Angled tube coil for air handling and air conditioning systems and methods

Abstract

A conditioning system includes a housing through which air flows from an air inlet to an air outlet along an air flow path and at least one tube coil arranged in the housing. The at least one tube coil has an elongated curvilinear cross-sectional shape. The air flow path includes air flow through the at least one tube coil at a first angle. The elongated curvilinear cross-sectional shape includes a minor dimension and a major dimension that is larger than the minor dimension. The at least one tube coil is arranged in the housing such that the major dimension of the elongated curvilinear cross-sectional shape is at the first angle.

Description

Attorney Docket No.: 5995.035W01ANGLED TUBE COIL FOR AIR HANDLING AND AIR CONDITIONING SYSTEMS AND METHODSCLAIM OF PRIORITY

[0001] This application claims priority to U.S. Provisional Application Serial No. 63 / 718,320, filed November 8, 2024, which is hereby incorporated by reference herein in its entirety.BACKGROUND

[0002] Tube coils are commonly employed in various types of air handling and air conditioning systems and can be formed from various cross-sectional shaped tubes and various materials, including various metals, alloys, polymers, ceramics, as examples. Some tube coils include a circular cross-sectional shape. Additionally, tube coils have been developed with an oval cross-sectional shape. Oval tube coils have been found to advantageously reduce air-side pressure drop across exchangers including such coils. Such oval tube coils can result in a reduced heat exchange capacity relative to, e.g., circular tube coils, but the pressure drop reduction can be significant enough to provide an overall benefit even accounting for the heat exchange reduction.SUMMARY

[0003] Examples according to this disclosure are directed to oval tube coils, which can be employed in a variety of types of condition devices and systems. For example, systems and methods according to this disclosure can include or be employed in computer room air handlers (CRAHs] and computer room air conditioners [CRACs], An example CRAH can include one or more tube coils, which are configured to circulate a heat exchange liquid (water, refrigerant, glycol, or a mixture, e.g. up to 30% glycol with water]]. The tube coils are disposed in a device through which air is directed to flow such that the air flows through / over / around / by the tube coils. As the air flows through the coils through which the heat exchange liquid is flowing, energy (e.g., latent and / or sensible] is exchanged between the air and the liquid. In an example, relatively hot return air flows through tube coil(s] circulating a relatively cool liquid and the liquid cools theAttorney Docket No.: 5995.035W01 air, which can then be supplied to cool an enclosed space and / or devices in the space, e.g., computers, servers, or other electronic devices.

[0004] Coils that utilize elliptical / oval / oblong tubes could benefit from a lower air pressure drop across the coil by lowering the amount of turbulence the air experiences. Existing oval tube coils are commonly designed for air flow entering and exiting the coil perpendicular to the intake / inlet face of the coil. And in some current CRAH units, coils are arranged in the CRAH such that the air enters and leaves the coil at a non-perpendicular angle. Examples according to this disclosure may function to reduce the amount of air pressure drop across a tube coil by arranging the cross-sectional profile of the coil in a particular orientation relative to air flow through the coil.

[0005] In examples according to this disclosure, the major axis of the tube coil cross- sectional shape is arranged parallel to the airflow through the coil. By aligning the tube coils with the direction of airflow, the turbulence of the air may decrease, which, in turn, may decrease the air pressure drop across the coil. Examples according to this disclosure can be employed in any conditioning unit including a tube coil and where airflow enters the coil at a non-perpendicular angle relative to the coil intake face.

[0006] In an example, a conditioning system includes a housing through which air flows from an air inlet to an air outlet along an air flow path and at least one tube coil arranged in the housing. The at least one tube coil has an elongated curvilinear cross-sectional shape. The air flow path includes air flow through the at least one tube coil at a first angle. The elongated curvilinear cross-sectional shape includes a minor dimension and a major dimension that is larger than the minor dimension. The at least one tube coil is arranged in the housing such that the major dimension of the elongated curvilinear cross-sectional shape is at the first angle.

[0007] In another example, a computer room air handler [CRAH] includes a housing through which air flows from an air inlet to an air outlet and at least one tube coil arranged in the housing and having a tube with an elongated curvilinear cross-sectional shape arranged in the housing. As air circulates through the CRAH, air flows through the at least one tube coil. The elongated curvilinear cross-sectional shape includes a major dimension that is larger than a minor dimension. The at least one tube coil is arranged in the housing such that the major dimension of the elongated curvilinear cross-sectional shape is parallel to air flow through the tube coilfs].Atorney Docket No.: 5995.035W01

[0008] In another example, a method includes directing air through a housing of a conditioning system from an air inlet to an air outlet and directing the air through a tube coil arranged in the housing along an air flow path at a first angle. The tube coil has an elongated curvilinear cross-sectional shape. The elongated curvilinear cross-sectional shape includes a minor dimension and a major dimension that is larger than the minor dimension. And the tube coil is arranged in the housing such that the major dimension of the elongated curvilinear cross- sectional shape is at the first angle.

[0009] This overview is intended to provide an overview of subject matter in the present application. It is not intended to provide an exclusive or exhaustive explanation of the invention. The detailed description is included to provide further information about the present application.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] In the drawings, which are not necessarily drawn to scale, like numerals may describe similar components in different views. Like numerals having different letter suffixes may represent different instances of similar components. The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present document.

[0011] FIG. 1 depicts an example computer room air handler (CRAH) in accordance with examples of this disclosure.

[0012] FIG. 2 depicts the liquid-to-air heat exchanger (LAHX) of the example CRAH of FIG. 1.

[0013] FIG. 3 depicts an elongated curvilinear cross-section of a tube coil in accordance with examples of this disclosure.

[0014] FIGS. 4A-4C depict example elongated curvilinear cross-sectional shapes of example tube coils according to this disclosure.DESCRIPTION

[0015] FIG. 1 depicts example CRAH 100 in accordance with this disclosure. CRAH 100 includes housing 102 in which filter section 103, liquid-to-air heat exchanger (LAHX) 104, and fan 106 are arranged. LAHX 104 includes tube coils 108 and 110. Tube coils 108 and 110 are arranged in an "A” configuration in example CRAH 100 with air flowing vertically downward from inlet 112 to outlet 114. Fan 106 is arranged toward outlet 114 end of CRAH and is configured to draw air fromAttorney Docket No.: 5995.035W01 inlet 112 to outlet 114. However, other examples according to this disclosure can include different types of conditioning units with one or more than two tube coils and / or other components, e.g., fan(s] arranged in different order within the conditioning unit Additionally, examples according to this disclosure can be arranged in different orientations and configured for air flow in different directions than example CRAH 100 of FIG. 1., including, e.g. horizontal layout with air flow from left to right (or right to left] or vertical layout with upward vertical air flow. For example, another example CRAH according to this disclosure can include upward vertical air flow through a housing in which two tube coils are arranged in a "V” configuration.

[0016] In examples, tube coilfs] can be arranged in a housing of an example CRAH or other type of condition system at a non-perpendicular angle to the direction of air flow through the CRAH from inlet to outlet Additionally, in examples, the air flow through the tube coilfs] within the housing of the CRAH can be nonperpendicular to the intake / inlet face of the coil. With reference to the example of FIG. 1, the overall flow of air through CRAH 100 from inlet 112 to outlet 114 is vertically down parallel to longitudinal axis 115 of the CRAH. In the "A" configuration of FIG. 1, tube coils 108 and 110 are arranged at an angle A, which is not perpendicular to longitudinal axis 115 (and the overall direction of air flow through CRAH 100 from inlet 112 to outlet 114], Additionally, air flow through tube coils 108 and 110 within housing 102 of CRAH 100 is at an angle B, which is not perpendicular to the intake / inlet face of the coils.

[0017] As schematically depicted in FIG. 1, air flows through CRAH 100 from inlet 112 to outlet 114. As air is channeled through CRAH 100, itflows through tube coils 108 and 110 at an angle that differs from the overall vertical direction of air flow through CRAH 100. Various characteristics, conditions, and / or structures can cause such air flow through a conditioning unit, including angled air flow through tube coils 108 and 110. Regardless, air flows through tube coils 108 and 110 at an angle, which is not perpendicular to the face of the tube coils. As will be described in greater detail with reference to FIG. 2, each of tube coils 108 and 110 include a elongated curvilinear cross-sectional shape including a major dimension that is larger than a minor dimension. Tube coils 108 and 110 are arranged such that the major dimension of the elongated curvilinear cross-sectional shape is parallel to the direction of air flow through the tube coils.Attorney Docket No.: 5995.035W01

[0018] FIG. 2 depicts LAHX 104 of example CRAH 100 of FIG. 1. LAHX 104 includes tube coils 108 and 110 arranged in an "A” configuration. Air flows through tube coils 108 along air flow path 200, which is at a first angle. Air flows through tube coils 110 along air flow path 202, which is at a second angle. The first and second angle can be different or the same. The value of the first and second angles can be expressed relative to different references / datums, e.g. the angle of air flow can be relative to the face of tube coils 108 and 110 or relative to vertical or horizontal. Each of tube coils 108 and 110 include elongated curvilinear cross- sectional shape 204. Tube coils 108 and 110 are arranged such that the major dimension of elongated curvilinear cross-sectional shape 204 is at the same angle as [parallel to] air flow through the tube coils, i.e. at the first angle of air flow 200 for tube coil 108 and the second angle of air flow 202 for tube coil 110.

[0019] FIG. 3 depicts one elongated curvilinear cross-section 204 of example tube coil 110 in greater detail. As depicted in FIG. 3, elongated curvilinear crosssection 204 of example tube coil 110 includes a major dimension, which may be referred to as a major axis, and which is larger than a minor dimension, which may be referred to as a minor axis. Air flow 202 through tube coil 110 is at second angle A, which in this example is defined relative to horizontal. Tube coil 110 is arranged in CRAH 100 such that the major dimension of elongated curvilinear cross-section 204 is at angle B, which is also defined relative to horizontal. The second angle A of air flow 202 through tube coil 110 and angle B of the major dimension of elongated curvilinear cross-section 204 of tube coil 110 are equal, which orients elongated curvilinear cross-section 204 such that the major dimension is parallel to the direction of air flow through tube coil 110.

[0020] The elongated curvilinear cross-sectional shape of tube coils in accordance with this disclosure can be, e.g. oval including elliptical. However, the cross-sectional shape may also be oblong. The elongated curvilinear cross-sectional shape includes a major dimension (e.g. length] that is larger than a minor dimension (e.g., width] and includes no sharp corners / vertices (e.g. a point at which two line or curve segments meet and terminate]. The elongated curvilinear cross-sectional shape of tube coils in accordance with examples of this disclosure can be, e.g., any closed planar curve without sharp corners / vertices.

[0021] FIGS. 4A-4C depict example elongated curvilinear cross-sectional shapes of example tube coils according to this disclosure. FIG. 4A depicts example elongated curvilinear cross-sectional shape 204 from the example of FIGS. 1-3. ElongatedAttorney Docket No.: 5995.035W01 curvilinear cross-sectional shape 204 is an elliptical shape with major dimension / axis that is larger than the minor dimension / axis. Elongated curvilinear cross-sectional shape 204 includes leading (e.g. in the direction of air flow] end 406 the curved profile of which is the same or substantially the same as trailing end 408. FIG. 4B depicts example elongated curvilinear cross-sectional shape 402 with a major dimension that is larger than a minor dimension. Elongated curvilinear cross- sectional shape 402 is an oblong shape with same / substantially similar curved leading and trailing ends 410, 412, which are blunter than leading and trailing ends 406, 408 of elongated curvilinear cross-sectional shape 204. FIG. 40 depicts example elongated curvilinear cross-sectional shape 404 with a major dimension that is larger than a minor dimension. Elongated curvilinear cross-sectional shape 404 includes a blunter curved leading end 414 than curved trailing end 416, i.e. leading end 414 is larger in the minor dimension direction than trailing end 416. Elongated curvilinear cross-sectional shape 404 is an example of an oval (may also be referred to as tear drop / egg I airfoil] shaped tube coil profile in accordance with examples of this disclosure.

[0022] The present application provides for the following exemplary embodiments or examples, the numbering of which is not to be construed as designating levels of importance:

[0023] Example 1 provides a conditioning system comprising: a housing through which air flows from an air inlet to an air outlet along an air flow path; and at least one tube coil arranged in the housing, wherein: the at least one tube coil has an elongated curvilinear cross-sectional shape; the air flow path includes air flow through the at least one tube coil at a first angle; the elongated curvilinear cross- sectional shape includes a minor dimension and a major dimension that is larger than the minor dimension; and the at least one tube coil is arranged in the housing such that the major dimension of the elongated curvilinear cross-sectional shape is at the first angle.

[0024] Example 2 provides the conditioning system of Example 1 and optionally wherein the elongated curvilinear cross-sectional shape is elliptical.

[0025] Example 3 provides the conditioning system of Example 1 and optionally wherein the elongated curvilinear cross-sectional shape is oblong.

[0026] Example 4 provides the conditioning system of Example 1 and optionally wherein the elongated curvilinear cross-sectional shape is oval.Attorney Docket No.: 5995.035W01

[0027] Example 5 provides the conditioning system of Example 1 and optionally wherein the at least one tube coil is arranged in the housing at a non-perpendicular angle to a longitudinal axis of the conditioning system.

[0028] Example 6 provides the conditioning system of Example 5 and optionally wherein the at least one tube coil comprises two tube coils arranged in the housing in an "A" configuration.

[0029] Example 7 provides the conditioning system of Example 5 and optionally wherein the at least one tube coil comprises two tube coils arranged in the housing in a "V” configuration.Example 8 provides the conditioning system of any one of Examples 1-7 and optionally wherein: the first angle is defined relative to a face of the at least one tube coil; and the first angle is not equal to 90 degrees.

[0030] Example 9 provides a computer room air handler (CRAH) comprising: a housing through which air flows from an air inlet to an air outlet; and two tube coils arranged in the housing in the housing, wherein: each of the two tube coils has an elongated curvilinear cross-sectional shape; the elongated curvilinear cross- sectional shape includes a minor dimension and a major dimension that is larger than the minor dimension; and each of the two tube coils is arranged in the housing such that the major dimension of the elongated curvilinear cross-sectional shape is parallel to an air flow path through the respective tube coil.

[0031] Example 10 provides the CRAH of Example 9 and optionally wherein the elongated curvilinear cross-sectional shape is elliptical.

[0032] Example 11 provides the CRAH of Example 9 and optionally wherein the elongated curvilinear cross-sectional shape is oblong.

[0033] Example 12 provides the CRAH of Example 1 and optionally wherein the elongated curvilinear cross-sectional shape is oval.

[0034] Example 13 provides the CRAH of Example 1 and optionally wherein the air flow path through each of the two tube coils is not perpendicular to a face of the respective tube coil.

[0035] Example 14 provides the CRAH of Example 1 and optionally wherein each of the two tube coils is arranged in the housing at a non-perpendicular angle to a longitudinal axis of the CRAH.

[0036] Example 15 provides the CRAH of Example 14 and optionally wherein each of the two tube coils is arranged in the housing in an "A" configuration.Attorney Docket No.: 5995.035W01

[0037] Example 16 provides the CRAH of Example 14 and optionally each of the two tube coils is arranged in the housing in a "V" configuration.

[0038] Example 17 provides a method comprising: directing air through a housing of a conditioning system from an air inlet to an air outlet; directing the air through a tube coil arranged in the housing along an air flow path at a first angle, wherein: the tube coil has an elongated curvilinear cross-sectional shape; the elongated curvilinear cross-sectional shape includes a minor dimension and a major dimension that is larger than the minor dimension; and the tube coil is arranged in the housing such that the major dimension of the elongated curvilinear cross- sectional shape is at the first angle.

[0039] Example 18 provides the method of Example 17 and optionally wherein the elongated curvilinear cross-sectional shape is elliptical, oblong, or oval.

[0040] Example 19 provides the method of Example 17 and optionally wherein the tube coil is arranged in the housing at a non-perpendicular angle to a longitudinal axis of the conditioning system.

[0041] Example 20 provides the method of any one of Examples 17-19 and optionally wherein: the first angle is defined relative to a face of the tube coil; and the first angle is not equal to 90 degrees.

[0042] The above description includes references to the accompanying drawings, which form a part of the description. The drawings show, by way of illustration, specific embodiments in which the invention can be practiced. These embodiments are also referred to herein as "examples.” Such examples can include elements in addition to those shown or described. However, the present inventors also contemplate examples in which only those elements shown or described are provided. Moreover, the present inventors also contemplate examples using any combination or permutation of those elements shown or described [or one or more aspects thereof), either with respect to a particular example (or one or more aspects thereof), or with respect to other examples (or one or more aspects thereof) shown or described herein.

[0043] All publications, patents, and patent documents referred to in this document are incorporated by reference herein in their entirety, as though individually incorporated by reference. In the event of inconsistent usages between this document and those documents so incorporated by reference, the usage in the incorporated reference(s) should be considered supplementary to that of this document; for irreconcilable inconsistencies, the usage in this document controls.Attorney Docket No.: 5995.035W01

[0044] In this document, the terms "a" or "an" are used, as is common in patent documents, to include one or more than one, independent of any other instances or usages of "at least one” or "one or more.” In this document, the term "or" is used to refer to a nonexclusive or, such that "A or B" includes "A but not B,” "B but not A,” and "A and B," unless otherwise indicated. In this document, the terms "including" and "in which" are used as the plain-English equivalents of the respective terms "comprising" and "wherein." Also, in the following claims, the terms "including" and "comprising" are open-ended, that is, a system, device, article, or process that includes elements in addition to those listed after such a term in a claim are still deemed to fall within the scope of that claim. Moreover, in the following claims, the terms "first,” "second,” and "third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects.

[0045] The above description is intended to be illustrative, and not restrictive. For example, the above-described examples (or one or more aspects thereof) may be used in combination with each other. Other embodiments can be used, such as by one of ordinary skill in the art upon reviewing the above description. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be interpreted as intending that an unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter may lie in less than all features of a particular disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate embodiment, and it is contemplated that such embodiments can be combined with each other in various combinations or permutations. The scope of the invention should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

[0046] Various aspects of the disclosure have been described. These and other aspects are within the scope of the following claims.

Claims

Attorney Docket No.: 5995.035W01CLAIMSWhat is claimed is:

1. A conditioning system comprising: a housing through which air flows from an air inlet to an air outlet along an air flow path; and at least one tube coil arranged in the housing, wherein: the at least one tube coil has an elongated curvilinear cross-sectional shape; the air flow path includes air flow through the at least one tube coil at a first angle; the elongated curvilinear cross-sectional shape includes a minor dimension and a major dimension that is larger than the minor dimension; and the at least one tube coil is arranged in the housing such that the major dimension of the elongated curvilinear cross-sectional shape is at the first angle.

2. The conditioning system of claim 1, wherein the elongated curvilinear cross-sectional shape is elliptical.

3. The conditioning system of claim 1, wherein the elongated curvilinear cross-sectional shape is oblong.

4. The conditioning system of claim 1, wherein the elongated curvilinear cross-sectional shape is oval.

5. The conditioning system of claim 1, wherein the at least one tube coil is arranged in the housing at a non-perpendicular angle to a longitudinal axis of the conditioning system.

6. The conditioning system of claim 5, wherein the at least one tube coil comprises two tube coils arranged in the housing in an "A” configuration.

7. The conditioning system of claim 5, wherein the at least one tube coil comprises two tube coils arranged in the housing in a "V” configuration.Attorney Docket No.: 5995.035W018. The conditioning system of any of claims 1-7, wherein: the first angle is defined relative to a face of the at least one tube coil; and the first angle is not equal to 90 degrees.

9. A computer room air handler [CRAH] comprising: a housing through which air flows from an air inlet to an air outlet; and two tube coils arranged in the housing in the housing, wherein: each of the two tube coils has an elongated curvilinear cross-sectional shape; the elongated curvilinear cross-sectional shape includes a minor dimension and a major dimension that is larger than the minor dimension; and each of the two tube coils is arranged in the housing such that the major dimension of the elongated curvilinear cross-sectional shape is parallel to an air flow path through the respective tube coil.

10. The CRAH of claim 9, wherein the elongated curvilinear cross-sectional shape is elliptical.

11. The CRAH of claim 9, wherein the elongated curvilinear cross-sectional shape is oblong.

12. The CRAH of claim 9, wherein the elongated curvilinear cross-sectional shape is oval.

13. The CRAH of claim 9, wherein the air flow path through each of the two tube coils is not perpendicular to a face of the respective tube coil.

14. The CRAH of claim 9, wherein each of the two tube coils is arranged in the housing at a non-perpendicular angle to a longitudinal axis of the CRAH.

15. The CRAH of claim 14, wherein each of the two tube coils is arranged in the housing in an "A” configuration.Attorney Docket No.: 5995.035W0116. The CRAH of claim 14, wherein each of the two tube coils is arranged in the housing in a "V” configuration.

17. A method comprising: directing air through a housing of a conditioning system from an air inlet to an air outlet; directing the air through a tube coil arranged in the housing along an air flow path at a first angle, wherein: the tube coil has an elongated curvilinear cross-sectional shape; the elongated curvilinear cross-sectional shape includes a minor dimension and a major dimension that is larger than the minor dimension; and the tube coil is arranged in the housing such that the major dimension of the elongated curvilinear cross-sectional shape is at the first angle.

18. The method of claim 17, wherein the elongated curvilinear cross-sectional shape is elliptical, oblong, or oval.

19. The method of claim 17, wherein the tube coil is arranged in the housing at a non-perpendicular angle to a longitudinal axis of the conditioning system.

20. The method of any of claims 17-19, wherein: the first angle is defined relative to a face of the tube coil; and the first angle is not equal to 90 degrees.

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