Abstract:
A system is disclosed that incorporates a generator for generating a liquid coolant. This invention provides a self-contained water (or similar liquid coolant) chilling system of suitable capacity to cool small to medium size structures, such as private residences and manufactured homes. The system utilizes an arrangement of heat-exchanging panels to pre-condition an ambient temperature air-stream, prior to passage through a pump-driven coolant spray. The system also provides several sub-systems for automatic coolant monitoring, chemical addition and periodic coolant replacement.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application claims the benefit of Provisional Application Serial No. 60/352,694, filed Jan. 28, 2002. 

   FIELD OF THE INVENTION 
   This invention relates to heat transfer apparatus and methods for providing conditioned air to habitable structures. 
   BACKGROUND OF THE INVENTION 
   Typically, cooling systems, such as those used for cooling structures, such as buildings and trailers, consist of systems that cool the air. The air-cooling is performed in many ways, such as using cooled refrigerant, cooled air or cooled water. Evaporative cooling systems have historically been less expensive than refrigerant systems. Evaporative systems that utilize the evaporation of water, such as those that use pads soaked with water and have air drawn through them, have been in use for many years. Such evaporative systems, however, tend to humidify the air within the structure, causing reduced occupant comfort after a certain dew point is reached. 
   The use of cooled water systems, such as those using cooling towers, is well-known in large-scale commercial applications. The residential use of circulating cooled water to cool the air within a structure has not been well received, due to set-up and operating costs. Additionally, the perceived negative aesthetics of most traditional cooled water systems has limited the broader adoption of use in residential applications. A cooling system that would economically and efficiently cool the air within a structure, using cooled liquid (water) to transfer the heat from the structure&#39;s air as a means to cool the air and not add humidity to the air, would be advantageous. 
   Accordingly, a primary object and feature of the present invention is to provide a system for cooling a liquid coolant. It is a further object and feature of the present invention to provide a system for using such liquid coolant that is of suitable capacity to cool small to medium-sized structures, such as private residences and manufactured homes. A further primary object and feature of the present invention is to provide such a system that is efficient, inexpensive, and handy. Other objects and features of this invention will become apparent with reference to the following descriptions. 
   SUMMARY OF THE INVENTION 
   In accordance with a preferred embodiment hereof, this invention provides a cooling system comprising, in combination: at least one container means for containing at least one liquid coolant supply, each such at least one container means having an interior and an exterior; at least one incoming air passage means for providing air passage into such at least one container means, and at least one outgoing air passage means for providing air passage out of such at least one container means; at least one air mover means for moving at least one first stream of air, from ambient air, through such at least one incoming air passage means into such at least one container means; located within such at least one container means, at least one spray means for spraying liquid coolant from the at least one liquid coolant supply through the at least one first stream of air; wherein such at least one container means is structured and arranged so that the at least one first stream of air becomes at least one coolant-holding second stream of air passing through such at least one outgoing air passage means; a thermal transfer means comprising at least portions of such at least one incoming air passage means and such at least one outgoing air passage means, for assisting thermal transfer between the at least one coolant-holding second stream of air and the at least one first stream of air; and at least one liquid coolant mover means for moving liquid coolant from the at least one liquid coolant supply through such at least one spray means; wherein such at least one container means comprises at least one coolant collection means for collecting liquid coolant. 
   Additionally, it provides such a system wherein a substantial portion of such at least one container means further comprises a thermal insulation means for thermally insulating such interior of such at least one container means from such exterior of such at least one container means. Further, it provides such a system wherein the liquid coolant from such at least one coolant collection means passes through a heat exchanger, then through such at least one spray means. 
   In accordance with another preferred embodiment hereof, this invention provides a cooling system comprising, in combination: at least one container structured and arranged to contain at least one liquid coolant supply, each such at least one container having an interior and an exterior; at least one incoming air passage structured and arranged to provide passage into such at least one container, and at least one outgoing air passage structured and arranged to provide passage out of such at least one container; at least one air mover structured and arranged to move at least one first stream of air, from ambient air, through such at least one incoming air passage into such at least one container; at least one sprayer, within such at least one container, structured and arranged to spray liquid coolant from the at least one liquid coolant supply through the at least one first stream of air; wherein such at least one container is structured and arranged so that the at least one first stream of air becomes at least one coolant-holding second stream of air passing through such at least one outgoing air passage; at least one thermal transfer system, including at least portions of such at least one incoming air passage and such at least one outgoing air passage, structured and arranged to assist thermal transfer between the at least one coolant-holding second stream of air and the at least one first stream of air; and at least one liquid coolant mover structured and arranged to move liquid coolant from the at least one liquid coolant supply through such at least one sprayer; wherein such at least one container comprises at least one coolant collector structured and arranged to collect liquid coolant. 
   Additionally, it provides such a system wherein a substantial portion of such at least one container further comprises a thermal insulation, structured and arranged to thermally insulate such interior of such at least one container from such exterior of such at least one container. Moreover, it provides such a system wherein the liquid coolant from such at least one coolant collector passes through a heat exchanger, then through such at least one sprayer. Further, it provides each and every novel detail, feature, article, process, system and/or method disclosed in or mentioned by or shown in this disclosure document. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Referring to the drawings: 
       FIG. 1  is a perspective view of a cooling system according to a preferred embodiment of the present invention; 
       FIG. 2  is a diagrammatic view of air and water through a preferred embodiment of the present invention; 
       FIG. 3  is a perspective view of the cooling system in  FIG. 1 , partially in section; 
       FIG. 4  is a sectional view through the section  4 — 4  of  FIG. 3 ; 
       FIG. 5  is a sectional view through the section  5 — 5  of  FIG. 4 ; 
       FIG. 5   a  is a detailed view through section  5   a — 5   a  of  FIG. 5 ; 
       FIG. 6  is a sectional view through the section  6 — 6  of  FIG. 5 ; 
       FIG. 7  is a sectional view through the section  7 — 7  of  FIG. 5 ; 
       FIG. 8  is a top view of the cooling system of  FIG. 3 , according to a preferred embodiment of the present invention; 
       FIG. 9  is a front side view of the cooling system of  FIG. 3 , according to a preferred embodiment of the present invention; 
       FIG. 10  is a right side view of the cooling system of  FIG. 3 , according to a preferred embodiment of the present invention; 
       FIG. 11  is a backside view of the cooling system of  FIG. 3 , according to a preferred embodiment of the present invention; 
       FIG. 12  is a left side view of the cooling system of  FIG. 3 , according to a preferred embodiment of the present invention; 
       FIG. 13  is an enlarged detailed view through the section  13 — 13  of  FIG. 6 ; 
       FIG. 14  is an enlarged detailed view through the section  14 — 14  of  FIG. 6 ; and 
       FIG. 15  is a sectional view of the cooling system with the hinged door in an open position. 
   

   DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
   Reference is now made to the drawings.  FIG. 1  is a perspective view of the cooling system  100 , according to a preferred embodiment of the present invention. Illustrated is a cooling system  100  used to generate a cooled liquid coolant that is delivered through at least one liquid coolant transfer system  150 , to at least one structure heat exchanger  102 , for cooling the air inside the interior of a habitable structure  104  through one or more air ducts  106 , as shown. 
     FIG. 2  is a diagrammatic view of air and liquid coolant through a preferred embodiment of the present invention. Preferably, the intake air  108  is drawn horizontally through at least one heat exchanger  110  by at least one blower  112  (embodying herein at least one air mover), as shown. Preferably, the air stream (embodying herein at least one first stream of air) is then forced up through at least one liquid coolant spray  114  (embodying herein at least one sprayer), and exhausted, vertically downward, through at least one heat exchanger  110  (embodying herein at least one container, structured and arranged so that the at least one first stream of air becomes at least one coolant-holding second stream of air passing through such at least one outgoing air passage). Preferably, the liquid coolant spray  114  is collected in at least one liquid coolant supply collector  116  (the above-described arrangement embodying herein at least one coolant collector structured and arranged to collect liquid coolant) and circulated by at least one pump  118  (embodying herein at least one liquid coolant mover structured and arranged to move liquid coolant from the at least one liquid coolant supply through such at least one sprayer), through the structure heat exchanger  102  within the interior of the habitable structure  104 , and back through the liquid coolant spray  114  (embodying herein an arrangement wherein the liquid coolant from such at least one coolant collector passes through a heat exchanger, then through such at least one sprayer), as shown. Preferably, the air inside the interior of the habitable structure  104  is blown over the structure heat exchanger  102  by external blower  120 , as shown. 
     FIG. 3  is a perspective view of the cooling system in  FIG. 1 , partially in section. Preferably, cooling system  100  comprises at least one container  122  (embodying herein at least one container structured and arranged to contain at least one liquid coolant supply, each such at least one container having an interior and an exterior), as shown. Preferably, the container  122  is constructed from a molded polymer material, such as polycarbonate, and is rectangular with an angular-shaped container base  123 . The angular container base  123  is preferably constructed from the same material as the container  1221 (under appropriate circumstances, materials other than molded polymer or polycarbonate may suffice). Preferably, the container  122  has at least one hinged lid  124 , pivoting on at least one hinge  125 , and at least one hinged door  126 , pivoting on at least one hinge  127  (the hinges are shown in greater detail in FIGS.  5  and  7 ). 
   Preferably, the container  122  is substantially lined with a radiant barrier  128  (herein embodying a substantial portion of such at least one container further comprising a thermal insulation, structured and arranged to thermally insulate such interior of such at least one container from such exterior of such at least one container). Preferably, the radiant barrier  128  is equal to “Microfoil” available from Packaging Technologies, Incorporated. Preferably, ambient intake air is drawn through the container  122  by blower  112  through at least one filter  130  (embodying herein, at least one incoming air passage structured and arranged to provide passage into such at least one container), as shown. The filter  130  is preferably at least one mesh screen sized such that large particles are filtered from entering the cooling system  100 . Preferably, the air is then drawn by blower  112  through at least one heat exchanger  110 . 
   Preferably, the heat exchanger  110  comprises three main sections; a first heat exchanger section  132  and a second heat exchanger section  134 , linked by a third section serving as an air transfer duct  136  (the three sections are more clearly illustrated in FIG.  4  and FIG.  5 ). Preferably, both first heat exchanger section  132  and second heat exchanger section  134  further comprise a plurality of heat-exchanging corrugated-panels  133 . Preferably, each heat exchange section comprises at least four heat-exchanging corrugated panels  133  made of aluminum (or galvanized steel covered with an epoxy powder coating to limit corrosion), and at least one heat-exchanging corrugated panel  133  made of fiberglass. The fiberglass panels preferably form the walls of the liquid coolant spray chamber  142 , as shown. The air transfer duct  136  is preferably comprised of at least one heat-exchanging corrugated panel  133 , preferably aluminum (or galvanized steel covered with an epoxy powder coating to limit corrosion), on the container  122  side of the duct, and at least one heat-exchanging corrugated panel  133 , preferably fiberglass, on the liquid coolant spray chamber  142  side of the duct, as shown. Under appropriate circumstances, other corrosive-resistant materials may be used in constructing the heat exchanger  110 . 
   The combined horizontal length of the two heat exchange sections  132  and  134  and the air transfer duct  136  is preferably about nine feet. Preferably, each of the heat-exchanging corrugated panels  133  has a first side and a second side, as shown. Preferably, the intake air stream travels across the first side of the heat exchanging corrugated panels  133  within the first heat exchange section  132 , then through the air transfer duct  136 , and finally across the first side of the heat exchanging corrugated panels  133  within the second heat exchange section  134  before exiting the heat exchanger  110  (embodying herein at least one thermal transfer system, including at least portions of such at least one incoming air passage and such at least one outgoing air passage, structured and arranged to assist thermal transfer between the at least one coolant-holding second stream of air and the at least one first stream of air). 
   Preferably, after exiting heat exchanger  110 , the air stream enters the blower chamber  138 , as shown. Preferably, blower  112  then discharges the air over an air deflector  140 , as shown. Preferably, the blower is a variable speed unit (preferably a Dayton® ⅓ horsepower variable speed blower, 1000 cfm to 2000 cfm air delivery, No. 5C092) mounted for bottom horizontal discharge, as shown. Preferably, the air stream is deflected by the air deflector  140  and is forced across the liquid coolant supply collector  116  and up through the liquid coolant spray  114 , in the liquid coolant spray chamber  142 , as shown. The deflector  140  is preferably comprised of curved polycarbonate. Under appropriate circumstances, the use of other materials in the construction of the air deflector  140  may suffice. 
   As previously mentioned, the walls of the liquid coolant spray chamber are preferably comprised of a corrugated fiberglass. As the air stream exits the liquid coolant spray chamber  142 , it is preferably deflected in three directions by at least one air deflector  144 . At least one air defector  144 , as shown in  FIG. 3 , is located, preferably, within the hinged lid  124  and is preferably comprised of polycarbonate and in a V-shaped configuration (under appropriate circumstances, other materials and deflector shapes may suffice). Preferably, the air is deflected vertically down across the second side of the heat-exchanging corrugated panels  133  located within the first heat exchanger section  132 , across the second side of the heat-exchanging corrugated panels  133  located within the second heat exchanger section, and down through at least one rear exhaust slot  148 . The rear exhaust slot  148 , as shown in  FIG. 3 , is preferably located between the air transfer duct  136  and the container  122 . Preferably, the air is then exhausted to the environment outside the container  122  (embodying herein at least one outgoing air passage structured and arranged to provide passage out of such at least one container). 
   Preferably, as shown in  FIG. 3 , the container base  123  of the cooling system  122  comprises the liquid coolant supply collector  116 , as shown. Preferably, located within the liquid coolant supply collector  116  is at least one pump  118 , as shown. Preferably, the pump  118  is used to transfer the cooled liquid coolant through at least one liquid coolant transfer system  150 , to at least one structure heat exchanger  102  for cooling the air inside the interior of at least one habitable structure  104  (as shown in FIG.  1 ), before returning to at least one liquid coolant spray assembly  152  within the liquid coolant spray chamber  142 . Preferably, the pump  118  is a submersible utility unit (Little Giant® ⅙ horsepower, No. 2P352, designed to pump at fourteen gallons per minute against fifteen feet of head). The liquid coolant transfer system  150  is preferably comprised of standard one-inch diameter thin-walled PVC piping and fittings (under appropriate circumstances, other materials and sizes may suffice). The pump  118  and the liquid coolant spray assembly  152  are further illustrated in  FIGS. 4 and 5 , respectively. 
     FIG. 4  is a sectional view through the section  4 — 4  of FIG.  3 . This figure more clearly illustrates the liquid coolant supply collector  116 , location of the pump  118 , and coolant spray assembly  152 . As shown in  FIG.4 , at least one float valve assembly  154  is preferably located within the liquid coolant supply collector  116 . Preferably, as shown, at least one standard float valve assembly (Watts Regulator float valve assembly, No. 2X768) is used to maintain the amount of liquid coolant in the liquid coolant supply collector  116 , as shown. Preferably, connected at the base of the float valve assembly  154  is liquid coolant supply tubing  155  (illustrated in  FIGS. 10 ,  11  and  12 ) for maintaining the minimum amount of liquid coolant in the liquid coolant supply collector  116 , as shown. Preferably, the liquid coolant supply tubing  155  is ¼ inch OD polyethylene tubing (under appropriate circumstances, other tubing materials may be utilized). In the preferred embodiment of the present invention, the capacity of the liquid coolant supply collector  116  is preferably about thirty-seven gallons. Preferably, as shown in  FIG. 4 , air deflector  140  is appropriately sized to sufficiently cover the float valve assembly  154 , protecting the assembly from the downward discharge of air from blower  112 , thereby accurately maintaining the optimal amount of liquid coolant in the liquid coolant supply collector  116 , as shown. The liquid coolant spray assembly  152  is preferably configured such that liquid coolant is evenly broadcast within substantially the entire liquid coolant spray chamber  142 , as shown. 
   Preferably located within the blower chamber  138  is at least one control panel  156  for housing controls to operate the cooling system  100 , as shown. Preferably, the electrical components of the cooling system  100  operate on 110 Volts. Additionally, the controllers {electronic or mechanical) housed in the control panel  156  preferably comprise controls {electronic or mechanical) for the operation of the blower  112  and the pump  118 . Further, the control panel  156  preferably houses at least one multi-station timer {electronic or mechanical), preferably two-station timer unit, with a user-adjustable timer function to initiate, at least once a week, an action to evacuate the liquid coolant supply collector  116 , and secondly, to initiate at least one action to add chemicals {i.e., surfactant, etc.) to the coolant system, as necessary. Preferably, with the hinged door  126  in an open position, the control panel  156  is accessible for service, as shown. 
   More clearly depicted in  FIG. 4  is the preferred air transfer duct  136  arrangement, structured to prevent the mixing of air moving within the heat exchanger  110  with the air or liquid entering or exiting the liquid coolant spray chamber  142 . Preferably, the air transfer duct is enclosed on the top and bottom by a continuous wood or plastic cover  137 , mechanically fastened or adhesively bonded to the side walls of the duct, as shown. 
     FIG. 5  is a sectional view through the section  5 — 5  of FIG.  4 . Preferably, as shown in  FIG. 5 , the first heat exchange section  132  and the second heat exchange section  134 , each comprise at least five heat-exchanging corrugated panels  133 , as shown. Preferably, each heat-exchanging corrugated panel  133  further comprises a first side and second side, with the first side of heat-exchanging corrugated panels  133  preferably forming at least two first side air channels  158 , with at least  400  square inches of cross-sectional area, open to transfer only intake air in a horizontal direction through the heat exchanger  110 . The first side air channels  158  formed by the first side of the heat-exchanging corrugated panels  133  are enclosed with a first side air channel top closure  157  and a first side air channel bottom closure  159  (as shown in FIG. 7 ). Preferably, the first side air channel top closure  157  and first side air channel bottom closure  159  function to isolate the horizontal intake airflow from other air flows within the heat exchanger  110 , as shown. Preferably, the first side air channel top closure  157  and first side air channel bottom closure  159  are constructed of wood or plastic formed to the shape of the heat-exchanging corrugated panels and mechanically fastened or adhesively-adhered to the top and bottom of the panels, as shown. The second side of the heat-exchanging corrugated panels  133  preferably form at least three second side air channels  160 , with at least 280 square inches of cross-sectional area, open only to vertically exhaust air deflected by air deflector  144  in a downward direction to the ambient environment, as shown. Preferably, the second side air channels  160  formed by the second side of the heat-exchanging corrugated panels  133 , further comprise a front and back end, with the front and back ends preferably sealed (closed) by either seam or spot welding  168  to isolate the exhaust air from other air flows, as shown. 
   Preferably, as shown in  FIG. 5 , the liquid coolant spray assembly  152  is essentially rectangular and sized to provide coolant spray to substantially the entire liquid coolant spray chamber  142 . The liquid coolant spray assembly  152  is preferably comprised of one-inch OD PVC piping and fittings with a plurality of holes drilled on the underside of the piping to effect the coolant spray, as shown (under appropriate circumstances, other piping materials may be used). 
     FIG. 5   a  is an enlarged detailed view through section  5   a — 5   a  of FIG.  5 . This detailed view illustrates the first side air channels  158  formed by the first side of heat-exchanging corrugated panels  133  that provide for passage of intake air into the cooling system  100 , and the second side air channels  160 , formed by the second side of the heat-exchanging corrugated panels  133 , that provide for passage of the outgoing air from the cooling system  100  (embodying herein at least one incoming air passage structured and arranged to provide passage into such at least one container and at least one outgoing air passage structured and arranged to provide passage out of such at least one container). As shown, the second side of the heat exchange panels  160  is isolated from other airflows, preferably, sealed (closed) by either seam or spot welding  168 , as shown. 
     FIG. 6  is a sectional view through the section  6 — 6  of FIG.  5 . As shown in  FIG. 6 , preferably, an electrically operated valve  162  is used to direct the flow of the liquid coolant from the pump  118 , either to the liquid coolant transfer system  150 , or to at least one liquid coolant discharge fitting  164 . In the preferred embodiment, the liquid coolant discharge fitting  164  is preferably at least one standard garden hose fitting and is used as a hose connection point for further directing the discharging liquid coolant periodically pumped from the cooling system  100 . 
     FIG. 7  is a sectional view through the section  7 — 7  of FIG.  5 . As shown in  FIG. 7 , at least one hinged lid  124  of the cooling system  100  pivots on at least one lid hinge  125 . Additionally,  FIG. 7  illustrates the relationship between the heat-exchanging corrugated panels  133 , the first side air channels  158  (that provide for horizontal passage of intake air into the cooling system  100 ), and the second side air channels  160  (that provide for vertical passage of the outgoing air from the cooling system  100 ). !Also illustrated are the first side air channel top closures  157  and first side air channel bottom closures  159 , as shown. 
     FIG. 8  is a top view of the cooling system  100  of  FIG. 3 , according to a preferred embodiment of the present invention.  FIG. 9  is a front side view of the cooling system  100  of  FIG. 3 , according to a preferred embodiment of the present invention.  FIG. 10  is a right side view of the cooling system  100  of  FIG. 3 , according to a preferred embodiment of the present invention. As shown in  FIG. 10 , more clearly illustrated from the right side view are the screen filter  130 , the liquid coolant supply tubing  155 , and the liquid coolant discharge fitting  164 .  FIG. 11  is a backside view of the cooling system  100  of  FIG. 3 , according to a preferred embodiment of the present invention.  FIG. 12  is a left side view of the cooling system  100  of  FIG. 3 , according to a preferred embodiment of the present invention. 
   As shown in  FIG. 12 , the door hinge  127  of the hinged door is more clearly illustrated.  FIG. 13  is an enlarged detailed view through the section  13 — 13  of FIG.  6 .  FIG. 13  shows the container  122  as substantially lined with at least one radiant barrier  128  (the radiant barrier material equal to “Microfoil” available from Packaging Technologies, Inc.). The radiant barrier  128  provides both insulation and a radiant shield for the container  122  (embodying herein a substantial portion of such at least one container further comprising a thermal insulation, structured and arranged to thermally insulate such interior of such at least one container from such exterior of such at least one container).  FIG. 14  is an enlarged detailed view through the section  14 — 14  of FIG.  6 .  FIG. 14  shows a detail at the angular container base  123 . Preferably, the angular container base  123  is lined with at least one radiant barrier  128  and fitted with at least one liquid coolant supply collector liner  166 . The liquid coolant supply collector liner  166  is preferably constructed from blow-molded polycarbonate (under appropriate circumstances, other liner materials may suffice).  FIG. 15  is a sectional view of the cooling system  100 .  FIG. 15  illustrates the cooling system  100  with the hinged door  126  in the open position. 
   Although applicant has described applicant&#39;s preferred embodiments of this invention, it will be understood that the broadest scope of this invention includes such modifications as diverse shapes and sizes and materials. Such scope is limited only by the below claims as read in connection with the above specification. Further, many other advantages of applicant&#39;s invention will be apparent to those skilled in the art from the above descriptions and the below claim.