Patent Application
20110179813
This invention relates generally to evaporative coolers, and more particularly to evaporative coolers having centrifugal fans.
Evaporative coolers may be used to cool air by causing air to flow across a wet evaporative media. The effectiveness of an evaporative cooler may depend in part on the ability of the cooler to move air through the evaporative cooler and the ability of the cooler to manage the evaporation of water into the air flowing through the evaporative cooler.
Numerous advances in the effectiveness of evaporative coolers have been proposed over the year. Improvements in evaporative coolers are nevertheless desired.
Aspects of the present invention relate to evaporative coolers. An evaporative cooler in accordance with aspects of the present invention includes a cooler housing, a centrifugal fan, and a motor. The cooler housing defines an interior region, a single air inlet, and an air outlet. The single air inlet is positioned to permit air flow into the interior region of the cooler housing generally along an inlet axis. The air outlet is positioned to permit air flow from the interior region of the cooler housing generally along an outlet axis. The inlet axis and outlet axis are angled with respect to one another such that the general direction of air flow into the interior region of the cooler housing through the single air inlet differs from the general direction of air flow from the interior region of the cooler housing through the air outlet. The centrifugal fan is mounted within the interior region of the cooler housing. The centrifugal fan is oriented to rotate about a vertical axis that is substantially orthogonal to the inlet and outlet axes. The motor is mounted within the interior region of the cooler housing and is coupled to the centrifugal fan. The motor is configured to rotate the centrifugal fan about the vertical axis.
In accordance with another aspect of the present invention, a method is disclosed for configuring an evaporative cooler having a pump configured to pump water to evaporative media. A cooler housing is provided, the cooler housing defining an interior region, a single air inlet positioned to permit air flow into the interior region of the cooler housing generally along an inlet axis, and an air outlet positioned to permit air flow from the interior region of the cooler housing generally along an outlet axis, the inlet axis and outlet axis being angled with respect to one another such that the general direction of air flow into the interior region of the cooler housing through the single air inlet differs from the general direction of air flow from the interior region of the cooler housing through the air outlet. A centrifugal fan is mounted within the interior region of the cooler housing such that the centrifugal fan is oriented to rotate about a vertical axis that is substantially orthogonal to the inlet and outlet axes. Finally, a motor is mounted within the interior region of the cooler housing such that the motor is configured to rotate the centrifugal fan about the vertical axis.
The invention is best understood from the following detailed description when read in connection with the accompanying drawing. Included in the drawing are the following figures:
Although the invention is illustrated and described herein with reference to specific embodiments, the invention is not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the invention.
The invention is best understood from the following detailed description when read in connection with the accompanying drawing figures, which show exemplary embodiments of the invention selected for illustrative purposes. The invention will be described with reference to the figures. Such figures are intended to be illustrative rather than limiting and are included herewith to facilitate the explanation of the present invention.
As an overview,
Cooler housing 102 defines the interior region of evaporative cooler 100. Cooler housing 102 further defines an air inlet 106 for permitting air flow into the interior region of cooler 100, and an air outlet 110 for permitting air flow out of the interior region of cooler 100. Air inlet 106 permits air flow generally along an inlet axis (indicated by inlet axis 107), while air outlet 110 permits air flow generally along an outlet axis (indicated by outlet axis 111).
Cooler housing 102 includes a side wall 104 and a front wall 108. Side wall 104 defines air inlet 106, and front wall 108 defines air outlet 110. Cooler housing 102 may optionally include only a single air inlet 106. Including only one air inlet 106 may improve air flow through cooler housing 102. Specifically, air flow through a primary inlet opening (as opposed to air flow through plural openings positioned about the cooler housing) is believed to reduce the generation of air turbulence and to promote an air flow pattern more like laminar flow.
As illustrated in
Additionally, side and front walls 104 and 108 may define air inlet and outlet 106 and 110 such that the height of air inlet and outlet 106 and 110 is longer than their width. This shape may provide for a larger volume of air flow into and out of cooler housing 102. It will be understood, however, that the shape of cooler housing 102 illustrated in
Cooler housing 102 may further include an inlet grating 112 covering air inlet 106 and an outlet grating 114 covering air outlet 110, as illustrated in
As illustrated in
Cooler housing 102 receives water for use in evaporative cooling. In an exemplary embodiment, cooler housing 102 defines a receptacle for receiving water in the interior region of cooler housing 102. The receptacle may be formed in a bottom portion of cooler housing 102, as illustrated in
Cooler housing 102 may further include a water access port 116 for allowing a user to provide water to the interior region of cooler housing 102, as illustrated in
Cooler housing 102 may be formed from a single integral piece of material, or from multiple pieces of material. Suitable materials for forming cooler housing 102 include, for example, acrylonitrile butadiene styrene (ABS), high-impact polystyrene (HIPS), polypropylene, polystyrene, and other suitable polymers or plastics. Other suitable materials for forming cooler housing 102 will be known to one of ordinary skill in the art from the description herein. Cooler housing 102 may be formed, for example, by injection molding.
Fan 120 blows air out of cooler housing 102. As illustrated in
Fan 120 includes a number of fan blades 124. Fan blades 124 are angled with respect to the direction of rotation of fan 120, as illustrated in
Fan 120 is positioned to facilitate air flow through cooler housing 102. As illustrated in
As illustrated in
Suitable materials for forming fan 120 include, for example, a combination of acrylonitrile butadiene styrene (ABS) and fiberglass or a combination of nylon and fiberglass. Other suitable materials for forming fan 120 will be known to one of ordinary skill in the art from the description herein. Fan 120 may be formed, for example, by injection molding.
Motor 130 rotates fan 120. Motor 130 is mounted within the interior region of cooler housing 102. As illustrated in
Motor 130 may be an electric motor. Suitable motors 130 for use with evaporative cooler 100 include permanent split capacitor motors. Other suitable motors 130 will be known to one of ordinary skill in the art from the description herein.
Evaporative cooler 100 may further include a motor housing 134. Motor housing 134 may surround motor 130. Motor housing 134 may protect motor 130 from contacting the water received in cooler housing 102. Motor housing 134 may be formed integrally with cooler housing 102. Alternatively, motor housing 134 may be formed separately and affixed to cooler housing 102. Motor housing 134 may be formed from the same materials as cooler housing 102. Other suitable materials for forming motor housing 134 will be known to one of ordinary skill in the art from the description herein.
Pump 142 pumps the water received in cooler housing 102. As illustrated in
Tube 148 receives water pumped by pump 142. Tube 148 is coupled to receive water from water outlet 146 of pump 142. Water pumped by pump 142 may travel out water outlet 146 and through tube 148. In an exemplary embodiment, tube 148 releases the water pumped by pump 142 at a top portion of evaporative media 113 when media 113 is coupled to inlet grating 112. The pumped water may then flow downward over evaporative media 113. Tube 148 may be formed from any suitable waterproof material.
Pump controller 150 controls the operation of pump 142. Pump controller 150 is electrically coupled to pump 142 in order to activate and deactivate pump 142. For example, controller 150 may be configured to activate pump 142 to pump water upon receipt of a signal. Additionally, controller 150 may be configured to deactivate pump 142 from pumping water upon receipt of another signal. A suitable pump controller 150 for controlling the operation of pump 142 will be understood by one of ordinary skill in the art from the description herein.
In an exemplary embodiment, float 160 includes a floating portion 162 and an elongated portion 164. The floating portion 162 of float 160 contacts the surface of the water received in cooler housing 102. The elongated portion 164 is coupled to and extends from floating portion 162. Elongated portion 164 of float 160 is received in a float guide 166 formed on the front wall 108 of cooler housing 102. Float guide 166 confines the movement of float 160 such that float 160 moves only in a substantially vertical direction. For example, as illustrated in
Float 160 may include further include a water level indicator 168 for visually indicating the level of water received in the receptacle defined by the cooler housing 102. Water level indicator 168 is formed on the elongated portion 164 of float 160. Water level indicator 168 may indicate the level of the water based on the height of floating portion 162 within cooler housing 102. In an exemplary embodiment, cooler housing 102 includes a port 118 for enabling a user to view water level indicator 168. Port 118 may be located near float guide 166 such that the water level indicator 168 of float 160 is visible through port 118, as shown in
For example, as illustrated in
Floating portion 162 of float 160 may be formed from any buoyant material or a substantially hollow body suitable for floatation. Suitable materials for forming floating portion 162 include, for example, acrylonitrile butadiene styrene (ABS), high-impact polystyrene (HIPS), polypropylene, polystyrene, and other suitable polymers or plastics. Other suitable materials for forming floating portion 162 will be known to one of ordinary skill in the art from the description herein. Elongate portion 164 of float 164 may be formed from any suitable materials, which will be known to one of ordinary skill in the art from the description herein. Elongate portion 164 and floating portion 162 may be formed from the same or different materials and may be integrally formed. While float 160 is illustrated having a floating portion 162 and an elongate portion 164, it will be understood that the shape and orientation of float 160 illustrated in
Elongated portion 264 of float 260 is rotatably mounted to the front wall of cooler housing 202 at a float pivot 266. Float pivot 266 confines the movement of float 260 such that float 260 rotates relative to float pivot 266. Thus, floating portion 262 may move up and down in elevation but along a generally arcuate path defined by elongated portion 264 responsive to changes in the water level of the water received in cooler housing 202.
Float 260 may further include a water level indicator 268 for visually indicating the level of water received in the receptacle defined by the cooler housing 202. Water level indicator 268 is coupled to the elongated portion 264 of float 260. Water level indicator 268 may indicate the level of the water based on the height of floating portion 262 within cooler housing 202. In an exemplary embodiment, cooler housing 202 includes a port for enabling a user to view water level indicator 268, similar to the port 118 disclosed with respect to evaporative cooler 100. The port may be located near float pivot 266 such that the water level indicator 268 of float 260 is visible through the port.
For example, as illustrated in
Floating portion 262 and elongated portion 264 of float 260 may be formed from the same materials as floating portion 162 and elongated portion 164 of float 160, respectively. While float 260 is illustrated having a floating portion 262 and an elongate portion 264, it will be understood that the shape and orientation of float 260 illustrated in
Returning to evaporative cooler 100, it may be desirable for float 160 to operate in conjunction with pump system 140. For example, it may be desirable that pump 142 not run when there is insufficient water in cooler housing 102 to pump, in order to avoid damage to pump 142. Accordingly, float 160 may operate such that pump controller 150 deactivates pump 142 when float 160 indicates a low level of water in cooler housing 102. Operation of float 160 in conjunction with pump system 140 will be described below. While the aspects of the invention will be discussed below with reference to float 160, it will be understood that the same aspects could be employed with the use of float 260.
Float 160 may include a magnet 170. Magnet 170 may be coupled to the elongated portion 164 of float 160, as illustrated in
Evaporative cooler 100 may further include a magnetic switch 172, as illustrated in
Magnetic switch 172 may be configured for activation by magnet 170 when a water level in the receptacle of cooler housing 102 is low. Accordingly, magnet 170 of float 160 may be positioned proximal to magnetic switch 172 when the water level is low within cooler housing 102. In an exemplary embodiment, as illustrated in
As described above, it may be desirable that pump 142 not run when there is insufficient water in cooler housing 102 to pump, in order to avoid damage to pump 142. Accordingly, magnetic switch 172 may be electrically coupled to pump 142. When magnetic switch 172 is activated by magnet 170, e.g., when there is a low level of water in cooler housing 102, magnetic switch 172 may deactivate pump 142.
Further, magnetic switch 172 may be electrically coupled to controller 150. When magnetic switch 172 is activated by magnet 170, e.g., when there is a low level of water in cooler housing 102, magnetic switch 172 may send a signal to controller 150, and controller 150 may deactivate pump 142.
Still further, magnetic switch 172 may be electrically coupled to an alarm 174 for alerting a user of evaporative cooler 100. When magnetic switch 172 is activated by magnet 170, e.g., when there is a low level of water in cooler housing 102, magnetic switch 172 may send a signal to alarm 174, and alarm 174 may alert a user that there is a low level of water in cooler housing 102. Alarm 174 may be a visual or audible alarm. In an exemplary embodiment, alarm 174 is a visible alarm located on the display 176 of evaporative cooler 100, as illustrated in
Operation of evaporative cooler 100 will now be described. Generally, the principles of air cooling are described below. Background information regarding evaporative coolers is available in U.S. patent application Ser. No. 12/037,348, which is incorporated herein by reference in its entirety.
In an exemplary embodiment, a user of evaporative cooler 100 may turn on fan 120. Fan 120 may rotate about the axis of rotation 122, thereby blowing air in the interior region of cooler housing 102 outwards and out of air outlet 110. As blown air flows out of air outlet 110 through outlet grating 114, other air flows into the interior region of cooler housing 102 through air inlet 106. Air flowing into cooler housing 102 may pass through inlet grating 112 and evaporative media 113. A user may adjust the speed of fan 120 and the direction of outlet grating 114 to generate a desired flow of air from evaporative cooler 100.
Pump system 140 may be employed to cool the air blown by evaporative cooler 100. As described above, pump system 140 may pump water received in cooler housing 102 up to a top portion of media 113. The pumped water may then flow downwards over evaporative media 113 by the force of gravity, and fall back down into the receptacle of cooler housing 102, to be recirculated. Evaporative media 113 may promote the evaporation of water flowing over evaporative media. This evaporating water may cool the air flowing into cooler housing 102 through evaporative media 113. This cooled air may then be blown out of cooler housing 102. Evaporative media 113 may be specially designed to promote the evaporation of water. Suitable materials for forming evaporative media 113 may include paper or cellulose, for example. Suitable evaporative media will be known to one of ordinary skill in the art from the description herein.
As described above, water level indicator 168 of float 160 may be used to determine the amount of water in cooler housing 102 to be circulated. As water evaporates during evaporative cooling, the water level in cooler housing 102 may lower. When a low water level is reached, magnet 170 may be configured to activate magnetic switch 172. Activation of magnetic switch 172 may cause alarm 174 to alert a user that the water level in cooler housing 102 is low, and needs to be refilled via water access port 116. Further, when a low water level is reached, magnetic switch 172 may deactivate pump 142, in order to prevent damage to pump 142 that may arise from operating pump 142 without water in cooler housing 102.
Accordingly, as set forth above, evaporative cooler 100 may be configured to deactivate pump 142 when a level of the water received in cooler housing 102 is low. A method for so configuring evaporative cooler 100 is disclosed in accordance with an aspect of the present invention. Float 160 is positioned in cooler housing 102 to float on water received in cooler housing 102. Optionally, float 160 may be positioned in float guide 166 such that float guide 166 confines the movement of float 160 in the substantially vertical direction. Magnetic switch 172 is mounted on cooler housing 102. Magnetic switch 172 is configured for activation when magnet 170 is proximal to magnetic switch 172. Further, magnetic switch 172 is electrically coupled to pump 142 such that pump 142 is deactivated when magnetic switch 172 is activated by magnet 170 of float 160.
Optionally, magnetic switch 172 may be electrically coupled to controller 150, and controller 150 may be electrically coupled to pump 142, such that controller 150 deactivates pump 142 when magnetic switch 172 is activated by magnet 170. Magnetic switch 172 may also be coupled to alarm 174 such that alarm 174 is activated when magnetic switch 172 is activated by magnet 170.
While preferred embodiments of the invention have been shown and described herein, it will be understood that such embodiments are provided by way of example only. Numerous variations, changes and substitutions will occur to those skilled in the art without departing from the spirit of the invention. Accordingly, it is intended that the appended claims cover all such variations as fall within the spirit and scope of the invention.
