Various types of heating units for heating water in spas/hot tubs have been developed. One type of known heater utilizes an electrical resistance element that generates heat when electrical current passes through the electrical resistance element. Heat generated by the electrical resistance element is transferred through electrically non-conductive material to the water from the spa/hot tub as it flows through the heater to thereby heat the water in the spa/hot tub. The chemicals and the like added to the water in a spa or hot tub may create a corrosive environment. The temperature extremes further contribute to creating a relatively harsh operating environment for heaters in such applications.
Also, known electrical heating units may not provide the desired degree of efficiency. Various types of heat pumps have been developed for use in heating swimming pools and the like. Although such heat pumps have been somewhat successful, they are generally too large and bulky for use in a compact spa/hot tub system. Furthermore, heat pumps developed for swimming pools are generally not designed to heat the water to higher temperatures as required for a typical spa/hot tub, and may also not be suitable for use in the uniquely harsh environment of a typical spa/hot tub. Still further, known electrical heaters for spas/hot tubs may have limited power, such that substantial time is required to bring the water in the spa/hot tub up to the desired temperature if the water was cooled after a period of non-use or the like.
One aspect of the present invention is a spa or hot tub system including a tub having an inner surface defining a tub cavity. The tub is configured to hold sufficient fluid to immerse at least a substantial portion of a user seated in the tub. The tub defines an upper peripheral edge extending around the cavity, and the inner surface of the tub is formed by an inner side wall having an upper portion adjacent the upper peripheral edge. The tub further defines a generally upright side wall forming an outer skirt having an enlarged outer tub surface facing outwardly. The tub defines an interior space between portions of the inner side wall and the outer side wall. The system further includes at least one fluid outlet for exit of fluid from the cavity, and a heat pump system including a water side heat exchanger and an air side heat exchanger. The heat pump system further includes a compressor, and refrigerant conduits fluidly interconnecting the water side heat exchanger and the air side heat exchanger to the compressor, and providing for flow of refrigerant through the water side heat exchanger and through the air side heat exchanger when compressed by the compressor. The water side heat exchanger, the air side heat exchanger, and the compressor may be positioned within the interior space of the tub. The system also includes a water pump and a plurality of fluid conduits fluidly interconnecting the pump to the water side heat exchanger and the fluid inlets and fluid outlet, such that the water pump circulates water from the tub cavity through the water side heat exchanger, such that the water is heated prior to flowing into the tub cavity through the fluid inlets. The system further includes a temperature sensor configured to sense a temperature of water in the tub. A controller is operably connected to the temperature sensor and to the heat pump system, and the controller is configured to control the heat pump system based, at least in part, on the temperature of the water in the tub.
For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in
With reference to
As shown in
An envelope or three-dimensional space 20 within cavity 8 receives a heat pump system 30 according to the present invention. The removable access panel 21 can be removed to provide access to the heat pump system 30 mounted in cavity 8. Although the size of the three-dimensional space or envelope 20 may be different for different spa/hot tub systems 1, in general, the size of cavity 8 is limited by the shape/size of the side walls of tub 3. Thus, the size of envelope 20 is also at least somewhat limited. The heat pump system 30 of the present invention is quite small/compact such that it fits within the three-dimensional space 20. In the illustrated example, the three-dimensional space or envelope 20 has a width “W” (
With further reference to
A controller 40 is operably connected to a temperature sensor 41 that is positioned such that it senses the temperature of the water 34 in the cavity 6. The controller 40 is operably connected to the electric heater 37 and the heat pump 30, and may also be connected to the pump 33. Although controller 40 may be configured to operate in different ways, it will typically operate as a thermostat to maintain the water in the tub 3 at a user-selected temperature. In the illustrated example, the tub 3 has a capacity of about 400-500 gallons of water, and the heat pump system 30 is preferably capable of maintaining the water in the tub at a temperature of 105° F., even if the spa/hot tub system 1 is placed in ambient temperatures of about 60° F. to about 140° F., and more preferably about 45° F. to about 140° F.
The heat pump system 30 includes fluid conduits 42 interconnecting the water side heat exchanger 31, air side heat exchanger 32, and other system components. The heat pump system 30 includes a four-way valve 45 having an inlet port 46 that receives hot compressed refrigerant 47 from a compressor 48. Refrigerant exiting outlet port 49 of four-way valve 45 flows through fluid conduit 50, and through an accumulator 51. The accumulator 51 is a conventional unit that collects any fluid in the refrigerant exiting outlet port 49 and thereby ensures that the fluid does not enter compressor 48.
Four-way valve 45 can be switched to a first position to provide for heating water in tub 3, or it can be switched to a second position to cool water in tub 3. Valve 45 includes a first two-way port 55, and a second two-way port 56. When four-way valve 45 is switched to a first position (heating), refrigerant 47 passes from inlet port 46 and exits first two-way port 55. In this configuration (heating), the refrigerant first flows through water side heat exchanger 31, and then flows through a bi-directional restrictor 60, through a bi-flow filter 61, through air side heat exchanger 32, and into second two-way port 56, and back out through outlet port 49. The bi-directional restrictor may be substantially similar to the restrictor of U.S. Pat. No. 5,265,438, issued on Nov. 30, 1993, the entire contents of which are incorporated by reference.
Alternately, when four-way valve 45 is configured to provide cooling, refrigerant 47 entering inlet port 46 is directed out the second two-way port 46, and the refrigerant 47 first passes through air side heat exchanger 32. In the cooling configuration, the gas 47 exits air side heat exchanger 32, flows through bi-directional filter 61, then through bi-directional restrictor 60, and then through water side heat exchanger 32, and then back into first two-way port 55, and out the outlet port 49 of four-way valve 45.
Thus, when the four-way valve 45 is in the heating configuration/mode, the heat pump system 30 heats the water 34 in the cavity 6. However, when the four-way valve 45 is in cooling configuration/mode, the heat pump system 30 cools the water 34 in cavity 6 of the primary structure 2. It will be understood that in very hot climates it may be desirable to cool the water 34 to provide a comfortable environment for users of the spa system 1.
With further reference to
In use, water 81 flows into opening 80 of internal tube 76, and exits at opening 82 at end 83 of tube 76 into internal cavity 84 formed by housing 70. A coiled tube 85 is coiled around internal tube 76 in a double helix, and includes a first end 86 extending through end wall 90 at end 73 of housing 70 to form an inlet 88. Coiled tube 85 further includes a second end 87 that also extends through end wall 90 of housing 70, thereby forming an outlet 89. Fittings 91 provide a fluid-tight seal between the ends 86 and 87 of coiled tube 85 and openings 92 and 93 in end wall 90 of housing 70.
As discussed above, water 81 flows through tube 76 when it enters heat exchanger 31a, and exits opening 82 of tube 76 into cavity 84 of housing 70. The water then flows in the direction of the arrows 94 through the space 95 between coiled tube 85 and inner cylindrical surface 96 of cylindrical body 71 of housing 70. The water then flows out of an opening 97 formed by a flange 98. Referring back to
In the illustrated example, the tubing used to form the coiled tube 85 (
In use, refrigerant 101 flows into inlet 88 formed by first end 86 of coiled tube 85. The refrigerant 101 travels through the helix formed by the outer coils 99 until it reaches end 102 of coiled tube 85. Refrigerant 101 then travels back through the inner helix formed by inner coils 100 directly adjacent internal tube 76. Refrigerant 103 then exits the first water side heat exchanger 31a at outlet 89.
When the heat pump system 30 is in the heating mode, refrigerant 101 entering the heat exchanger 31A is quite hot relative to the water 81 entering heat exchanger 31A at opening 80, such that heat exchanger 31A heats the water before it is returned to the tub 3 through conduit 43 and water jets 15. As discussed above, when heat pump system 30 is being utilized to heat water 34 in tub 3, electric heater 37 may also be activated to thereby heat the water 34 in a very rapid manner. Alternately, if the heat pump system 30 is being utilized to cool the water 34 in tub 3, the refrigerant 101 entering heat exchanger 31A will be colder than the water 81 entering heat exchanger 31a, such that heat exchanger 31A acts to cool the water 34 in tub 3.
With further reference to
With further reference to
With further reference to
The polymer housings of the water side heat exchangers 31A and 31B, and the stainless steel coils for the refrigerant are both very corrosion resistant, such that the water side heat exchangers 31A and 31B are very durable despite the harsh environment resulting from chemicals and the like typically utilized in water circulated in spas and hot tubs. Although the tubing for the coolant has been described as being made of stainless steel, it will be understood that titanium tubing or other tubing made of highly corrosion-resistant material may also be utilized for the coolant tubing disposed within the housing of heat exchangers 31A and 31B. Also, although polymer material is preferred for the housings of heat exchangers 31A and 31B, other suitable materials may also be utilized.
The water side heat exchangers 31A and 31B are not only very durable and corrosion-resistant, but they are also compact relative to the amount of heating and/or cooling they provide. A typical spa/hot tub has a water capacity of about 400-500 gallons. A heat pump having a capacity of about 1 ton is typically specified for such applications to provide sufficient heating (or cooling) for a spa/hot tub of this size. It will be appreciated that the dimensions given above for the water side heat exchangers 31A and 31B, and for the heat pump system 30 are relatively small for a heat pump of this capacity.
The compact configuration and small size of the heat pump system 30 and water side heat exchangers 31A and 31B permit the heat pump to be integrated into a spa/hot tub 1, without requiring that components be positioned outside the primary structure 2 of the spa/hot tub system 1. Furthermore, the heat pump system 30 provides sufficient capacity to maintain the water in the spa/hot tub system 1 at a temperature of 105° F. through a range of ambient temperatures from 45°-140° F. In this way, the heat pump system 1 can accommodate a wide range of ambient conditions yet still provide for efficient heating and/or cooling of the water in the spa/hot tub system 1. It will be understood that more or less capacity may be required for some applications.
The heat pump system 1 of the present invention may preferably provide up to about 5.5 kilowatts of heat to the water being heated utilizing only 1 kilowatt of input power. This amount of heat is about the same as a typical spa or hot tub heater having a 5.5 kilowatts capacity. If the conventional electric heater 37 (
In the foregoing description, it will be readily appreciated by those skilled in the art that modifications may be made to the invention without departing from the concepts disclosed herein. Such modifications are to be considered as included in the following claims, unless these claims by their language expressly state otherwise.
This is a continuation of International Application PCT/US2008/059225, with an international filing date of Apr. 3, 2008. PCT Application No. PCT/US2008/059225 claims the benefit of U.S. Provisional Application No. 60/909,869, filed on Apr. 3, 2007, entitled SPA HAVING HEAT PUMP SYSTEM. The entire contents of the above-identified International Application and Provisional Application are incorporated herein by reference.
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Number | Date | Country | |
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Parent | PCT/US2008/059225 | Apr 2008 | US |
Child | 12571780 | US |