Modular heat pump system

Abstract

An HVAC system utilizes one or more modular heat pump units installed within an outer wall or corner of a building, and one or more active registers. A central hub, which can be integrated into a modular HVAC unit, receives input from thermostats and sensors in the building and adjusts operation of the modular HVAC units and active registers to distribute conditioned air throughout the building. The system provides convenience and comfort of a traditional split HVAC system with significantly reduced installation and maintenance costs. The modular HVAC unit includes an interchangeable cartridge that contains the active components of a heat pump. Cartridges of different capacities can be installed as required, and are easily swapped out for maintenance, servicing, and replacement. A user can control the system using traditional-style thermostats and with a smart phone, tablet or computer. A cloud server provides backup services and remote access to the system.

What is claimed is: 
     
         1 . An in-wall enclosure for mounting a modular HVAC cartridge within a space defined by an exterior sheathing of a building, a first vertical stud, and a second vertical stud, comprising:
 an indoor duct opening and an outdoor duct opening defined therein;   an outdoor air inlet defined therein; and   a front opening exposing a cavity configured to operatively receive a modular HVAC cartridge.   
     
     
         2 . The in-wall enclosure in accordance with  claim 1 , further comprising:
 an indoor duct extending from the indoor duct opening to an indoor duct outlet; and   an outdoor duct extending from the outdoor duct opening to an outdoor duct outlet.   
     
     
         3 . The in-wall enclosure in accordance with  claim 1 , further comprising a condensate outlet port. 
     
     
         4 . The in-wall enclosure in accordance with  claim 1 , further comprising an electrical connector disposed in the cavity. 
     
     
         5 . The in-wall enclosure in accordance with  claim 4 , wherein the electrical connector is positioned to electrically engage a mating connector provided on the modular HVAC cartridge when the modular HVAC cartridge is positioned in the in-wall enclosure. 
     
     
         6 . A modular HVAC cartridge, comprising:
 a housing having at least a rear side, a top side, and a front side, the housing dimensioned to mate with the cavity of an in-wall enclosure;   an indoor air port defined in the housing and configured to mate with the indoor duct of an in-wall enclosure;   an outdoor air port defined in the housing and configured to mate with the outdoor duct of an in-wall enclosure;   an indoor air inlet defined in the housing;   an outdoor air inlet defined in the housing;   an indoor coil disposed between the indoor air inlet and the indoor air port;   an indoor fan for moving indoor air from the indoor air inlet to the indoor air port;   an outdoor coil disposed between the outdoor air inlet and the outdoor air port;   an outdoor fan for moving outdoor air from the outdoor air inlet to the outdoor air port; and   a compressor in fluid communication with the indoor coil and the outdoor coil for performing a vapor-compression cycle.   
     
     
         7 . The modular HVAC cartridge in accordance with  claim 6 , further comprising:
 an indoor condensate pan positioned beneath the indoor coil; and   an outdoor condensate pan positioned beneath the outdoor coil.   
     
     
         8 . The modular HVAC cartridge in accordance with  claim 7 , further comprising a drain pipe having an upper end and a lower end, wherein the upper end is in fluid communication with the indoor condensate pan, and wherein the lower end is in fluid communication with the outdoor condensate pan. 
     
     
         9 . The modular HVAC cartridge in accordance with  claim 6 , further comprising a control module, comprising:
 a controller including a processor and a memory including instructions executable by the processor which, when executed by the processor, cause the processor to adjust the operation of the indoor fan, the outdoor fan, and/or the compressor; and   a communications interface.   
     
     
         10 . The modular HVAC cartridge in accordance with  claim 9 , wherein the memory further includes instructions executable by the processor which, when executed by the processor, cause the processor to receive, from the communications interface, an operational parameter of the modular HVAC cartridge and/or to transmit, to the communications interface, an operational status of the modular HVAC cartridge. 
     
     
         11 . The modular HVAC cartridge in accordance with  claim 6 , further comprising a peripheral dock having a data interface compatible with a device selected from the group consisting of a CO 2  sensor, a video camera, a smart phone, a lighting controller, room lights, an audio playback device, and a flat panel interface. 
     
     
         12 . The modular HVAC cartridge in accordance with  claim 11 , wherein the peripheral dock includes an electrical power connector. 
     
     
         13 . The modular HVAC cartridge in accordance with  claim 6 , wherein the indoor coil is divided into two sections that may be selectively coupled in a parallel configuration to facilitate a heating or cooling mode, or in a serial configuration to facilitate a dehumidification mode. 
     
     
         14 . A modular HVAC system, comprising:
 a modular HVAC unit;   a control hub in operative communication with the modular HVAC unit;   a temperature sensor in operative communication with the control hub;   an active register in operative communication with the control hub; and   a mobile device in operative communication with the control hub.   
     
     
         15 . The modular HVAC system in accordance with  claim 14 , wherein the mobile device comprises a processor and a memory including instructions executable by the processor which, when executed by the processor, cause the mobile device to transmit a temperature setpoint to the control hub and/or to receive an operational status from the control hub. 
     
     
         16 . The modular HVAC system in accordance with  claim 14 , wherein the control hub comprises a processor and a memory including instructions executable by the processor which, when executed by the processor, cause the control hub to:
 receive a temperature setpoint from the mobile device;   receive a temperature measurement from the temperature sensor; and   transmit an operational parameter to the active register based on the temperature setpoint and the temperature measurement.   
     
     
         17 . The modular HVAC system in accordance with  claim 14 , wherein the control hub comprises a processor and a memory including instructions executable by the processor which, when executed by the processor, cause the control hub to:
 receive a temperature setpoint from the mobile device;   receive a temperature measurement from the temperature sensor; and   transmit an operational parameter to the modular HVAC unit based on the temperature setpoint and the temperature measurement.   
     
     
         18 . The modular HVAC system in accordance with  claim 14 , further comprising a thermostat in operative communication with the control hub. 
     
     
         19 . The modular HVAC system in accordance with  claim 18 , wherein the control hub comprises a processor and a memory including instructions executable by the processor which, when executed by the processor, cause the control hub to:
 receive a temperature setpoint and/or an operational parameter from the thermostat; and   transmit an operational parameter to the modular HVAC unit based on the temperature setpoint and/or the operational parameter.   
     
     
         20 . The modular HVAC system in accordance with  claim 14 , further comprising a remote server in operative communication with the control hub, the remote server comprising:
 a processor; and   a memory including instructions executable by the processor which, when executed by the processor, cause the remote server to:
 receive one or more operational parameters from the control hub; 
 store the received operational parameters in a backup database; and 
   transmit one or more of the stored operational parameters to the control hub.   
     
     
         21 . The modular HVAC system in accordance with  claim 14 , further comprising a remote server in operative communication with the control hub, the remote server comprising:
 a processor; and   a memory including instructions executable by the processor which, when executed by the processor, cause the remote server to:
 receive one or more operational parameters from the mobile device; and 
 transmit one or more of the received operational parameters to the control hub. 
   
     
     
         22 . The modular HVAC system in accordance with  claim 14 , wherein the active register comprises:
 a communications interface;   a fan; and   a controller comprising a processor, and a memory including instructions executable by the processor which, when executed by the processor, cause the active register to:   receive a fan command from the control hub; and
 adjust the speed of the fan in accordance with the fan command. 
   
     
     
         23 . The modular HVAC system in accordance with  claim 14 , wherein the active register comprises:
 a communications interface;   a fan; and   a controller comprising a processor, and a memory including instructions executable by the processor which, when executed by the processor, cause the active register to:   receive a setpoint temperature from the control hub;   receive a temperature measurement from the temperature sensor; and   adjust the fan speed in accordance with the setpoint temperature and the temperature measurement.   
     
     
         24 . The modular HVAC system in accordance with  claim 23 , wherein the memory of the active register further includes instructions executable by the processor which, when executed by the processor, cause the active register to transmit the fan speed to the control hub.