Climate-Control System With Sensible and Latent Cooling

The present disclosure relates to a climate-control system with sensible cooling and latent cooling.

This section provides background information related to the present disclosure and is not necessarily prior art.

Conventional vapor-compression systems are often used to cool a space and reduce humidity within the space. While such systems have generally been effective means to cool a space and reduce humidity, there is a need for a system that provides more efficient and more customized sensible and latent cooling over a wider range of outdoor weather conditions. The present disclosure provides such a system for providing more customized and efficient sensible and latent cooling in the space.

This section provides a general summary of the disclosure and is not a comprehensive disclosure of its full scope or all its features.

In one form, the present disclosure provides a climate-control system including a vapor-compression circuit and an air handler assembly. The vapor-compression circuit may include a compressor, an outdoor heat exchanger, an expansion device, and an indoor heat exchanger. The compressor is configured to circulate a working fluid through the vapor-compression circuit. The outdoor heat exchanger is in fluid communication with the compressor. The expansion device is in fluid communication with the outdoor heat exchanger. The indoor heat exchanger includes a conduit that is in fluid communication with the expansion device. The air handler assembly is configured to force air across the conduit of the indoor heat exchanger. The air handler assembly may include an airflow device having a valve and an air-to-air heat exchanger. The air-to-air heat exchanger may include a first heat-exchanger duct and a second heat-exchanger duct. Air flowing through the first heat-exchanger duct may be in a heat-transfer relationship with air flowing through the second heat-exchanger duct. The airflow device may define a first airflow path and a second airflow path. The first airflow path may include the first heat-exchanger duct. The second airflow path may bypass the first heat-exchanger duct.

In some configurations of the climate-control system of the above paragraph, the valve is movable between a first position and a second position. In the first position, the valve may allow air to flow through the first airflow path and may prevent air from flowing through the second airflow path. In the second position, the valve may allow air to flow through the second airflow path and may prevent air from flowing through the first airflow path.

In some configurations of the climate-control system of either or both of the above paragraphs, the valve is movable to a third position in which the valve allows a first portion of air entering the airflow device to flow through the first airflow path and allows a second portion of air entering the airflow device to flow through the second airflow path.

In some configurations of the climate-control system of any one or more of the above paragraphs, a control module controls movement of the valve based on humidity data received from a humidistat.

In some configurations of the climate-control system of any one or more of the above paragraphs, the humidistat measures humidity of the air upstream of the airflow device.

In some configurations of the climate-control system of any one or more of the above paragraphs, the control module compares a measured humidity value from the humidistat to a predetermined limit.

In some configurations of the climate-control system of any one or more of the above paragraphs, the control module compares a measured humidity value from the humidistat to a humidity setpoint.

In some configurations of the climate-control system of any one or more of the above paragraphs, the predetermined limit is higher than the humidity setpoint.

In some configurations of the climate-control system of any one or more of the above paragraphs, the first and second airflow paths are fluidly connected to an evaporator duct that provides air from the airflow device to the indoor heat exchanger.

In some configurations of the climate-control system of any one or more of the above paragraphs, the evaporator duct provides air to the second heat-exchanger duct downstream of the indoor heat exchanger.

In some configurations of the climate-control system of any one or more of the above paragraphs, the airflow device includes a housing in which the valve is disposed.

In some configurations of the climate-control system of any one or more of the above paragraphs, the first and second airflow paths diverge from each other downstream of a first air inlet of the housing and converge with each other downstream of the first heat-exchanger duct and upstream of a first air outlet of the housing.

In some configurations of the climate-control system of any one or more of the above paragraphs, the air-to-air heat exchanger is disposed within the housing.

In some configurations of the climate-control system of any one or more of the above paragraphs, the first air inlet of the housing is coupled with a return-air duct and receives air from the return-air duct.

In some configurations of the climate-control system of any one or more of the above paragraphs, the second heat-exchanger duct defines a second air inlet of the airflow device and a second air outlet of the airflow device.

In some configurations of the climate-control system of any one or more of the above paragraphs, the second air outlet is coupled with a supply-air duct and provides air to the supply-air duct.

In some configurations of the climate-control system of any one or more of the above paragraphs, the second heat-exchanger duct defines a third airflow path through the airflow device.

In another form, the present disclosure provides an air handler assembly for a climate-control system. The air handler assembly may include a return-air duct, a housing, a valve, an air-to-air heat exchanger, an evaporator duct, an evaporator, and a supply-air duct. The housing may include a first air inlet, a first air outlet, a first airflow path, and a second airflow path. The first air inlet may be coupled with the return-air duct and receives air from the return-air duct. The valve may be disposed within the housing and may be movable between a first position allowing airflow through the first airflow path and preventing airflow through the second airflow path and a second position allowing airflow through the second airflow path and preventing airflow through the first airflow path. The air-to-air heat exchanger may be disposed within the housing and may include a first heat-exchanger duct and a second heat-exchanger duct. Air flowing through the first heat-exchanger duct may be in a heat-transfer relationship with air flowing through the second heat-exchanger duct. Air flows through the first heat-exchanger duct when the valve is not in the second position. Air flows through the second heat-exchanger duct when the valve is in the first position and when the valve is in the second position. The evaporator duct may be coupled with the first air outlet and the second heat-exchanger duct. The evaporator duct may receive air from the first air outlet and may provide air to the second heat-exchanger duct. The evaporator may be disposed within the evaporator duct and may include a conduit that is configured to receive working fluid from a vapor-compression system. The supply-air duct may be coupled with the second heat-exchanger duct and may receive air from the second heat-exchanger duct.

In some configurations of the air handler assembly of the above paragraph, the valve is movable to a third position in which the valve allows a first portion of air entering the housing to flow through the first airflow path and allows a second portion of air entering the housing to flow through the second airflow path.

In some configurations of the air handler assembly of either or both of the above paragraphs, a control module controls movement of the valve based on humidity data received from a humidistat.

In some configurations of the air handler assembly of any one or more of the above paragraphs, the humidistat measures humidity of the air upstream of the housing.

In some configurations of the air handler assembly of any one or more of the above paragraphs, the control module compares a measured humidity value from the humidistat to a predetermined limit.

In some configurations of the air handler assembly of any one or more of the above paragraphs, the control module compares a measured humidity value from the humidistat to a humidity setpoint.

In some configurations of the air handler assembly of any one or more of the above paragraphs, the predetermined limit is higher than the humidity setpoint.

In some configurations of the air handler assembly of any one or more of the above paragraphs, the second heat-exchanger duct defines a third airflow path through the housing.

Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

Example embodiments will now be described more fully with reference to the accompanying drawings.

Example embodiments are provided so that this disclosure will be thorough and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected, or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer, or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer, or section discussed below could be termed a second element, component, region, layer, or section without departing from the teachings of the example embodiments.

Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

With reference to, a climate-control systemis provided. As will be described in more detail below, the systemis operable to provide sensible cooling and latent cooling (dehumidification) simultaneously and independently of each other. As shown in, the systemincludes a vapor-compression circuitand an air handler assembly. The air handler assemblymay be installed inside of a building or home, for example. The air handler assemblymay provide air cooled and/or dehumidified to a room or space within the building or home.

As shown in, the vapor-compression circuitmay include a compressorand an outdoor heat exchanger (e.g., a condenser), an expansion device(e.g., an expansion valve or capillary tube), and an indoor heat exchanger (e.g., an evaporator).

The compressormay pump working fluid (e.g., a refrigerant) through the vapor-compression circuit. The compressorcould be a scroll compressor (including first and second scrolls with intermeshing spiral wraps), for example, or any other type of compressor such as reciprocating (including a piston reciprocatingly received in a cylinder) or rotary vane compressor (including a rotor rotating within a cylinder), for example. The compressorcould be a variable-capacity compressor operable in full capacity mode and a reduced capacity mode. In some configurations, the compressorcould include additional or alternative capacity modulation capabilities (e.g., variable-speed motor, vapor injection, blocked suction, etc.). The compressormay include a suction inletand a discharge outlet. The inletmay receive working fluid from the indoor heat exchanger. The working fluid received through the inletmay be compressed (by a compression mechanism) in the compressorand may be discharged through the outlet.

The outdoor heat exchangermay include a coil or conduitthat receives working fluid discharged from the outletof the compressor. A fan (not shown) may force air (e.g., outdoor ambient air) across the coil of the outdoor heat exchangerto facilitate heat transfer between the outdoor ambient air and working fluid flowing through the coil of the outdoor heat exchanger. The outdoor heat exchangerand the compressormay be disposed outdoors (i.e., outside of a building, home, or other space to be cooled by the system). The indoor heat exchangerand expansion devicemay be disposed indoors (i.e., inside of the building, home, or other space to be cooled by the system).

From the outdoor heat exchanger, the working fluid flows through the expansion deviceand then through the indoor heat exchanger. The indoor heat exchangermay include a coil or conduitthat receives working fluid from the expansion device. The indoor heat exchangermay be disposed within the air handler assemblysuch that air flowing through the air handler assemblymay flow across or through the indoor heat exchanger. A fan(disposed within the air handler assemblyor otherwise positioned to force air to flow throughout the air handler assembly) may force air across the indoor heat exchangerto facilitate heat transfer between air in the air handler assemblyand working fluid in the indoor heat exchanger.

In some configurations, the vapor-compression circuitmay include one or more reversing valves operable to switch operation of the vapor-compression circuitbetween a cooling mode and a heating mode.

The air handler assemblymay include a return-air duct, an airflow device(shown in), an evaporator duct, and a supply-air duct. As described above, the air handler assemblymay include a fan that may be disposed in the return-air duct, the airflow device, the evaporator duct, or the supply-air duct, for example. An air filter may also be disposed in any of the return-air duct, the airflow device, the evaporator duct, or the supply-air duct, for example.

The return-air ductmay receive air from one or more rooms or spaces of the building or home and may provide air to the airflow device. The airflow devicemay be fluidly coupled with the return-air duct, the evaporator duct, and the supply-air duct.

The airflow devicemay include a housing, a valve, and a heat exchanger. The airflow devicemay define a first airflow path, a second airflow path, a first air inlet, a first air outlet, a second air inlet, and a second air outlet. In the example shown in the figures, the housingdefines the second airflow path, the first air inlet, and the first air outlet. In the example shown in the figures, the heat exchangerdefines the second air inletand the second air outlet. The housingand the heat exchangercooperate to define the first airflow path.

shows the fandisposed in the evaporator duct, downstream of the first air outlet, and upstream of the evaporator. It will be appreciated, however, that the fancould be positioned in any suitable location in the air handler assemblyto force air through the assembly.

The return-air ductmay be coupled with the first and second airflow paths,such that air in the return-air ductmay flow into the first airflow pathand/or into the second airflow path. Air within the first airflow pathis fluidly isolated from air within the second airflow path. That is, the first and second airflow paths,diverge from each other within the housing(e.g., downstream of the first air inlet, at or near the valve) and converge with each other at or near the first air outlet. Air flowing through the first airflow pathflows through the heat exchanger. Air flowing through the second airflow pathbypasses the heat exchanger.

The valvemay be movable among a first position () in which air from the return-air ductis allowed to flow through the first airflow pathand is prevented from flowing through the second airflow path, a second position () in which air from the return-air ductis allowed to flow through the second airflow pathand is prevented from flowing through the first airflow path, and a third position () in which a portion of air from the return-air ductis allowed to flow through the first airflow pathand another portion of air from the return-air ductis allowed to flow through the second airflow path. It will be appreciated that the valvecould be movable to additional positions between the first and second positions to adjust the amount of air that is allowed to flow through the first airflow pathand the amount that is allowed to flow through the second airflow path. In some configurations, the valvemay be movable to an infinite number of positions between the first and second positions.

In the particular example shown in, the valveis a plate or damper flap that is rotatably mounted to a wallthat separates the first and second airflow paths,in the housing. A motor (not shown) may drive the valveamong the first, second, and third positions. A control module may control operation of the valvebased (at least in part) on a relative humidity of air in the return-air ductor air in the space or room to be cooled. The relative humidity may be measured by a humidistat() that may be mounted to the return-air ductor mounted in the space or room to be cooled. The control module may also control operation of the compressorbased (at least in part) on a temperature measurement from a thermostat and/or a humidity measurement from the humidistat.