Airflow Diffuser Between Blower and Coil to Reduce Moisture Carryover
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Solution Overview
Problem
High-velocity airflow in HVACR units can blow condensate off refrigerant coils, leading to moisture carryover and corrosion, requiring larger drain pans and reducing system efficiency, while also causing airflow to circulate backward through the blower.
Innovation Solution
A diffuser comprising a plurality of diffuser elements is placed between the blower and refrigerant coil to deflect and spread the airflow, reducing velocity and moisture carryover, and arranged in various configurations such as cylindrical, semi-cylindrical, planar, or L-shaped brackets to optimize airflow distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-velocity airflow is used through the refrigerant coil, then cooling efficiency is improved, but moisture carryover increases causing corrosion and contamination
Solution Approach 1:
A diffuser is introduced as an intermediary component between the blower and refrigerant coil. The diffuser mediates the airflow by reducing its velocity and redistributing it uniformly across the coil surface, thereby maintaining cooling efficiency while preventing moisture carryover that would cause corrosion and contamination
Solution Approach 2:
The diffuser changes the physical parameters of the airflow by reducing velocity and increasing distribution uniformity. This parameter transformation allows the airflow to cool the coil effectively without reaching velocities that would blow condensate off the coil and cause moisture carryover
2Productivity
If high-velocity airflow is used through the refrigerant coil, then cooling capacity is improved, but drain pan size must increase to handle moisture accumulation
Solution Approach 1:
The diffuser acts as a mediator that prevents excessive moisture accumulation by controlling airflow velocity. This eliminates the need for oversized drain pans, as the diffuser ensures moisture remains on the coil where it can be properly drained through standard-sized pans
Solution Approach 2:
The diffuser performs preliminary action by pre-conditioning the airflow before it reaches the refrigerant coil. By reducing velocity and improving distribution in advance, the diffuser prevents the moisture accumulation problem that would otherwise require larger drain pans
3Productivity
If high-velocity airflow is used through the refrigerant coil, then system performance is improved, but airflow circulates backward through the blower reducing efficiency
Solution Approach 1:
The diffuser serves as an intermediary that directs airflow properly through the refrigerant coil. By establishing uniform flow distribution and appropriate velocity, the diffuser prevents vortex formation and backward circulation that would cause energy losses and reduced system efficiency
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces moisture carryover, allows for smaller drain pans and shorter air handler units, lowering costs and improving system efficiency by ensuring airflow travels only in one direction through the refrigerant coil.
Implementation Method 1
The diffuser elements are arranged and/or configured to deflect the airflow, spreading it over more of the refrigeration coil and reducing the velocity of air passing through any particular point in the refrigeration coil
Implementation Method 2
cooling the airflow after it exists the diffuser, using a refrigeration coil
Data Source
AI summary
A heating, ventilation, air conditioning and refrigeration system includes a diffuser comprising a plurality of diffuser elements located between a blower driving airflow through the system and a refrigeration coil used to cool the airflow prior to the distribution of the airflow to a building. Locating diffusers between the blower and the refrigeration coil reduces the extent to which the airflow carries moisture from condensate on the refrigeration coil, and can prevent circulation of air backwards through the refrigeration coil.