Adiabatic Cooling System with Pad Support

The application is a continuation of U.S. patent application Ser. No. 18/340,768, filed Jun. 23, 2023, now published as U.S. Patent Publication No. 20240426487, and entitled “Adiabatic Cooling System with Pad Support” which is incorporated by reference in its entirety.

This disclosure relates in general to adiabatic cooling systems, and more particularly to an adiabatic cooling system with pad support.

Cooling systems are used in many types of residential and commercial applications. As one example, commercial refrigeration systems are used by many types of businesses such as supermarkets and warehouses.

Cooling systems may use adiabatic cooling processes to pre-cool intake air that enters an outdoor condenser unit. For example, intake air may first pass through a wet pad or mesh material. Heat transfer with water on the material pre-cools the intake air. In examples, any adiabatic water system may be applicable to carbon dioxide (CO) gas coolers, and adiabatic systems using other suitable refrigerants may utilize condensers. This disclosure recognizes drawbacks and disadvantages of conventional approaches to providing adiabatic cooling. For example, conventional pads used for adiabatic cooling may be supported by a gutter disposed underneath that functions to collect and provide drainage to the water leaving the pads. The weight of the pads and the collected water can structurally damage the gutter and induce leaking.

This disclosure provides a technical solution to problems of previous adiabatic cooling technology, including those recognized above, by providing a bracket to structurally support the adiabatic pads. The bracket is positioned within a gutter underneath the adiabatic pads and allows water to flow therethrough and into the gutter from the pads. The water is then drained and circulated for re-use by the system. By using the bracket, the gutter does not have to receive and structurally support the weight of the adiabatic pads.

Certain embodiments may include none, some, or all of the above technical advantages. One or more other technical advantages may be readily apparent to one skilled in the art from the figures, descriptions, and claims included herein.

In an embodiment, an adiabatic cooling system includes a condenser coil and one or more adiabatic pads positioned such that intake air for the adiabatic cooling system passes through the one or more adiabatic pads prior to contacting the condenser coil. The adiabatic cooling system further includes a gutter disposed underneath each of the one or more adiabatic pads configured to receive water exiting from the one or more adiabatic pads. The adiabatic cooling system further includes a bracket disposed within and secured to the gutter configured to support the one or more adiabatic pads, wherein at least one of the one or more adiabatic pads is disposed on top of the bracket.

Gas cooling systems are used in many types of residential and commercial applications. As one example, commercial refrigeration systems are used by many types of businesses such as supermarkets and warehouses. Many cooling systems use adiabatic cooling processes to pre-cool air before it enters an outdoor condenser unit. For example, large commercial refrigeration systems may include air cooled condensers where cooling pads are contacted with water in order to pre-cool intake air before it contacts condenser coils. In these examples, any adiabatic water system may be applicable to carbon dioxide (CO) gas coolers, and adiabatic systems using other suitable refrigerants may utilize condensers. While pre-cooling air using cooling pads aids in the overall efficiency of cooling systems in certain environmental conditions, existing configurations with drainage components, such as a gutter, are problematic. Existing configurations provide the gutter structurally supporting the weight of the cooling pads, wherein the gutter may fail and encounter leakage of any collected fluids.

To address these and other limitations of previous adiabatic cooling system technology, embodiments of this disclosure facilitate improved adiabatic cooling. The following describes adiabatic cooling systems with a bracket functioning with the gutter to structurally support the cooling pads.

illustrate an adiabatic cooling system, according to certain embodiments. In some embodiments, adiabatic cooling systemincludes one or more condenser coils, a plurality of adiabatic pads, one or more fans, a controller, and a pad pivoting system. In some embodiments, adiabatic cooling systemmay include pad frames(as best seen in) that each hold a respective adiabatic pad. Water, from a water distribution system (described further below) comprising a one or more nozzles, tubing, and a pump, is selectively applied to adiabatic padsin order to cool intake airas it enters adiabatic cooling systembut before contacting condenser coils. Pad pivoting systemmay be mechanically coupled to adiabatic padsor pad framesin order to cause adiabatic padsto move between open and closed positions as described herein. Controlleris communicatively coupled to pad pivoting systemand instructs pad pivoting systemto move adiabatic padsbetween the open and closed positions.

In general, adiabatic cooling systemutilizes multiple adiabatic cooling padsthat may each be rotated, pivoted, or otherwise moved about a center pivot pointbetween open and closed positions. In typical adiabatic cooling systems, adiabatic pads are stationary and are always in the air-intake path of intake airregardless of the mode of operation of the cooling system. This may decrease the efficiency of such systems since intake airmust be pulled through adiabatic padseven when pre-cooling is not needed (e.g., in dry modes of operation). Adiabatic cooling system, on the other hand, may utilize split adiabatic padsthat may be rotated, pivoted, or otherwise moved based on whether or not pre-cooling is needed. For example, adiabatic cooling systemmay move adiabatic padsto their open positions (e.g., as illustrated in) when pre-cooling is not needed (e.g., in dry modes of operation). In the open position, intake airfor adiabatic cooling systementers adiabatic cooling systemand contacts condenser coilswithout passing through adiabatic pads. This may decrease electricity requirements for adiabatic cooling systemand may increase efficiency since intake airis not forced to flow through adiabatic pads. However, when pre-cooling is needed (e.g., a wet mode of operation), adiabatic cooling systemmay move adiabatic padsto their closed positions. In the closed position (e.g., as illustrated in), intake airfor adiabatic cooling systempasses through adiabatic padsprior to contacting condenser coils. This selective opening and closing of adiabatic padsmay enable adiabatic cooling systemto conserve resources such as electricity since adiabatic padsmay be removed from the air-intake path when adiabatic padsare not needed (e.g., in a dry mode of operation).

Adiabatic cooling systemmay be a system used to cool a refrigerant by condensing it from its gaseous state to its liquid state. In most commercial refrigeration applications, adiabatic cooling systemis located outdoors and is fluidly coupled to indoor portions of the system (e.g., air handlers) via one or more refrigerant lines. In some embodiments, adiabatic cooling systemis a cooling tower. Adiabatic cooling systemincludes one or more condenser coilsand one or more motors that turn one or more fans. Fansdraw intake airinto adiabatic cooling systemand through condenser coils, thereby cooling and condensing the refrigerant and providing cooling to adiabatic cooling system. In certain environmental situations (e.g., in high temperatures or a wet mode of operation), fansdraw intake airinto adiabatic cooling systemthrough adiabatic padsthat have been sprayed with water. When adiabatic padsare not needed to pre-cool intake air(e.g., in low temperatures or a dry mode of operation), fansdraw intake airinto adiabatic cooling systemwithout passing through adiabatic pads. By bypassing adiabatic padswhen pre-cooling of intake airis not needed, the load on fansis thereby reduced. This decreases power requirements and increases the efficiency of adiabatic cooling system. In alternate embodiments, the adiabatic padsmay be stationary and the fansmay draw the intake airthrough the adiabatic padswhen pre-cooling is not needed.

During operation in the wet mode, the adiabatic cooling systemmay collect any water exiting or being discharged from the adiabatic padsfrom a gutterdisposed underneath the adiabatic pads. In embodiments, the guttermay be configured to facilitate drainage of water from the adiabatic padsand may additionally function as a water source for providing water to the adiabatic pads(via the tubingand pumpas discussed below). In previous embodiments, the adiabatic pads, or the pad frames, may have been disposed directly on top of and onto the gutter, wherein the gutterhad to provide structural support. The present disclosure provides the gutterincorporating usage of one or more brackets (see) to improve performance of the gutterand of the adiabatic cooling system.

Adiabatic padsmay be made of any appropriate material that is capable of receiving and retaining water from a water distribution system. As a specific example, adiabatic padsmay be made of a mesh material through which intake airpasses before it enters condenser coils. As intake airpasses through the wet mesh material of adiabatic pads, it cools and helps improve the efficiency of adiabatic cooling system. Adiabatic padsmay be in any appropriate size, shape, and configuration and are not limited to those illustrated in the included figures. In some embodiments, adiabatic padsmay be housed by pad frames, described in more detail below. In other embodiments, adiabatic padsmay be directly coupled to adiabatic cooling systemwithout using pad frames.

In some embodiments, adiabatic cooling systemincludes pad framesto hold adiabatic pads. Pad framesmay be formed from any appropriate material such as metal or plastic. As illustrated in, some pad framesmay include a top portion and bottom portion that allows adiabatic padsto easily slide into and out of pad frames. This allows adiabatic padsto be easily removed (e.g., for cleaning or replacement) and installed in pad frames. As described in more detail below, pad framesmay be pivotally coupled to adiabatic cooling systemat an end or center pivot pointof pad frame. In some embodiments, pad framesare mechanically and/or electrically coupled to pad pivoting systemin order to be moved between open and closed positions by pad pivoting system.

Controlleris any appropriate device or circuitry that controls functions of adiabatic cooling system. Controllermay be within or coupled to adiabatic cooling system, or it may be separate from adiabatic cooling systemin some embodiments. In some embodiments, controlleris a circuit board within adiabatic cooling system.

In some embodiments, controllerincludes an interface, one or more memory devices, and a processor. Controllermay also include additional components typically included within a controller for a cooling system, such as a power supply, relays, and the like. The interface of controllermay be a conventional interface that is used to receive and transmit data for a controller, such as a micro-controller.

The one or more memory devices of controllermay store operating instructions to direct the operation of the processor of controllerwhen initiated thereby. In some embodiments, the memory of controller, or at least of portion thereof, is a non-volatile memory. The operating instructions may correspond to algorithms that provide the functionality of the methods and algorithms disclosed herein. In some embodiments, the processor of controllermay be a microprocessor. The interface, processor, and memory of controllermay be coupled together via conventional means to communicate information.

In some embodiments, adiabatic cooling systemincludes a manual control. In general, manual controlis any user-operated device (e.g., switch, button, control, etc.) on adiabatic cooling systemthat allows a user to control the positions of adiabatic pads. For example, a technician may operate manual controlin order to move adiabatic padsfrom their closed positions to their open positions. This would allow, for example, the technician to gain access to condenser coils(e.g., in order to power-wash condenser coils) and to easily remove adiabatic padsfor cleaning or replacement. Manual controlmay also be operated in order to move adiabatic padsfrom their open positions to their closed positions (e.g., after maintenance of adiabatic cooling systemand adiabatic padsis complete). In some embodiments, manual controlmay be communicatively coupled to controllerand/or pad pivoting systemin order to provide manual control of the positions of adiabatic pads.

Pad pivoting systemmay be any electrical or mechanical system (e.g., electromechanical system) that is configured to move adiabatic padsor pad framesbetween their open and closed positions. In some embodiments, pad pivoting systemincludes a rack and pinion. In such an embodiment, a toothed rack portion of rack and pinion is coupled to each adiabatic pador pad frame, and the rack portion is mechanically coupled to a pinion portion of rack and pinion (e.g., via a gear). A motor turns the pinion portion of rack and pinion, which thereby moves the rack and all pad framesor adiabatic padscoupled to the rack. In general, pad pivoting systemmay be communicatively coupled to controller, thereby enabling controllerto instruct pad pivoting systemto move adiabatic padsor pad framesbetween the open and closed positions.

In operation, adiabatic cooling systemmay selectively move adiabatic padsbetween their closed positions (e.g., as illustrated in) and their open positions (e.g., as illustrated in). In embodiments that include pad frames, adiabatic cooling systemmoves adiabatic padsbetween their closed positions and their open positions by moving the pad frames. When adiabatic padsare in the closed position, intake airfor adiabatic cooling systempasses through adiabatic padsprior to contacting condenser coils. When adiabatic padsare in the open position, intake airfor adiabatic cooling systemis unimpeded by adiabatic padssince intake airdoes not pass through adiabatic padsprior to contacting condenser coils. As a result, the efficiency of adiabatic cooling systemmay be improved because fansdo not have to pull intake airthrough adiabatic padswhen pre-cooling is not needed.

Various conditions or signals may be utilized by controllerto determine whether adiabatic padsshould be in their closed or open positions. In some embodiments, ambient temperatures may be used to control the positions of adiabatic pads. For example, if the ambient temperature surrounding adiabatic cooling systemas determined by a temperature sensor is greater than or equal to a certain temperature (e.g., 70 degrees Fahrenheit), controllermay determine that adiabatic cooling systemshould be in a wet mode of operation and thereby instruct pad pivoting systemto move adiabatic padsto their closed positions so that intake airmay be pre-cooled prior to contacting condenser coils. If the ambient temperature surrounding adiabatic cooling systemas determined by a temperature sensor is less than a certain temperature (e.g., 70 degrees Fahrenheit), controllermay determine that adiabatic cooling systemshould be in a dry mode of operation and thereby instruct pad pivoting systemto move adiabatic padsto their open positions so that intake airis not pre-cooled prior to contacting condenser coils.

In some embodiments, an input to a water distribution system for adiabatic padsmay be used in parallel by pad pivoting systemto open or close adiabatic pads. For example, if the water distribution system for adiabatic padsis enabled in order to start spraying water on adiabatic pads, pad pivoting systemmay move adiabatic padsfrom their open positions to their closed positions. Likewise, if the water distribution system for adiabatic padsis disabled in order to cease spraying water on adiabatic pads, pad pivoting systemmay move adiabatic padsfrom their closed positions to their open positions.

illustrates a diagram showing a portion of the adiabatic cooling system(referring to). In embodiments, the nozzlesare operable to provide water to the adiabatic pads. This disclosure contemplates any number of nozzlesbeing positioned to provide water to the adiabatic pads. The nozzle(s)may be coupled to a water source via tubing. The water source may be a container or tray holding water. The water source may be connected to a municipal water supply or other supply of water (e.g., to refill or maintain a necessary volume of water in the water source). In certain embodiments, the water source may be fluidly coupled to the gutter, wherein the water discharged from the adiabatic padsand collected by the guttermay be re-used.

The pumpmay drive a flow of water from the water source out of the nozzle(s)and onto the adiabatic pads. The pumpmay be any appropriate pump for providing the flow of water at a sufficient pressure to produce the discharged water. For example, the pumpmay be a high-pressure fluid pump, such as a motor-driven pump that increases the pressure of water flowing through tubing. Without limitations, the adiabatic cooling systemmay employ a separate pumpper nozzle, a shared pumpproviding flow to each nozzle, or a combination thereof. In some embodiments, the water source may be pressurized, and the pumpmay be replaced with a valve that opens to allow the flow of pressurized water out of the nozzle(s).

The controller(referring to) may provide for operating the pump. For example, the controllermay cause the pumpto activate to provide the water when the adiabatic cooling systemis to operate in a wet mode. As water is provided to the adiabatic pads, the intake airproduced by the fansmay be pre-cooled prior to engaging with the condenser coils.

illustrates a portion of the adiabatic cooling system(referring to). In the illustrated embodiment, a portion of the components of the adiabatic cooling systemis not illustrated in order to depict certain components unable to be seen in an assembled configuration. As illustrated, the adiabatic cooling systemmay comprise a baseconfigured to receive and house at least the one or more condenser coils(referring to) and the adiabatic pads(referring to). In embodiments, a housing may be constructed upon and integrated with the baseto produce an assembled adiabatic cooling system. As illustrated, the guttermay be coupled to a side of the base. The guttermay be disposed along a lengthwise side of the baseand may comprise a similar length with reference to the base. In other embodiments, the guttermay be shorter or longer than the base. The guttermay be any suitable size, height, shape, and any combination thereof. Further, the guttermay comprise any suitable materials, such as metals, nonmetals, polymers, composites, and any combinations thereof. The guttermay be configured to receive water exiting or being discharged from the adiabatic padsduring operation of the adiabatic cooling system. The guttermay comprise a sloped bottom surface in order to direct the received water towards a drain or port located proximate to one end of the gutter.

In embodiments, the adiabatic cooling systemmay comprise at least one bracket. While the present depiction inillustrates a plurality of brackets, the present disclosure may provide for usage of a singular bracketwith the adiabatic system. Each bracketmay be any suitable size, height, shape, and any combination thereof. Further, each bracketmay comprise any suitable materials, such as metals, nonmetals, polymers, composites, and any combinations thereof. Without limitations, each bracketmay be comprised of galvanized steel, stainless steel, aluminum, and the like. Further, each bracketmay comprise a corrosion-resistant coating or have corrosion resistant properties. The bracket(s)may be securably coupled to the gutterand may be substantially disposed within the gutter. For example, the guttermay comprise a set of walls(wherein a first wall and second wall of the set of wallswill be referred to as “first wall” and “second wall,” respectively) having a flangeextending perpendicularly therefrom. As illustrated, each bracketmay be secured to the flangeof the second wallthrough the use of suitable fasteners. As described further below, the bracketmay employs tabs for coupling to the flange, wherein the tabs may be disposed out of gutterand on top of the flange, but the remaining portion of the bracketmay be disposed within an internal volume defined by the gutter.

illustrate front, isometric views of the bracket. The bracketmay be configured to structurally support one or more adiabatic pads(referring to), thereby alleviating the gutter(referring to) from supporting the weight of the adiabatic pads. For example, at least one adiabatic padmay be disposed on top of the bracketin an assembled configuration of adiabatic cooling system(referring to). In embodiments, the bracketmay be configured to support the weight of at least one adiabatic padwhen wetted (i.e., about 60-90 lbs.). The bracketmay comprise a base surface, a first tab, a second tab, a first gusset, a second gusset, and a front surface. In embodiments, the base surfaceof the bracketmay disposed within the gutterbetween the set of walls(referring to) and below the flanges(referring to). The base surfacemay define one or more openingsconfigured to allow water exiting from the adiabatic padsto pass through bracketand into the gutter. Each of the one or more openingsmay be any suitable size and/or shape. As illustrated, the bracketcomprises two openings, but the present disclosure is not limited to said number of openings. Each openingmay comprise the same size and/or shape as the other openings. In other embodiments, each openingmay comprise a different size and/or shape. The configuration of the one or more openingsin relation to the base surfacemay accommodate at least a minimum value of surface area of an adiabatic pad. In an example, the base surfacemay be capable of receiving at least 50% of the surface area for a single adiabatic pad.

As illustrated, both the first taband the second tabmay be offset vertically from the base surface. The first tabmay be coupled to a first legextending upwards from the base surface. Likewise, the second tabmay be coupled to a second legextending upwards from the base surface, the second legbeing disposed at an opposite end of a length of the base surfacefrom the first leg. Both the first legand the second legmay comprise substantially the same dimensions and at least an equivalent height. The first taband the second tabmay be disposed in parallel. The first tabmay define a first holeand the second tabmay define a second hole, wherein both the first holeand the second holemay be configured to couple the bracketto the flangeof the gutter.

In embodiments, both the first gussetand the second gussetmay extend downwards from the base surfaceat opposing sides of the base surface, the second gussetbeing in parallel to the first gusset. The first gussetmay be disposed perpendicular to both the base surfaceand the first leg. Both the first gussetand the second gussetmay be configured to facilitate transfer of a moment produced by the weight of at least one of the adiabatic padson top of the base surfaceinto or towards the gutter. The size and/or shape of the first gussetand the second gussetmay be designed to aid in transferring the produced moment. For example, the first gussetand second gussetmay comprise a triangular shape having a bottom endthat tapers towards the front surfaceof the bracket. The increasing height of the first gussetand second gussetfrom in relation of the length along the base surfacefrom the front surfaceto the first and second legs,provides structural support to receive a produced moment from a force proximate to the area of the base surfacenear front surface.

Each of the first gussetand second gussetmay have a tab extending therefrom to stabilize the bracketand provide surface area for transferring the moment along an internal side of the gutter(i.e., second wallof). As illustrated, a first gusset tabmay be coupled to a side of the first gusset, the first gusset tabbeing parallel to the first leg. A second gusset tabmay be coupled to a side of the second gusset, the second gusset tabbeing parallel to the first gusset tab. Each of the first gusset taband second gusset tabmay be disposed along the internal side of second wallof gutterand may transfer a produced moment into the gutter. In embodiments, the guttermay be reinforced by the base(referring to) or some other suitable structure capable of receiving such moments and/or forces.

In the illustrated embodiment, the front surfacemay extend downwards from the base surfaceby a certain distance. The front surfacemay be disposed against another internal side of the gutter(i.e., first wallof) opposite from the first and second gusset tabs,. In alternate embodiments, the front surfacemay face the internal side of gutterbut may not necessarily be disposed flush or against said internal side of gutter. In certain embodiments, the front surfacemay define one or more holesconfigured to couple the front surfaceto the gutter. For example, the guttermay be warped or may have experienced some plastic deformation. To attempt to mitigate certain effects of the plastic deformation, a technician may secure the first wallof the gutterto the front surfacevia the one or more holes.

The present disclosure may provide an improved adiabatic cooling systemhaving one or more bracketssecurably coupled to the gutterto support the weight of at least one adiabatic pad. The bracketmay allow for the exiting water from the adiabatic padsto drain therethrough into the gutter, and the attachment points via the first and second tabs,may be disposed above the water line within the gutter, thereby avoiding leakage.

While several embodiments have been provided in the present disclosure, it should be understood that the disclosed systems and methods might be embodied in many other specific forms without departing from the spirit or scope of the present disclosure. The present examples are to be considered as illustrative and not restrictive, and the intention is not to be limited to the details given herein. For example, the various elements or components may be combined or integrated in another system or certain features may be omitted, or not implemented.

In addition, techniques, systems, subsystems, and methods described and illustrated in the various embodiments as discrete or separate may be combined or integrated with other systems, modules, techniques, or methods without departing from the scope of the present disclosure. Other items shown or discussed as coupled or directly coupled or communicating with each other may be indirectly coupled or communicating through some interface, device, or intermediate component whether electrically, mechanically, or otherwise. Other examples of changes, substitutions, and alterations are ascertainable by one skilled in the art and could be made without departing from the spirit and scope disclosed herein.

To aid the Patent Office, and any readers of any patent issued on this application in interpreting the claims appended hereto, applicants note that they do not intend any of the appended claims to invoke 35 U.S.C. § 112 (f) as it exists on the date of filing hereof unless the words “means for” or “step for” are explicitly used in the particular claim.