Systems and Methods for Warm Air Pre-Cooling

Abstract

Several methods and systems for pre-cooling warm air in a cooling system are disclosed. The warm air may be return air, fresh air or a combination of return and fresh air. Condensate from a primary cooling element is applied to the wet side of an air-to-air heat exchanger while the warm air passes through the dry side of the heat exchanger. The warm air is pre-cooled by the transfer of heat from the warm air to the condensate, reducing overall energy consumption in the cooling system.

We claim: 
     
         1 . A method for pre-cooling a warm airflow in a cooling system, the method comprising:
 providing an air-to-air heat exchanger, wherein the heat exchanger has a wet side and a dry side;   collecting a condensate produced within the cooling system; and   applying the condensate to the wet side of the heat exchanger, thereby drawing heat from the warm airflow flowing in the dry side of the heat exchanger.   
     
     
         2 . The method of  claim 1  wherein the wet side of the heat exchanger includes one or more wet side channels, and wherein applying the condensate to the wet side includes applying a condensate airflow to propel the condensate through the wet side channels. 
     
     
         3 . The method of  claim 2  wherein the condensate airflow also blows evaporated condensate out of the wet side. 
     
     
         4 . The method of  claim 1  wherein the wet side of the heat exchanger includes one or more wet side channels, wherein the wet side channels have interior surfaces, and wherein applying the condensate to the wet side includes applying at least some of the condensate to at least a portion of the interior surfaces. 
     
     
         5 . The method of  claim 4  wherein at least a portion of at least one of the interior surfaces is coated with a hydrophilic coating to promote the spread of condensate on the coated interior surfaces. 
     
     
         6 . The method of  claim 1  wherein the wet side of the heat exchanger includes one or more wet side channels, and wherein applying the condensate to the wet side includes spraying the condensate into the wet side channels. 
     
     
         7 . A system for pre-cooling a warm airflow, the system comprising:
 a cooling system that has a primary cooling element, wherein, in operation, the primary cooling element generates a condensate;   a heat exchanger positioned upstream from the primary cooling element in the warm airflow, wherein the heat exchanger has a wet side and a dry side, and wherein, in operation, warm air passes through the dry side; and   a condensate application module for applying the condensate to the wet side of the heat exchanger,   wherein, in operation, the warm airflow is pre-cooled by a transfer of heat from the warm airflow to the condensate in the wet side of the heat exchanger, thereby vaporizing the condensate.   
     
     
         8 . The system of  claim 7  wherein the primary cooling element is an evaporator. 
     
     
         9 . The system of  claim 7  wherein the condensate application module includes a pump that is fluidically coupled to a condensate reservoir in which the condensate collects, and wherein, in operation, the pump applies the condensate to the wet side of the heat exchanger. 
     
     
         10 . The system of  claim 7  further comprising a condensate fan to generate a condensate airflow to propel the condensate through the wet side of the heat exchanger. 
     
     
         11 . The system of  claim 7  further wherein a condensate airflow is generated by diverting a portion of the warm airflow through the wet side of the heat exchanger as a condensate airflow, wherein the condensate airflow propels the vaporized condensate through the wet side of the heat exchanger. 
     
     
         12 . The system of  claim 7  further wherein, after passing through the heat exchanger, pre-cooled warm air is further cooled by passing it through the primary cooling element to form supply air, and wherein a condensate airflow is generated by diverting a portion of the supply air through the wet side of the heat exchanger as a condensate airflow, wherein the condensate airflow propels the condensate through the wet side of the heat exchanger. 
     
     
         13 . The system of  claim 7  wherein the condensate application module utilizes gravity to transport condensate to the wet side of the heat exchanger. 
     
     
         14 . The system of  claim 7  wherein the wet side of the heat exchanger includes one or more wet side channels. 
     
     
         15 . The system of  claim 7  further comprising a hydrophilic coating applied to at least a portion of at least one of the wet side channels.