# US 12,181,179 B2 · Hybrid heat pump with improved dehumidification

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- Number: US 12,181,179 B2
- Document ID: US12181179B2
- Status: Granted
- Kind: B2
- Application number: 17/823,782
- Filed: 2022-08-31
- Published: 2022-12-29
- Granted: 2024-12-31
- Earliest claimed: 2016-11-09
- Assignees: Climate Master, Inc.
- Applicants: Climate Master, Inc.
- Inventors: Michael F. Taras; Michael S. Privett
- Web page: https://patentgrep.com/patent/US12181179B2

## CPC

- F24F 5/00: Air-conditioning systems or apparatus not covered by F24F1/00 or F24F3/00 {, e.g. using solar heat or combined with household units such as an oven or water heater}
- F25B 13/00: Compression machines, plants or systems, with reversible cycle (defrosting cycles F25B47/02)
- F25B 30/02: of the compression type
- F25B 49/02: for compression type machines, plants or systems
- F28C 1/00: Direct-contact trickle coolers, e.g. cooling towers (building construction E04H5/12; enclosed spaces cooled by trickle F25; components parts of trickle coolers F28F25/00; {indirect-contact cooling towers F28B1/06})
- F25B 2313/004: Outdoor unit with water as a heat sink or heat source
- F25B 2400/0403: for condensers
- F25B 2600/13: Pump speed control
- F25B 2600/2501: Bypass valves
- F25B 2600/2513: Expansion valves
- Y02B 30/70: Efficient control or regulation technologies, e.g. for control of refrigerant flow, motor or heating
- F24F: AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING (removing dirt or fumes from areas where they are produced B08B15/00; vertical ducts for carrying away waste gases from buildings E04F17/02; tops for chimneys or ventilating shafts, terminals for flues F23L17/02)
- F25B: REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F28C: HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA COME INTO DIRECT CONTACT WITHOUT CHEMICAL INTERACTION (safety devices in general F16P; fluid heaters having heat generating means F24H; with an intermediate heat-transfer medium coming into direct contact with heat-exchange media F28D15/00 - F28D19/00; details of heat-exchange apparatus of general application F28F)
- Y02B: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS

## Abstract

A hybrid heat pump system comprising a heat pump loop integrated with a hydronic loop. The hybrid heat pump system offers multiple modes of operation to provide increased versatility and improved performance. Each of the loops can operate independently. In addition, the loops can operate in conjunction with each other in both heating and cooling modes. Still further, the hydronic loop can provide a reheat function when the heat pump loop is operating in the cooling mode to provide improved dehumidification of the air delivered to the conditioned space. The heat pump loop may include a hot gas bypass functionality for capacity control and/or freeze protection. The hydronic heat exchanger and the space heat exchanger of the heat pump loop may be combined in a compact single slab construction with a slit fin preventing cross-conduction between the heat exchanger sections.

## Claims

### Claim 1

A hybrid heat pump system for conditioning air in a space, the hybrid heat pump system comprising:
a heat pump loop comprising:
a compressor having a discharge outlet and a suction port;
a source heat exchanger;
a space heat exchanger;
an expansion valve positioned between the space heat exchanger and the source heat exchanger;
a reversing valve positioned downstream of the discharge outlet and configured to:
direct refrigerant alternately to the source heat exchanger or the space heat exchanger from the discharge outlet; and
return the refrigerant to the suction port from the other of the source heat exchanger and the space heat exchanger;
a hydronic loop comprising a hydronic heat exchanger;
a blower configured to direct air along an air flow path to provide conditioned air to the space, wherein the hydronic heat exchanger and the space heat exchanger are positioned in series along the air flow path; and
a control system configured to selectively operate the heat pump loop and the hydronic loop in a plurality of operating modes based on a space set point temperature and an actual space air temperature;
wherein the plurality of operating modes includes a plurality of cooling modes, and wherein the control system is configured to operate the heat pump loop and the hydronic loop in one of the plurality of cooling modes in response to determining that the actual space air temperature is greater than the space set point temperature, and
wherein the plurality of cooling modes includes a heat pump loop cooling mode for which the control system is configured to activate the heat pump loop when a hydronic loop temperature is greater than a predetermined temperature that is less than the space set point temperature by at least a predetermined value.

### Claim 2

A hybrid heat pump system for conditioning air in a space, the hybrid heat pump system comprising:
a heat pump loop comprising:
a compressor having a discharge outlet and a suction port;
a source heat exchanger;
a space heat exchanger;
an expansion valve positioned between the space heat exchanger and the source heat exchanger;
a reversing valve positioned downstream of the discharge outlet and configured to:
direct refrigerant alternately to the source heat exchanger or the space heat exchanger from the discharge outlet; and
return the refrigerant to the suction port from the other of the source heat exchanger and the space heat exchanger;
a hydronic loop comprising a hydronic heat exchanger;
a blower configured to direct air along an air flow path to provide conditioned air to the space, wherein the hydronic heat exchanger and the space heat exchanger are positioned in series along the air flow path; and
a control system configured to selectively operate the heat pump loop and the hydronic loop in a plurality of operating modes based on a space set point temperature and an actual space air temperature;
wherein the plurality of operating modes includes a plurality of cooling modes, and wherein the control system is configured to operate the heat pump loop and the hydronic loop in one of the plurality of cooling modes in response to determining that the actual space air temperature is greater than the space set point temperature, and
wherein the plurality of cooling modes includes a hydronic loop cooling mode for which the control system is configured to activate the hydronic loop when a hydronic loop temperature is less than a predetermined temperature that is less than the space set point temperature by at least a predetermined value.

### Claim 3

A hybrid heat pump system for conditioning air in a space, the hybrid heat pump system comprising:
a heat pump loop comprising:
a compressor having a discharge outlet and a suction port;
a source heat exchanger;
a space heat exchanger;
an expansion valve positioned between the space heat exchanger and the source heat exchanger;
a reversing valve positioned downstream of the discharge outlet and configured to:
direct refrigerant alternately to the source heat exchanger or the space heat exchanger from the discharge outlet; and
return the refrigerant to the suction port from the other of the source heat exchanger and the space heat exchanger;
a hydronic loop comprising a hydronic heat exchanger;
a blower configured to direct air along an air flow path to provide conditioned air to the space, wherein the hydronic heat exchanger and the space heat exchanger are positioned in series along the air flow path; and
a control system configured to selectively operate the heat pump loop and the hydronic loop in a plurality of operating modes based on a space set point temperature and an actual space air temperature;
wherein the plurality of operating modes includes a plurality of cooling modes, and wherein the control system is configured to operate the heat pump loop and the hydronic loop in one of the plurality of cooling modes in response to determining that the actual space air temperature is greater than the space set point temperature, and
wherein the plurality of cooling modes includes a combined heat pump loop and hydronic loop cooling mode for which the control system is configured to:
activate the hydronic loop when a hydronic loop temperature is less than a predetermined temperature that is less than the space set point temperature by at least a predetermined value; and
activate the heat pump loop when the hydronic loop is activated and at maximum capacity.

### Claim 4

A hybrid heat pump system for conditioning air in a space, the hybrid heat pump system comprising:
a heat pump loop comprising:
a compressor having a discharge outlet and a suction port;
a source heat exchanger;
a space heat exchanger;
an expansion valve positioned between the space heat exchanger and the source heat exchanger;
a reversing valve positioned downstream of the discharge outlet and configured to:
direct refrigerant alternately to the source heat exchanger or the space heat exchanger from the discharge outlet; and
return the refrigerant to the suction port from the other of the source heat exchanger and the space heat exchanger;
a hydronic loop comprising a hydronic heat exchanger;
a blower configured to direct air along an air flow path to provide conditioned air to the space, wherein the hydronic heat exchanger and the space heat exchanger are positioned in series along the air flow path; and
a control system configured to selectively operate the heat pump loop and the hydronic loop in a plurality of operating modes based on a space set point temperature and an actual space air temperature;
wherein the plurality of operating modes includes a plurality of heating modes, and wherein the control system is configured to operate the heat pump loop and the hydronic loop in one of the plurality of heating modes in response to determining that the actual space air temperature is less than the space set point temperature, and
wherein the plurality of heating modes includes a heat pump loop heating mode for which the control system is configured to activate the heat pump loop when a hydronic loop temperature is less than a predetermined temperature that is greater than the space set point temperature by a predetermined value.

### Claim 5

A hybrid heat pump system for conditioning air in a space, the hybrid heat pump system comprising:
a heat pump loop comprising:
a compressor having a discharge outlet and a suction port;
a source heat exchanger;
a space heat exchanger;
an expansion valve positioned between the space heat exchanger and the source heat exchanger;
a reversing valve positioned downstream of the discharge outlet and configured to:
direct refrigerant alternately to the source heat exchanger or the space heat exchanger from the discharge outlet; and
return the refrigerant to the suction port from the other of the source heat exchanger and the space heat exchanger;
a hydronic loop comprising a hydronic heat exchanger;
a blower configured to direct air along an air flow path to provide conditioned air to the space, wherein the hydronic heat exchanger and the space heat exchanger are positioned in series along the air flow path; and
a control system configured to selectively operate the heat pump loop and the hydronic loop in a plurality of operating modes based on a space set point temperature and an actual space air temperature;
wherein the plurality of operating modes includes a plurality of heating modes, and wherein the control system is configured to operate the heat pump loop and the hydronic loop in one of the plurality of heating modes in response to determining that the actual space air temperature is less than the space set point temperature, and
wherein the plurality of operating modes includes a hydronic loop heating mode for which the control system is configured to activate the hydronic loop when a hydronic loop temperature is greater than a predetermined temperature that is greater than the space set point temperature by a predetermined value.

### Claim 6

A hybrid heat pump system for conditioning air in a space, the hybrid heat pump system comprising:
a heat pump loop comprising:
a compressor having a discharge outlet and a suction port;
a source heat exchanger;
a space heat exchanger;
an expansion valve positioned between the space heat exchanger and the source heat exchanger;
a reversing valve positioned downstream of the discharge outlet and configured to:
direct refrigerant alternately to the source heat exchanger or the space heat exchanger from the discharge outlet; and
return the refrigerant to the suction port from the other of the source heat exchanger and the space heat exchanger;
a hydronic loop comprising a hydronic heat exchanger;
a blower configured to direct air along an air flow path to provide conditioned air to the space, wherein the hydronic heat exchanger and the space heat exchanger are positioned in series along the air flow path; and
a control system configured to selectively operate the heat pump loop and the hydronic loop in a plurality of operating modes based on a space set point temperature and an actual space air temperature;
wherein the plurality of operating modes includes a plurality of heating modes, and wherein the control system is configured to operate the heat pump loop and the hydronic loop in one of the plurality of heating modes in response to determining that the actual space air temperature is less than the space set point temperature, and
wherein the plurality of operating modes includes a combined heat pump loop and hydronic loop heating mode for which the control system is configured to:
activate the hydronic loop when a hydronic loop temperature is greater than a predetermined temperature that is greater than the space set point temperature by a predetermined value; and
activate the heat pump loop when the hydronic loop is activated and at maximum capacity.

### Claim 7

A hybrid heat pump system for conditioning air in a space, the hybrid heat pump system comprising:
a heat pump loop comprising:
a compressor;
a source heat exchanger;
a space heat exchanger;
a reversing valve configured to:
selectively direct refrigerant from the compressor to one of the source heat exchanger and the space heat exchanger; and
selectively return the refrigerant to the compressor from the other of the source heat exchanger and the space heat exchanger;
a hydronic loop comprising a hydronic heat exchanger that is in series with the space heat exchanger along an air flow path for providing conditioned air to the space; and
a control system configured to selectively operate the heat pump loop and the hydronic loop in a plurality of operating modes based on a space set point temperature and an actual space air temperature;
wherein the plurality of operating modes includes a plurality of cooling modes, and wherein the control system is configured to operate the heat pump loop and the hydronic loop in one of the plurality of cooling modes in response to determining that the actual space air temperature is greater than the space set point temperature, and
wherein the plurality of cooling modes includes a heat pump loop cooling mode for which the control system is configured to activate the heat pump loop when a hydronic loop temperature is greater than a predetermined temperature that is less than the space set point temperature by at least a predetermined value.

### Claim 8 (depends on 7)

The hybrid heat pump system of claim 7, wherein the compressor includes a discharge outlet and a suction port, and wherein the reversing valve includes a first port positioned downstream of the discharge outlet, a second port positioned upstream of the suction port, a third port fluidly connected to the source heat exchanger, and a fourth port fluidly connected to the space heat exchanger.

### Claim 9 (depends on 8)

The hybrid heat pump system of claim 8, wherein the reversing valve is configured to:
selectively direct the refrigerant from the discharge outlet to one of the source heat exchanger and the space heat exchanger; and
selectively return the refrigerant to the suction port from the other of the source heat exchanger and the space heat exchanger.

### Claim 10

A hybrid heat pump system for conditioning air in a space, the hybrid heat pump system comprising:
a heat pump loop comprising:
a compressor;
a source heat exchanger;
a space heat exchanger;
a reversing valve configured to:
selectively direct refrigerant from the compressor to one of the source heat exchanger and the space heat exchanger; and
selectively return the refrigerant to the compressor from the other of the source heat exchanger and the space heat exchanger;
a hydronic loop comprising a hydronic heat exchanger that is in series with the space heat exchanger along an air flow path for providing conditioned air to the space; and
a control system configured to selectively operate the heat pump loop and the hydronic loop in a plurality of operating modes based on a space set point temperature and an actual space air temperature;
wherein the plurality of operating modes includes a plurality of cooling modes, and wherein the control system is configured to operate the heat pump loop and the hydronic loop in one of the plurality of cooling modes in response to determining that the actual space air temperature is greater than the space set point temperature, and
wherein the plurality of cooling modes includes a hydronic loop cooling mode for which the control system is configured to activate the hydronic loop when a hydronic loop temperature is less than a predetermined temperature that is less than the space set point temperature by at least a predetermined value.

### Claim 11

A hybrid heat pump system for conditioning air in a space, the hybrid heat pump system comprising:
a heat pump loop comprising:
a compressor;
a source heat exchanger;
a space heat exchanger;
a reversing valve configured to:
selectively direct refrigerant from the compressor to one of the source heat exchanger and the space heat exchanger; and
selectively return the refrigerant to the compressor from the other of the source heat exchanger and the space heat exchanger;
a hydronic loop comprising a hydronic heat exchanger that is in series with the space heat exchanger along an air flow path for providing conditioned air to the space; and
a control system configured to selectively operate the heat pump loop and the hydronic loop in a plurality of operating modes based on a space set point temperature and an actual space air temperature;
wherein the plurality of operating modes includes a plurality of cooling modes, and wherein the control system is configured to operate the heat pump loop and the hydronic loop in one of the plurality of cooling modes in response to determining that the actual space air temperature is greater than the space set point temperature, and
wherein the plurality of cooling modes includes a combined heat pump loop and hydronic loop cooling mode for which the control system is configured to:
activate the hydronic loop when a hydronic loop temperature is less than a predetermined temperature that is less than the space set point temperature by at least a predetermined value; and
activate the heat pump loop when the hydronic loop is activated and at maximum capacity.

### Claim 12

A hybrid heat pump system for conditioning air in a space, the hybrid heat pump system comprising:
a heat pump loop comprising:
a compressor;
a source heat exchanger;
a space heat exchanger;
a reversing valve configured to:
selectively direct refrigerant from the compressor to one of the source heat exchanger and the space heat exchanger; and
selectively return the refrigerant to the compressor from the other of the source heat exchanger and the space heat exchanger;
a hydronic loop comprising a hydronic heat exchanger that is in series with the space heat exchanger along an air flow path for providing conditioned air to the space; and
a control system configured to selectively operate the heat pump loop and the hydronic loop in a plurality of operating modes based on a space set point temperature and an actual space air temperature;
wherein the plurality of operating modes includes a plurality of heating modes, and wherein the control system is configured to operate the heat pump loop and the hydronic loop in one of the plurality of heating modes in response to determining that the actual space air temperature is less than the space set point temperature, and
wherein the plurality of heating modes includes a heat pump loop heating mode for which the control system is configured to activate the heat pump loop when a hydronic loop temperature is less than a predetermined temperature that is greater than the space set point temperature by a predetermined value.

### Claim 13

A hybrid heat pump system for conditioning air in a space, the hybrid heat pump system comprising:
a heat pump loop comprising:
a compressor;
a source heat exchanger;
a space heat exchanger;
a reversing valve configured to:
selectively direct refrigerant from the compressor to one of the source heat exchanger and the space heat exchanger; and
selectively return the refrigerant to the compressor from the other of the source heat exchanger and the space heat exchanger;
a hydronic loop comprising a hydronic heat exchanger that is in series with the space heat exchanger along an air flow path for providing conditioned air to the space; and
a control system configured to selectively operate the heat pump loop and the hydronic loop in a plurality of operating modes based on a space set point temperature and an actual space air temperature;
wherein the plurality of operating modes includes a plurality of heating modes, and wherein the control system is configured to operate the heat pump loop and the hydronic loop in one of the plurality of heating modes in response to determining that the actual space air temperature is less than the space set point temperature, and
wherein the plurality of operating modes includes a hydronic loop heating mode for which the control system is configured to activate the hydronic loop when a hydronic loop temperature is greater than a predetermined temperature that is greater than the space set point temperature by a predetermined value.

### Claim 14

A hybrid heat pump system for conditioning air in a space, the hybrid heat pump system comprising:
a heat pump loop comprising:
a compressor;
a source heat exchanger;
a space heat exchanger;
a reversing valve configured to:
selectively direct refrigerant from the compressor to one of the source heat exchanger and the space heat exchanger; and
selectively return the refrigerant to the compressor from the other of the source heat exchanger and the space heat exchanger;
a hydronic loop comprising a hydronic heat exchanger that is in series with the space heat exchanger along an air flow path for providing conditioned air to the space; and
a control system configured to selectively operate the heat pump loop and the hydronic loop in a plurality of operating modes based on a space set point temperature and an actual space air temperature;
wherein the plurality of operating modes includes a plurality of heating modes, and wherein the control system is configured to operate the heat pump loop and the hydronic loop in one of the plurality of heating modes in response to determining that the actual space air temperature is less than the space set point temperature, and
wherein the plurality of operating modes includes a combined heat pump loop and hydronic loop heating mode for which the control system is configured to:
activate the hydronic loop when a hydronic loop temperature is greater than a predetermined temperature that is greater than the space set point temperature by a predetermined value; and
activate the heat pump loop when the hydronic loop is activated and at maximum capacity.