horizontal direction, one of ordinary skill in the art would understand that the body of the condenser 16 may also be curved in a way to optimize airflow between the external air drawn in through the external air intake grates, the condenser fans 24, the condenser 16, and the hot air exit vent 38. Furthermore, the exact form and extent of the curvature for the condenser body will be determined based on specific operational parameters desired when taking into account the present teachings.
The connection tubing may be associated with the evaporator tubing and the condenser tubing to allow for the flow of refrigerant from the compressor 12 to the evaporator 18. The connection tubing may be coiled in a serpentine path, and may further include an expansion valve located adjacent to the condenser 16, which may be for example and without limitation a capillary expansion valve. The expansion valve quickly decreases the cross-sectional flow area of the connection tubing and thus drops the pressure of the refrigerant flowing out of the condenser 16, which changes the state of the refrigerant form a high-pressure hot liquid to a low-pressure cold boiling liquid. The compressor 12 may be associated with the evaporator 18 and condenser 16 through a series of compressor tubing, which is preferably arranged in a coiled configuration so as to act as a spring between the compressor 12 and the rest of the components in the air conditioner 10. By acting as a spring, the compressor tubing mechanically isolates the compressor 12 from the evaporator 18 and condenser 16 assemblies, which is desirable because the compressor 12 causes a large amount of vibration during operation, which may damage the other components if not isolated. Where a thermoelectric heat pump is used in place of a compressor 12, the connection tubing between the evaporator 18 and condenser 16 is not required, as the coolant remains within the evaporator tubing and condenser tubing separately. In such an embodiment the thermoelectric heat pump is thermally associated with and arranged between the evaporator 18 and the condenser 16, such that the cold side of the thermoelectric heat pump is thermally associated with the evaporator to cool the coolant contained in the evaporator tubing, while the hot side of the thermoelectric heat pump is thermally associated with the condenser to transfer heat into the coolant contained in the condenser tubing. In such an arrangement, the evaporator and condenser tubing may each be formed as a heat pipe, which is well known heat transfer device, and the coolant used may be, for example and without limitation, a liquid such as methanol or acetone.
As discussed above, the refrigerant that leaves the compressor 12 is in a high-pressure hot gaseous state as it enters the condenser 16, which is cooled by drawing in external ambient air from outside of the space to be cooled, and utilizing air movers (e.g., condenser fans 24) to move the relatively cooler external air through the condenser 16. The external air is drawn in to the back portion of the internal cavity of the housing 20 through one or more external air intake grates 33. The external air intake grates 33 may be located at locations of the housing best suited for ingestion by the condenser fans 24, for example as part of the back plate 32, as will be described in more detail. The external air is expelled towards the condenser 16 to cool the condenser body and the refrigerant circulating within the condenser tubing. As the external air blows through the body of the condenser 16, the high-pressure hot gaseous refrigerant flowing through the condenser tubing is in cooled liquid state when it leaves the condenser 16. The external air blown through the body of the condenser exits the face of the condenser body as hot air through the hot air exit vents 38, which may be located at the back portion of the housing 20 as grates or vents aligned with the body of the condenser 16, as shown in
The interior face of the air conditioner 10 has a face plate 30 that serves as a handle 36, a control knob 52 (shown in
The air conditioner 10 may also include an electronics enclosure 40 for, for example, electronics and a capacitor, positioned adjacent to the evaporator 18 and configured to fit within the face plate 30. The electronics are positioned so that they can be manipulated by a control knob protruding from the face plate 30. The capacitor is electronically connected to the compressor 12.
The compressor 12 is centrally mounted between the two sets of fans 24 and 26 which may be symmetrically arranged on opposing sides of the compressor 12. This configuration inside of the housing 20 provides a balanced design and enables a compact arrangement of the components. Another advantage of the centrally located compressor 12 is that it can be mounted using horizontal mounting fixtures (e.g., mounting feet 46 shown in
The positioning of the cold air exit vent 44 on the top portion of the housing 20 reduces re-ingestion of cold air back into the room air intake grate, thus increasing the efficiency and effectiveness of the present air conditioner 10. In known air conditioner units, the cold air exit vent is usually located on the front of the housing, such as near the top edge of the face plate. As cold air is expelled through such a cold air exit vent, the air “sinks” in the downward direction due to the higher density of cooler air, and in the process of sinking some of the already-cooled air is re-ingested into the air conditioner through the room air intake grate located on the front of the housing, resulting in inefficiencies for the system. The present air conditioner 10 addresses this issue by positioning the cold air exit vent 44 on the top portion of the housing at a sufficient distance away from the face plate 30 and room air intake grate 34 located at the front of the housing 20 and utilizes the curved turning vanes to expel the cooled air upwardly at an angle into the room.
The lower manifold 48 (and upper manifold 50) are preferably formed as separately-molded pieces. Conventional air conditioning units usually include a bottom plate (instead of a manifold) or a bottom tray that all major components are affixed to and a metal sheet enclosure which provides less than ideal structural integrity for the unit. The clam shell manifolds 48, 50 combine to hold internal components in place while adding structural integrity to the overall unit.
In use, the interior room air is drawn in through the room air intake (at grate 34) and is cooled by the relatively colder surfaces of the fins of the evaporator body due to the cold boiling liquid refrigerant flowing through the evaporator tubing. As the cooled interior room air exits the back of the evaporator body, the cooled air is guided upwards and back into the interior of the room or building by an air guide assembly through the cold air exit vent 44 located at the top portion of the housing. The thermal energy (i.e. heat) from the cooled interior room air IA is transferred into the refrigerant that flows through the evaporator tubing of the evaporator, which is in turn warmed from a low-pressure cold boiling liquid into a low-pressure cold gas as the refrigerant flows from the evaporator 18 through the accumulator 14 and into the compressor 12 to be pressurized and heated. The accumulator 14 ensures that any liquid left in the refrigerant is removed before the refrigerant enters the compressor 12, so as not to damage the compressor 12 when the gaseous refrigerant is pressurized and heated.
Returning to the unique shape and configuration of the present condenser 16, which in combination with the other components of the air conditioner 10 addresses the disadvantages and issues in known air conditioners to achieve higher airflow and energy efficiency while maintaining a compact and low-profile design. By bending the condenser 16 into a C-shape design to approximate the perimeter of the air conditioner and maximize available surface area for the condenser fans 24, a significantly larger face area of the condenser 16 is created which reduces air pressure and allows more air to be delivered by the same fan system. Furthermore, the location of the condenser fans 24 promotes even airflow of air over the condenser 16. In the case of air being blown into the inside surface of the condenser 16, the use of an external ring 54 on each of the individual condenser fans 24 (as shown in
If condensate cannot be used for further cooling of the condenser 16, such as in the case of microchannel condensers, which are sensitive to corrosive ionic impurities in the condensate water, the condenser fans 24 may pull air from inside the internal plenum of the condenser 16, and blow the heated air out of the back of the air conditioner 10 through the back plate 32. In both airflow cases, the bent shape of the condenser 16, which follows the perimeter of the air conditioner 10 in a rounded shape, offers significant face area of the heat exchanger, while limiting the visual size of the air conditioner. Furthermore, the C-shaped contour of the condenser 16 follows the perimeter of the condenser fans 24, which further reduces the visual profile of the air conditioner 10.
An additional feature of the C-shaped of the condenser 16 is that the open area of the condenser 16, in this case located at the bottom middle of the air conditioner 10 as shown in
Whether the condenser fans 24 blow into the plenum formed by the condenser 16 or out into the ambient air behind the window air conditioner 10, the design also has the added benefit of improving the inlet conditions of the condenser fans 24 by creating straight airflow velocity vector as air enters the fan. Since the condenser fans 24 are relatively unobstructed both upstream and downstream of the fans (whether configured as axial or crossflow fans), this has the added benefit of improving fan performance in terms of airflow, but also in terms of the sound generated by the fan, since inlet vortexes generated by poor inlet conditions interact with the fan blades in ways that are deleterious to both acoustics and fan efficiency. In this manner, the overall noise of the air conditioner 10 can be reduced leading to a better user experience.
The present air conditioner 10 having a C-shaped condenser 16 arranged over and around the condenser fans 24 can also be implemented through various alternate embodiments, which may be used to address constraints dictated by a variety of conditions, including the physical size of the air conditioner 10, the system layout or configuration, the control of costs of components, or the capacity required of the air conditioner 10 or cooling system. In the following description, all heat transfer mechanisms, including gases, liquids, or other mechanisms for removing or transferring heat are implied when the word air is used or the word or words airflow or air flow are used.
An alternative approach to handling air flow through the condenser 16 can be addressed with variations on the fan design, for situations such as when a sharper turn is required for the air to exit through the condenser 16, when higher pressure is required to get the necessary air volume through the condenser 16, or when a varied flow through different sections of the condenser 16 is warranted for efficiency. Size considerations may permit or dictate further fan options, such as when the condenser 16 is large enough to partially or completely encircle the fan enclosure. In the case where limited distance is available for the condenser fans 24, a centrifugal fan or radial fan or mixed flow fan can be placed inside each curved portion of the C-shaped condenser 16, allowing the natural action of the centrifugal fan's right angle flow from intake to exhaust to draw air into the end of the fan and expel it directly into the body of the condenser 16. Additionally, if conditions dictate higher pressure or more evenly controlled flow over the surface of the condenser 16, there are multiple alternative fan and enclosure designs as fan, duct, and straightening vane combinations will enable control the airflow more precisely to extract as much heat from the refrigerant as it passes through the condenser 16.
Combination fan designs such as mixed flow fans or crossflow fans can be used with a variation to their typical axial flow implementation, where the use of different fans can provide higher pressure and lower volume flow. In the case of a mixed flow fan, where the natural pattern of the air as the fan accelerates it is to angle outward as shown in
Additional improvements to the efficiency of condenser 16 are possible by establishing an uneven flow of the refrigerant through the condenser 16, or an uneven profile of the condenser 16 to better match the uneven air flow or fluid flow that is characteristic of any air conditioning or other heat transfer system. As air or a fluid is accelerated, the inertia of the moving air or fluid makes it impossible to turn the air or fluid quickly enough to evenly pass through all of the heat transfer area of the condenser 16. In a design where the condenser 16 has headers on each end, differing tube sizes, tube lengths, fin sizes or contours, fin configurations, or surface treatments can essentially throttle the flow of the heat transfer air or fluid to maximize the efficiency of the heat transfer for specific areas of the condenser 16 due to uneven flow conditions.
Making further reference to the illustrative drawings, as shown in
One of ordinary skill in the art would appreciate that various aesthetic changes may be made to the present air conditioner without departing from the inventive features and components discussed herein.
Other aspects of the present low profile air conditioner design are set forth in U.S. patent application Ser. No. 15/784,768 for “Air Conditioner and An Air Conditioner Housing,” which in turns claims the benefit of Provisional Application No. 62/408,811, which are hereby incorporated by reference.
Although the preferred configuration of the window air conditioner in the present application has been described with the compressor being arranged along a direction that is perpendicular to the direction along which the bodies of the evaporator and condenser extend,
Alternatively, each centrifugal evaporator fan 26 can be driven by its own motor 42, which would allow each evaporator fan to operate separately at its own fan speed, and along its own rotational axis which may be offset from the rotational axis of the other evaporator fan. Having the two evaporator fans 26 arranged along slightly offset rotational axes may be desirable in order to meet space constraints within the window air conditioner housing, so that other components may be arranged near the fans, or can be done to optimize the desired airflow and pressure created by the evaporator fans. In this alternate embodiment, each axial condenser fan 24 is driven by its own motor 42, which can be incorporated into the fan itself and integrated within the fan hub. The axial condenser fans 24 each rotate around an axis that is substantially perpendicular to the rotational axis of the centrifugal evaporator fans. As discussed above, the separately operated axial condenser fans 24 can each rotate at a different fan speed, and may be arranged with respect to the condenser 16 and the rest of the assemblies to maximize airflow and pressure to achieve desirable efficiencies and flow rates.
Accordingly, even though the figures in the present application show embodiments utilizing a certain combination of motors and fans, and specific arrangement of the horizontally mounted compressor with respect to the fans, and forming the non-linear condenser as two separate portions instead of one single continuous body, such configurations should not be interpreted as being a limitation on the present invention.
This application claims the benefit of Provisional Application No. 62/505,448, filed on May 12, 2017, which is incorporated herein by reference as if fully set forth.
Number | Date | Country | |
---|---|---|---|
62505448 | May 2017 | US |