LIQUID-DESICCANT STACK WITH INTEGRATED FLUID DISTRIBUTION

TECHNICAL FIELD

The disclosure relates generally to heating ventilation and cooling systems and, more particularly, to mass transfer assemblies for heating ventilation and cooling systems.

BACKGROUND

Heating ventilation and cooling (HVAC) systems generally cool ambient or room temperature air using a vapor compression refrigeration cycle. The HVAC systems may include a heat exchanger that operates to remove heat from a refrigerant. For example, the heat exchanger may include plates or coils through which the refrigerant flows. A fan may blow air across the plates or coils to cool the refrigerant flowing within. Less frequently, the heat exchangers may include a liquid desiccant to dehumidify the air during the cooling process.

SUMMARY

In some examples, a mass transfer apparatus includes a stack that includes a plurality of plates, where the stack defines alternating conditioning channels and exhaust channels. The mass transfer apparatus also includes a fluid distribution system adapted to distribute a conditioning fluid to the conditioning channels and a working fluid to the exhaust channels. The fluid distribution system includes a conditioning supply line defined in part by a first hole in an upper portion of each of the plurality of plates, and a working supply line defined in part by a second hole in the upper portion of each of the plurality of plates. The conditioning supply line is adapted for supplying the conditioning fluid to the conditioning channels, and the working supply line adapted for supplying the working fluid to the exhaust channels. The fluid distribution system further includes a conditioning return line passing through a first hole in a lower portion of each of the plurality of plates and adapted for collecting the conditioning fluid, and a working return line passing through a second hole in the lower portion of each of the plurality of plates and adapted for collecting the working fluid. The fluid distribution system is adapted to prevent mixing of the conditioning fluid and the exhaust fluid.

In some examples, a mass transfer apparatus includes a first plate and a second plate opposite the first plate. The mass transfer apparatus also includes a first header coupled to the first plate and the second plate. The first header includes a first entry aperture, a first exit aperture, and a first passageway, where the first passageway is adapted to receive a first fluid from the first entry aperture and provide the first fluid to the first exit aperture. The mass transfer apparatus further includes a second header coupled to the first plate and the second plate. The second header includes a second entry aperture, a second exit aperture, and a second passageway, where the second passageway is adapted to receive a second fluid from the second entry aperture and provide the second fluid to the second exit aperture.

In some examples, a method to distribute fluids within a mass transfer apparatus includes receiving a conditioning fluid within a conditioning supply line. The method also includes providing the conditioning fluid from the conditioning supply line to conditioning channels of a stack defining alternating conditioning channels and exhaust channels. Further, the method includes receiving a working fluid within a working supply line. The method also includes providing the working fluid from the working supply line to the exhaust channels. The method further includes providing the conditioning fluid from the conditioning channels to first wicking material. The method also includes collecting at least portions of the conditioning fluid from the from the first wicking material within a conditioning return line. Further, the method includes providing the working fluid from the exhaust channels to second wicking material. The method also includes collecting at least portions of the working fluid from the second wicking material within a working return line.

BRIEF DESCRIPTION OF THE DRAWINGS

The following drawings are illustrative of particular embodiments of the present disclosure and therefore do not limit the scope of the present disclosure. The drawings are not to scale and are intended for use in conjunction with the explanations in the following detailed description.

FIG. 1A illustrates a mass transfer apparatus, in accordance with one embodiment;

FIG. 1B illustrates portions of the mass transfer apparatus of FIG. 1A, in accordance with one embodiment;

FIG. 1C illustrates portions of the mass transfer apparatus of FIG. 1A, in accordance with one embodiment;

FIG. 2A illustrates portions of a header assembly for a mass transfer apparatus, in accordance with one embodiment;

FIG. 2B illustrates the header of the header assembly of FIG. 2A, in accordance with one embodiment;

FIG. 3A illustrates portions of a header assembly for a mass transfer apparatus, in accordance with one embodiment;

FIG. 3B illustrates the header of the header assembly of FIG. 3A, in accordance with one embodiment;

FIG. 3C illustrates a side view of a portion of the header assembly of FIG. 3A, in accordance with one embodiment;

FIG. 4A illustrates portions of a header assembly for a mass transfer apparatus, in accordance with one embodiment;

FIG. 4B illustrates the header of the header assembly of FIG. 4A, in accordance with one embodiment;

FIG. 5A illustrates a plate for a mass transfer apparatus, in accordance with on embodiment;

FIG. 5B illustrates further views of the mass transfer apparatus of FIG. 5A, in accordance with one embodiment;

FIG. 5C illustrates further views of the mass transfer apparatus of FIG. 5A, in accordance with one embodiment;

FIG. 5D illustrates further views of the mass transfer apparatus of FIG. 5A, in accordance with one embodiment;

FIG. 5E illustrates further views of the mass transfer apparatus of FIG. 5A, in accordance with one embodiment;

FIG. 6 illustrates a flowchart of an example method to distribute fluids within a mass transfer apparatus, in accordance with one embodiment;

FIG. 7A illustrates portions of the mass transfer apparatus of FIG. 1A, in accordance with one embodiment;

FIG. 7B illustrates portions of the mass transfer apparatus of FIG. 1A, in accordance with one embodiment;

FIG. 8A illustrates portions of the mass transfer apparatus of FIG. 1A, in accordance with one embodiment;

FIG. 8B illustrates portions of the mass transfer apparatus of FIG. 1A, in accordance with one embodiment;

FIG. 9A illustrates a mass transfer apparatus, in accordance with one embodiment;

FIG. 9B illustrates portions of the mass transfer apparatus of FIG. 9A, in accordance with one embodiment; and

FIG. 9C illustrates portions of the mass transfer apparatus of FIG. 9A, in accordance with one embodiment.

DETAILED DESCRIPTION

The following discussion omits or only briefly describes conventional features of heat and mass exchangers that are apparent to those skilled in the art. It is noted that various embodiments are described in detail with reference to the drawings, in which like reference numerals represent like parts and assemblies throughout the several views. Reference to various embodiments does not limit the scope of the claims attached hereto. Additionally, any examples set forth in this specification are intended to be non-limiting and merely set forth some of the many possible embodiments for the appended claims. Further, particular features described herein can be used in combination with other described features in each of the various possible combinations and permutations.

Unless otherwise specifically defined herein, all terms are to be given their broadest reasonable interpretation including meanings implied from the specification as well as meanings understood by those skilled in the art and/or as defined in dictionaries, treatises, etc. It must also be noted that, as used in the specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless otherwise specified, and that the terms “includes” and/or “including,” when used in this specification, specify the presence of stated features, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. In the description, relative terms such as “horizontal,” “vertical,” “up,” “down,” “top,” and “bottom” as well as derivatives thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing figure under discussion. These relative terms are for convenience of description and normally are not intended to require a particular orientation. Terms including “above” versus “below,” “inwardly” versus “outwardly,” “longitudinal” versus “lateral,” and the like are to be interpreted relative to one another or relative to an axis of elongation, or an axis or center of rotation, as appropriate. Terms concerning attachments, coupling, and the like, such as “connected” and “interconnected,” refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. The terms “operatively connected,” “operably connected,” and the like are such attachments, couplings, or connections that allow the pertinent structures to operate as intended by virtue of that relationship.

Embodiments of the present disclosure relate generally to heating ventilation and cooling (HVAC) systems and, more particularly, to mass transfer assemblies that facilitate the distribution of multiple fluids to dehumidify and transfer heat from a fluid, such as air. The multiple fluids may include, for example, a conditioning fluid (e.g., a liquid desiccant, water) and a working fluid (e.g., water, refrigerant, liquid desiccant, etc.). Further, the mass transfer assemblies may provide both a dehumidification stage and an indirect evaporative cooling stage for conditioning air. For instance, a mass transfer assembly may include two fluid distribution systems, with a first fluid distribution system configured to distribute a conditioning fluid, and a second fluid distribution system configured to distribute a working fluid. The first and second fluid distribution systems may include a stack of plates configured to provide alternating channels for distribution of the conditioning and working fluids. Further, the mass transfer assembly may include barriers that guide and restrict airflow to maintain separation between conditioning and exhaust channels. In some examples, the first fluid distribution system provides a conditioning fluid, such as liquid desiccant, to wicking material to dehumidify air as it passes through the conditioning channel. In addition, the second fluid distribution system may provide a working fluid, such as water, to wicking material along the exhaust channel to provide indirect evaporative cooling of the supply air. In some instances, a first fan may provide a stream of air to the air supply channel, and a second fan may provide a stream of exhaust to the exhaust channel.

Referring to the drawings, FIG. 1A illustrates an example mass transfer apparatus 100 that provides both a dehumidification stage 197 and an indirect evaporative cooling stage 199. Mass transfer apparatus 100 may be employed within an air conditioner, a regenerator, or any other suitable system requiring heat transfer, for example. In one or more examples, mass transfer apparatus 100 provides a fluid distribution system that is adapted to distribute a conditioning fluid, such as liquid desiccant, to conditioning channels and a working fluid, such as water, to exhaust channels, where the flow of both the conditioning fluid and the working fluid participate to transfer heat from a supply of air.

Mass transfer apparatus 100 may include a stack that includes a plurality of plates that define alternating conditioning channels and exhaust channels. As illustrated herein, mass transfer apparatus 100 includes a first plate 102 and a second plate 104. Although only two plates are shown for simplicity, a stack may include multiple first plates 102 and second plates 104, where first plates 102 and second plates 104 alternate. Each first plate 102 includes a first side 102A and a second side 102B, and each second plate 104 includes a first side 104A and a second side 104B. First side 102A of first plate 102 and second side 104B of second plate 104 may define a conditioning channel 180 for an air supply stream (e.g., outside air, mixed air, process stream, etc.). In addition, first side 104A of second plate 104 and a second side 102B of another first plate 102 may define an exhaust channel 190 for an exhaust stream. As such, a stack can include a plurality of alternating first plates 102 and second plates 104 that define alternating conditioning channels 180 and exhaust channels 190 for a cross-flow configuration.

First plate 102 may include a wicking material 175 (e.g., a conditioning fluid wick) that extends longitudinally along at least a portion of first side 104A (e.g., 40% to 70% of first side 104A). As described herein, a conditioning fluid, such as a liquid desiccant, may be provided to wicking material 175 to dehumidify the air supply proceeding through conditioning channel 180. Second plate 104 may also include wicking material 175 along a portion of second side 104B. In some examples, a size (e.g., a length and width) of the wicking material 175 along the first side 102A of first plate 102 matches (e.g., is the same, or nearly the same, as) a size of the wicking material 175 along the second side 104B of second plate 104. In some examples, wicking material 175 is secured to first side 102A of first plate 102, and another wicking material 175 is secured to second side 104B of second plate 104. For instance, an adhesive may be used to secure wicking material 175 to first side 102A of first plate 102 and the other wicking material 175 to second side 104B of second plate 104. Additionally, each side of each plate may include spacers 152 (e.g., spacing restrictors), which may keep one plate distanced from another to allow for the flow of fluid through a corresponding channel. For instance, the spacers 152 located on first side 102A of first plate 102 keep the first plate 102 a distance away from the second side 104B of the second plate 104.

Further, in some examples, second plate 104 may include wicking material 176 (e.g., a working fluid wick) that extends longitudinally along first side 104A. As described herein, a working fluid, such as water, may be provided to the wicking material 176 to provide an indirect evaporative cooling stage to the conditioning channel. For instance, as exhaust proceeds through exhaust channel 190, water evaporates from the wicking material 176 thereby cooling plate 104 and, indirectly, cooling the air supply stream flowing through the conditioning channel 180.

To facilitate the distribution of the conditioning and working fluids, mass transfer apparatus 100 includes conditioning fluid distribution headers 106, 107, 108, working fluid distribution headers 110, 112, 120, conditioning fluid collectors 140, 142, 150, and working fluid collectors 136, 137, 138. The distribution headers 106, 107, 108, 110, 112, 120 are positioned such that corresponding apertures are aligned, and are attached such that water-tight seals are established around each of the apertures. For instance, conditioning fluid distribution header 106 may be positioned along a top portion of the second side 102B of first plate 102, and working fluid distribution header 110 may be positioned along a top portion of the first side 102A of the first plate 102. The distribution headers 106, 110, may be attached (e.g., glued, bonded, welded) to the respective sides of the first plate 102 to secure them in place, for example. Similarly, working fluid distribution header 120 may be positioned and glued along a top portion of the second side 104B of the second plate 104, and conditioning fluid distribution header 107 may be positioned and glued along the top portion of the first side 104A of the second plate 104. Further, working fluid distribution header 112 may be positioned between, and glued to, working fluid distribution header 110 and working fluid distribution header 120. Conditioning fluid distribution header 108 may be positioned along, and glued to, conditioning fluid distribution header 107. Another conditioning fluid distribution header 106 may be positioned along conditioning fluid distribution header 108 such that conditioning fluid distribution header 108 is positioned between conditioning distribution header 107 and the other conditioning fluid distribution header 106. As discussed below with respect to FIGS. 7A and 8A, tabs and recesses of adjacent distribution headers 106, 107, 108, 110, 112, 120 may be aligned.

The apertures of the conditioning fluid distribution headers 106, 107, 108 and the working fluid distribution headers 110, 112, 120 are aligned to define a fluid distribution channel for distribution of a fluid, such as a fluid distribution channel for a conditioning fluid and another fluid distribution channel for a working fluid. As illustrated, each of the conditioning fluid distribution headers 106, 107, 108 and the working fluid distribution headers 110, 112, 120 include various apertures. For instance, conditioning fluid distribution header 106 includes three apertures 106A, 106B, 106C, working fluid distribution header 110 includes three apertures 110A, 110B, 110C, and working fluid distribution header 112 includes three apertures 112A, 112B, 112C. In addition, working fluid distribution header 120 includes three apertures 120A, 120B, 120C, conditioning fluid distribution header 107 includes three apertures 107A, 107B, 107C, and conditioning fluid distribution header 108 includes three apertures 108A, 108B, 108C. Although the conditioning fluid distribution headers 106, 107, 108 and the working fluid distribution headers 110, 112, 120 are each illustrated with these three apertures, in some examples, the conditioning fluid distribution headers 106, 107, 108 and the working fluid distribution headers 110, 112, 120 can include more than, or less, than these three apertures.

In some examples, a first set of corresponding apertures 106A, 107A, 108A, 110A, 110A, 112A, and 120A provide for a flow of working fluid, and a second set of corresponding apertures 106C, 107C, 108C, 110C, 112C, and 120C provide for a flow of conditioning fluid. For example, as indicated by arrow 165, corresponding apertures 106C, 107C, 108C, 110C, 112C, and 120C of distribution headers 106, 107, 108, 110, 112, 120, may define a conditioning supply line through which a condition fluid is provided. For instance, the conditioning fluid may proceed through an aperture 108C of conditioning fluid distribution header 108, then through an aperture 107C (e.g., a conditioning feed opening) of conditioning fluid distribution header 107, proceed through an aperture 105 of second plate 104, and through an aperture 120C of working fluid distribution center 120. The conditioning fluid may continue and proceed through aperture 112C of working fluid distribution header 112, then through aperture 110C of working fluid distribution header 110, proceed through an aperture 103 of first plate 102, and through an aperture 106C of conditioning fluid distribution header 106.

Moreover, as the conditioning fluid enters the corresponding aperture 108C of conditioning fluid distribution header 108, the fluid may also proceed along channel 108D and into one or more distribution channels 107D of conditioning fluid distribution header 107. Further, the one or more distribution channels 107D may provide the conditioning fluid to corresponding apertures 104E of second plate 104, and onto the wicking material 175. Likewise, conditioning fluid may flow through one or more distribution channels 106D of conditioning fluid distribution header 106 and through corresponding apertures 102E of first plate 102, and onto the wicking material 175. For example, FIG. 7A illustrates this flow of the conditioning fluid through the mass transfer apparatus 100, as indicated by the arrows. Further, FIG. 7B illustrates another view of the working fluid distribution headers 112, 120. FIG. 7B also illustrates the alignment of recesses 702 of working fluid distribution headers 112 and 120 with tabs 720 of working fluid distribution headers 112 and 120, as well as tabs and recesses of conditioning fluid distribution header 107, as indicated by the dashed line.

Referring back to FIG. 1A, a second set of corresponding apertures 106A, 107A, 108A, 110A, 112A, and 120A provide for a flow of working fluid, such as water. For example, as indicated by arrow 169, corresponding apertures 106A, 107A, 108A, 110A, 112A, and 120A of distribution headers 106, 107, 108, 110, 112, 120, may define a working supply line through which a working fluid is provided. For instance, the working fluid may proceed through an aperture 108A of conditioning fluid distribution header 108, then through an aperture 107A (e.g., a conditioning feed opening) of conditioning fluid distribution header 107, proceed through an aperture 105 of second plate 104, and through an aperture 120A of working fluid distribution center 120. The working fluid may continue and proceed through aperture 112A of working fluid distribution header 112, then through aperture 110A of working fluid distribution header 110, proceed through an aperture 103 of first plate 102, and through an aperture 106A of conditioning fluid distribution header 106.

Moreover, as the working fluid enters the corresponding aperture 112A of working fluid distribution header 112, the fluid may also proceed along channel 112D and into one or more distribution channels 110D of working fluid distribution header 110. Further, the one or more distribution channels 110D may provide the fluid to corresponding apertures 102D of first plate 102, and onto the wicking material 176. Similarly, as the working fluid enters the corresponding aperture 112A of working fluid distribution header 112, the working fluid may also flow into one or more distribution channels 120D of working fluid distribution header 120. Further, the one or more distribution channels 120D may provide the working fluid to corresponding apertures 104D of second plate 104, and onto the corresponding wicking material 176.

Similarly, a third set of corresponding apertures 106B, 107B, 108B, 110B, 112B, and 120B provide for another flow of working fluid, such as water. For example, as indicated by arrow 167, corresponding apertures 106B, 107B, 108B, 110B, 112B, and 120B of distribution headers 106, 107, 108, 110, 112, 120, may define a working supply line through which a working fluid is provided.

For example, FIG. 8A illustrates this flow of the working fluid through the mass transfer apparatus 100, where the working fluid flows through two working fluid distribution channels, as indicated by the arrows. Further, FIG. 8B illustrates another view of the working fluid distribution channels. FIG. 8B also illustrates the alignment of tabs and recesses of conditioning fluid distribution headers 107 and 108.

Referring back to FIG. 1A, working fluid distribution header 110 includes a barrier 171 that restricts airflow into the conditioning channel 180. Instead, the airflow proceeds as indicated by the arrows for the conditioning channel 180 Similarly, second plate 104 includes barrier 173 that restricts the flow out of the exhaust channel 190, forcing the flow to proceed as indicated by the arrows for the exhaust channel 190.

Similarly, the collectors 136, 137, 138, 140, 142, 150 are positioned such that corresponding apertures are aligned. Collectors 136, 137, 138, 140, 142, 150 may receive fluid that flows down through corresponding wicking material 175, 176, and provide a return line for the corresponding fluid. For instance, collector 138 may be positioned over collector 137 such that corresponding apertures 138A, 137A align. A face of collector 138 may be glued to a face of collector 137, for instance. Furthermore, the set of collectors 137, 138 may be positioned along a bottom portion of wicking material 176. In this example, a plurality of spacers 133 are positioned along an edge (e.g., trailing edge) of second plate 104 along first side 104A. The plurality of spacers 133 may provide stability between second plate 104 and a first plate 102 (e.g., when positioned between first side 104A of second plate 104 and a second side 102B of first plate 102). When assembled, the set of working fluid collectors 137, 138 may receive working fluid from wicking material 176. For instance, distribution channels 120D may provide working fluid to wicking material 176. The working fluid proceeds downward through the wicking material 176, and falls onto inclined surfaces 137B, 138B of working fluid collectors 137, 138, respectively. Inclined surfaces 137B, 138B may be inclined at any suitable angle, such as at an angle in a range of 5 degrees to 35 degrees. The working fluid proceeds along inclined surfaces 137B, 138B until reaching apertures 137A, 138A. Apertures 137B, 138B of inclined surfaces 137B, 138B, along with corresponding apertures in collectors 150, 142, 140, and 136, form a working fluid return line for working fluid received from wicking material 176. Similarly, distribution channels 110D of working fluid distribution header 106 may provide working fluid to wicking material 176 on the second side 102B of first plate 102. Further, working fluid collector 136 may receive working fluid from the wicking material 176, and may provide the working fluid to the working fluid return line.

For instance, as indicated by the arrows, FIG. 8A illustrates working fluid proceeding through wicking material 176 and falling onto inclined surfaces 137B, 138B of working fluid collectors 137, 138, respectively. Inclined surfaces 137B, 138B direct the working fluid to corresponding apertures 137A, 138A, and the working fluid proceeds out aperture 138A of collector 138. Further, FIG. 8B illustrates the alignment of recesses 802 of distribution headers 108 and 107 with tabs 820 of distribution headers 108 and 107.

Referring back to FIG. 1A, inclined surfaces 140B, 142B of conditioning fluid collectors 140, 142, respectively, receive conditioning fluid from wicking material 175. For instance, conditioning fluid may proceed from distribution channels 106D, 107D through wicking material 175 and onto inclined surfaces 140B, 142B of conditioning fluid collectors 140, 142. Inclined surfaces 140B, 142B may be inclined at any suitable angle, such as an angle within the range of 5 degrees to 35 degrees. The conditioning fluid proceeds along inclined surfaces 140B, 142B until reaching apertures 140A, 142A. Apertures 140A, 142A of inclined surfaces 140B, 142B, along with corresponding apertures in collectors 136, 137, 138, and 150, form a conditioning fluid return line for conditioning fluid received from wicking material 175. Similarly, an inclined surface of conditioning fluid collector 150, along with inclined surface 142B of collector 142, may receive conditioning fluid from the wicking material 175 on the second side 104B of second plate 104. The conditioning fluid may flow down the inclined surfaces until reaching the conditioning fluid return line defined by the corresponding apertures of collectors 136, 137, 138, 140, 142, 150.

For instance, as indicated by the arrows, FIG. 7A illustrates conditioning fluid proceeding through wicking material 175 and falling onto inclined surfaces 140B, 142B of collectors 140, 142, respectively. Inclined surfaces 140B, 142B direct the conditioning fluid to corresponding apertures 140A, 142A, and the working fluid proceeds out the corresponding aperture 136A of working fluid collector 136.

In some examples, conditioning fluid is provided to the conditioning supply line from a conditioning distribution reservoir. For instance, the conditioning distribution reservoir may extend longitudinally away from the conditioning supply line. In some examples, the conditioning return line provides the collected conditioning fluid to a conditioning collection reservoir. The conditioning collection reservoir may extend longitudinally away from the conditioning return line, for example. In some examples, the conditioning distribution reservoir and the conditioning collection reservoir are on the same side of at least one plate, such as the first side 104A of the second plate 104. In some examples, the conditioning distribution reservoir and the conditioning collection reservoir are on opposite sides of at least one plate.

In some examples, working fluid is provided to the working supply line from a working distribution reservoir. For instance, the working distribution reservoir may extend longitudinally away from the working supply line. In some examples, the working return line provides the collected working fluid to a working collection reservoir. The working collection reservoir may extend longitudinally away from the working return line, for example. In some examples, the working distribution reservoir and the working collection reservoir are on the same side of at least one plate, such as the second side 102B of the first plate 102. In some examples, the working distribution reservoir and the working collection reservoir are on opposite sides of at least one plate.

In some examples, plates 102, 104, distribution headers 106, 107, 108, 110, 112, 120, and collectors 136, 137, 138, 140, 142, 150 are manufactured from a metal, such as aluminum. In some examples, plates 102, 104, distribution headers 106, 107, 108, 110, 112, 120, and collectors 136, 137, 138, 140, 142, 150 are manufactured from any other suitable material.

FIG. 1B illustrates an enlarged view of a portion of the mass transfer apparatus 100 of FIG. 1A. As illustrated, barrier 173 prevents (e.g., blocks) airflow coming out of the exhaust channel 190, forcing the exhaust stream to proceed as indicated by the arrows illustrated for the exhaust channel 190. In addition, spacers 152 separate first plate 102 from second plate 104. Thus, for example, spacers 152 can assist in preventing first plate 102 from crashing in on second plates 104 when under pressure (e.g., air pressure). Spacers 152 may be manufactured out of any suitable material including metal (e.g., aluminum), rubber, plastic, or any other suitable material.

FIG. 1C illustrates a cross-sectional and enlarged view of a portion of the mass transfer apparatus 100 of FIG. 1A. Working fluid distribution header 108 includes channel 108D, which may provide a working fluid, such as water, to distribution channels 107D of conditioning fluid distribution header 107. The distribution channels 107D provide the working fluid to wicking material 176. Further illustrated is an aperture 108B of distribution header 108, which is part of a conditioning fluid supply line to the mass transfer apparatus 100.

FIG. 2A illustrates a distribution header assembly 200 that includes a distribution header 202, a first side support 204A, and a second side support 204B. The distribution header 202 includes an aperture 206 that may, for instance, define a portion of a fluid supply line, such as a working fluid supply line. Further, distribution header 202 includes a first pocket 209 and a second pocket 211. Each of the first pocket 209 and the second pocket 211 may be a recessed portion of the distribution header 202. Additionally, distribution header 202 includes an aperture 208B that can provide a fluid, such as a conditioning fluid, to channel 208A. The channel 208A may provide the fluid to first pocket 209. Similarly, aperture 210B can provide a fluid, such as a conditioning fluid, to channel 210A. Channel 210A may provide the fluid to second pocket 211.

In some examples, distribution header assembly 200 includes wicking material 176. The wicking material 176 may include portions within first pocket 209 and second pocket 211. As such, channels 208A, 210A can provide fluid, such as conditioning fluid, to the portions of the wicking material 176 within first pocket 209 and second pocket 211.

FIG. 2B illustrates the distribution header 202 of FIG. 2A. The wicking material 176, in some examples, sits over channels 208A, 210A. As fluid flows through channels 208A, 210A, the fluid is absorbed by the wicking material 176.

FIG. 3A illustrates a distribution header assembly 300 that includes a distribution header 302, a first side support 304A, and a second side support 304B. The distribution header 302 includes an aperture 306 that may, for instance, define a portion of a fluid supply line, such as a working fluid supply line. Further, distribution header 302 includes a first pocket 309 and a second pocket 311. Each of the first pocket 309 and the second pocket 311 may be a recessed portion of the distribution header 302. Additionally, distribution header 302 includes an aperture 308B that can provide a fluid, such as a conditioning fluid, to a corresponding channel 308A. The channel 308A may provide the fluid to distribution channels 312A, 312B, 312C, 312D. The channel 308A and the distribution channels 312A, 312B, 312C, 312D can provide the fluid to first pocket 309. Similarly, aperture 310B can provide a fluid, such as a conditioning fluid, to a corresponding channel 310A. Channel 310A may provide the fluid to distribution channels 313A, 313B, 313C, 313D. The channel 310A and the distribution channels 313A, 313B, 313C, 313D can provide the fluid to second pocket 311. Further, an indentation channel 317 allows for a sealant, such as an o-ring or dispensable sealant, to be placed. The sealant prevents the fluid from straying outside of first pocket 309 and second pocket 311.

In some examples, distribution header assembly 300 includes wicking material 176. The wicking material 176 may include portions placed within first pocket 309 and second pocket 311. As such, channels 308A, 310A, and their corresponding distribution channels 311A, 311B, 311C, 313A, 313B, 313C, 313D, can provide fluid, such as conditioning fluid, to the portions of the wicking material 176 within first pocket 309 and second pocket 311.

FIG. 3B illustrates the distribution header 302 of FIG. 3A. The wicking material 176, in some examples, sits over channels 308A, 310A and corresponding distribution channels 311A, 311B, 311C, 313D, 313A, 313B, 313C, 313D such that as the fluid flows through channels 308A, 310A and distribution channels 311A, 311B, 311C, 311D, 313A, 313B, 313C, 313D, the fluid is absorbed by the wicking material 176. FIG. 3C illustrates a cross-sectional and enlarged view of a portion of the distribution header assembly 300 of FIG. 3A. As illustrated, on a first side 301 of distribution header 302 a channel 308A provides fluid to distribution channel 312B. Wicking material 176 sits over the channel 308A and the distribution channel 312B, and absorbs fluid from the channel 308A and the distribution channel 312B. Similarly, on a second side 303 of distribution header 302, a channel (not illustrated) provides fluid to a distribution channel 328B. Wicking material 176 sits over the channel and distribution channel 328B, and absorbs fluid from the channel and the distribution channel 328B.

FIGS. 4A and 4B illustrate a distribution header 400 that includes an aperture 406 that may, for instance, define a portion of a fluid supply line, such as a working fluid supply line. Further, distribution header 400 includes a first pocket 409 and a second pocket 311. Each of the first pocket 409 and the second pocket 411 may be a recessed portion of the distribution header 400. Additionally, distribution header 400 includes an aperture 408B that can provide a fluid, such as a conditioning fluid, to a corresponding channel 408A. The channel 408A may provide the fluid to first pocket 409. Similarly, aperture 410B can provide a fluid, such as a conditioning fluid, to a corresponding channel 310A. The channel 310A can provide the fluid to second pocket 411.

In some examples, distribution header 400 includes wicking material 176. The wicking material 176 may include portions placed within first pocket 409 and second pocket 411. As such, channels 408A, 410A can provide fluid, such as conditioning fluid, to the portions of the wicking material 176 within first pocket 409 and second pocket 411. Further, an indentation channel 412 allows for a sealant, such as an o-ring or dispensable sealant, to be placed. The sealant prevents the fluid from straying outside of first pocket 409 and second pocket 411.

FIGS. 5A, 5B, 5C, 5D, and 5E illustrate portions of a molded (e.g., embossed or thermoformed) mass transfer apparatus 500. The mass transfer apparatus 500 may also be referred to as an evaporative cooler. As illustrated in FIG. 5A, the mass transfer apparatus 500 includes a header 503, a footer 504, a first plate 515, and a second plate 516. The first plate 515 may be attached to the second plate 516 such that a seal is formed around a perimeter of the intersection of the first plate 515 and the second plate 516. For example, the first plate 515 may be glued, bonded, or welded to the second plate 516. Similarly, the header 503 and the footer 504 may be attached to the first plate 515 and second plate 516. For example, the header 503 and the footer 504 may be glued, bonded, or welded to the first plate 515 and the second plate 516. The header 503 includes at least one aperture 505, and the second header includes at least one aperture 535. The apertures 505, 535 may provide a fluid pathway for fluid, such as an entrance and an exit, respectively, for working fluid. The header 503 and the footer 504 facilitate fluid flow, as described herein.

The mas transfer apparatus 500 also includes standoffs (e.g., variable spacing restrictors) 552 to provide spacing for a fluid flow 517 between the first plate 515 and the second plate 516 of the mass transfer apparatus 500. Fluid flow 517 may be, for instance, an air supply stream (e.g., mixed air stream). For instance, the first plate 515 and the second plate 516 may form an interior channel that allows for the fluid flow 517. Further, first plate 515 defines a side of a channel that allows for a fluid flow 590. Fluid flow 590 may be, in some examples, an exhaust flow of an exhaust stream. For instance, two mass transfer apparatus 500 may be positioned adjacent to each other to define an exhaust channel for the fluid flow 590. The first plate 515 of the first mass transfer apparatus 500, and the second plate 516 of the second mass transfer apparatus 500, may form the exhaust channel for the fluid flow 590. As illustrated, fluid flow 590 may proceed longitudinally along first plate 515 before being directed upwards and out of the mass transfer apparatus 500. The mass transfer apparatus 500 further includes wicking material 575, 576 that allows for indirect evaporative cooling of the fluid flow 517, or direct evaporative cooling of the flow 590.

FIG. 5B illustrates an enlarged view of the mass transfer apparatus 500. End caps 512 allow for the receiving of a fluid to distribute within the header 503. For instance, and as illustrated in FIG. 5C, end cap 512 and passageways 513A, 513B allow for a fluid stream 523, such as a flow of a working fluid, within the mass transfer apparatus 500. The fluid stream 523 may enter from the side of the second plate 516 through aperture 505 and into passageways 513A, 513B defined by header 503 through respective openings 572A, 572B. In addition, the fluid stream 523 may flow into end cap 512, where end cap 512 includes an opening 573 that allows the fluid to proceed to wicking material 576 (e.g., of another mass transfer apparatus 500).

Similarly, and as illustrated in FIG. 5D, footer 504 includes an endcap 532 that allows for a fluid flow within footer 504. As illustrated in FIG. 5E, a fluid flow 550 may enter in a cavity 545 adjacent end cap 532, and proceed through a passageway 505 defined by footer 504 and out an opening 537.

FIG. 6 is a flowchart of a method 600 to distribute fluids within a mass transfer apparatus, such as mass transfer apparatus 100. Beginning at step 602, a conditioning fluid is received within a conditioning supply line. For example, distribution headers 106, 107, 108, 110, 112, 120 of mass transfer apparatus 100 may define a conditioning supply line through which a condition fluid is provided. At step 604, the conditioning fluid is provided from the conditioning supply line to conditioning channels of a stack defining alternating conditioning channels and exhaust channels. For example, multiple alternating first plates 102 and second plates 104 of mass transfer apparatus may define alternating conditioning channels and exhaust channels, where the distribution headers 106, 107, 108, 110, 112, 120 facilitate distribution of the conditioning fluid from the conditioning supply line to the conditioning channels.

Further, at step 606, a working fluid is received within a working supply line. For example, distribution headers 106, 107, 108, 110, 112, 120 of mass transfer apparatus 100 may also define a working supply line through which a working fluid is provided. At step 608, the working fluid is provided from the working supply line to the exhaust channels. For instance, the distribution headers 106, 107, 108, 110, 112, 120 of mass transfer apparatus 100 may facilitate distribution of the working fluid from the working supply line to the exhaust channels.

Proceeding to step 610, the conditioning fluid is provided from the conditioning channels to wicking material. For instance, as described herein, the distribution headers 106, 107, 108, 110, 112, 120 of mass transfer apparatus 100 may provide the conditioning fluid to wicking material 175 within the condition channels. At step 612, a conditioning return line collects at least portions of the conditioning fluid from the conditioning channels. For example, collectors 140, 142, 150 may receive fluid that flows through corresponding wicking material 175, where the collected conditioning fluid is provided to apertures of collectors 140, 142, 150 that define a conditioning return line.

Further, at step 614, the working fluid is provided from the exhaust channels to wicking material. For instance, as described herein, the distribution headers 106, 107, 108, 110, 112, 120 of mass transfer apparatus 100 may provide the working fluid to wicking material 176 within the exhaust channels. At step 616, a working return line collects at least portions of the working fluid from the wicking material. For example, collectors 136, 137, 138 may receive working fluid that flows through the wicking material 176, where the collected working fluid is provided to apertures of collectors 136, 137, 138 that define a working return line.

FIGS. 9A, 9B, and 9C illustrate an example mass transfer apparatus 900 that provides both a dehumidification stage 997 and an indirect evaporative cooling stage 999. Mass transfer apparatus 900 may be employed within an air conditioner, a regenerator, or any other suitable system requiring heat and mass transfer, for example. Mass transfer apparatus 900 provides a fluid distribution system that is adapted to distribute a conditioning fluid, such as liquid desiccant, to conditioning channels and a working fluid, such as water, to exhaust channels, where the flow of both the conditioning fluid and the working fluid participate to transfer heat from a supply of air. Mass transfer apparatus 900 differs, however, from mass transfer apparatus 100 in how it distributes the conditioning fluid and working fluid, as described herein.

With reference to FIG. 9A, mass transfer apparatus 900 includes a stack including a first plate 902 and a second plate 904. Although only two plates are shown for simplicity, a stack may include multiple first plates 902 and second plates 904, where first plates 902 and second plates 904 alternate. Each first plate 902 includes a first side 902A and a second side 902B, and each second plate 904 includes a first side 904A and a second side 904B. First side 902A of first plate 902 and second side 904B of second plate 904 may define a conditioning channel 980 for an air supply stream (e.g., outside air, mixed air, process stream, etc.). In addition, first side 904A of second plate 904 and a second side 902B of another first plate 902 may define an exhaust channel 990 for an exhaust stream. As such, a stack can include a plurality of alternating first plates 902 and second plates 904 that define alternating conditioning channels 980 and exhaust channels 990 for a substantially counter-flow configuration.

First plate 902 may include a wicking material 975 (e.g., a conditioning fluid wick) that extends longitudinally along at least a portion of first side 902A. Second plate 904 may also include wicking material 975 along a portion of second side 904B. Additionally, each side of each plate may include spacers 952 (e.g., spacing restrictors) which, as described herein, may keep one plate distanced from another to allow for the flow of fluid through a corresponding channel. Further, second plate 904 may include wicking material 976 (e.g., a working fluid wick) that extends longitudinally along first side 904A. As described herein, a working fluid, such as water, may be provided to the wicking material 976 to provide an indirect evaporative cooling stage to the conditioning channel. For instance, as exhaust proceeds through exhaust channel 990, water evaporates from the wicking material 976 thereby cooling plate 904 and, indirectly, cooling the air supply stream flowing through the conditioning channel 980.

To facilitate the distribution of the conditioning and working fluids, mass transfer apparatus 900 includes conditioning fluid distribution header 910, working fluid distribution header 912, conditioning fluid collector 940, and working fluid collector 938. The distribution headers 910, 912, first plate 902, and second plate 904 are positioned such that corresponding apertures 910A, 912A, 903A, 905A, 910B, 912B, 903B, 905B, and 910C, 912C, 903C, 905C are aligned. Further, distribution headers 910, 912, first plate 902, and second plate 904 are attached such that water-tight seals are established around each of the apertures 910A, 912A, 903A, 905A, 910B, 912B, 903B, 905B, and 910C, 912C, 903C, 905C. For instance, conditioning fluid distribution header 910 may be positioned and attached (e.g., glued, bonded, welded) between a top portion of the first side 902A of the first plate 902, and a top portion of the second side 904B of the second plate 904. Similarly, working fluid distribution header 912 may be positioned and attached between a top portion of the first side 904A of the second plate 904, and a top portion of a second side 902B of another adjacent first plate 902.

The apertures 910A, 910B, 910C of the conditioning fluid distribution header 910 and the apertures 912A, 912B, 912C of the working fluid distribution header 912 are aligned with apertures 903A, 903B, 903C of the first plate 902 and the apertures 905A, 905B, 905C of the second plate 904 to define fluid distribution channels for distribution of fluids, such as a fluid distribution channel for a conditioning fluid and another fluid distribution channel for a working fluid. As illustrated, each of the conditioning fluid distribution header 910 and the working fluid distribution header 912 include various apertures. For instance, conditioning fluid distribution header 910 includes three apertures 910A, 910B, 910C. Similarly, working fluid distribution header 912 includes three apertures 912A, 912B, 912C. Furthermore, first plate 902 includes three apertures 903A, 903B, 903C, and second plate 904 includes three apertures 905A, 905B, 905C. Although the conditioning fluid distribution header 910, the working fluid distribution header 912, the first plate 902, and the second plate 904 are each illustrated with these three apertures, in some examples, the conditioning fluid distribution header 910, the working fluid distribution header 912, the first plate 902, and the second plate 904 can include more than, or fewer than three apertures.

In some examples, a first set of corresponding apertures 903A, 910A, 905A, and 912A and/or a second set of corresponding apertures 903B, 910B, 905B, and 912B provide for a flow of working fluid. Further, in some instances, a third set of corresponding apertures 903C, 910C, 905C, and 912C provide for a flow of conditioning fluid.

For example, and with reference to FIG. 9B, corresponding apertures 903C, 910C, 905C, and 912C may define a conditioning supply line through which a condition fluid is provided, as indicated by arrow 965. For instance, the conditioning fluid may proceed through the aperture 912C (e.g., a conditioning feed opening) of the working fluid distribution header 912, and then proceed through the aperture 905C of the second plate 904. The conditioning fluid may further proceed through the aperture 910C of the conditioning fluid distribution header 910, and proceed through the aperture 903C of the first plate 902. Moreover, as the conditioning fluid enters the corresponding aperture 910C of the conditioning fluid distribution header 910, the fluid may also proceed along channel 910D and into one or more distribution channels 910E of the conditioning fluid distribution header 910. As illustrated, the conditioning fluid distribution header 910 may include one or more distribution channels 910E on each side, such that the conditioning fluid is provided to wicking material 975 along the first side of the first plate 902, as well as along the second side 904B of the second plate 904, as indicated by the broken-line arrows.

In addition, the conditioning fluid collector 940 and working fluid collector 938 are positioned such that corresponding apertures are aligned. Collectors 940, 938 may receive fluid that flows down through corresponding wicking material 975, 976, respectively, and provide a return line for the corresponding fluid. For instance, the working fluid collector 938 may be positioned over the conditioning fluid collector 940 such that corresponding apertures 938B, 940B align.

The conditioning fluid collector 940 may be positioned along a bottom portion of wicking material 975, and may receive conditioning fluid from wicking material 975. For instance, distribution channel 910E may provide conditioning fluid to wicking material 975. The conditioning fluid proceeds downward through the wicking material 975, and falls onto an inclined surface 941 of the conditioning fluid collector 940. The conditioning fluid proceeds along inclined surface 941 until reaching aperture 940B. Aperture 940B of the conditioning fluid collector 940, along with corresponding aperture 938B in working fluid collector 938, form a conditioning fluid return line for conditioning fluid received from wicking material 975, as indicated by arrow 977.

Furthermore, and with reference to FIG. 9C, corresponding apertures 903A, 910A, 905A, and 912A may define a working supply line through which a working fluid is provided, as indicated by arrow 967. For instance, the working fluid may proceed through the aperture 912A (e.g., a working feed opening) of the working fluid distribution header 912, and then proceed through the aperture 905A of the second plate 904. The working fluid may further proceed through the aperture 910A of the conditioning fluid distribution header 910, and proceed through the aperture 903A of the first plate 902. Moreover, as the working fluid enters the corresponding aperture 912A of the working fluid distribution header 912, the fluid may also proceed along channel 912D and into one or more distribution channels 912E of the working fluid distribution header 912. As illustrated, the working fluid distribution header 912 may include one or more distribution channels 912E on each side, such that the working fluid is provided to at least a portion of the wicking material 976 along the first side 904A of the second plate 904, as well as along a second side 902B of an adjacent first plate 902.

Similarly, corresponding apertures 903B, 910B, 905B, and 912B may define a second working supply line through which the working fluid is provided, as indicated by arrow 969. For instance, the working fluid may proceed through the aperture 912B of the working fluid distribution header 912, and then proceed through the aperture 905B of the second plate 904. The working fluid may further proceed through the aperture 910B of the conditioning fluid distribution header 910, and proceed through the aperture 903B of the first plate 902. Moreover, as the working fluid enters the corresponding aperture 912B of the working fluid distribution header 912, the fluid may also proceed along channel 912F and into one or more distribution channels 912G of the working fluid distribution header 912. As illustrated, the working fluid distribution header 910 may include one or more distribution channels 912G on each side, such that the working fluid is provided to a portion of the wicking material 976 along the first side 904A of the second plate 904, as well as along a second side 902B of an adjacent first plate 902.

In addition, the working fluid collector 938 may be positioned along a bottom portion of wicking material 976, and may receive working fluid from wicking material 976. For instance, distribution channels 912E, 912G may provide working fluid to wicking material 976. The working fluid proceeds downward through the wicking material 976, and falls onto an inclined surface 939 of the working fluid collector 938. The working fluid proceeds along inclined surface 939 until reaching aperture 938A. Aperture 938A of the working fluid collector 938, along with a corresponding aperture 940A in conditioning fluid collector 940, form a working fluid return line for working fluid received from wicking material 976, as indicated by arrow 973. Referring back to FIG. 9A, in some examples, conditioning fluid distribution header 910 may include a barrier 971 that restricts airflow into the conditioning channel 980. Instead, the airflow proceeds as indicated by the arrows for the conditioning channel 980. Similarly, working fluid collector 938 may include a barrier 981 that restricts the flow out of the exhaust channel 990, forcing the flow to proceed as indicated by the arrows for the exhaust channel 990.

At least some of the embodiments described herein provide a mass transfer apparatus that provides multiple fluid distribution systems within alternating conditioning channels and exhaust channels defined by adjacent plates. For example, one fluid distribution system may distribute a conditioning fluid, such as liquid desiccant, to wicking material within the conditioning channels. Another fluid distribution system may distribute a working fluid, such as water, to wicking material within the exhaust channels. Each of the fluid distribution systems may be enabled by fluid distribution headers that operate to distribute the various fluids to corresponding wicking materials, and distribution collectors that collect the various fluids after flowing through the respective wicking materials and keep the fluids separated.

The conditioning channels may receive a flow of air, such as outside air (e.g., mixed air), to be conditioned (e.g., cooled), and the conditioning fluid may dehumidify the air as it passes through the conditioning channels. The conditioning channels may supply the conditioned air as a supply of air to, for example, a building (e.g., industrial building) or home.

Further, the exhaust channels may receive a portion of the conditioned (dehumidified) air exiting the conditioning channels, and the portion of conditioned air flowing through the exhaust channel may absorb water from the wicking material of the exhaust channels, which will function to further cool the air flowing through the conditioning channels. For instance, heat may transfer from the wicking material to the exhaust air, which provides further cooling to the supply air on an adjacent conditioning channel. The exhaust channels may supply the exhaust air to outside, such as outside the building or home.

The various embodiments described above are provided by way of illustration only and should not be construed to limit the claims attached hereto. Those skilled in the art will readily recognize various modifications and changes that may be made without following the example embodiments and applications illustrated and described herein, and without departing from the spirit and scope of the following claims.

LIQUID-DESICCANT STACK WITH INTEGRATED FLUID DISTRIBUTION

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