Thermally actuated phase change operated control valve for use in an energy conservation system

A thermally actuated phase change operated control valve has, a valve body with a bore therethrough the walls of which define a valve chamber, the valve body has a manifold assembly about the valve body and a medially disposed first port means in the valve body connects the valve chamber with the manifold assembly. Spaced second and third port means in the valve body respectively disposed on opposite sides of said first port means permit valve head means slidably disposed in said valve chamber for movement relative said first port means to direct fluid either from the valve chamber to one or the other of said second and third port means or vice versa depending on whether the control valve is operated as a diverter valve or as a mixing valve or if desired one of the spaced second or third port means can be rendered inoperative and the control valve can be operated as a thermal check valve. The valve head means is moved to and fro in the longitudinal axis of the valve chamber by a phase change power element also mounted in the valve chamber which is responsive to variations in temperature of the fluid flowing therethrough. The valve head is fixedly connected and movable with the phase change power element so that delivery of fluid to or from one or the other or both of the spaced second and third port means is accomplished as a function of the variations in temperature of the fluid passing through the valve chamber.

BACKGROUND OF THE INVENTION 
This invention relates generally to control valves utilized in energy 
conservation systems and more particularly to a thermally actuated phase 
change operated control valve for use in an energy conservation system for 
recovering heat from the refrigerant to water heat exchanger in a 
refrigeration cycle for an air conditioning system. 
It is a known practice to heat water by reclaiming heat from the high 
temperature discharge gases of the compressor in a refrigeration cycle. In 
many instances this rejected heat is disposed to waste. However, the 
concept of reclaiming heat from the high temperature discharge gases of a 
compressor in a refrigeration cycle is particularly applicable to an air 
conditioning system where the refrigeration cycles operate at somewhat 
higher temperature and pressure levels because such reclaimed heat can be 
applied to usable purposes. 
By removing heat from the high temperature discharge gases of the 
compressor in the refrigeration cycle or heat pump cycles of an air 
conditioning system before these gases are passed to a conventional 
condensing stage in such air conditioning systems, substantial heat 
recovery can be effected in a range from 4500 to 5500 BTU/hr per ton of 
unit capacity. 
This is accomplished by inserting a suitable refrigerant-to-water heat 
exchanger between the compressor discharge and the inlet to the condensor 
in such air conditioning systems. 
In effect condensing is accomplished in two steps. First, the 
desuperheating step where substantial quantities of heat are reclaimed and 
then the condensing step where the cooled gases are subjected to the 
conventional condensing for the refrigerant cycle. 
Such an arrangement must of course be optimized by properly sizing the heat 
exchanger to provide the proper heat transfer capacity so that the heat is 
recovered without effecting the operation of the refrigeration cycle for 
the air conditioning system. If the heat exchanger is sized too large, the 
high temperature discharge gases from the compressor will condense to 
refrigerant liquid in the desuperheating step which will result in reduced 
head pressures, thus reducing capillary tube or expansion valve capacities 
and performance of the refrigeration cycle for the air conditioning 
system. 
In the present invention a temperature actuated phase change operated 
control valve is provided for use in an improved circulating water system 
adapted for the recovery of waste heat by operative association with a 
waste heat source such as a refrigerant-to-water heat exchanger for the 
desuperheating of the high temperature discharge gases of the refrigerant 
cycle for an air conditioning system; a heat exchanger in a solar heat 
system; a heat exchanger in circulating grates of a fire place system; a 
heat exchanger in or about the stack for flue gas etc. 
SUMMARY OF THE INVENTION 
Thus, the present invention covers a thermally actuated phase change 
operated control valve having a valve body with a bore therethrough the 
walls of which define a valve chamber, the valve body having manifold 
assembly about the medial section thereof operatively associated with 
medially disposed port means which connects and communicates the valve 
chamber with the manifold assembly, and spaced port means in the valve 
body respectively on opposite sides of the medially disposed port means, 
phase change power means is slidably mounted in the valve chamber and 
movable to and from in the longitudinal axis thereof responsive to 
variations in temperature of the fluid flowing therethrough, and valve 
head means is fixedly connected and movable with the phase change power 
element relative the medially disposed port means so that delivery of 
fluid to or from one or the other or both of the spaced port means to or 
from the valve chamber means is accomplished as a function of the 
variations in the temperature of said fluid passing through the valve 
chamber. 
Additionally, the present invention covers the combination for recovering 
heat from a refrigerant cycle of a water circulating system for a 
refrigerant-to-water heat exchanger in said refrigerant cycle including, 
an inlet for water, pump means circulating such water, a hot water storage 
tank, an outlet for delivering heated water at usable temperatures for any 
desired use, and conduit means for connecting the same to each other; with 
at least one thermally actuated phase change operated diverter valve 
connected to receive water from said hot water storage tank and to deliver 
the same to or to by-pass the same about said heat exchanger, at least one 
thermally actuated phase change operated mixing valve heating, a first 
port connected to the water inlet for the water circulating system, a 
second port connected to the water circulating system to receive heated 
water therefrom, and an outlet for discharging water heated to a 
predetermined temperature for any desired use, and at least one thermally 
actuated phase change operated thermal check valve connected between the 
heat exchanger and the hot water storage tank and to the mixing valve to 
deliver heated water to said mixing valve and for returning water to said 
hot water storage tank for maintaining the level of heated water therein. 
Accordingly, it is an object of the present invention to provide an 
improved thermally actuated phase change operated control valve preferably 
applicable for use in the water circulating system for a 
refrigerant-to-water heat exchanger in a refrigeration system. 
It is another object of the present invention to provide an improved 
thermally actuated phase change operated control valve adaptable for use 
in a refrigerant-to-water heat exchanger in a refrigeration cycle adapted 
to permit water in the water circulating system to be delivered to or to 
be diverted about the heat exchanger. 
It is another object of the present invention to provide an improved 
thermally actuated phase change operated control valve adaptable for a 
water circulating system for a refrigerant-to-water heat exchanger in a 
refrigeration cycle adaptable to mix heated water from the system and cold 
water from a given source and to pass the same at usable temperatures to 
any desired use. 
It is a still further object of the present invention to provide an 
improved thermally actuated phase change operated control valve adaptable 
for a water circulating system for the refrigerant to water heat exchanger 
in a refrigeration cycle to act as a thermal check valve and to permit 
water to pass through said control valve at a predetermined temperature. 
It is another object of the present invention to combine a water 
circulating system for a refrigerant-to-water heat exchanger in a 
refrigerant cycle with a plurality of thermally actuated phase change 
operated control valves to effect energy conservation by recovering 
otherwise wasted heat from said refrigeration cycle. 
It is a still further object of the present invention to provide a 
thermally actuated phase change operated control valve having a centrally 
disposed manifold around the valve body thereof which coacts with 
rectangular shaped ports in the valve body and a valve head for regulating 
the area of the openings of said ports for providing improved transfer of 
fluid from the valve chamber in the valve body to the manifold.

Referring to FIG. 1 of the drawings a refrigerant-to-water heat exchanger 
10 in a refrigeration cycle for an air conditioning system is illustrated 
diagramatically. 
Refrigerant discharge in the form of hot compressed gas from the compressor 
11 of the refrigerant system is passed through line 12 in the heat 
exchanger 10. 
Non-contacting refrigerant-to-water heat exchangers such as the heat 
exchanger 10 are well known to those skilled in the art and therefore are 
not more fully described herein. 
CIRCULATING WATER SYSTEM 
The circulating water system 15 for circulating water to the heat exchanger 
10 receives water from any suitable source through inlet line 16 which 
will be under conventional supply line pressures of about 30-70 P.S.I. 
From line 16 the relatively cold source water can pass through delivery 
line 17 to the hot water storage tank 18. And through line 19 to a first 
inlet 20 of a thermally actuated phase change operated control valve 21. A 
second inlet 22 will receive heated fluid from the circulating water 
system 15 to permit the control valve 21 to act as a mixing valve as 
hereinafter described for delivering water at usable temperatures through 
a suitable outlet as at 23. 
A conventional globe valve 17a is provided in line 17 in the event it is 
necessary to cut off the supply of source water to the hot water storage 
tank 18 for purposes of repair or maintenance. 
The hot water storage tank 18 has a discharge outlet 24 which communicates 
with a drain 25. 
Circulating pump 26 for the system has its suction line 27 connected to the 
discharge outlet 24 of the hot water storage tank 18. Suction line 27 will 
also have a conventional globe valve 28 therein in order to cut off the 
flow of water to the pump 26 if it becomes necessary to repair, maintain 
or replace this pump. 
The discharge side of circulating pump 26 communicates through discharge 
line 29 with the inlet 30 of a second thermally actuated phase change 
operated control valve 31 to which the discharge line 29 is connected. 
Thermally actuated phase change operated control valve 31 acts as a 
diverter valve in that it has spaced outlets as at 32 and 33 which are on 
opposite sides of the inlet 30 so that water delivered through the inlet 
30 depending on the operation of the control valve 31 can be passed either 
through outlet 32 or outlet 33 or through both outlets 32 and 33 in any 
given ratio depending upon the manner in which the control valve is 
required to operated within the predetermined temperature range for the 
particular diverter valve as is more fully described hereinafter. 
The outlet 32 communicates with one end of line 34 which passes through the 
heat exchanger 10 for heat exchange relation with the refrigerant passing 
through line 12 in the heat exchanger 10 and the end of line 34 remote 
from the outlet 32 communicates with the inlet 35 of a third thermally 
actuated phase change operated control valve 36 which serves as a 
thermally operated check valve to deliver heated water through the outlet 
37 and connecting line 38 to the hot water supply inlet 22 for the mixing 
valve 21. 
The operation of the above described circulating water system for 
recovering heat from the refrigeration cycle is predetermined by two 
factors. First the temperature at which the mixing valve 21 is to supply 
hot water for use generally in a range from 120.degree. F. to 160.degree. 
F., and second the temperature setting for the hot water in the hot water 
storage tank 18 of about 180.degree. F. or higher to obtain maximum system 
efficiency. 
In the operation of the circulating water system even though each of the 
respective thermally actuated phase change operated control valves 21, 31 
and 36 have substantially similar structure as is hereinafter more fully 
described they each perform a different function in the operation of this 
system. 
Control valve 31 is in the closed loop between the hot water storage tank 
18 and the refrigerant to water heat exchanger 10. The function of control 
valve 31 is to sense the temperature of the water delivered by the 
circulating pump 26 from the bottom of the hot water storage tank 18. If 
this water is cold the control valve 31 will operate to pass the water 
from the inlet line 30 to the outlet line 32 connected in turn to the line 
34 so that this cold water can pass through the refrigerant to water heat 
exchanger 10 and thereby pick up useful heat. However, the control valve 
31 is so set that if the water delivered by the circulating pump 26 from 
the bottom of the hot water storage tank 18 is above the predetermined 
setting of the control valve 31 generally in the order of 165.degree. F. 
and therefore requires no further heating, the water will pass from the 
inlet 30 to the outlet 33 so that it by-passes the heat exchanger 10 and 
since the water is at a useable temperature above 140.degree. F. the 
control valve 36 will permit the water to pass to the mixing valve 21 or 
return to the hot water storage tank 18 through connecting line 39. 
The control valve 21 is connected into the system and acts to automatically 
proportion the mixture of cold water delivered through cold water inlet 
port 20 and heated water inlet port 22 so that the water delivered through 
the outlet port 23 will be at the pre-established or predetermined outlet 
temperature for the heated water to be supplied for use. 
The structure and operation of the control valves 21, 31 and 36 is best 
understood by reference to FIG. 4 which is a cross-section taken through 
control valve 31. 
Thus control valve 31 which operates as a diverting valve includes, a valve 
body 41 having, a bore 42 the walls of which define a valve chamber 43. 
The valve body is provided with spaced ports as at 44a and 44b which 
communicate with a manifold 44c in turn for this form of the control valve 
connected to the inlet 30 to provide means for delivering water from the 
circulating system to the valve chamber 43. On opposite sides of the ports 
44a and 44b, ports are provided as at 45 and 46 which communicate 
respectively with the spaced outlets 32 and 33 connected to the valve body 
41. The ports 44a and 44b are rectangular in shape and provide increased 
water flow between the chamber 43 and the manifold 44c on movement of 
valve head 47 relative these ports to control and regulate the flow of 
water from the valve chamber 43 to either or both of the outlet ports 45 
and 46. 
Valve head 47 is slidably disposed in bore 42 and is mounted on and movable 
with and moved by a phase change power element 48 which is disposed in the 
longitudinal axis of the valve chamber 43. Phase change power element 48 
is held in a calibrated initial position between a resilient member 49 and 
a calibrating assembly generally designated 50 disposed in the valve body 
at opposite ends of the valve chamber and on opposite sides of the phase 
change power element 48, as is shown in FIG. 4 of the drawings. 
The resilient member 49 at all times urges the phase change power element 
48 into firm engagement with the calibration assembly 50 but due to the 
resilient character of the resilient member 49 permits the phase change 
power element to expand and contract with variations in temperature of the 
water being circulated from the circulating system 15 through the control 
valve 31. 
Since the valve head 47 is fixedly connected about the phase change power 
element 48 it will be moved therewith and will change position to vary the 
area of the openings respectively of the inlet ports 44a and 44b so as to 
deliver more or less fluid to one or the other of the outlet ports 45 or 
46. 
Further as shown at FIGS. 4 and 6 of the drawings, the valve head 47 is 
sized relative the inlet ports 44a and 44b so that the width thereof is 
less than the width of the rectangular openings defining the inlet ports 
44a and 44b. This construction is necessary because the operator for 
moving the valve head 47 is the phase change power element 48 and this 
sizing of the valve head will insure that there will always be fluid 
flowing through the fluid flow chamber 43 in each given valve the 
temperature of which will at all times actuate the phase change power 
element and thus prevent a dangerous build up of pressure in any of the 
respective valves illustrated. 
A phase change power element such as element 48 is a device which can be 
purchased on the open market. This device includes, a cup shaped housing 
51 for holding a phase change material 52, a diaphragm 53 which closes the 
cup shaped housing and a closure member 54 which seals the diaphragm 
assembly 53 in assembled position. The diaphragm assembly 53 is 
operatively connected to a push rod 55 which extends through the closure 
member all of which is shown in FIG. 4 of the drawings. 
In the construction shown in FIG. 4, the push rod 55 is set in a bore 56 of 
the calibrating screw 57 and is maintained in engagement with the 
calibrating screw 57 by means of the resilient member 49. By removing the 
cap 58 and inserting a screw driver in the slot 59 on the exterior portion 
of the calibrating screw 57 the phase change power element 48 and the 
valve head 57 can be moved in the longitudinal axis of the valve chamber 
43 so that the same is positioned as desired relative the inlet ports 44a 
and 44b. 
As the temperature of the water entering the valve chamber 43 varies the 
phase change material 52 will expand or contract and the diaphragm member 
53 which is mounted on the push rod 55 will cause the phase change power 
element to change its position proportionally to said expansion or 
contraction of the phase change material. 
In operation when the water is below a predetermined temperature of about 
155.degree. F. in the setting range for the phase change material 52, the 
phase change material will contract and the resilient element 49 will 
cause the phase change power element 48 to move so that all of the water 
from the inlet ports 44a and 44b will pass through the outlet 32 to line 
34 in the heat exchanger 10. However if the water is above a temperature 
of about 165.degree. F. within the setting range for the phase change 
material 52, the phase change material will expand and the phase change 
power element 48 will be removed against the resilient element 49 so that 
all of the water from the inlet ports 44a and 44b will be caused to pass 
through the outlet 33 to by-pass the heat exchanger 10. At positions 
between these temperature limits, a portion of water will by-pass the heat 
exchanger 10 and a portion will pass to the heat exchanger 10. 
FIG. 7 shows that the temperature actuated phase change operated thermal 
check valve 36 differs from control valve 31 only to the extent that one 
of the ports normally communicating with the valve chamber 43 is closed 
off by a threaded closure member 60. 
Thermal check valve 36 is otherwise identical in structure to control valve 
31 and like parts accordingly have like character numerals. 
In this form of the control valve however because there is only a single 
inlet 35 and a single outlet 37 the phase change power element 48 will be 
selected with a phase change material which will cause the inlet ports 44a 
and 44b to open when the temperature of the water flowing into the valve 
chamber 43 of control valve 36 exceeds a predetermined minimum temperature 
for example 150.degree. F. within the settable range for the phase change 
power element. When the inlet ports 44a and 44b are so opened water will 
pass from the inlet 35 to the outlet 37 and thence by a line 38 to either 
the mixing valve 21 or the hot water storage tank 18. Thermal check valve 
36 insures that even though no heat is available from the heat source 
namely heat exchanger 10, and the water entering control valve 31 is cold 
that no water can enter line 38 feeding the hot water storage tank 18 
and/or the mixing valve 21. 
An intentional bleed, not showing, can be provided across the valve head 47 
to insure better valve response during closing and/or the approach of the 
valve head 47 to its closed position relative the associated valve ports 
in accordance with the expansion and contraction of the phase change 
material therein so as to pass through the ports 44a and 44b a total 
volume of water to the manifold 44c at the desired or useable temperature 
for delivery to the desired use through the outlet 23. 
Thus a single valve construction has been disclosed which is versatile in 
operation as a function of the manner in which the inlets and outlets to 
the valve are connected and the ports in the valve are operated. This is 
illustrated in that valve 31 operates as a diverter valve, valve 36 as a 
thermal check valve, and valve 21 as a mixing valve as will now be 
described with reference to the operation of the water circulating system 
wherein the operation of this valve provides for energy conservation in 
that heat which has heretofore been wasted is now recovered or reclaimed 
and usefully applied. 
OPERATION 
In operation, the glove valves 17a and 28 are moved to open position and 
the circulating pump 26 is placed into operation. 
The system is characterized by a closed loop which acts to maintain the 
temperature of the water in the hot water storage tank at temperatures as 
high as 180.degree. F. Connected to the closed loop circuit is the mixing 
valve which mixes a portion of the heated water from the closed loop with 
a portion of the cold source water to provide the required water at 
useable temperatures for the desired application or use. 
The centrifugal pump 26 acts to circulate and mix water in the closed loop. 
Thus referring to FIG. 1 the circulating pump 28 draws water from the 
bottom of the hot water storage tank 18 and discharges the same through 
line 29 to the control valve 31. 
If the temperature of the water is below a predetermined temperature of 
155.degree. F. within the settable range for the phase change material in 
control valve 31 all of the water will be passed through port 45, outlet 
32 and line 34 in the heat exchanger 10. In heat exchanger 10 the water 
will flow in non-contacting heat exchange relation with the hot 
refrigerant gas passing through line 12 and will absorb a portion of the 
available heat from the super heated gas refrigerant. 
The water in line 34 then flows to the inlet 35 of thermal check valve 36 
and if the temperature of the water exceeds 150.degree. F. within the 
settable range of the phase change material it will pass from the inlet 35 
through ports 44a and 44b and manifold 44c on the check valve 36 to the 
outlet 37. The outlet in turn will deliver the heated water through line 
38 and 39 back to the storage tank 18 if the mixing valve 21 is not 
drawing water from the closed loop system for mixture with sourced water 
as above described. 
If however the mixing valve 21 is drawing water from the closed loop for 
mixture with closed source water, then a portion of the heated water from 
line 38 and a portion of the heated water from the hot water storage tank 
18 will pass directly to the inlet 22 of the control valve 21 as is 
clearly shown in FIG. 1 of the drawings. 
If the water delivered or discharged by pump 26 through line 29 to the 
inlet 30 of control valve 31 is above a predetermined temperature of say 
165.degree. F. then the water will be diverted so as to flow through the 
outlet 33 through line 33a to a point on line 34 downstream from the point 
where it exits from the heat exchanger 10 and it passes through line 34 to 
the inlet 35 of the thermal check valve 36. In thermal check valve 36, if 
the temperature is still sufficiently high, water will pass through the 
ports 44a and 44b into the valve chamber 43 of the thermal check valve 36 
and thence to the outlet 37 for return through lines 38 and 39 to the hot 
water storage tank 18 and/or to the mixing valve 21 of the mixing valve is 
delivering water for the desired application or use. 
Those skilled in the art will readily understand that the superheat from 
the compressed gas of a refrigeration cycle is only representative of one 
type of wasted heat that can be recovered. Therefore, it will be 
understood that the circulating water system disclosed and the thermally 
actuated phase change operated control valves utilized in such system for 
energy conservation in accordance with the present invention can be 
operatively associated with other wasted heat sources without departing 
from the scope of the present invention. 
Such other sources of "free" or wasted heat will include solar energy, heat 
from fireplaces, heat from the chimney stack of a heating system, flue 
gases from ovens, etc. Non-contacting heat exchangers such as the 
refrigerant-to-gas heat exchanger 10 can be added to such sources of 
wasted heat to enable the system in accordance with the present invention 
to operate in the same manner as has been hereinabove described. 
It will be understood that the invention is not to be limited to the 
specific construction or arrangement of parts shown but that they may be 
widely modified within the invention defined by the claims.