Evaporative fluid cooling apparatuses and methods thereof

• US 10,208,986 B2
• Filed: 01/15/2016
• Issued: 02/19/2019
• Est. Priority Date: 01/15/2016
• Status: Active Grant

• Current Assignee: Great Source Innovations LLC
• Original Assignee: Great Source Innovations LLC
• Inventors: McDonnell, Gerald, Cheesman, Jeffrey
• Primary Examiner(s): Febles, Antonio R
• Application Number:
  US14/997,057
• Publication Number:
  US 20170205093A1
• Time in Patent Office: 1,131 Days
• CPC Class Codes: F24F 11/79 for controlling the direction of the supplied air
• CPC Class Codes: F24F 13/14 built up of tilting members, e.g. louvre
• CPC Class Codes: F24F 13/20 Casings or covers
• CPC Class Codes: F24F 13/30 Arrangement or mounting of heat-exchangers
• CPC Class Codes: F24F 5/0035 using evaporation
• CPC Class Codes: F25B 1/00 Compression machines, plants or systems with non-reversible cycle F25B3/00, F25B5/00, F25B6/00, F25B7/00, F25B9/00 take precedence
• CPC Class Codes: F25B 13/00 Compression machines, plants or systems, with reversible cycle defrosting cycles F25B47/02
• CPC Class Codes: H05K 7/20827 within rooms for removing heat from cabinets, e.g. air conditioning devices
• CPC Class Codes: Y02B 30/54 Free-cooling systems

Abstract

An evaporative fluid cooling apparatus includes a cooling housing, at least two fluid coils, an air movement apparatus, and one or more spray apparatuses. The cooling housing defines a cooling chamber with an air housing input and an air housing output. The fluid coils are positioned in and extend across at least a portion of the cooling chamber in a spaced apart stacked arrangement. One of the fluid coils is positioned closer to the air housing output and has a first fluid input configured to be coupled to a fluid return from one or more air handler devices and a first fluid output coupled to a second fluid input to the other fluid coil. The other fluid coil is positioned closer to the air housing input and has a second fluid output configured to be coupled to a fluid supply to the air handler devices.

Claims

1. A cooling apparatus comprising:

at least one air handler device;

at least two fluid cooling devices positioned in and extending across at least a portion of a cooling chamber in a spaced apart stacked arrangement, one of the fluid cooling devices positioned closer to an air output having a first fluid input coupled to a fluid return from the at least one air handler device and a first fluid output coupled to a second fluid input to the other one of the fluid cooling devices that is positioned closer to an air input with the other one of the fluid cooling devices having a second fluid output coupled to a fluid supply to the at least one air handler device; and

at least one of an air movement apparatus positioned to provide air flow from the air input through the cooling chamber and out the air output when activated or one or more spray apparatuses positioned to spray a fluid on at least one of the at least two fluid cooling devices when activated.

2. The apparatus as set forth in claim 1 further comprising:

a compressor chiller having a first compressor chiller output coupled to the first fluid input of the one of the fluid cooling devices and a second compressor chiller output coupled to the fluid supply to the at least one air handler device;

at least one temperature monitoring device that is configured to monitor a temperature of a fluid at the second fluid output of the other one of the fluid cooling devices;

a first diverter valve apparatus having an input coupled to the first fluid output of the one of the fluid cooling devices, one output coupled to the second fluid input to the other one of the fluid cooling devices, and another output coupled to a first compressor chiller input of the compressor chiller; and

a second diverter valve apparatus having an input coupled to the first fluid output of the other one of the fluid cooling devices, one output coupled to the fluid supply to the at least one air handler device, and another output coupled to a second compressor chiller input of the compressor chiller.

3. The apparatus as set forth in claim 2 further comprising:

an evaporative cooler management computing device coupled to at least the temperature monitoring device and the compressor chiller;

wherein the evaporative cooler management computing device comprises a memory coupled to at least one processor which is configured to be capable of executing programmed instructions comprising and stored in the memory to;

determine when a monitored temperature of the fluid at the second fluid output of the other one of the fluid cooling devices exceeds a first stored threshold temperature; and

engage the compressor chiller to provide additional cooling of at least a portion of the fluid at the second fluid output of the other one of the fluid cooling devices when the monitored temperature is determined to exceed the first stored threshold temperature.

4. The apparatus as set forth in claim 3 wherein the first stored threshold temperature comprises a wet bulb temperature of at least 60 degrees or an ambient temperature of at least 80 degrees.

5. The apparatus as set forth in claim 3 wherein the evaporative cooler management computing device is further coupled to at least the first diverter valve apparatus and the second diverter valve apparatus and wherein the processor is configured to be capable of executing one or more additional programmed instructions comprising and stored in the memory to:

engage the first diverter valve apparatus to divert at least a portion of the fluid at the another output to the compressor chiller when the monitored temperature is determined to exceed the first stored threshold temperature; and

engage the second diverter valve apparatus to divert at least a portion of the fluid at the second fluid output of the other one of the fluid cooling devices to the compressor chiller when the monitored temperature is determined to exceed the first stored threshold temperature.

6. The apparatus as set forth in claim 5 wherein the processor is further configured to be capable of executing one or more additional programmed instructions for the instruction to engage the compressor chiller to provide additional cooling that comprise and are stored in the memory to:

determine an amount the monitored temperature exceeds a first stored threshold temperature; and

adjust the engagement of one or more of the compressor chiller, the first diverter valve apparatus, and the first diverter valve apparatus based on the determined amount the monitored temperature exceeds the first stored threshold temperature.

7. The apparatus as set forth in claim 5 further comprising:

at least one refrigerant cooling device positioned in and extending across at least a portion of the cooling chamber, the at least one refrigerant cooling device having a first refrigerant fluid input coupled to a fluid return from a refrigerant system and a first refrigerant fluid output coupled to a fluid supply to the refrigerant system; and

at least one refrigerant pump coupled to pump refrigerant through the at least one refrigerant cooling device;

wherein the processor is further configured to be capable of executing one or more additional programmed instructions that comprise and are stored in the memory to;

determine when the monitored temperature of the fluid at the second fluid output of the other one of the fluid cooling devices exceeds a second stored threshold temperature; and

engage the at least one refrigerant pump to pump refrigerant through the at least one refrigerant cooling device when the monitored temperature is determined to exceed the second stored threshold temperature.

8. The apparatus as set forth in claim 7 wherein the at least one refrigerant pump further comprises a frictionless pump.

9. The apparatus as set forth in claim 1 further comprising the air movement apparatus positioned to provide air flow from the air input through the cooling chamber and out the air output when activated and the one or more spray apparatuses positioned to spray a fluid on at least one of the at least two fluid cooling devices when activated, wherein the one or more spray apparatuses further comprise:

a collection device positioned to capture the fluid sprayed by the one or more spray apparatuses; and

a recirculation device configured to supply the fluid in the collection device to the one or more spray apparatuses.

10. The apparatus as set forth in claim 1 further comprising:

a cooling housing that defines the cooling chamber with the air input and the air output; and

one or more controllable vents positioned at least between the at least two fluid cooling devices; and

wherein the processor is further configured to be capable of executing one or more additional programmed instructions that comprise and are stored in the memory to;

determine when a monitored temperature of the fluid at the second fluid output of the other one of the fluid cooling devices exceeds a third stored threshold temperature; and

engage one or more of the controllable vents to move to at least a partially open position to provide additional air flow into the cooling chamber when the monitored temperature is determined to exceed the third stored threshold temperature.

11. The apparatus as set forth in claim 10 further comprising

an adjustable barrier positioned in the cooling housing that divides at least a portion of the cooling chamber into at least two regions;

wherein at least one of the fluid cooling devices further comprises at least two separate fluid cooling devices coupled in series, each of the at least two separate fluid cooling devices positioned in and extending across at least a portion of one of the regions in the cooling chamber, one of the at least two separate fluid cooling devices has a first fluid input coupled to a fluid return from the at least one air handler device and the other one of the at least two separate fluid cooling devices has a first fluid output coupled to a second fluid input to the other one of the fluid cooling devices; and

wherein the air movement apparatus is positioned to provide air flow from the air input through the cooling chamber and out the air output when activated and the one or more spray apparatuses is positioned to spray a fluid on at least one of the at least two fluid cooling devices when activated, wherein the air movement apparatus further comprises at least two separate air movement apparatuses each positioned in one of the regions in the cooling chamber to provide air flow from the air housing input through the cooling chamber and out the air housing output when activated.

12. The apparatus as set forth in claim 11 further comprising an evaporative cooler management computing device that comprises a memory coupled to at least one processor which is configured to be capable of executing programmed instructions comprising and stored in the memory to:

control activation and a rate of operation of the at least two separate air movement apparatuses and of the one or more spray apparatuses based on at least one characteristic.

13. The apparatus as set forth in claim 11 wherein the at least the other one of the fluid cooling devices further comprises at least two additional separate fluid cooling devices coupled in series, each of the at least two additional separate fluid cooling devices positioned in and extending across at least a portion of one of the regions in the cooling chamber, one of the at least additional two separate fluid cooling devices has a second fluid input coupled to the first fluid output of the other one of the at least two separate fluid cooling devices and a second fluid output coupled to a fluid supply to the at least one air handler device.

14. A method for making a cooling system, the method comprising:

providing at least one air handler device;

positioning at least two fluid cooling devices in and extending across at least a portion of a cooling chamber in a spaced apart stacked arrangement, one of the fluid cooling devices positioned closer to an air output having a first fluid input coupled to a fluid return from the at least one air handler device and a first fluid output coupled to a second fluid input to the other one of the fluid cooling devices that is positioned closer to an air input with the other one of the fluid cooling devices having a second fluid output coupled to a fluid supply to the at least one air handler device; and

positioning at least one of an air movement apparatus to provide air flow from the air input through the cooling chamber and out the air output when activated or one or more spray apparatuses to spray a fluid on at least one of the at least two fluid cooling devices when activated.

15. The method as set forth in claim 14 further comprising:

coupling a compressor chiller having a first compressor chiller output to the first fluid input of the one of the fluid cooling devices and a second compressor chiller output to the fluid supply to the at least one air handler device;

providing at least one temperature monitoring device that is configured to monitor a temperature of a fluid at the second fluid output of the other one of the fluid cooling devices;

coupling of a first diverter valve apparatus an input to the first fluid output of the one of the fluid cooling devices, one output to the second fluid input to the other one of the fluid cooling devices, and another output to a first compressor chiller input of the compressor chiller; and

coupling of a second diverter valve apparatus an input to the first fluid output of the other one of the fluid cooling devices, one output to the fluid supply to the at least one air handler device, and another output to a second compressor chiller input of the compressor chiller.

16. The method as set forth in claim 15 further comprising:

coupling an evaporative cooler management computing device to at least the temperature monitoring device and the compressor chiller;

wherein the evaporative cooler management computing device comprises a memory coupled to at least one processor which is configured to be capable of executing programmed instructions comprising and stored in the memory to;

determine when a monitored temperature of the fluid at the second fluid output of the other one of the fluid cooling devices exceeds a first stored threshold temperature; and

engage the compressor chiller to provide additional cooling of at least a portion of the fluid at the second fluid output of the other one of the fluid cooling devices when the monitored temperature is determined to exceed the first stored threshold temperature.

17. The method as set forth in claim 16 wherein the first stored threshold temperature comprises a wet bulb temperature of at least 60 degrees or an ambient temperature of at least 80 degrees.

18. The method as set forth in claim 16 wherein the evaporative cooler management computing device is further coupled to at least the first diverter valve apparatus and the second diverter valve apparatus and wherein the processor is configured to be capable of executing one or more additional programmed instructions comprising and stored in the memory to:

engage the first diverter valve apparatus to divert at least a portion of the fluid at the another output to the compressor chiller when the monitored temperature is determined to exceed the first stored threshold temperature; and

engage the second diverter valve apparatus to divert at least a portion of the fluid at the second fluid output of the other one of the fluid cooling devices to the compressor chiller when the monitored temperature is determined to exceed the first stored threshold temperature.

19. The method as set forth in claim 18 wherein the processor is further configured to be capable of executing one or more additional programmed instructions for the instruction to engage the compressor chiller to provide additional cooling that comprise and are stored in the memory to:

determine an amount the monitored temperature exceeds a first stored threshold temperature; and

adjust the engagement of one or more of the compressor chiller, the first diverter valve apparatus, and the first diverter valve apparatus based on the determined amount the monitored temperature exceeds the first stored threshold temperature.

20. The method as set forth in claim 18 further comprising:

positioning in and extending across at least a portion of the cooling chamber the at least one refrigerant cooling device having a first refrigerant fluid input coupled to a fluid return from a refrigerant system and a first refrigerant fluid output coupled to a fluid supply to the refrigerant system; and

coupling at least one refrigerant pump to pump refrigerant through the at least one refrigerant cooling device;

wherein the processor is further configured to be capable of executing one or more additional programmed instructions that comprise and are stored in the memory to;

determine when the monitored temperature of the fluid at the second fluid output of the other one of the fluid cooling devices exceeds a second stored threshold temperature; and

engage the at least one refrigerant pump to pump refrigerant through the at least one refrigerant cooling device when the monitored temperature is determined to exceed the second stored threshold temperature.

21. The method as set forth in claim 20 wherein the at least one refrigerant pump further comprises a frictionless pump.

22. The method as set forth in claim 14 further comprising positioning the air movement apparatus to provide air flow from the air input through the cooling chamber and out the air output when activated and the one or more spray apparatuses positioned to spray a fluid on at least one of the at least two fluid cooling devices when activated, wherein the one or more spray apparatuses further comprise:

a collection device positioned to capture the fluid sprayed by the one or more spray apparatuses; and

a recirculation device configured to supply the fluid in the collection device to the one or more spray apparatuses.

23. The method as set forth in claim 14 further comprising:

providing a cooling housing that defines the cooling chamber with the air input and the air output; and

providing one or more controllable vents located at least between the at least two fluid cooling devices; and

wherein the processor is further configured to be capable of executing one or more additional programmed instructions that comprise and are stored in the memory to;

determine when a monitored temperature of the fluid at the second fluid output of the other one of the fluid cooling devices exceeds a third stored threshold temperature; and

engage one or more of the controllable vents to move to at least a partially open position to provide additional air flow into the cooling chamber when the monitored temperature is determined to exceed the third stored threshold temperature.

24. The method as set forth in claim 23 further comprising

positioning an adjustable barrier in the cooling housing that divides at least a portion of the cooling chamber into at least two regions;

wherein at least one of the fluid cooling devices further comprises at least two separate fluid cooling devices coupled in series, each of the at least two separate fluid cooling devices positioned in and extending across at least a portion of one of the regions in the cooling chamber, one of the at least two separate fluid cooling devices has a first fluid input coupled to a fluid return from the at least one air handler device and the other one of the at least two separate fluid cooling devices has a first fluid output coupled to a second fluid input to the other one of the fluid cooling devices; and

wherein the air movement apparatus is positioned to provide air flow from the air input through the cooling chamber and out the air output when activated and the one or more spray apparatuses is positioned to spray a fluid on at least one of the at least two fluid cooling devices when activated, wherein the air movement apparatus further comprises at least two separate air movement apparatuses each positioned in one of the regions in the cooling chamber to provide air flow from the air housing input through the cooling chamber and out the air housing output when activated.

25. The method as set forth in claim 24 further comprising providing an evaporative cooler management computing device that comprises a memory coupled to at least one processor which is configured to be capable of executing programmed instructions comprising and stored in the memory to:

control activation and a rate of operation of the at least two separate air movement apparatuses and of the one or more spray apparatuses based on at least one characteristic.

26. The method as set forth in claim 24 wherein the at least the other one of the fluid cooling devices further comprises at least two additional separate fluid cooling devices coupled in series, each of the at least two additional separate fluid cooling devices positioned in and extending across at least a portion of one of the regions in the cooling chamber, one of the at least additional two separate fluid cooling devices has a second fluid input coupled to the first fluid output of the other one of the at least two separate fluid cooling devices and a second fluid output coupled to a fluid supply to the at least one air handler device.