CONDENSATE EVAPORATOR FOR INDOOR UNIT OF A SPLIT AIR CONDITIONER

[0001]

[0002] The object of our invention is a condensate re-humidification equipment for the indoor unit of a split air conditioning system, for humidification that maintains the air humidity of the room during cooling.

[0003] It is known that when air conditioners are used in cooling mode, they dry the air in the airspace of the room, if there is humidity content. This drying effect can be quite drastic, which can have a negative impact on human health and the built environment, so it is necessary to humidify the airspace during cooling.

[0004]

[0005] Generally, the humidification of air-conditioned rooms is solved with separate hu midifying devices independent of air conditioners, which require a sufficient quality - preferably mineral-free - water supply for their operation. Such equipment is, for example, a product of the Phillips factory, which was presented on the world wide web at the following https://www.philips.hu/c-p/HU4813_10/series-2000-humidifyer site.

[0006]

[0007] A humidifying device connected to fan-coil AC systems is described in patent document KR 100708556 Bl. This equipment delivers filtered and UVC light- disinfected water vapor into the air space of the refrigerated/heated room by evaporating the mains’ water from the connected, purpose-built supply line into the draft generated by the fan of the fan-coil cooling-heating equipment, while the condensate generated during air cooling is normally drained out.

[0008]

[0009] On the world wide web, the https://www.orionairsales.co.uk/daikin-air-conditioning-ftxz 50nvlb-wall-mounted-uru ru-sarara-7-humidification-heat-pump-a-5kwl7000btu-240v50hz- 4809-p.asp availability is the Japanese company Daikin ( Umeda Center Bldg., 2-4-12, Nakazaki- Nishi, Kita-ku, Osaka, 530-8323 Japan) FTXZ25NV1B, FTXZ35NV1B, FTXZ50NV1B, RXZ25NV1B, RXZ35NV1B, RXZ50NV1B series Inverter Split AC product line. In these air conditioners, with the help of an additional device located in the outdoor unit, the humidity of the outdoor air is returned to the air-blowing opening of the indoor unit. The disadvantage of this complex solution, which also requires the construction of an additional pipeline, is that according to the manufacturer's data, up to 450 ml of water can be sprayed per hour, while indoor units of air conditioners can take 600-1200 ml of water from indoor air per hour in cooling mode. Another dis advantage can be mentioned the need to clean the air from the outdoors in several stages, for which additional system elements are required.

[0010] In split-ACs, the draining of the condensate from the system generated in the indoor unit is always taken care of. This is usually handled by leading the liquid into the sewer or directing it to the outdoor unit, and from there it is resolved by dripping it in the outdoors.

[0011] On the world wide web, at https://www.wigam.it/it/prodotto/dissipatore-di-condensa availability is the description of the HYPPO condensate evaporative split AC produced by WIGAM (Loc. Spedale 10/b - 52018 Castel San Niccolo AR). However, this solution is not aimed at humidifying the indoor air, but at "eliminating" condensate as unnecessary waste, without drip and flow, without the use of sewers, where the device equipped with the outdoor unit evaporates condensate from the indoor unit into the open air by the way of boiling with a relatively high demand for electricity con sumption.

[0012] Each of these known solutions replace the loss of humidity in the cooled room with humidity from water that is from external sources outside the split AC.

[0013] Once we have realized that the loss of humidity in rooms air-conditioned by split AC-s during cooling is in the condensate generated in the indoor unit, the airspace’s humidity can be maintained without an external water source by returning the water condensed in cooling mode in the indoor unit. Since we could not find a solution using the water condensed in the indoor unit as a water source among the known solutions, we set the goal of maintaining the air humidity of the rooms air-conditioned with split AC with an equipment that returns the water condensed in the indoor unit during cooling to the air of the room by humidifying it.

[0014]

[0015] The object of our invention is therefore a condensation humidification equipment for a split air conditioner indoor unit for humidification that maintains the air humidity of the room during cooling.

[0016] The resulting equipment according to our invention is based on the recognition that condensate generated in the indoor unit of the split air conditioner can be easily transferred to an evaporation device by gravity, and if that low mineral content condensate is extracted, cleaned and sterilized, it can be used to replace the loss of humidity.

[0017] The condensate evaporation equipment according to our invention has a low-voltage electrical energy source with transformer, minimum water level indicator, maximum water level indicator, evaporation space including water space, water filter insert, air flow sensor, air blower fan and associated air filter insert, air intake opening, vapor flue, floating water level indicator, humidity sensor, bottom plate, On-Off switch, control dial and a cover piece. The equipment is connected to the condensate pipeline of the indoor unit of the split-system air conditioner through a tapping fitting that is connected to an electromagnetically controlled shut-off valve. The condensate pipeline is connected to the inlet of a condensate tank through a condensate collection pipe. The condensate tank is connected to a water space with a supply pipe that can be opened and closed with a supply valve; the water space has ultrasonic evaporators, a maximum water level indicator and a micro-switch. The equipment is also equipped with a UVC light source, a light- sensing transmitter, a condensate sensor placed in the heat exchange fins of the indoor unit and supplied with a controller that controls the ul trasonic evaporators, electromagnetic closing valve, airflow sensor, supply valve, con densation sensor, humidity sensor, UVC light source, transformer, operating indicator light, On-Off switch, water level indicators, blower fan, timer and control dial.

[0018] The equipment is attached to a support bracket in one of its realizations.

[0019] In another realization of the equipment, between the indoor unit of the split air con ditioner and the equipment there is a foam rubber seal and reflective film.

[0020] In another realization of the equipment, UVC resistant reflective film is glued to the inner surfaces of the cover piece, the vapor flue and the airflow guide piece that are il luminated by the UVC light source.

[0021] According to another method of implementation of the equipment, it has an essential oil storage integrated into the air filter.

[0022] In another method of implementation of the equipment, the equipment is connected to the split air-conditioner by placing the equipment inside the indoor unit.

[0023] With this invention solution we can ensure that the humidity of the air in rooms cooled by split air conditioners does not fall below the health-required limit, thereby reducing the undesirable effects of the room’ s low humidity air on living creatures and the built environment. Such evaporation equipment does not need to be filled with human assistance, it is not necessary to provide it with a connection to the water main, it is not necessary to obtain mineral-free water or to produce such water, since it is available as condensate, and only when it is most needed.

[0024] The condensate “produced” by the indoor unit of the split air conditioner is collected in a condensate tank specially designed for slow liquid flow, filling and draining controlled by electronic signals adapted to the rate of condensation and the evaporation performance of the ultrasonic evaporators and from there enters into the evaporation space.

[0025] In the lower segment of the evaporation space, according to the performance of the air conditioners at least one or more commercially available ultrasonic water evaporators make cold vapor from the condensate, which is transmitted through a vapor flue by at least one or more air blower fans in front of or under the air-outlet of the air conditioner. The dry air that flows out of the air conditioner at high speed, by pulling this vapor with it, disperses it in the cooled airspace, but the cold vapor can be also dispersed in the airspace without the help of the air conditioning draft, with the equipment's own fan with a scaled power.

[0026] An unexpected effect is also an outcome that enhances cooling efficiency, when the introduced cold vapor absorbs heat from the temperature of the environment, thereby reducing the energy demand of cooling. This reduction in energy consumption may be greater than the amount of energy required for evaporation.

[0027] The invention is described in detail on the following Figures:

[0028]

[0029] [Fig.1] is the external front view of the equipment with a cover piece.

[0030] [Fig.2] is the front view of the equipment without the cover piece 10 and vapor flue

22

[0031] [Fig.3] is the A-A section image of the equipment

[0032] [Fig.4] is the B-B section image of the equipment

[0033]

[0034] In its preferred embodiment as shown in Figures 1.2.3.4, the invention is placed on a support bracket T at the bottom of the AC indoor unit F, preferably symmetrically in the middle, made of a steel plate of 1 mm material thickness, punched and formed with folds and/or holes, and must be attached to the mounting plane at a minimum of two or more mounting points. The support bracket T lies on the same mounting plane as the air conditioner indoor unit F, with screw fastening and reaching under certain parts of the air conditioner indoor unit F to fix the various components and covers with screws. The cover piece 10 made of UV-resistant polycarbonate and the bottom plate 29, as well as the vapor flue 22 airflow guide 34 made of UV-resistant polycarbonate, are also installed on the support bracket T with screw fastening.

[0035] The support bracket T also serves as a protective grounding node, so it is necessary to connect the protective grounding of the electrical network and the protective conductor connections of the electrical components.

[0036] According to the preferred embodiment of the invention shown on figures 2,3, 4, a tapping fitting 1 is inserted into the condensate drain pipe K of the air conditioner indoor unit F in such a way that the condensate can flow into the condensate collecting pipe 2 by gravity, which delivers the condensate to the condensate tank 4. Between the transparent UV-resistant polyethylene or silicone-based condensate collector tube 2 and the condensate tank 4, an electromagnetic shut-off valve 3 is placed, which receives the electrical energy required for its operation from the Control Unit V via 0.5 mm2 insulated copper lines. [0037] The location and connection points of the inlet 5 for receiving the condensate collection pipe 2 on the condensate tank 4, which is made of transparent UV-resistant polycarbonate or any other UV-resistant transparent plastic, must be determined so that it can be connected from above, vertically and from the side, horizontally as well.

[0038] The design of the condensate tank 4 must be such that the fresh water does not flow immediately into the supply pipe 15 at the bottom of the condensate tank 4, the liquid must be passed through a forced path inside the condensate tank 4 to remain suf ficiently exposed to UVC light. The condensate tank 4 receives the supply of air and water from the condensate drain pipe K. The connection of the condensate collecting pipe 2 from the indoor unit F of the air conditioner F is most preferably positioned to the condensate tank 4 at the bottom of the cover of the indoor unit F of the air con ditioner, close to the mounting plane (retaining wall).

[0039] If the condensate drain pipe K of the indoor unit of the air conditioner F is mounted outside the wall, the "tap" can also be carried out on this external section, from where the condensate can be drained to the inlet 5 from the side. At the top of the condensate tank 4, below the inlet 5, there is a water filter insert 7, which can be replaced or cleaned. For this reason, the design of the top of the condensate tank 4 sufficiently supports the replacement of the water filter insert 7 after the cover element 10 has been removed. The water filter insert 7 is intended to prevent unwanted contaminants from entering the condensate tank 4 and the water space 19.

[0040] The minimum volume of the condensate tank 4 allows a maximum performance of at least half an hour, which is particularly important from a bacteriological point of view, i.e., due to the maintenance of the exposure time of the UVC light achieved by the slow liquid flow. A tank full indicator 11 is placed in the condensate tank 4, which closes or opens a microswitch 12 with a float as shown in [Fig.2], which receives an electrical supply via a 2 X 0.5 mm2 insulated copper wire and signals the Control Unit V when the water level reached to 60% of the condensate tank’s 4 capacity. At the bottom of the condensate tank 4 there is a supply pipe 15 which extends over the water space of the evaporator space 6, where it ensures a suitable water level. To prevent overfilling, a supply valve 18 is fitted in the supply pipe 15, which closes or opens the supply pipe 15 by electromagnetic actuation and receives its power supply from the Control Unit V via a 0.5 mm2 insulated copper line.

[0041] The maximum water level in the water space 19 depends on the performance and design of the evaporator heads. The water level of the water space 19 is followed by a floating water level indicator 23 which closes or opens the microswitch 12, and in a further preferred embodiment a light sensor is used to trigger the microswitch 12 of the water level indicators 24 and 25. The floating water level indicator 23 is located as far as possible from the water supply point of the water space 19 in order to ensure the accuracy of the water level measurement. Depending on the required power, at a suitable distance from each other one or more ultrasonic evaporators with a diameter of 25 mm to 40 mm can be arranged on the bottom plate 29 that is closing the water space 19 from below, the ultrasonic evaporators, denoted U1 and U2 in [Fig.2], receive their 12 V or 24 V supply from the Control Unit V on 0.5 mm2 insulated Cu wires under or behind the water space 19. The bottom plate 29 is housing a minimum of one or more air blower fans 20 operated by an electric current of 12 or 24 V, which draws air in through an air inlet 17 at the bottom of the bottom plate 29, that includes a replaceable and / or cleanable air filter insert 21, and through the evaporator space 6 and the vapor flue 22 blows it out together with the cold steam generated in the evaporator space 6.

[0042] The vapor flue 22 is designed so that it directs the vapor directly in front of the air conditioner outlet and the velocity of the escaping humid air is sufficient to exit to the air conditioning draft and so that the electrical components outside the vapor flue and inside the equipment’s cover piece do not come into contact with the vapor and that the air escaping from the indoor unit must not enter the evaporator space 6. Reflective film 14 is also placed on the part of the airflow guide 34 that covers the UV-protected space.

[0043] The air blower fan 20 receives a 12 or 24 V supply from Control Unit V on 3 x 0.5 mm2 insulated copper wire, and its air delivery capacity is also adapted to the maximum capacity of the evaporator heads and the dimensions of the vapor flue 22. The air filter insert 21 located between the air intake 17 and the air blower fan 20 can be easily removed and replaced or cleaned from below. Its dimensions allow for at least 1 or more months of operation without cleaning or replacement. This sizing is decisive both in sizing the required delivery power of the air blower fan 20 and in designing the size and geometry of the vapor flue 22. In a further preferred em bodiment, the air filter insert 21 includes an essential oil reservoir so that the blower fan 20, together with the cold vapor, is capable of conveying fragrances to the re frigerated air space.

[0044] The low-voltage components receive their power supply from transformer E via Control Unit V, which converts 230V / 50Hz and 110V / 60Hz electricity from the mains to 24, 12 V or 24, 12 and 5 V. Control Unit V is located in the UVC-protected area of the transformer E.

[0045] The following components are connected to Control Unit V:

[0046] U 1 and U2 Ultrasonic Evaporators - electromagnetic shut-off valve 3 - air flow sensor 8 - supply valve 18 - condensate sensor 26 - humidity sensor 27 - UVC light source 28- transformer E - operation indicator light 31 - On-Off switch 30 - mi croswitch 12 - air blower fan 20 - timer 16 - control dial 32.

[0047] The task of Control Unit V is to supply the subcomponents with electrical current and to process the signals of the transmitters, on the basis of which the components are started and stopped, and to operate the operating lights 31.

[0048] One or more UVC light sources 28, even in the form of an LED strip, are placed in the inner part covered by the cover piece 10. The UVC light source 28 can be operated from a 5 V or 12 V or 24 V supply voltage. The intensity and power of the light must be adapted to the amount of condensed water that can be stored inside the equipment and to the geometric shape of the containers, so that the condensed water entering the interior is exposed to UVC radiation of adequate intensity for the minimum time required before evaporation.

[0049] The internal components are made of UV-resistant material and the components that do not come into contact with water and vapor are mounted obscured from the light source. The light source is powered from Control Unit V via a 2x0.5 mm2, double- insulated, Cu cable.

[0050] During the operation of the humidification, the UVC light source 28 is continuously monitored by the light sensor 33. In the absence of UVC light, humidification does not turn on.

[0051] The cover piece 10 and the bottom plate 29 are non-translucent and the outer surface is of a color and surface that conforms to the conventional plastic cover of air con ditioners. It can be made of polycarbonate or other plastics. A flexible, easily com pressible foam rubber seal 9 is placed between the cover piece 10 and the non-UV resistant cover of the air conditioner. The front side is partially open and the cover piece 10 is flue shaped, which together with the vapor flue piece 22 and the airflow guide 34 completes the vapor flue.

[0052] A UVC-resistant reflective film 14 is applied to the inner surface of the cover piece 10 that is illuminated by UVC light source 28, and to the non-UV-resistant affected parts of the cover of the air-conditioning body.

[0053] The condensate sensor 26 is connected to the Control Unit V by means of a connecting cable. The connecting cable is 2x0.5 mm2 Cu, double insulated wire. In the thermometer embodiment of the condensate sensor 26, it is located between the cooling fins of the air conditioner, while in a further preferred embodiment it is inserted into the condensate collecting pipe 2 as a liquid flow sensor.

[0054] The humidity sensor 27 should be located above the air intake at the top of the indoor unit so that you can measure the humidity of the air coming from the room correctly. It is powered by the Control Unit V via a 0.5 mm2 double-insulated Cu cable. The present invention presented in this preferred embodiment illustrated in FIGS. 1. and 2, the desired humidity level can be set by the user, with the help of the control dial 32, that is connected to Control Unit V and the humidity sensor 27 via a 0.5 mm2 copper wire and is placed on the cover piece 10. [0055] The UVC light source 28 operates at wavelengths between 254 and 265 nm, ensuring the most efficient sterilization.

[0056] The design of the bottom plate 29 after the removal of the cover element 10 suf ficiently supports the cleaning of the ultrasonic evaporators Ul, U2, which is also due during the periodic cleaning required for the air conditioners.

[0057] On-Off switch 30: closes or interrupts the power supply phase conductor. Another preferred embodiment is that the switch can physically close or open the condensate pipe 2 together with the power supply. The On-Off switch 30 is located at an easily ac cessible height. The On-Off switch 30 is connected to Control Unit V and the electric mains via 3 x 1.5 mm2 double-insulated Cu wires.

[0058] Operating lights 31 :

[0059] 31 a) In ON position red light is lit

[0060] 31 b) in standby mode it turns yellow

[0061] 31 c) During humidifying, this light turns green.

[0062] Furthermore, upon UVC radiation, its violet-colored light becomes visible to the user on a selected, transparent portion of the coating.

[0063] The control dial 32 allows the user to change the level of the ON signal of the humidity sensor 27 to the desired humidity value. It is electrically connected to Control Unit V.

[0064] A light sensor transmitter 33 starts the timer 16, so it must be integrated into its circuit and then to the rest of the equipment.

[0065] The airflow guide 34 helps to remove vapor and covers spaces to be blocked from vapor.

[0066] The invention is activated when the indoor unit F of the air conditioner is switched on and the heat exchanger fins of the air cooler unit drops to a temperature below 15 degrees Celsius and this is indicated to Control Unit V by the condensate sensor 26. In a further preferred embodiment of the invention, a liquid flow meter inserted in the condensate collecting pipe 2 detects the onset of condensation and gives a signal to Control Unit V. On the ON signal of the condensate sensor 26, the humidity sensor 27 measures the relative humidity of the room air, and if it does not reach the value set on the control dial 32, the UVC light source 28 is switched on first, that is being detected by the light sensor 33 and starts the timer 16, or opens the electromagnetic shot-off valve 3 via Control Unit V, giving way to the condensate required for its operation.

[0067] When the appropriate amount of condensation fluid is available, indicated by the minimum water level sensor 24 to Control Unit V, or the UVC light source 28 has been operating for a minimum time sufficient for sterilization, then timer 16 signals ON to Control Unit V that turns the blower fan 20 on; when it is already in operation, and the Control Unit V also receives feedback from the air flow sensor 8, the Control Unit V switches on the ultrasonic evaporator U1 - i.e. in the preferred embodiment shown in [Fig.2] one of the ultrasonic evaporators Ul, U2 or sets both their power output to 50% - and then, when the condensate tank 4 is 60% full, sets both ultrasonic evaporators to 100% based on the signal from the microswitch 12. From now on until the minimum water level indicator 24 is OFF, both evaporators U 1 and U2 operate continuously at full power. In the water space 19, the water level must be kept within limits for efficient vapor generation that is being monitored by the water level sensors 24, 25. in the water space 19.

[0068] The Invention operates with the help of the following components, subject to the following conditions:

[0069] I. the 27 humidity sensor generates an ON signal for Control Unit V in case the humidity level is below the required value set on the control dial 32.

[0070]

[0071] II. the 26 condensate sensors below 15°C transmit an ON signal to Control Unit V and opens the electromagnetic shot-off valve 3.

[0072]

[0073] III. the minimum water level indicator 24, generates an ON signal for Control Unit V when the minimum water level reached.

[0074]

[0075] IV. the 16 timer generates an ON signal when the UVC light source 28 is in operation for a minimum sufficient time to sterilize, and from this time until the turn off generates an ON signal. When the UVC light turns off it will generate an OFF signal.

[0076]

[0077] V. The timer 16 detects the existence or absence of light based on the signal of the light-sensing transmitter 33.

[0078]

[0079] VI. the airflow sensor 8 generates an ON signal to Control Unit V when air movement is generated by the blower fan 20.

[0080]

[0081] VII. the tank level indicator 11 affects the micro-switch 12, so when the condensate tank 4 is 60% full, it generates an ON signal to Control Unit V.

[0082] When the I and II signals are ON, the UVC light source 28 and the timer 16 of the Control Unit V are switched on, and the electromagnetic shot-off valve 3 is opened, and the water space 19 starts to fill with condensate through the condensate tank 4.

[0083] If all five signals (I. II. III. IV.V.) are ON, the 20 blower fans will turn on.

[0084] When all six signals (I. II. III. IV. V. VI.) are switched on, half of the ultrasonic evaporators Ul, U2 or 50% of the power of the ultrasonic evaporators are switched on, the humidification starts.

[0085] When all 7 signals (I. II. III. IV. V. VI. VII.) are switched on, the Ul, U2 ultrasonic evaporators are switched to 100% power, the humidification is now operating at full power. When the minimum water level indicator 24 is OFF, the humidification and the blower fan 20 stop, and the UVC light source 28 operates for a minimum time sufficient for sterilization. When the humidity above the required value is reached, the humidification also stops, the UVC light source 28 remains in operation for a minimum time sufficient for sterilization, and then the Invention is in standby mode.

[0086] At the OFF signal of the condensate sensor 26, the humidification continues to work until the minimum water level indicator 24 generates an OFF signal, at which point the Ul, U2 ultrasonic evaporators and the blower fan 20 stop working; the UVC light source 28 is still working for a minimum of time enough for sterilization, and then they turn off. If the condensate sensor 26 generates an ON signal, the operating process described above will start again.

[0087] When the Control Unit V is working, a microcomputer (PIC or EPROM) controls the peripherals based on a pre-written program and user setup including the combined signals of the water level, humidity, temperature, light, and its impact time, as well as the values set on control dial 32 and the airflow sensor 8, i.e. the operation of UVC light source 28 for a sufficient period of time, the control of the water level by opening and closing the valves, the operation of the blower fan 20, and the operation of the Ul, U2 ultrasonic evaporators and their performance.

[0088] The advantage of this invention over the previously known humidification processes lies in the fact that it uses "distilled water" directly as fuel as a by-product of the operation of indoor units of split air conditioners, filters it, disinfects it with UVC light source 28, and atomizes it into aerosol particles with ultrasonic evaporators Ul and U2. Thus, the Invention automatically replaces the air moisture missing directly at the place of evaporation, there is no need to build a separate pipeline or human assistance to replenish the liquid and to control the humidification demand.

[0089] The germ-free environment achieved by the 28 UVC light sources ensures that no habitat favorable to bacteria can be created in the interiors of the Invention, thus making the cold vapor entering the air space germ-free.

[0090] The Invention can produce as much humidity as the condensation produced by condensate formation. If the amount of condensate fluid is greater than the invention is capable of or considers it necessary to evaporate based on its adjustment, then over the filled system, through the tapping fitting 1, the excess condensate will simply flow into the drainage pipe system, which is already installed for the air conditioner. This fluid treatment and evaporation process results in a water vapor free of minerals and other impurities or pathogens that can be returned to the room's airspace. [0091] The incorporative dimensions and design of our invention allow it to be placed under the cover plate of the indoor unit of the air conditioner. It is also possible to retrofit the evaporative component of the invention, and in this case, there is no need to break down the refrigerant-filled or electronic system elements of the air conditioner, only the connection to the service wires is necessary for operation.

[0092] LIST OF MARKINGS [0093]