Progress: Portable AC Unit

For my final project, I have made great strides in completing my portable AC unit. This unit derives from creating a heat exchanger utilizing airflow into a ice filled cooler.

Other than the aesthetic side of things, which I am currently further exploring options, the unit has made great progress and is fully operational.

Since my great strides in progress over spring break, I have not embarked on much, school is surely ramping up for this last stretch.

Regardless, there is always room for improvements and I believe for my aesthetic approach I will paint it. I got inspiration from my father’s car color being a “cement gray”. I believe this is a professional and modern color and will explore such a paint.

Other than all of what will come, lets highlight what has been done.

Carefully utilizing a sawzall and with careful tracing, I tried to cut as exact as possible to fit the necessary pipeing. Additionally, fasteners were needed for the installation of the fan. This would have been better if I had a drill attachment that makes the holes for you, yet it was a great cut in the budget to acquire such tool.

Upon installation, I carefully caulked the holes to ensure the insulation. This is likely the most vital part of the process as you do not want a significant breach in your insulation for a project like this to ensure maximum efficiency of your AC unit. The biggest issue with this was caulking the inside part of the outlet (the white vent seen in the bottom right of the featured image) as it was constrained with the walls of the cooler being tight and the caulk gun being big. Had to rub it on by finger, yet it is impossible to see the job on the underside and very difficult to fit a finger in the tight space on the closer wall to the vent.

Here is where I am now, and I am happy so far.

My only issue with the design is that the air being pulled in from the fan is adjacent to the outlet. This means that some of the cooler air will be reused. Maybe it is a blessing in disguise, yet I am upset. The purpose behind this orientation is because I wanted air inside the cooler to have opposing entrance and exit points so air can circulate through ice before exiting again.

I have yet to fill it with ice, but in normal testing, there is a significant amount of airflow from the project. For this I am very happy as I will not be so hot in the summer months.

Thank you.