Robert
CUPPETILLI
Heating System
Heating
up: Inventor says system ‘a gold mine with no end'
by Darrell Clem
Canton inventor Robert Cuppetilli has received a patent for a
secondary heating system he says will sharply reduce energy
consumption, slash customer bills and create thousands of jobs
for companies that install it.
“This is like a gold mine with no end in the bank,”
Cuppetilli, 72, said, sitting in a Canton home where he
already has installed the new system.
A consultant and former demolition business owner, Cuppetilli
has enlisted partners and formed Sunrise Mechanical Inc., in
hopes of marketing what he calls an industry-changing creation
that has prototypes for natural gas, propane, fuel oil and
electric heating systems.
He also has a separate patent pending for a secondary cooling
system he says will dramatically curb energy usage and reduce
consumer bills.
Cuppetilli has compared his energy usage and customer bills
with those of friends and neighbors who don't have the
secondary heating system, and he has kept charts to show the
results.
Last December, a Plymouth woman who has a home similar in size
to Cuppetilli's 5,875-square-foot house had a utility bill of
$631 compared to his $192, even though she kept her
temperature setting at 62 degrees compared to his 71 degrees.
Cuppetilli has compared several homes with similar results.
Joe Barone, a business partner and attorney, has been
impressed by the results.
“The numbers are there, and they're quite phenomenal,” he
said. “I think he's got something here.”
Cuppetilli estimates his invention can reduce heating costs by
67 percent or more. He hopes to secure bids from companies for
the exclusive right to manufacture and distribute the
secondary heating system.
Essentially, the heating system operates in supplemental mode
to carry water from a water heater to the heat exchanger
within an air passage in the furnace. Air within the air
passage passes through the heat exchanger and is heated from
the water. Then, the water returns to the water tank.
Meanwhile, a supplemental thermostat connected to the system
controls an air circulator for the furnace without requiring
the furnace to be activated. The furnace will turn on and heat
the air only if the supplemental mode isn't sufficient to
maintain the desired temperature.
Cuppetilli also uses coils and soapstone, which retains heat
for 48 hours, for the system that gravity-feeds heat through
his house without requiring much work from the furnace. A
thermostat for the secondary heating system is set higher than
the one for the furnace.
“What controls this whole thing is the thermostat,” Cuppetilli
said, adding later, “The only thing I really use off the
furnace is the blower. I figure I'm saving about 67 percent on
my heating bill.”
It sounds complicated, and it is. Cuppetilli concedes he has
spent hours explaining his invention to industry insiders.
Yet, he seems confident it works — and Barone and others say
he has the statistics to show it.
If he gets his invention marketed, Cuppetilli said the system
could be installed without affecting a furnace's warranty.
Cuppetilli has sought bids from 29 furnace companies, and he
would get royalties. He said utility companies, which stand to
lose revenue, “don't want to see this.”
Even so, he said his invention could create thousands of jobs
in an economy that sorely needs them. Moreover, he said he
will dictate that all parts used for installation are made in
America.
“I want to keep the work here,” he said.
US2009078783
SECONDARY HEATING AND COOLING
SYSTEM
Abstract -- A heating and
cooling system operates in a supplemental heating mode or a
supplemental cooling mode. In supplemental heating mode, the
system carries water from a hot water supply of the water
heater to a heat exchanger within an air passage in the
furnace to heat the building. In the supplemental cooling
mode, the system carries cool water from a cool water storage
tank to the heat exchanger within the furnace to assist in
cooling the building.
BACKGROUND OF THE INVENTION
[0002] This invention relates to a heating system and cooling
system. More particularly, this invention relates to a system
for supplementing a main heating system and main cooling
system.
[0003] Conventional heating systems for homes generally
include a water heater and a furnace. The furnace typically
provides hot air to warm the interior temperature of the house
while the water heater provides hot water for the household.
An air conditioner provides cool air to the building. The
energy requirements of the furnace are substantially greater
than the energy requirements of the hot water heater. In
addition, water temperatures are less affected by
environmental changes than air within a house.
[0004] An apparatus and method for supplementing a furnace to
heat a building and an air conditioner to cool a building
while decreasing overall utility costs is needed.
SUMMARY OF THE INVENTION
[0005] A heating system operates in normal and supplemental
modes to increase system efficiency and reduce overall cost.
[0006] A heating system for use in heating a residential
dwelling includes a furnace and a water heater. In
supplemental mode the system carries water from the hot water
supply from the water heater to a heat exchanger within an air
passage for the furnace. A water return passage returns the
water from the air passage back to the water heater. Air
within the air passage passes through the heat exchanger and
is heated from the water within. The water then returns to the
water tank through a water return passage.
[0007] A supplemental thermostat is connected to the system to
control an air circulator for the furnace without requiring
the furnace to be activated. In supplemental mode the air
circulator operates at a reduced speed compared to the speed
when in normal mode such that, the system is continuing to
warm the air enough to maintain the temperature without
cycling on and off. A main thermostat, for the furnace, would
preferably be set at a lower desired temperature than the
supplemental thermostat. Thus, the system will only operate in
normal mode if supplemental mode is not sufficient to maintain
the desired temperature.
[0008] A cooling system for use in cooling a residential
dwelling includes an air conditioner and a holding tank. In
supplemental mode the system carries water from the cold water
supply from the holding tank to a cooling coil. A water return
passage returns the water from the cooling coil back to the
holding tank. There is soapstone in the holding tank to aid in
keep the water cool.
[0009] These and other features of the present invention can
be best understood from the following specification and
drawings, the following of which is a brief description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a
schematic illustration of an example heating system of the
present invention.

[0011] FIG. 2 is a
schematic illustration of an example cooling system of the
present invention.

DETAILED DESCRIPTION OF THE
PREFERRED EMBODIMENT
[0012] A heating and cooling system 10 (or "HVAC system") is
shown schematically in FIG. 1. The system 10 is preferably for
use in heating a home or other residential dwelling. The
system 10 includes a furnace 12 and a water heater 14. The
furnace 12 and water heater 14 may operate on natural gas,
electricity, oil or any available energy source. The furnace
12 has a thermostat 16 to control furnace operation and a
control line 18 to connect the thermostat 16 to the furnace
12. The thermostat 16 is mounted within the house remote from
the furnace 12 in an easily accessible area to the user. The
system 10 may also include an air conditioner coil 20
(condenser) attached to the furnace 12, so that the system can
provide hot and cool air for the home. An air passage 22
extends from the furnace 12 to carry the heated or cooled air
(airflow indicated with arrow A) through the home.
[0013] An air circulator 24 incorporated in the furnace 12
controls the airflow through the air passage 22 and includes a
control 26 to control the volume of air that is circulated
through the home. Typically the air circulator 24 includes a
fan 28. The speed of the fan 28 is set by the control 26 which
receives input from the thermostat 16 to turn the fan 28 on or
off or adjust a variable speed.
[0014] The water heater 14 includes a cold water supply 30
leading into a water tank 32 and a hot water supply 34 leading
from the water tank 32. Water, indicated by arrow W, from the
ground supply enters the water tank 32 through the cold water
supply 30. The water is heated within the water tank 32 and
exits through the hot water supply 34 to be distributed at
desired locations throughout the house. The water heater 14
also includes a water tank drain valve 36. The water tank
drain valve 36 is normally used to drain water from the tank
32 during maintenance or repair. During typical operation of
the water heater 14 the water tank drain valve 36 is closed to
retain the water within the water tank 32.
[0015] During normal system 10 operation the furnace 12
receives a control input from the thermostat 16 based upon the
desired interior temperature of the home and the actual
interior temperature of the home. When the difference in
temperature has reached a predetermined level the system 10 is
activated to either warm or cool the air. The air is
distributed through the home through the air passage 22 until
the thermostat 16 senses the actual interior temperature is
the same as the desired interior temperature. Activating the
furnace 12 requires power to heat the air and to activate the
air circulator 24 to distribute the air. The fan 28 may have
one operating speed or may be variable speed, and is either
rotating or stationary.
[0016] When difference between the actual home temperature and
the desired home temperature is large enough to require
heating the home, but not large enough to require the furnace
12, the system 10 operates in supplemental mode.
[0017] A water supply passage 38 carries water from the water
heater 14 to the air passage 22 for the furnace 12. The water
supply passage 38 is connected to the hot water supply 34
leading from the water tank 32 to the house. Thus, the water
within the water supply passage 38 has been heated by the
water heater 14. A water return passage 40 returns the water
from the air passage 22 back to the water heater 14. The water
return passage 40 preferably is connected to the water tank 32
at the water drain valve 36. The water supply passage may be
connected to the water tank 32 in another manner that allows
water to return to the water tank 32, but is preferably
connected at a lower end of the water tank 32.
[0018] The water passes through the water supply passage 38 to
a heat exchanger 42 within the air passage 22. Air within the
air passage 22 passes through the heat exchanger 42 and is
heated from the water within the heat exchanger 42. The water
then returns to the water tank 32 through the water return
passage 40. The heat exchanger 42 is preferably a water coil
heat exchanger. Water coil heat exchangers are specifically
designed for carrying water through the heater exchanger coils
44. The coils 44 are typically copper and aluminum, or
entirely aluminum.
[0019] A supplemental thermostat 46 is connected to the air
circulator 24. A supplemental control line 48 also leads to
the air circulator 24. The supplemental control line 48 is
separate from the main control line 18. The supplemental
thermostat 46 and control line 48 allow the air circulator 24
to be controlled in supplemental mode without requiring the
furnace 12 to be activated. The air circulator 24 is used to
activate the fan 28 and create air flow through the air
passage 22 when in the supplemental mode. In supplemental mode
the fan 28 will operate at a reduced speed compared to the fan
speed when in normal mode. If the control 26 for the fan 28
does not provide variable speed capability, a rheostat or
other power control can be added so that the speed of the fan
28 is reduced in supplemental mode. Optionally, in some
situations, the fan 28 may not be necessary in supplemental
mode, as the air may circulate sufficiently purely by
convection.
[0020] The supplemental thermostat 46 is set at a desired
temperature. When the actual temperature drops below the
desired temperature, as sensed by the supplemental thermostat
46, water is passed through the supply passage 38 to the heat
exchanger 42. The thermostat sends a signal to the air
circulator 24 to begin fan 28 operation. The supplemental
thermostat 46 is connected to an electric supply valve 50 and
an electric return valve 52. The thermostat 46 can shut off
water flow through the supply passage 38 and return passage 40
when the actual temperature is the same as the desired
temperature. Preferably, the fan speed 28 is set at low
revolutions per minute such that, in supplemental mode, the
system 10 is continuing to warm the air enough to maintain the
temperature without cycling the system on and off. The main
thermostat 16 would preferably be set at a lower desired
temperature than the supplemental thermostat 46. Thus, the
system will only operate in normal mode if supplemental mode
is not sufficient to maintain the desired temperature. The
system 10 could operate in both normal mode and supplemental
mode at the same time. In other words, the supplemental mode
continues to operate when the normal mode is switched on.
[0021] The hot water could circulate continuously through the
heat exchanger 42 and the heat could circulate by convection
through the house most of the time, with the furnace 12
switched on only when necessary.
[0022] By maintaining a desired temperature with the system 10
in supplemental mode, operation of the furnace 12 is reduced.
The reduced operation of the furnace 12 saves on energy costs
for the system 10.
[0023] Manual supply valve 54 can be used to override the
system 10 and prevent water flow through the supply passage
38. Likewise, manual return valve 56 can be used to override
the system 10 and prevent water flow through the return
passage 40. The manual valves 54, 56 can be used to prevent
water flow to the system 10 in warmer months.
[0024] In another embodiment, a separate auxiliary cooling
system 67, shown in FIG. 2, can be connected to the supply
passage 38 and the return passage 40 of the heating system 10
(without or without the supplementary heating system). Cold
water is initially supplied by the cool water intake 66
through the fresh water inlet 59. When the air conditioner 20
turns on, the auxiliary cooling system 67 is activated. The
pump 62 is connected to the main thermostat 16 (FIG. 1) such
that when the air conditioner 20 is turned on, the pump 62
will begin to circulate water in the system 67 to the coil 42
above the air conditioner 20 (FIG. 1).
[0025] The system includes two shut off valves 57, one each
located on the outline pipe 56 and the return pipe 61, which
can be used to shut down the system (e.g. in the winter, when
the supplementary heating system is being used). These valves
57 can also be used to connect the auxiliary cooling system 67
with the supply passage 38 and the return passage 40 of the
heating system 10. Temperature gages 60 are located on the
outline pipe 56 and the return pipe 61 to send water
temperature information to the thermostat 16 (FIGS. 1 and 2).
An air separator 63 is included on the return pipe 61 to
increase efficiency and remove air from the system. A drain
plug 65 on the holding tank 55 is connected to a water return
passage 40, which drains the water in the system and the tank
55.
[0026] During the initial startup of the system 67, the water
is delivered through the cool water intake 66. After the
initial activation of the system, the water will remain in the
system, being pumped to the secondary coil 54 through the
outline pipe 56 and back to a holding tank 55 through the
return pipe 61. The holding tank is preferably made of any
non-corrosive material and would be well insulated. In one
embodiment, the holding tank 55 is 33.7 gallons and 18 inches
long by 12 inches wide by 36 inches tall.
[0027] When the air conditioner 20 is turned off, the holding
tank 55 stores the water to keep it at the cool temperature.
Rools of soapstone 64 are placed in the water in the interior
of the holding tank, preferably four rools with two pieces of
soapstone to each rool. In one embodiment, the soapstone is 17
inches long by 3.5 inches wide by 1.25 inches thick and rests
on a 1.5 degree angle.
[0028] After the initial startup, the thermostat 16 switches
on the pump 62 to circulate the cold water in the tank 55
through the coil 42 whenever the air conditioner 20 is turned
on. This cold coil 42 in addition to the air conditioner 20
cools the home more quickly, so that the air conditioner 20
does not have to run as long, thereby saving energy.
[0029] In an alternate mode of operation, or additionally, the
pump 62 could switch on whenever the thermostat 16 detects
that the temperature in the home has risen above a first
cooling threshold and switches the air conditioner 20 on
whenever the thermostat 16 detects that the temperature in the
home has risen above a second cooling threshold, higher than
the first cooling threshold. When the water temperature
measured by temperature gages 60 indicates that the water has
risen above a threshold water temperature, then the water will
not be able to provide sufficient cooling, and the air
conditioner 20 is switched on.
[0030] The thermostat 16 may include a processor with software
or a simple circuit for controlling the operation of the
various pumps, valves, furnace, air conditioner, etc. as
described above. Because the air condition 20 will run less,
it may be necessary to take other steps to reduce the humidity
in the home, such as adding air boosters.
[0031] Although a preferred embodiment of this invention has
been disclosed, a worker of ordinary skill in this art would
recognize that certain modifications would come within the
scope of this invention. For that reason, the following claims
should be studied to determine the true scope and content of
this invention.
US7628337
Secondary Heating System
Abstract -- A heating
system operates in supplemental mode to carry water from a hot
water supply of the water heater to a heat exchanger within an
air passage in the furnace. A water return passage returns the
water from the air passage back to the water heater. Air
within the air passage passes through the heat exchanger and
is heated from the water within. The water then returns to the
water tank through a water return passage. A supplemental
thermostat is connected to the system to control an air
circulator for the furnace without requiring the furnace to be
activated. The furnace will turn on and heat the air only if
supplemental mode is not sufficient to maintain the desired
temperature.
BACKGROUND OF THE INVENTION
[0001] This invention relates to a heating system. More
particularly, this invention relates to a system for
supplementing a main heating system.
[0002] Conventional heating systems for homes generally
include a water heater and a furnace. The furnace typically
provides hot air to warm the interior temperature of the house
while the water heater provides hot water for the household.
The energy requirements of the furnace are substantially
greater than the energy requirements of the hot water heater.
In addition, water temperatures are less affected by
environmental changes than air within a house.
[0003] An apparatus and method for supplementing a furnace to
heat a building while decreasing overall utility costs is
needed.
SUMMARY OF THE INVENTION
[0004] A heating system operates in normal and supplemental
modes to increase system efficiency and reduce overall cost.
[0005] A heating system for use in heating a residential
dwelling includes a furnace and a water heater. In
supplemental mode the system carries water from the hot water
supply from the water heater to a heat exchanger within an air
passage for the furnace. A water return passage returns the
water from the air passage back to the water heater. Air
within the air passage passes through the heat exchanger and
is heated from the water within. The water then returns to the
water tank through a water return passage.
[0006] A supplemental thermostat is connected to the system to
control an air circulator for the furnace without requiring
the furnace to be activated. In supplemental mode the air
circulator operates at a reduced speed compared to the speed
when in normal mode such that, the system is continuing to
warm the air enough to maintain the temperature without
cycling on and off. A main thermostat, for the furnace, would
preferably be set at a lower desired temperature than the
supplemental thermostat. Thus, the system will only operate in
normal mode if supplemental mode is not sufficient to maintain
the desired temperature.
[0007] These and other features of the present invention can
be best understood from the following specification and
drawings, the following of which is a brief description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a
schematic illustration of an example heating system of the
present invention.

DETAILED DESCRIPTION OF THE
PREFERRED EMBODIMENT
[0009] A heating and cooling system 10 (or "HVAC system") is
shown schematically in FIG. 1. The system 10 is preferably for
use in heating a home or other residential dwelling. The
system 10 includes a furnace 12 and a water heater 14. The
furnace 12 and water heater 14 may operate on natural gas,
electricity, oil or any available energy source. The furnace
12 has a thermostat 16 to control furnace operation and a
control line 18 to connect the thermostat 16 to the furnace
12. The thermostat 16 is mounted within the house remote from
the furnace 12 in an easily accessible area to the user. The
system 10 may also include an air conditioner 20 attached to
the furnace 12, so that the system can provide hot and cool
air for the home. An air passage 22 extends from the furnace
12 to carry the heated or cooled air (airflow indicated with
arrow A) through the home.
[0010] An air circulator 24 incorporated in the furnace 12
controls the airflow through the air passage 22 and includes a
control 26 to control the volume of air that is circulated
through the home. Typically the air circulator 24 includes a
fan 28. The speed of the fan 28 is set by the control 26 which
receives input from the thermostat 16 to turn the fan 28 on or
off or adjust a variable speed.
[0011] The water heater 14 includes a cold water supply 30
leading into a water tank 32 and a hot water supply 34 leading
from the water tank 32. Water, indicated by arrow W, from the
ground supply enters the water tank 32 through the cold water
supply 30. The water is heated within the water tank 32 and
exits through the hot water supply 34 to be distributed at
desired locations throughout the house. The water heater 14
also includes a water tank drain valve 36. The water tank
drain valve 36 is normally used to drain water from the tank
32 during maintenance or repair. During typical operation of
the water heater 14 the water tank drain valve 36 is closed to
retain the water within the water tank 32.
[0012] During normal system 10 operation the furnace 12
receives a control input from the thermostat 16 based upon the
desired interior temperature of the home and the actual
interior temperature of the home. When the difference in
temperature has reached a predetermined level the system 10 is
activated to either warm or cool the air. The air is
distributed through the home through the air passage 22 until
the thermostat 16 senses the actual interior temperature is
the same as the desired interior temperature. Activating the
furnace 12 requires power to heat the air and to activate the
air circulator 24 to distribute the air. The fan 28 may have
one operating speed or may be variable speed, and is either
rotating or stationary.
[0013] When difference between the actual home temperature and
the desired home temperature is large enough to require
heating the home, but not large enough to require the furnace
12, the system 10 operates in supplemental mode.
[0014] A water supply passage 38 carries water from the water
heater 14 to the air passage 22 for the furnace 12. The water
supply passage 38 is connected to the hot water supply 34
leading from the water tank 32 to the house. Thus, the water
within the water supply passage 38 has been heated by the
water heater 14. A water return passage 40 returns the water
from the air passage 22 back to the water heater 14. The water
return passage 40 preferably is connected to the water tank 32
at the water drain valve 36. The water supply passage may be
connected to the water tank 32 in another manner that allows
water to return to the water tank 32, but is preferably
connected at a lower end of the water tank 32.
[0015] The water passes through the water supply passage 38 to
a heat exchanger 42 within the air passage 22. Air within the
air passage 22 passes through the heat exchanger 42 and is
heated from the water within the heat exchanger 42. The water
then returns to the water tank 32 through the water return
passage 40. The heat exchanger 42 is preferably a water coil
heat exchanger. Water coil heat exchangers are specifically
designed for carrying water through the heater exchanger coils
44. The coils 44 are typically copper and aluminum, or
entirely aluminum.
[0016] A supplemental thermostat 46 is connected to the air
circulator 24. A supplemental control line 48 also leads to
the air circulator 24. The supplemental control line 48 is
separate from the main control line 18. The supplemental
thermostat 46 and control line 48 allow the air circulator 24
to be controlled in supplemental mode without requiring the
furnace 12 to be activated. The air circulator 24 is used to
activate the fan 28 and create air flow through the air
passage 22 when in the supplemental mode. In supplemental mode
the fan 28 will operate at a reduced speed compared to the fan
speed when in normal mode. If the control 26 for the fan 28
does not provide variable speed capability, a rheostat or
other power control can be added so that the speed of the fan
28 is reduced in supplemental mode. Optionally, in some
situations, the fan 28 may not be necessary in supplemental
mode, as the air may circulate sufficiently purely by
convection.
[0017] The supplemental thermostat 46 is set at a desired
temperature. When the actual temperature drops below the
desired temperature, as sensed by the supplemental thermostat
46, water is passed through the supply passage 38 to the heat
exchanger 42. The thermostat sends a signal to the air
circulator 24 to begin fan 28 operation. The supplemental
thermostat 46 is connected to an electric supply valve 50 and
an electric return valve 52. The thermostat 46 can shut off
water flow through the supply passage 38 and return passage 40
when the actual temperature is the same as the desired
temperature. Preferably, the fan speed 28 is set at low
revolutions per minute such that, in supplemental mode, the
system 10 is continuing to warm the air enough to maintain the
temperature without cycling the system on and off. The main
thermostat 16 would preferably be set at a lower desired
temperature than the supplemental thermostat 46. Thus, the
system will only operate in normal mode if supplemental mode
is not sufficient to maintain the desired temperature. The
system 10 could operate in both normal mode and supplemental
mode at the same time. In other words, the supplemental mode
continues to operate when the normal mode is switched on.
[0018] By maintaining a desired temperature with the system 10
in supplemental mode, operation of the furnace 12 is reduced.
The reduced operation of the furnace 12 saves on energy costs
for the system 10.
[0019] Manual supply valve 54 can be used to override the
system 10 and prevent water flow through the supply passage
38. Likewise, manual return valve 56 can be used to override
the system 10 and prevent water flow through the return
passage 40. The manual valves 54, 56 can be used to prevent
water flow to the system 10 in warmer months.
[0020] Although a preferred embodiment of this invention has
been disclosed, a worker of ordinary skill in this art would
recognize that certain modifications would come within the
scope of this invention. For that reason, the following claims
should be studied to determine the true scope and content of
this invention.