Patent Publication Number: US-2011048051-A1

Title: Heating Ventilation Air Conditioner (HVAC) Compressor Efficiency Enhancement Apparatus

Description:
PRIORITY 
     The present invention claims priority under 35 USC section 119 and based upon a provisional application with a Ser. No. 61/275,273 which was filed on Aug. 27, 2009. 
    
    
     TECHNICAL FIELD 
     The present invention relates generally to heating ventilation air conditioner (hereafter HVAC) compressors, and more particularly to an apparatus to enhance the efficiency of air conditioner compressor units. 
     BACKGROUND 
     This relates to a heating ventilation air condition (HVAC) compressor equipment efficiency enhancement apparatus, specifically to a method of converting the cooling fluid used in the compressor of HVAC compressor equipment into a liquid state in a manner more efficient than heretofore known, utilized, or otherwise implemented in HVAC compressor equipment. 
     Following the implementation of the Montreal Protocol limiting the use of CFC (chlorofluorocarbon) and other halogenated hydrocarbon fluids used in air conditioning equipment, the operating conditions for air conditioner compressor units is approximately Eighty-five (85) Degrees Fahrenheit and temperatures below Eighty-five (85) Degrees Fahrenheit. The efficiency of an air conditioner compressor unit decreases as the external air temperature exceeds approximately Eighty-five (85) Degrees Fahrenheit. Generally, in the air conditioning industry, the capacity of the air conditioning equipment to reduce the temperature of the air in the area to be cooled through the air conditioning process is deemed to be approximately a maximum of approximately Twenty (20) Degrees Fahrenheit. Furthermore, the ability of the evaporator unit to remove excessive water contained in the ambient air (that is, the air to be cooled by the air conditioning equipment) is also diminished when the external air temperature exceeds about Eighty-five (85) Degrees Fahrenheit. 
     Industry standard air conditioning equipment includes both a compressor for converting the cooling fluid from a gaseous state to a liquid state and an evaporative unit for converting the cooling fluid from a liquid state to a gaseous state. The compressor unit and the evaporative unit are connected via a series of valves and piping to maintain the cooling fluid in the desired state as it passes through the condensing and evaporation stages of the air conditioning cycle. From this description, it is obvious that the energy removed from the air in the interior of a structure plus the loss of efficiency associated with the many elements of the air conditioning apparatus is directly related or directly proportional to the energy consumed to convert the cooling fluid from a gaseous state to a liquid state. In commercially available air conditioning equipment, the efficiency of the cooling fluid compression and expansion cycle is enhanced via the incorporation of a fan to cause outside ambient air to pass over the surface of the coils of the compressor unit and thus assist in the conversion of the cooling fluid from the gaseous state to the liquid state. 
     The use of a liquid, especially water, as a mist or spray onto the compressor coils to assist the ambient air to cool the surface of the compressor unit coils is well known to those skilled in the art. There are numerous strategies described in the literature for accomplishing the use of water mist or spray to assist the ambient air and the compressor unit to transform the coolant fluid from the gaseous state to the liquid state. However, due to design weaknesses, excessive operational complexity and cost, or ineffective utilization of coolant capacity of the water mist/spray, each of the heretofore known strategies has failed to be accepted and incorporated into the HVAC units used for conditioning the interior air of homes and businesses. 
     Also important to the performance of a system for enhancing the efficiency of an air conditioning compressor cycle is the ability of the water spraying or misting system to effectively wet and cool the coils located around the perimeter of the air conditioner (hereafter “AC’) compressor unit. If the coils are not properly wetted by water spray or mist, the dry coils remain heated and, therefore, the ability of the AC compressor unit to liquefy the cooling fluid is significantly diminished. During normal operating conditions, it is not uncommon for the surface temperature of the coils of the AC compressor unit to be above One Hundred Twenty-five (125) Degrees Fahrenheit. Optimal wetting coverage of the AC compressor coils by the water spraying or misting units is crucial for achieving cooling of the coils via the vaporization of water sprayed onto the surface of the coils. 
     Locating the water spraying or misting nozzles on the outside of the AC compressor housing intuitively should be the most effective due to the direction of flow of the ambient air being drawn into the unit through and across the coils and then being expelled through the top of the AC compressor unit. However, locating the water spraying or misting nozzles on the outside of the AC compressor unit housing directly exposes the water spraying or misting nozzles and the accompanying piping structure to the most severe weather environmental factors plus the dangers associated with lawn and facility maintenance as well as persons engaged in work or other activities in close proximity to the AC compressor unit. For these reasons, it is asserted herein that positioning the water spraying and misting nozzles should be located on the inside space of the AC compressor housing. 
     Below are a few prior art references. 
     U.S. Pat. No. 4,240,265 Dec. 23, 1980 Faxon
 
U.S. Pat. No. 4,576,012 Mar. 18, 1986 Luzenbeig
 
U.S. Pat. No. 4,974,422 Dec. 4, 1990 Kocher
 
U.S. Pat. No. 6,438,977 Aug. 27, 2002 McKay
 
     SUMMARY 
     An air conditioning apparatus to enhance the performance of an air conditioning (HVAC) equipment may include an air conditioning unit including a condenser coil; a spraying apparatus to spray a fluid onto the condenser coil of the air conditioning apparatus whenever the air conditioning apparatus is operating. 
     The spraying apparatus may be connected to a supply of fluid and an electrically operated solenoid valve may control the spraying apparatus by controlling the supply of fluid to the spraying apparatus. 
     A drain valve unit may drain the fluid from the air conditioning apparatus and the drain valve unit may be located at the lowest point of a piping network to deliver the fluid to the spraying apparatus. 
     The spraying apparatus may include a spray nozzle having a spray angle of 90 degrees to 150 degrees, and the spray apparatus may provide a flat spray pattern. 
     The spray apparatus may provide a rectangular spray pattern, and the spray apparatus may provide a conical spray pattern. 
     The spray apparatus may discharge between 1 to 64 fluid ounces of water per minute, and the spray apparatus may include a single spray nozzle to wet each surface of the condenser coil. 
     The spray apparatus may include only two spray nozzles to wet each surface of the condenser coil, and spray apparatus may include only four spray nozzles to wet each surface of the condenser coil. 
     The air conditioner unit may include a self-actuated and self-sealing valve to drain the excess water from the air conditioner unit. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention may be understood by reference to the following description taken in conjunction with the accompanying drawings, in which, like reference numerals identify like elements, and in which: 
         FIG. 1  illustrates a perspective view of the invention as incorporated in an HVAC unit; 
         FIG. 2  illustrates a first spray pattern generated by the present invention; 
         FIG. 3  illustrates a second spray pattern generated by the present invention; 
         FIG. 4  illustrates a third spray pattern generated by the present invention; 
         FIG. 5  illustrates a first angle of the spray pattern generated by the present invention; 
         FIG. 6  illustrates a second angle of the spray pattern of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     Specifically,  FIG. 1  shows the following features of the instant invention: 
     REFERENCE NUMERALS 
     
         
         
           
               1 . Air conditioner compressor unit condenser coils 
               2 . Air conditioner compressor unit compressor 
               3 . Air conditioner compressor unit fan 
               4 . Connection to water supply (pressurized) 
               5 . Connection of the electrical supply to the solenoid valve 
               6 . Electrically-actuated solenoid valve 
               7 . Piping to supply water from connection to water supply (pressurized) 
               8 . Water spray nozzles 
               9 . Drain valve to empty unused water from piping 
           
         
       
    
     The present invention is capable of dramatically decreasing the use, and thereby the cost, of electrical energy to cool commercial buildings and residential housing units utilizing HVAC systems that utilize an evaporative coolant fluid which exists in the air conditioner compressor condenser coils in a gaseous state and must be converted to a liquefied state to function as a cooling agent while concurrently making said HVAC systems provide cool air to said commercial buildings and residential housing units which is of the same or lower temperature than currently-utilized industry standard HVAC systems without the present invention installed therein. 
     The elements of the present invention may include an air conditioner apparatus consisting of a compressor unit, an expansion (evaporation) unit, an air movement apparatus which may be a fan or blower for moving the cooled air away from the expansion (evaporation) unit and another fan for moving the heated air away from the compressor unit and ancillary equipment for the effective operation of the AC equipment. In the present invention, water spraying and/or misting nozzles are mounted inside the housing of the AC compressor unit to effectively allow water to be sprayed through the water spraying and misting nozzles onto the AC compressor unit coils, the water spraying and/or misting nozzles may be supplied with pressurized fluid“,” for example water from the water supply system servicing the building (whether a home or business). The flow of water from the water supply to the water spraying and misting nozzles may be controlled by a valve which, in turn, is operated by an electric solenoid actuator. The electric solenoid actuator receives an electrical signal from the electrical control unit of the AC compressor unit of the AC compressor motor and associated compressor unit fan. Whenever the AC compressor motor and associated compressor unit fan receives a signal to begin operating to compress and liquefy the evaporative coolant, the unit sending the signal or electrical command to the AC compressor motor and associated compressor unit fan also sends a signal“,” which may be delayed“,” to the electric solenoid to actuate the valve and send water to the water spraying and/or misting nozzles. The coordination of the operation of the AC compressor motor, the associated compressor unit fan“,” and the spraying of water onto the compressor coils creates the near optimum efficiency conditions, as well as a reduction of energy necessary, for liquefying the evaporative coolant in the AC compressor unit. The water spray nozzles are constructed and designed to maximize the water coverage and wetting of the air conditioner compressor condenser unit coils of both commercial and residential air conditioning condenser compressor units. 
     Accordingly, several advantages of the present invention are to provide an improved means for enhancing the efficiency of air conditioning compressor cycles through the use of sprayed water onto the air conditioning compressor coils and thereby wetting the coils and achieving enhanced efficiency, as well as greatly increased energy efficiency of the HVAC unit by decreasing the amount of energy necessary to liquefy the cooling fluid used in HVAC units to convert the evaporative coolant used therein from a gaseous state to a liquid state. The invention described herein provides for, and permits, a reduction of the energy necessary to cool the air in both commercial buildings and residential housing units. Implementation of the invention will result in monetary savings to the user of HVAC units with the described invention incorporated therein and also reduce the overall consumption of energy by consumers of electricity used to cool both commercial buildings and residential housing units. 
     Still further advantages will become apparent from a study of the following description and accompanying drawing. 
     The present invention may effectively accomplish the result of increasing the efficiency of commercial and residential building unit HVAC units and decreasing the amount of energy expended to achieve the desired cooling effect of said HVAC units with the use of as few as 2 water spray nozzles and the use of as many as 12 water spray nozzles. The network piping is designed for each air conditioning apparatus compressor condenser unit to provide the most effective delivery of water to the spray nozzles and thus enhance the wetting of the air conditioner compressor condenser unit coils of the air conditioner compressor condenser unit. 
     The water spray nozzles are constructed and designed to maximize the water coverage and wetting of the air conditioner compressor condenser unit coils of both commercial and residential air conditioning condenser compressor units. 
     The drain valve unit is located at the lowest point of the piping network utilized to deliver cooling water to the inside of the air conditioning compressor condenser unit. This placement of the drain valve facilitates the draining of water remaining in the piping system at the end of the air conditioning apparatus condenser operating cycle and thereby preventing damage to the electrically-actuated solenoid valve, the network of piping, and the spray nozzles during low temperature conditions which may result in the formation of ice inside the piping system. 
     The piping system and water spray nozzles may be installed, as well as modified following installation, to permit one water spray nozzle to rotate to wet each individual interior flat surface of the air conditioning compressor condenser unit of the HVAC system in which the present invention is utilized. Alternatively, the spray nozzle may spray at 360° in order to reach the interior flat surface of the air conditioning compressor condenser unit. 
     The piping system and water spray nozzles may be installed, as well as modified following installation, to permit two water spray nozzles to rotate or spray at approximately 180° to wet each individual flat surface of the air conditioning compressor condenser unit of the HVAC system in which the present invention in utilized. 
     The piping system and water spray nozzles may be installed, as well as modified following installation, to permit four water spray nozzles to rotate or spray approximately 90° to wet each individual flat surface of the air conditioning compressor condenser unit of the HVAC system in which the present invention in utilized. 
     The drain valve unit may be located at the lowest point of the piping system past the point of placement of the solenoid valve to allow for the most complete possible draining of water from the piping and water nozzles which are incorporated in the present invention. 
     The drain valve may be positioned in a downward protruding piping leg attached to one of the vertical legs of the piping system. 
       FIG. 1  is a schematic drawing showing three dimensions of an HVAC compressor unit with the present invention incorporated in said HVAC unit. Element  1  shows the air conditioner compressor condenser coils. Element  2  shows the air conditioner compressor unit. Element  3  shows the air conditioner compressor unit fan. Element  4  shows the connection to the water supply used to supply water to the spray nozzles which spray water on the air conditioner compressor unit coils ( 1 ). Element  5  shows the connection to the electrical supply to the solenoid valve ( 6 ) which delivers the water to the spray nozzles ( 8 ) from the water supply connection ( 4 ). Element  6  shows the electrically-actuated solenoid valve which delivers the water to the spray nozzles ( 8 ) from the connection to the water supply ( 4 ). Element  7  shows the piping to supply water from the connection to water supply ( 4 ) to the spray nozzles ( 8 ). Element  8  shows the water spray nozzles located in the interior of the HVAC unit and which spray water onto the interior surface of the air conditioner compressor unit condenser coils ( 1 ) and thus cool the evaporative coolant fluid in an energy efficient manner to liquefy the evaporative coolant fluid contained in the air conditioner compressor unit condenser coils ( 1 ) from a gaseous state to a liquid state. Element  9  shows the drain valve to empty unused water from the piping ( 7 ) and spray nozzles ( 8 ) after the spraying cycle is complete. 
     EXAMPLE 1 
     A commercial air conditioning condenser unit was utilized to evaluate the performance of the present invention. In the first evaluation, the performance of the air conditioner condenser unit was operated without the elements of the present invention and, secondly and thirdly, with the elements of the present invention installed and operational. The conditions at the time each test was conducted were: Outside air temperature of 84 degrees Fahrenheit and Relative Humidity of 41%. 
     In the first series of tests in the which the elements of the present invention were not operational, the following information was obtained: During steady-state operation, the temperature of the air entering the air conditioner condenser unit was 84 degrees Fahrenheit and the relative humidity was 41%, and the temperature of the air exiting the air conditioner condenser unit was 101 degrees Fahrenheit. The electrical measurements during steady-state operation were 13.9 Amperes of current in each of the three “legs” of the electric power supply and the line voltage was 207.3 volts. The air conditioner coolant vapor and liquid exhibited pressure values of 235 psig and 74 psig, respectively. 
     In the second series of tests in which the elements of the present invention were operational, the following information was obtained: During steady-state operation, the temperature of the air entering the air conditioner condenser unit ( FIG. 1 , No.  2 ) was 84 degrees Fahrenheit and the Relative Humidity was 41%, and the temperature of the air exiting the air conditioner condenser unit ( FIG. 1 , No.  2 ) was 90 degrees Fahrenheit. The electrical measurements during steady-state operation were 13.3 Amperes of current in each of the three “legs” of the electric power supply and the line voltage was 207.1 volts. The air conditioner coolant vapor and liquid exhibited pressure values of 212 psig and 72 psig, respectively. The number of water spray nozzles ( FIG. 1 , No.  8 ) utilized during this test was 6. Each water spray nozzle ( FIG. 1 , No.  8 ) delivered approximately 9 fluid ounces of water per minute to the air conditioner compressor unit condenser coils ( FIG. 1 , No.  1 ) of the air conditioner condenser unit ( FIG. 1 , No  2 ). The temperature of the water delivered to the water spray nozzles ( FIG. 1 , No.  8 ) was 88 degrees Fahrenheit. 
     In the third series of tests in which the elements of the present invention were operational, the following information was obtained: During steady-state operation, the temperature of the air entering the air conditioner condenser unit ( FIG. 1 , No.  2 ) was 84 degrees Fahrenheit and the Relative Humidity was 41%, and the temperature of the air exiting the air conditioner condenser unit ( FIG. 1 , No.  2 ) was 90 degrees Fahrenheit. The electrical measurements during steady-state operation were 13.3 Amperes of current in each of the three “legs” of the electric power supply and the line voltage was 206 volts. The air conditioner coolant vapor and liquid exhibited pressure values of 215 psig and 66 psig, respectively. The number of water spray nozzles ( FIG. 1 , No.  8 ) utilized during this test was 8. Each water spray nozzle ( FIG. 1 , No.  8 ) delivered approximately 9 fluid ounces of water per minute to the air conditioner compressor unit condenser coils ( FIG. 1 , No.  1 ) of the air conditioner condenser unit ( FIG. 1 , No.  2 ). The temperature of the water delivered to the water spray nozzles ( FIG. 1 , No.  8 ) was 88 degrees Fahrenheit. 
     EXAMPLE 2 
     A residential air conditioning condenser unit was utilized in a manner similar to the above Example 1. 
     In the first evaluation, the performance of the air conditioner condenser unit was operated without the elements of the present invention and, secondly and thirdly, with the elements of the present invention installed and operational. The conditions at the time each test was conducted were: Outside air temperature of 91 degrees Fahrenheit and Relative Humidity of 38%. 
     In the first series of tests in the which the elements of the present invention were not operational, the following information was obtained: 
     During steady-state operation, the temperature of the air entering the air conditioner condenser unit was 91 degrees Fahrenheit and the relative humidity was 38%, and the temperature of the air exiting the air conditioner condenser unit was 113 degrees Fahrenheit. The electrical measurements during steady-state operation were 17.5 Amperes of current and the line voltage was 238 volts (4165 watts) (service rated as single phase with 240 volts). The air conditioner coolant vapor and liquid exhibited pressure values of 185 psig and 70 psig, respectively. 
     In the second series of tests in which the elements of the present invention were operational, the following information was obtained: During steady-state operation, the temperature of the air entering the air conditioner condenser unit ( FIG. 1 , No.  2 ) was 91 degrees Fahrenheit and the Relative Humidity was 38%, and the temperature of the air exiting the air conditioner condenser unit ( FIG. 1 , No.  2 ) was 97 degrees Fahrenheit. The electrical measurements during steady-state operation were 13.5 Amperes of current and the line voltage was 238 volts (3123 watts) (service rated as single phase with 240 volts). The air conditioner coolant vapor and liquid exhibited pressure values of 160 psig and 72 psig, respectively. The number of water spray nozzles ( FIG. 1 , No.  8 ) utilized during this test was 6 which may direct the water outwards from the center. Each water spray nozzle ( FIG. 1 , No.  8 ) delivered approximately 9 fluid ounces of water per minute to the air conditioner compressor unit condenser coils ( FIG. 1 , No.  1 ) of the air conditioner condenser unit ( FIG. 1 , No.  2 ). The temperature of the water delivered to the water spray nozzles ( FIG. 1 , No.  8 ) was 78 degrees Fahrenheit. 
     In the third series of tests in which the elements of the present invention were operational, the following information was obtained: During steady-state operation, the temperature of the air entering the air conditioner condenser unit ( FIG. 1 , No.  2 ) was 99 degrees Fahrenheit and the Relative Humidity was 43%, and the temperature of the air exiting the air conditioner condenser unit ( FIG. 1 , No.  2 ) was 102 degrees Fahrenheit. The electrical measurements during steady-state operation were 14.4 Amperes of current and the line voltage was 239 volts (3442 watts) (service rated as single phase with 240 volts). The air conditioner coolant vapor and liquid exhibited pressure values of 158 psig and 68 psig, respectively. The number of water spray nozzles ( FIG. 1 , No.  8 ) utilized during this test was 4 which may be directed outwards and which may be substantially centered with respect to the external walls of the air conditioner. Each water spray nozzle ( FIG. 1 , No.  8 ) delivered approximately 9 fluid ounces of water per minute to the air conditioner compressor unit condenser coils ( FIG. 1 , No.  1 ) of the air conditioner condenser unit ( FIG. 1 , No.  2 ). The temperature of the water delivered to the water spray nozzles ( FIG. 1 , No.  8 ) was 78 degrees Fahrenheit. 
     There are numerous spray patterns which may be employed with the present invention. For example,  FIG. 2  illustrates a substantially rectangular spray pattern  201  which may be formed from the spray nozzle  8 . 
       FIG. 3  illustrates a conical spray pattern  301  from the spray nozzle  8 . 
       FIG. 4  illustrates a flat spray pattern  401  from the spray nozzle  8 . 
       FIG. 5  illustrates that the angle “a” of the spray pattern is approximately 90°. 
       FIG. 6  illustrates that the angle “b” of the spray pattern is approximately 150°. 
     Operation: 
     In operation, the present invention may be suited for application to commercial building and residential housing unit HVAC systems through the connection of the placement of the water spray nozzles ( FIG. 1 , No.  8 ) in the interior of the HVAC unit where water is sprayed outwards upon the interior side of the air conditioner compressor condenser coils ( FIG. 1 , No.  1 ) and which provides an energy efficient manner by which to convert the evaporative coolant fluid from a gaseous state to a liquid state, said water spray nozzles ( FIG. 1 , No.  8 ) may be supplied with a fluid such as water or other appropriate fluid via piping ( FIG. 1 , No.  7 ) from the fluid (water) supply ( FIG. 1 , No.  4 ), and said water being delivered from the water supply ( FIG. 1 , No.  4 ) through the piping ( FIG. 1 , No.  7 ) to the water spray nozzles ( FIG. 1 , No.  8 ) and controlled by an electrically-actuated solenoid valve ( FIG. 1 , No.  6 ) which is supplied with electricity from the electrical supply to the HVAC air conditioner compressor unit fan ( FIG. 1 , No.  5 ). The electrically-actuated solenoid valve ( FIG. 1 , No.  6 ) controls the flow of water to the water spray nozzles ( FIG. 1 , No.  8 ) from the water supply ( FIG. 1 , No.  4 ) by permitting the flow of water to the water spray nozzles ( FIG. 1 , No.  8 ) during the time period when the HVAC system which utilizes the present invention is actually operating; thus, neither water nor electrical energy is used when the HVAC system is not operational. 
     Furthermore, the present invention may be the only apparatus currently known in the industry which is capable of dramatically decreasing the use, and thereby the cost, of electrical energy to cool commercial buildings and residential housing units utilizing HVAC systems that utilize an evaporative coolant fluid which exists in the air conditioner compressor condenser coils in a gaseous state and should be converted to a liquefied state to function as a cooling agent while concurrently making said HVAC systems provide cool air to said commercial buildings and residential housing units which is of the same or lower temperature than currently-utilized industry standard HVAC systems without the present invention installed therein. 
     Additionally, the present invention may be the only apparatus currently known which incorporates an automatically operating drain valve to empty any unused water remaining in the piping ( FIG. 1 , No.  7 ) and the water spray nozzles ( FIG. 1 , No.  8 ) at the termination of each and every operating cycle of the HVAC unit. This is a helpful element of the present invention for use of the same in HVAC-use areas where temperatures below the freezing point of water are encountered. Furthermore, the automatic draining of unused water from the system reduces the system maintenance requirements. The drained water may be reused in order to conserve the amount of water actually used. 
     While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the invention to the particular forms disclosed.