Dehumidification system having a coil split subcooler for removing moisture from an air flow and methods thereof

Abstract

A dehumidification system is provided that includes a coil split subcooler having a plurality of splits that each include at least one circuit for removing moisture from an air flow. In addition, a system and method for modulating the capacity of a subcooler are provided whereby the rate in which moisture is removed from an air flow can be optimized.

1 . A dehumidification system comprising: 
 a subcooler having a plurality of splits, wherein each split includes at least one circuit.    
     
     
         2 . The system of    claim 1   , wherein the subcooler comprises a first and a second split that each receive refrigerant from a receiver, wherein the first and second split each include a plurality of circuits, and wherein each circuit connects to one split at a first end, passes through a tube system, and connects to an outlet at a second end.  
     
     
         3 . The system of    claim 2   , wherein the subcooler outlet is connected to an evaporator, wherein the evaporator is connected to a compressor, and wherein the compressor is connected to a condenser.  
     
     
         4 . The system of    claim 3   , further comprising an expander disposed between the subcooler and the evaporator, wherein refrigerant enters the expander at approximately 70° F. to approximately 80° F. and exits the expander at approximately 30° F. to approximately 40° F.  
     
     
         5 . The system of    claim 4   , further comprising a remote condenser connected to the compressor, wherein the remote condenser allows the condenser to be bypassed.  
     
     
         6 . The system of    claim 2   , wherein the refrigerant enters the subcooler at approximately 100° F. to approximately 120° F. and exist the subcooler at approximately 70° F. to approximately 80° F.  
     
     
         7 . The system of    claim 2   , wherein the refrigerant received from the receiver is completely liquid.  
     
     
         8 . The system of    claim 2   , wherein each split includes a plurality of circuits.  
     
     
         9 . The system of    claim 1   , further comprising a mechanism for measuring humidity, wherein the mechanism controls the splits based on a humidity value, wherein a split is activated when the humidity value falls below a predetermined level.  
     
     
         10 . A dehumidification system that receives a humidified air flow and outputs a dehumidified air flow, comprising: 
 a subcooler having a plurality of splits, wherein each split includes at least one circuit;    a mechanism for activating and de-activating each split;    a system for measuring humidity of the humidified air flow; and    a system for controlling an amount of refrigerant passing through each split based on measured humidity.    
     
     
         11 . The system of    claim 10   , wherein the controlling system activates a split when the measured humidity falls below a predetermined level and de-activates a split when the humidity rises above the predetermined level.  
     
     
         12 . The system of    claim 10   , wherein moisture is removed from the humidified air flow at a rate of at least 10 pounds of water per hour when the humidified air flow has a relative humidity less than 35%, when utilizing a 60,000 BTU/HR capacity dehumidifier.  
     
     
         13 . The system of    claim 10   , further comprising: 
 a receiver for providing non-vaporous refrigerant to the splits;    an expander, coupled to an outlet of the subcooler, wherein the refrigerant flows from the subcooler to the expander at a temperature in a range of approximately 70° F. to approximately 80° F.;    an evaporator, coupled to an outlet of the expander, wherein the refrigerant flows from the expander to the evaporator at a temperature in a range of approximately 30° F. to approximately 40° F;    a compressor, coupled to an outlet of the evaporator, wherein the refrigerant flows from the evaporator to the compressor at a temperature in a range of approximately 45° F. to approximately 55° F.;    a condenser, coupled to an outlet of the compressor, wherein the refrigerant flows from the compressor to the condenser at a temperature in a range of approximately 140° F. to approximately 150° F.; and    wherein an outlet of the condenser is coupled to the receiver, wherein the refrigerant flows from the condenser to the receiver at a temperature in a range of approximately 100° F. to approximately 120° F.    
     
     
         14 . An air dehumidification and drying system, comprising: 
 a drying booth for drying waterborne coatings; and    a dehumidification system, operatively attached to the drying booth, wherein the dehumidification system comprises a subcooler having a plurality of splits, wherein each split includes at least one circuit.    
     
     
         15 . The system of    claim 14   , further comprising a filtration system, operatively attached to the drying booth, for filtering a re-circulated air flow, wherein the air flow is directed from the drying booth, through the filtration system, through the dehumidification system, and returned to the drying booth.  
     
     
         16 . The system of    claim 14   , further comprising a system for measuring a humidity value of an air flow, wherein the splits of the subcooler are controlled based on the humidity value.  
     
     
         17 . The system of    claim 16   , wherein one or more splits are activated when the humidity value falls below a predetermined level.  
     
     
         18 . The system of    claim 14   , wherein the subcooler cools non-vaporous refrigerant by at least approximately 30° F.  
     
     
         19 . The system of    claim 14   , wherein the dehumidification system further comprises an expander connected to an outlet of the subcooler, an evaporator connected to an outlet of the expander, a compressor connected to an outlet of the evaporator, and a condenser connected to an outlet of the compressor.  
     
     
         20 . The system of    claim 19   , wherein the dehumidification system further comprises a receiver for feeding non-vaporous refrigerant to the subcooler.  
     
     
         21 . The system of    claim 19   , wherein the dehumidification system further comprises a remote condenser connected to the outlet of the compressor, and wherein the remote condenser allows the condenser to be bypassed.  
     
     
         22 . The system of    claim 14   , wherein each split includes a plurality of circuits.  
     
     
         23 . A method of modulating the capacity of a subcooler, comprising the following steps: 
 providing a dehumidification system that includes a subcooler having a plurality of splits that each include at least one circuit;    directing an air flow through the dehumidification system;    measuring a humidity value of the air flow; and    controlling the splits based on the humidity value.    
     
     
         24 . The method of    claim 23   , wherein the step of providing a dehumidification systems comprises the steps of: 
 providing an expander operatively attached to an outlet of the subcooler;    providing an evaporator operatively attached to an outlet of the expander;    providing a compressor operatively attached to an outlet of the evaporator;    providing a condenser operatively attached to an outlet of the compressor; and    providing a receiver operatively attached to an outlet of the condenser, wherein the receiver feeds non-vaporous refrigerant to the subcooler.    
     
     
         25 . The method of    claim 23   , further comprising the steps of: 
 providing non-vaporous refrigerant to the subcooler; and    cooling the refrigerant by at least approximately 30F. in the subcooler.    
     
     
         26 . The method of    claim 23   , further comprising the step of providing a drying booth operatively attached to the dehumidification system.  
     
     
         27 . The method of    claim 23   , wherein the measuring step comprises the steps of: 
 measuring humidity of the air flow; and    transmitting the measured humidity to the splits.    
     
     
         28 . The method of    claim 27   , wherein the controlling step includes the steps of: 
 receiving the measured humidity;    activating at least one split when the measured humidity falls below a predetermined level; and    de-activating at least one split when the measured humidity rises above a predetermined level.    
     
     
         29 . A method of removing moisture from air, comprising the following steps: 
 providing a dehumidification system including a subcooler having a plurality of splits that each include at least one circuit;    flowing non-vaporous refrigerant from a condenser to the subcooler;    modulating the capacity of the subcooler by controlling the splits;    flowing the refrigerant from the subcooler to an expander;    flowing the refrigerant from the expander to an evaporator; and    removing moisture from an air flow by directing the air flow over the evaporator.    
     
     
         30 . The method of    claim 29   , wherein the removing step comprises the step of removing moisture from the air flow at a rate of at least 5 pounds of water per hour when the air flow has a relative humidity of approximately 30%, when utilizing a 60,000 BTU/HR capacity dehumidifier.  
     
     
         31 . The method of    claim 29   , wherein the removing step comprises the step of removing moisture from the air flow at a rate of at least 16 pounds of moisture per hour when the air flow has a relative humidity of approximately 40%, when utilizing a 60,000 BTU/HR capacity dehumidifier.  
     
     
         32 . The method of    claim 29   , further comprising the steps of: 
 flowing the refrigerant from the evaporator to a compressor; and    flowing the refrigerant from the compressor to the condenser.    
     
     
         33 . The method of    claim 29   , wherein the modulating step comprises the steps of: 
 measuring a humidity value of the air flow;    transmitting the humidity value to the splits; and    controlling the splits based on the transmitted humidity value.    
     
     
         34 . The method of    claim 33   , wherein the controlling step comprises the steps of: 
 activating a split when the humidity value falls below a predetermined level; and    de-activating a split when the humidity value rises above the predetermined level.    
     
     
         35 . A method for drying waterborne coatings, comprising the following steps: 
 providing an article coated with a waterborne coating;    directing an air flow over the coated article; and    removing moisture from the air flow by directing the air flow to a dehumidification system having a subcooler including a plurality of splits, wherein each split includes at least one circuit.    
     
     
         36 . The method of    claim 35   , further comprising the steps of: 
 measuring a humidity value of the air flow; and    controlling the splits of the subcooler based on the humidity value.    
     
     
         37 . The method of    claim 36   , further comprising the step of transmitting the humidity value to the subcooler, before the controlling step.  
     
     
         38 . The method of    claim 37   , wherein the controlling step comprises the steps of: 
 receiving the transmitted humidity value; and    activating or de-activating a splits based on the humidity value.    
     
     
         39 . The method of    claim 35   , further comprising the step of providing a drying booth, prior to providing a coated article.  
     
     
         40 . The method of    claim 39   , further comprising the step of directing the air flow into a filtration system, prior to the removing step.  
     
     
         41 . The method of    claim 40   , further comprising the step of drying the coated article by directing the air flow from the dehumidification system to the drying booth, after the removing step.