Patent Description:
The present application relates generally to liquid desiccant air conditioning systems and, more specifically, to improved panel assembly blocks in such systems facilitating heat and/or moisture transfer between air, heat transfer fluid, and liquid desiccant streams.

<CIT> discloses a three-way heat exchanger that includes a plate block structure that houses a series of membrane plates that cool and dehumidify an air stream flowing there between. Desiccant enters the plate block structure through supply ports, flows across the membrane plates and exits through drain ports. A cooling fluid is supplied through ports, provides a cooling fluid flow inside the membrane plates, and exit through ports.

A three-way heat exchanger for a liquid desiccant air-conditioning system according to the invention is defined in claim <NUM>. The three-way heat exchanger comprises a plurality of panel assemblies for a liquid desiccant air-conditioning system. Each of the panel assemblies comprises a frame, two plates joined to the frame, and microporous sheets on the plates. The frame borders a given space, and includes a liquid desiccant inlet port, a liquid desiccant outlet port, a heat transfer fluid inlet port, and a heat transfer fluid outlet port. Each of the plates has an outer surface and an inner surface. The plates are joined to opposite sides of the frame to define a heat transfer fluid channel in the given space defined by the inner surfaces of the plates and the frame. The heat transfer fluid inlet port and the heat transfer fluid outlet port are in fluid communication with the heat transfer fluid channel. The microporous sheets permit transfer of water vapor therethrough. Each microporous sheet covers the outer surface of a different one of the two plates and defines a liquid desiccant channel between the microporous sheet and the outer surface of the plate. The liquid desiccant inlet port and the liquid desiccant outlet port are in fluid communication with the liquid desiccant channel. The panel assemblies are stacked such that a microporous sheet on one panel assembly faces a microporous sheet on an adjacent panel assembly and defines an airflow channel therebetween. The liquid desiccant inlet ports of the panel assemblies are aligned to form a liquid desiccant inlet manifold. The liquid desiccant outlet ports of the panel assemblies are aligned to form a liquid desiccant outlet manifold. The heat transfer fluid inlet ports of the panel assemblies are aligned to form a heat transfer fluid inlet manifold. The heat transfer fluid outlet ports of the panel assemblies are aligned to form a heat transfer fluid outlet manifold.

According to the invention, a method for manufacturing a three-way heat exchanger for a liquid desiccant air-conditioning system is defined in claim <NUM>. The method includes the steps of manufacturing each of a plurality of panel assemblies and arranging the panel assemblies in a stack to form the heat exchanger. The panel assemblies are manufactured by: (i) covering an outer surface of each of two plates with a microporous sheet permitting transfer of water vapor therethrough, such that a liquid desiccant channel is defined between each microporous sheet and the outer surface of each plate; and (ii) joining the two plates to opposite sides of a frame. The frame borders a given space. The frame includes a liquid desiccant inlet port, a liquid desiccant outlet port, a heat transfer fluid inlet port, and a heat transfer fluid outlet port. The plates each have an inner surface opposite the outer surface, and the plates are joined to the opposite sides of the frame to define a heat transfer fluid channel in the given space defined by the inner surfaces of the plates and the frame. The heat transfer fluid inlet port and the heat transfer fluid outlet port are in fluid communication with the heat transfer fluid channel. The liquid desiccant inlet port and the liquid desiccant outlet port are in fluid communication with the liquid desiccant channel. The panel assemblies are arranged in a stack such that one of the microporous sheets on one panel assembly faces one of the microporous sheets on an adjacent panel assembly and defines an airflow channel therebetween. The liquid desiccant inlet ports of the panel assemblies are aligned to form a liquid desiccant inlet manifold, and the liquid desiccant outlet ports of the panel assemblies are aligned to form a liquid desiccant outlet manifold. The heat transfer fluid inlet ports of the panel assemblies are aligned to form a heat transfer fluid inlet manifold, and the heat transfer fluid outlet ports of the panel assemblies are aligned to form a heat transfer fluid outlet manifold.

<FIG> illustrates an exemplary prior art liquid desiccant air conditioning system as disclosed in <CIT> used in a cooling and dehumidifying mode of operation. A conditioner <NUM> comprises a set of <NUM>-way heat exchange plate structures that are internally hollow. A cold heat transfer fluid is generated in a cold source <NUM> and introduced into the plates. A liquid desiccant solution at <NUM> is flowed onto the outer surface of the plates. The liquid desiccant runs along the outer surface of each of the plates behind a thin membrane, which is located between the air flow and the surface of the plates. Outside air <NUM> is blown between the set of conditioner plates. The liquid desiccant on the surface of the plates attracts the water vapor in the air flow and the cooling water (heat transfer fluid) inside the plates helps to inhibit the air temperature from rising. The treated air <NUM> is introduced into a building space.

The liquid desiccant is collected at the other end of the conditioner plates at <NUM> and is transported through a heat exchanger <NUM> to the liquid desiccant entry point <NUM> of the regenerator <NUM> where the liquid desiccant is distributed across similar plates in the regenerator. Return air, outside air <NUM>, or a mixture thereof is blown across the regenerator plates and water vapor is transported from the liquid desiccant into the leaving air stream <NUM>. An optional heat source <NUM> provides the driving force for the regeneration. A hot heat transfer fluid <NUM> from a heat source can be flowed inside the plates of the regenerator similar to the cold heat transfer fluid in the conditioner. Again, the liquid desiccant is collected at one end of the plates and returned via the heat exchanger to the conditioner. Since there is no need for either a collection pan or bath, the desiccant flow through the regenerator can be horizontal or vertical.

In order for the liquid desiccant to sufficiently completely wet out the membrane, the liquid desiccant is distributed over substantially the full surface of the plate behind the membrane. This can be done through a combination of pressure driven flow of the liquid desiccant through a < <NUM> thick channel with a geometry that ensures that the channel is filled. Resistance to the liquid desiccant flow at the end of the panel can be used to further improve wetting out at a given pressure drop between the liquid desiccant inlet and outlet.

An optional heat pump <NUM> can be used to provide cooling and heating of the liquid desiccant. It is also possible to connect a heat pump between the cold source <NUM> and the hot source <NUM>, which is thus pumping heat from the cooling fluids rather than the liquid desiccant. Cold sources could comprise an indirect evaporative cooler, a cooling tower, geothermal storage, cold water networks, black roof panel that cools down water during the night, and cold storage options like an ice box. Heat sources could include waste heat from power generation, solar heat, geothermal heat, heat storage, and hot water networks.

<FIG> illustrates an exemplary prior art <NUM>-way heat exchanger comprising a set of plate structures stacked in a block as disclosed in <CIT>. A liquid desiccant enters the structure through ports <NUM> and is directed behind a series of membranes as described in <FIG>. The liquid desiccant is collected and removed through ports <NUM>. A cooling or heating fluid is provided through ports <NUM> and runs counter to the air stream <NUM> inside the hollow plate structures, again as described in <FIG> and in more detail in <FIG>. The cooling or heating fluids exit through ports <NUM>. The treated air <NUM> is directed to a space in a building or is exhausted as the case may be. The figure illustrates a <NUM>-way heat exchanger in which the air and heat transfer fluid are in a primarily vertical orientation.

<FIG> schematically illustrates operation of an exemplary prior art membrane plate assembly or structure as disclosed in <CIT>. The air stream <NUM> flows counter to a cooling fluid stream <NUM>. Membranes <NUM> contain a liquid desiccant <NUM> that is falling along the wall <NUM> that contains the heat transfer fluid <NUM>. Water vapor <NUM> entrained in the air stream is able to transfer through the membrane <NUM> and is absorbed into the liquid desiccant <NUM>. The heat of condensation of water <NUM> that is released during the absorption is conducted through the wall <NUM> into the heat transfer fluid <NUM>. Sensible heat <NUM> from the air stream is also conducted through the membrane <NUM>, liquid desiccant <NUM> and wall <NUM> into the heat transfer fluid <NUM>.

<CIT> discloses various membrane plate structures for liquid desiccant air conditioning systems. <CIT> discloses manufacturing methods and details for manufacturing membrane plate structures.

Various embodiments disclosed herein relate to improved panel assemblies that can be stacked into three-way heat exchanger blocks for use in liquid desiccant air-conditioning systems, including in dedicated outdoor air systems (DOAS). The panel assemblies improve heat exchanger performance by enabling more uniform air and heat transfer fluid flows via more uniformly consistent air channels and heat transfer fluid distribution manifolds. Product life expectancy is also increased for various reasons, including that glue bonds are replaced with laser heat welds in accordance with one or more embodiments. Other direct or indirect heat welds are also possible including induction welding. One advantage of such processes is that the welds do not adversely affect or damage the membrane. In addition, the panel assemblies can be more easily manufactured by eliminating slow robot or manual gluing steps. Such gluing steps are not suited for high-volume manufacturing and increase risks for leaks. Additionally, the improved panel design allows for easy assembly. Furthermore, individual panel assemblies in a block may be easily replaced if needed due to the O-ring construction of the panel assembly block.

<FIG> is an exploded view showing construction of a panel assembly <NUM> in accordance with one or more embodiments. Multiple such panel assemblies are joined in a stacked arrangement to form a three-way heat exchanger block for a liquid desiccant air-conditioning system as will be further described below.

Each panel assembly includes a frame <NUM> circumscribing or bordering a central space <NUM>. Two plates <NUM>, each having inner and outer surfaces, are joined to the frame (e.g., by welding). The inner surfaces of the plates face each other and define a heat transfer fluid channel therebetween in the central space. A netting or mesh <NUM> may be disposed in the heat transfer fluid channel to maintain the heat transfer fluid channel thickness under negative pressure and to cause turbulence in the heat transfer fluid flow.

The frame also includes an inlet open space <NUM> and an outlet open space <NUM> forming channels or manifolds for distributing and collecting liquid desiccant flowing through the panel assembly as will be further described below.

The outer surface of each plate is covered by a microporous sheet or membrane <NUM> permitting transfer of water vapor therethrough. The microporous sheet and the outer surface of the plate define a liquid desiccant channel therebetween.

Multiple panel assemblies are stacked next to or on each other such that a microporous sheet on one panel assembly faces a microporous sheet on an adjacent panel assembly, defining an airflow channel between the microporous sheets.

In accordance with one or more embodiments, the frame includes various built-in features that, among other things, maintain the geometry of the channels to help provide equal fluid flows across a panel and in between panels. The features include ports, standoffs, and corner pieces. The ports facilitate flow of heat transfer fluid through the heat transfer fluid channels and liquid desiccant through the liquid desiccant channels. Having these features on the frame rather than the plates enables a greatly simplified plate design and provides numerous advantages over the prior art panel structures. For example, the plates <NUM> can be flat sheets. In some embodiments, the plates can be covered by dot features, which can be added by thermoforming, embossing, or similar techniques. The dot features cover the plates uniformly, reducing stresses that can lead to warping of the plates. Flatness of the panels impacts the transfer of heat and humidity between the air and the desiccant.

In accordance with one or more embodiments, the frame comprises an injection molded polymer. It may include energy absorbing doping like carbon black (when laser welded) or other absorbing additives or conductive fibers (when RF/induction-welded) as will be described in further detail below.

In accordance with one or more embodiments, the frame has an integral one-piece construction. In accordance with one or more alternate embodiments, the frame comprises multiple separate pieces that are joined together to form the frame structure.

The mesh <NUM> in the heat transfer fluid channel helps to maintain the heat transfer fluid channel thickness, particularly if the panel assembly is run under negative pressure to facilitate flow of the heat transfer fluid.

The plates are covered by the membranes <NUM>, which can be heat sealed to the plates in a pattern to form the desiccant channel between the membrane and the plate. The sealing can be direct if the polymers for the plate and the membrane can be welded, e.g., if they are both polyolefins. A cap layer can be added to the plate prior to welding to improve the quality or ease of formation of the heat weld.

<FIG> is an interior view of a panel assembly <NUM> in accordance with one or more embodiments showing the frame with features exaggerated in size for purposes of illustration. The features include ports <NUM>, <NUM>, <NUM>, <NUM> and spacers or standoffs <NUM>. <FIG> also shows weld lines <NUM>, <NUM>, <NUM> for connecting the frame to the plates. The weld lines <NUM> define and form the heat transfer fluid channel. The weld lines <NUM>, <NUM> form channels through which a liquid desiccant is distributed and collected, respectively, in the panel assembly. Openings <NUM> in each of the plates shown in <FIG> are exaggerated in size in <FIG> for purposes of illustration. These openings are aligned with the upper and lower open spaces <NUM>, <NUM> formed in the frame.

The frame can be injection molded with high stability and reliability and minimal warp. The frame defines the height of the heat transfer fluid channel. It also provides rigidity to the panel assembly. The frame is dimensioned to allow use of injection molding to manufacture the frame, which enables precisely defined features.

It is advantageous to locate the features on the frame rather than the plates. Injection molding the features in the plates is difficult given that the plate should be thin (preferably < <NUM> for a <NUM>-<NUM> panel) to reduce heat resistance between the heat transfer fluid and the air. The thermal resistance of the panel directly drives the approach temperature and thus the effectiveness of the heat exchanger.

The frame can be precisely formed using injection molding to construct high performance panels. For instance, the dimensions of frame can be controlled within less than <NUM>. Flatness of the whole structure can be controlled to within a few mms across the full panel (e.g., covering an area of about <NUM> square feet). The frame incorporates all features needed to connect the panels together and to do that with high accuracy and reliability. This enables the plates to therefore have a simple design, which is suitable for thermoforming and which minimizes stresses during thermoforming.

The liquid desiccant ports <NUM> and <NUM> are connected to the liquid desiccant inlet and outlet channels or manifolds <NUM>, <NUM>, respectively. The desiccant enters the inlet desiccant channel <NUM> via micro channels <NUM>. The die cut holes <NUM> in plates at the desiccant manifold provide a pathway for the liquid desiccant between the thermoformed plates and the membrane and exit via die cut holes <NUM> in the plates back to the liquid desiccant channel <NUM> between the plates. Micro channels <NUM> connect the outlet channel <NUM> to the port <NUM>.

The heat transfer fluid ports <NUM>, <NUM> are connected to the heat transfer fluid channel <NUM> between adjacent plates by channels <NUM>, <NUM>.

Netting <NUM> is inserted in the heat transfer fluid channel to enable more constant heat transfer fluid flow rates along all paths between ports <NUM>, <NUM>, provide a generally uniform flow distribution between panels and maintain heat transfer fluid channel height. The netting also provides turbulation of the heat transfer fluid to increase heat transfer. A wide variety of netting materials may be used. For example, the netting may comprise the same polymer material as the plates (e.g., polypropylene, polyethylene, and Acrylonitrile butadiene styrene (ABS)).

An O-ring or gasket <NUM> at each of the ports creates a seal between adjacent panel assemblies. In accordance with one or more embodiments, the panel assemblies are pulled together using bolts extending through the holes <NUM> surrounding the ports and secured with nuts. The bolts create sufficient tension compression to ensure leak-free connections at the O-rings or gaskets <NUM>.

The desiccant and heat transfer fluid ports <NUM>, <NUM>, <NUM>, <NUM> are shown at the side of the panel assembly block extending into the path of the airflow. As a result, the micro channels <NUM>, <NUM> are substantially horizontal. This provides enough space for having injection molded moveable pins in the inlet and outlet desiccant channels in the frame and in the heat transfer fluid channel. The movable pins create the micro channels in the frame during injection molding. Locating the ports at their particular locations reduces panel width, increases the air path, and allows for different housing designs. The form factor of the panel structure can be a significant design consideration and it will be understood by those skilled in the art that several design options are possible. Given the wide range of applications for the panels, from transportation to industrial and residential, being able to change the form factor of the panel may be important to enable cost effective solutions.

The standoffs or spacers <NUM> set and maintain the separation between adjacent panel assemblies defining the height of the air channel preferably to within a tolerance of <NUM> to <NUM>.

The plates can be welded to the frame using, e.g., RF welding or laser welding via paths <NUM>, <NUM>, <NUM>.

Examples of suitable microporous membranes are disclosed in <CIT>, which is incorporated by reference herein. By way of example, suitable commercially available membranes can include membranes used in batteries. In one exemplary embodiment, the membranes have <NUM>-<NUM>% openness and pore sizes of less than <NUM> micron, and a thickness of less than <NUM> microns. In one exemplary embodiment, the membrane is the EZ2090 polypropylene, microporous membrane from Celgard. The membrane is approximately <NUM>% open area and has a typical thickness of about <NUM>. This type of membrane is structurally very uniform in pore size and is thin enough to not create a significant thermal barrier. Other possible membranes include membranes from <NUM>, Lydall, and other manufacturers.

<FIG> is a side view of the panel structure illustrating the use of the standoffs <NUM> in setting channel heights and ports, which define the thickness of the air channel <NUM> between two stacked panel assemblies <NUM>.

The corners of the frame each include an angled part <NUM> (shown in <FIG>), including the heat transfer fluid channel to the ports <NUM>, <NUM>. The angled part also helps keep the netting <NUM> in place, intentionally blocking the top and bottom of the heat transfer fluid channel. The vertical areas <NUM> remain open. Heat transfer fluid first flows into these areas <NUM> and then moves in a direction perpendicular to the vertical areas <NUM> across the plate. In one exemplary embodiment, this structure causes the heat transfer fluid to flow through the netting in a direction counter to the air direction.

In accordance with one or more embodiments, the panel structure is oriented to allow for vertical desiccant flow combined with vertical air and heat transfer fluid flows. In one or more embodiments, the panel structure is oriented for horizontal air and heat transfer fluid flows, but vertical desiccant flow. In one or more alternate embodiments, the panel structure is oriented for horizontal desiccant, air, and heat transfer fluid flows. The seal strength can be designed to allow for pressurized rather than mostly gravity driven desiccant flow.

<FIG> schematically illustrates an exemplary formed plate <NUM> for use in a panel assembly in accordance with one or more embodiments. The plate <NUM> has a significantly simplified structure compared to prior art plate designs. In accordance with one or more exemplary embodiments, the plate is made out of thinly extruded (< <NUM> thick) polymers, which could, e.g., be polypropylene, polyethylene, ABS and many other polymers. Additives that improve conductivity can allow for thicker and thus stiffer plates. The plates can be thermoformed, embossed, or alternatively created through injection molding with a pattern of raised features <NUM> to which a membrane <NUM> can be heat sealed. The membrane is also sealed around the flat outer border <NUM> of the plate. One objective is to create a desiccant channel with an average height of less than <NUM> that can ensure that the desiccant flows over the panel at a velocity of less than <NUM>/min. The actual velocity depends on viscosity and thus on desiccant concentration and temperature as well as pressure.

The plate includes die cut holes <NUM> (shown in <FIG> to be exaggerated in size for purposes of illustration) on top and on the bottom that allow desiccant to enter and exit the panel via the desiccant ports <NUM>, <NUM> from the desiccant manifolds <NUM>, <NUM> behind the plates.

<FIG> schematically illustrates how the frame and plates can be welded together. A panel assembly is comprised of the frame <NUM> and two thermoformed plates <NUM>. A membrane <NUM> is heat-sealed to the thermoformed plates at raised dots or lines <NUM>. The height of the feature <NUM> determines the height of the desiccant channel <NUM>. The membrane <NUM> is microporous, allowing the desiccant in the channel <NUM> to absorb or desorb humidity from the air in the air channel <NUM> in-between panels. These membranes can be extremely thin and open with thicknesses of less than <NUM> micron and openness well over <NUM>%, as discussed above.

The plates can have a cap layer to improve the seal with the membrane. However, direct sealing of membrane to the plate is possible, particularly if they are made with a suitable combination of polyolefins.

Sealing the frame and the thermoformed plates together creates a desiccant channel with die cut holes <NUM> that allow the desiccant in manifold <NUM> to enter or exit the desiccant channel <NUM>.

Before sealing the thermoformed plates to the frame, netting <NUM> is inserted in the heat transfer fluid channel <NUM>. With heat transfer fluid pulled through the channel at negative pressure, the netting <NUM> sets the height of the heat transfer fluid channel. To allow the heat transfer fluid to be transferred through the heat transfer fluid channel under positive pressure, the netting <NUM> would need to be fixed and preferably welded to the thermoformed plate <NUM>.

The sealing of the thermoformed plates <NUM> to the frame <NUM> is done at weld lines <NUM> using induction, RF, laser, or other welding techniques that can preferably heat material at a location away from the welding tool and thus away from the membrane <NUM>. The welds <NUM> can be the same as lines <NUM>, <NUM>, <NUM> in <FIG>. In the case of laser welding, a wavelength is selected for the tool for which the membrane and thermoformed materials are transparent, but which can be absorbed by the frame. Absorption of the laser energy by the frame can be achieved by adding carbon to otherwise transparent polymers like polypropylene or by using polymers that are natural absorbers at that frequency. Alternatively, fibers can be added to the frame to facilitate RF welding, which can enable welding complete blocks rather than individual panel assemblies. The frame should be heated close to the plate, but away from the membrane, which needs to be separated from the plate by a space equal to the height of the desiccant channel <NUM>.

As shown in <FIG>, the injection molded frame <NUM> has various features that support the building of a panel assembly stack with defined air gaps <NUM> between adjacent panel assemblies. <FIG> shows a corner with two panel assemblies around a port <NUM>. Each panel assembly has two sheets <NUM>. The corner is shown with an O-ring <NUM> to provide a leak free connection between the panel assemblies, rather than a gasket or a welded connection. One skilled in the art would understand that a variety of connection methods could be used. The cost effectiveness of various connection methods depends on volumes and the usage of the parts. For example, O-rings give greater flexibility and thus shock resistance to a stack of panel than a corner welded connection. The panel assemblies can have a precise definition with low tolerances for the air gap <NUM>. This enables generally equal air distribution, which significantly improves performance. The features include corner features <NUM> around the desiccant and heat transfer fluid manifolds formed by connected ports <NUM> of panel assemblies. The corners can include a feature <NUM> to receive O-rings <NUM>. Alternatively, features can be added to allow heat sealing at the corners <NUM> using, e.g., laser, induction or RF welding. Together with the standoffs <NUM>, they ensure that the height of the panel is generally uniform not just between panels but along the entire length of the panels.

Moving these features away from the formed plates <NUM> to the frame <NUM> significantly reduces the complexity of the plates <NUM>. By reducing complexity and ensuring uniformity across the plate, stresses are generally minimized, improving the flatness of the formed plate <NUM>. An injection molded frame <NUM> is able to maintain accuracy of features within <NUM>, a significant improvement over the replicability of similar features previously integrated into the prior art thermoformed plates.

The core of the plates <NUM> is flat to facilitate the accurate sealing of the plates <NUM> to the frame at <NUM>, ensuring a strong and consistent seal.

The liquid desiccant panel assemblies in accordance with various embodiments provide several technical advantages over the prior art, including the following.

In one or more embodiments, the fluid passageways into heat transfer fluid and desiccant channels from the main manifolds at the ports provide flow restriction enabling better panel-to-panel desiccant and heat transfer fluid flow distribution within a block assembly. The fluid passageways are sized for manufacturability via injection molding, provide desired fluid pressure drops, and have sufficient strength for the laser-welding.

Controlling the air spaces between panel assemblies via the air separator standoffs <NUM> improves panel-to-panel air distribution and uniformity of the air gap <NUM>, thereby improving efficiency as well as stack rigidity.

In one or more embodiments, the heat transfer fluid and the desiccant each have only one entry port and one exit port to reduce number of fluid seals and required connections, reducing manufacturing complexity and improving reliability.

In one or more embodiments, the netting or mesh <NUM> in the heat transfer fluid channel <NUM> is free-floating with keyed features, which eliminate any mechanical stresses due to thermal expansion, while ensuring optimal flow distribution within and between panels by defining fluid resistance. The mesh <NUM> defines the heat transfer fluid channel thickness under negative heat transfer fluid pressure ensuring that mesh determines heat transfer fluid and thus air channel thickness and consistency. The mesh <NUM> also improves panel rigidity during high airflow.

Having certain features on the thermoplastic frame <NUM> instead of on the plates <NUM> allows for plastic welding, fluid delivery, heat transfer fluid channel formation, and uniform air gaps when panel assemblies are stacked. A laser transparent thermoformed plate <NUM> with dot features <NUM> and subsequently heat-sealed membrane <NUM> is laser-welded to the frame <NUM>. The frame <NUM> may be comprised of a thermoplastic with laser-absorbing additive. Sequencing limits weld formation to the thermoform/frame interface, avoiding heat-sealing of the membrane <NUM> to the thermoform at critical locations. The thickness of the corner feature <NUM> sets the air gap after assembly with O-rings <NUM>.

In one or more embodiments, the plate thermoforms <NUM> are fabricated from a transparent thermoplastic with raised dots <NUM> that define the desiccant channel <NUM> height, helping ensure a uniform distribution of desiccant. The semipermeable membrane <NUM>, which also has suitable laser transmissivity (e.g., at <NUM> or <NUM>) is heat sealed to the thermoform plates <NUM>, either directly to the thermoform plate <NUM> or to an optional lower-melting cap layer thereon. The frames <NUM> may be fabricated from a thermoplastic with carbon black doping or other laser-absorbing additive. The mesh plate or other heat transfer fluid turbulator plate <NUM> is inserted in center of the frame <NUM>. The thermoform plate <NUM> is laser welded with the heat-sealed membrane <NUM> to the frame <NUM> on one side, followed by another thermoform plate <NUM> to the opposite side of the frame <NUM>. The mesh or heat transfer fluid turbulator <NUM> is enclosed in the interior. The so formed panel assembly <NUM> is then ready for stacking with other panel assemblies into a block assembly via O-rings <NUM>.

In accordance with one or more embodiments, the set of stacked panel assemblies <NUM> is supported in a housing structure to form a plate assembly block. It is desirable that the housing and connections around the panel assembly stack not be bulky. A bulky housing can substantially increase the size of liquid desiccant system and create form factors that are different from existing units built around desiccant wheels, coils, plate heat exchangers etc. It is also desirable not to have connections positioned to multiple sides of the block, which can make installation difficult and time consuming. It is desirable to allow all maintenance to be performed from one side of the block, which would reduce the space needed for the unit. It is desirable for the units to be manufactured by commercial production processes. The units should pass UL fire resistance as well as other tests, including transportation, vibration, and handling tests, and be able to withstand both very high and very low transportation and storage temperatures that can significantly exceed operational conditions. It is desirable for the units to be designed for safe handling, e.g., to discourage picking up the modules at potential breakpoints like manifolds. Material costs and the time needed to build the housing impact manufacturing costs significantly, and as panel production costs drop, the cost of housing becomes relatively more important. It is therefore desirable to for the housing to be inexpensively built.

<FIG> illustrates an exemplary panel assembly block <NUM> comprising a set of stacked panel assemblies <NUM> enclosed in a housing structure <NUM> in accordance with one or more embodiments.

<FIG> is an exploded view illustrating another exemplary housing structure <NUM> for the panel assembly block in accordance with one or more embodiments. The housing structure <NUM> includes a plurality of housing plates <NUM>, <NUM>, <NUM>, <NUM> covering opposite sides and the top and bottom of the stacked panel assembly. The front and back of the stacked panel assembly are only partially covered by housing panels <NUM> to permit airflow through the unit. A metal filter <NUM> may be secured to the front side of the housing using clamps <NUM>.

The housings for the panel assemblies are designed for use in various liquid desiccant air conditioning systems, including in Dedicated Outside Air Systems (DOAS) for commercial buildings. The life of these units is significantly lower than the life of the buildings in which the units are installed, which can lead to several replacements of HVAC units. Therefore, it would be desirable for a housing design that can be used as a drop-in for existing units.

Similar panel assembly blocks can be used in other air handlers for commercial systems as well as for humidity control in industrial applications. Similar panel assembly blocks can also be used in multi-dwelling residential units, which may be smaller with different form factors.

In accordance with one or more embodiments, the panel assembly blocks are sized for one- or two-man handling and fast low-cost shipping for replacement.

The housing structure for the panel assemblies provides sealing and pathways for process air while it is treated (e.g., cooled and dehumidified) in the conditioner. A similar housing structure can be used for the regeneration panel assembly block where the liquid desiccant is treated (e.g., reconcentrated using heat).

In accordance with one or more embodiments, the panel assembly blocks for conditioning and regeneration can be identical. In some embodiments, the blocks are different, e.g., if insulation is required in the regenerator or if the regenerator unit is located separately or has different fire safety requirements. The blocks can be used without insulation, e.g., when located in conditioned or regeneration air stream.

In accordance with one or more embodiments, connections for heat transfer fluid and liquid desiccant are located on only one side of the unit to permit easier installation.

The O-rings <NUM> between adjacent panel assemblies enable easy assembly and disassembly of the block unit.

The housing is configured such that the clamps <NUM> that latch onto the metal filter <NUM> can be used for attachment to a plenum divider wall <NUM>, which separates the block inlet air stream from the exit air stream as shown in <FIG>. The metal filter <NUM> sits between the incoming air and the block. The block itself is positioned inside the treated air to minimize loss.

On the bottom side <NUM> of the housing structure, a break <NUM> in the air seal is made to allow for any condensation or desiccant to be collected. The break in the air seal is at the airflow exit end of the block so that any air leaking through this path has gone through the most of the active area of the panels before exiting. The bottom of the housing has a foam air seal layer to close off the air channels. In case of a membrane or heat transfer fluid channel leak, the desiccant or heat transfer fluid will collect at the bottom of the panel from where it flows through a hole back into a desiccant tank. To prevent it from flowing into the duct, an exit <NUM> is created that allows the desiccant to pass from the panel to a space inside the housing from where it flows through a tube back into the main desiccant system. A small amount of air might escape through this path, which is why it is located near the end of the block where any leaked air will have been substantially already processed.

The liquid desiccant or condensate can either be collected in a separate container or recirculated back into the system. The desiccant can be collected in a container under the block from the desiccant purge in the block. Alternatively, it can flow back into the desiccant tank. This is preferably done only if the desiccant quality is not affected.

To construct a panel assembly block, the panel assemblies <NUM> are first assembled into a stack with the heat transfer fluid ports and liquid desiccant ports of each of the panel assemblies aligned to form heat transfer fluid and liquid desiccant port manifolds, respectively.

The tension bolts <NUM> are passed through the housing and the panel assemblies and are subsequently tightened. The tension bolts <NUM> press the corners of the panel assemblies together. The pressure ensures a sufficient seal with the O-rings <NUM> in the panel corners. The O-ring structure allows the panel assemblies to absorb the impact of shocks and drops by providing some flexibility unlike, e.g., a welded part that could break in the process. Flat gaskets could be used instead of O-rings, assuming the panels are sufficiently flat. Alternatively, the seals between the panels that create the port manifolds can be formed through induction welding or RF welding, e.g., by incorporating RF receptors in the form of fibers or extra parts in the corners themselves.

The housing structure can be configured for a variety of directions of air, liquid desiccant, and heat transfer fluid flows as illustrated in <FIG>. The panel blocks may be configured for vertical, horizontal upright, and horizontal flat airflow. In a vertical airflow panel, the air and desiccant can flow down, while the heat transfer fluid flows up. In an upright panel with horizontal airflow, the desiccant can still flow down from top to bottom but the air is fed in horizontally. The heat transfer fluid can run counterflow to the air.

In one or more embodiments, the panel blocks can be configured as in-ceiling units and other flat units the panels can be put down in an essentially horizontal position, with the air, heat transfer fluid, and the desiccant all flowing horizontally. Heat transfer fluid and desiccant flows can be all horizontal, all vertical, or both depending on what is needed meet form factor requirements at optimal performance. Liquid desiccant flow may be pressure and/or gravity driven flow.

In the <FIG> embodiment, the air flow is horizontal, the liquid desiccant flow is vertical, and the heat transfer fluid flow is also vertical (and preferably in counterflow to the liquid desiccant flow). In the <FIG> embodiment, all the flows are horizontal with heat transfer fluid in counterflow to the air flow. The liquid desiccant flow can run either counterflow or crossflow to the airflow, depending on the form factor of the panel. It will be understood to those skilled in the art that other flow arrangements like vertical airflow with parallel liquid desiccant and counterflow heat transfer fluid flow are also possible, especially if desiccant flow is driven by pressure rather than gravity.

For a "horizontal flat" panel assembly arrangement, an incline in the panel is desirable to help ensure that any captured air in the heat transfer or desiccant fluids can be removed at the relatively low flow rates inside the panels. The incline can be slight. While flow rates are higher in the ports and manifolds, it is desirable to nevertheless have exits on top or a side of the unit unless form factors for the unit require otherwise, e.g. for ceiling units. Passive draining of the desiccant (and heat transfer fluid) from the unit can be enabled from the lowest point, which tends to be the entry by allowing flow back to the desiccant tank.

The panel assemblies are connected via O-rings or gaskets <NUM>, and the panel assembly stack is kept under compression using tension bars <NUM>. Alignment holes around the manifold port are used to provide consistent alignment of the panel assembly stack. The alignment holes around the manifold ports also inhibit rotation of the connected ports of adjacent panel assemblies.

The features in the housing can be machined in extruded sheets or injection molded. It will be understood by those skilled in the art that other ways of forming the features are also possible.

Extruded housing sheets are lower in cost in smaller quantities but require multiple different cuts and additional piping. Injection molding the parts can significantly reduce the number of parts but involves the high cost of a complex mold. Molding can also provide sufficient stiffness and strength to the housing at lower weights.

In injection molded housing designs, the liquid desiccant and heat transfer fluid passageways can be formed using gas injection molding, such that the cross-sectional area is sufficient to facilitate the required heat transfer fluid and desiccant flow for all of panels in the stack. Clamping on the gas assisted molded housing can be done with the bolts, clamps or ratchets to ensure sufficient pressure to maintain the O-ring seals in the desiccant and heat transfer fluid ports.

As shown in <FIG>, the panel assemblies <NUM> are clamped between housing plates <NUM> and <NUM>. Passageway <NUM> for the liquid desiccant leading to the liquid desiccant ports <NUM>, <NUM> and passageways <NUM> for the heat transfer fluid leading to the heat transfer fluid ports <NUM>, <NUM> are preferably on only one side of the module for ease of connection and maintenance. This also allows the modules to be positioned close to each other, which reduces unit size and allows for plenum air velocities in the supply duct similar to that of current coils and wheels. This enables drop-in replacement as a result of the comparable footprint and total size.

In <FIG>, heat transfer fluid enters through the passageway <NUM> at the bottom of the module and desiccant enters through the passageway <NUM> at the top, while the respective exits are on the opposite side of the housing.

The stack of panels can be hung from clamps to minimize stress and maintain air gaps and panel shape.

Parts <NUM> and <NUM> on the top and bottoms of the module provide air seals around the panel assembly stack, while part <NUM> also contains a drain for any condensate or liquid desiccant leaks back to the desiccant tank or to a separate container.

The housing material and geometry provide a high level of stiffness to maintain block geometry under high stress loads. This in combination with the inner block materials and in particular with O-ring or gasket connections with flexible connections provides resilience to impacts and vibration without damaging critical seals.

Claim 1:
A three-way heat exchanger for a liquid desiccant air-conditioning system, the three-way heat exchanger comprising a plurality of panel assemblies, each panel assembly comprising:
a frame (<NUM>) bordering a given space, the frame (<NUM>) including a liquid desiccant inlet port (<NUM>), a liquid desiccant outlet port (<NUM>), a heat transfer fluid inlet port (<NUM>), and a heat transfer fluid outlet port (<NUM>);
two plates (<NUM>), each having an outer surface and an inner surface, wherein the plates (<NUM>) are joined to opposite sides of the frame (<NUM>) to define a heat transfer fluid channel (<NUM>) in the given space defined by the inner surfaces of the plates (<NUM>) and the frame (<NUM>), wherein the heat transfer fluid inlet port (<NUM>) and the heat transfer fluid outlet port (<NUM>) are in fluid communication with the heat transfer fluid channel (<NUM>); and
two microporous sheets (<NUM>) permitting transfer of water vapor therethrough, each microporous sheet (<NUM>) covering the outer surface of a different one of the two plates (<NUM>) and defining a liquid desiccant channel between the microporous sheet (<NUM>) and the outer surface of the plate (<NUM>), wherein the liquid desiccant inlet port (<NUM>) and the liquid desiccant outlet port (<NUM>) are in fluid communication with the liquid desiccant channel;
wherein the liquid desiccant inlet ports (<NUM>) of the frames (<NUM>) of the panel assemblies are aligned to form a liquid desiccant inlet manifold, the liquid desiccant outlet ports (<NUM>) of the frames (<NUM>) of the panel assemblies are aligned to form a liquid desiccant outlet manifold, wherein the heat transfer fluid inlet ports (<NUM>) of the frames (<NUM>) of the panel assemblies are aligned to form a heat transfer fluid inlet manifold, and the heat transfer fluid outlet ports (<NUM>) of the frames (<NUM>) of the panel assemblies are aligned to form a heat transfer fluid outlet manifold; and
wherein the plurality of panel assemblies have a stacked arrangement such that a microporous sheet (<NUM>) on one panel assembly faces a microporous sheet (<NUM>) on an adjacent panel assembly and defines an airflow channel therebetween.