US20090211732A1

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Publication number: US20090211732A1
Application number: US12/034,711
Authority: US
Inventors: Lakhi Nandlal Goenka
Original assignee: Individual
Current assignee: Hanon Systems Corp
Priority date: 2008-02-21
Filing date: 2008-02-21
Publication date: 2009-08-27
Also published as: DE102009000767A1

Abstract

A thermal energy exchanger for a heating, ventilating, and air conditioning system is disclosed, the thermal energy exchanger includes a phase change material disposed therein, whereby the phase change material is at least one of encapsulated by a thermally conductive material and impregnated with a thermally conductive material.

Description

FIELD OF THE INVENTION

The invention relates to a climate control system for a vehicle and more particularly to a thermal energy exchanger for a heating, ventilating, and air conditioning system.

BACKGROUND OF THE INVENTION

A vehicle typically includes a climate control system which maintains a temperature within a passenger compartment of the vehicle at a comfortable level by providing heating, cooling, and ventilation. Comfort is maintained in the passenger compartment by an integrated mechanism referred to in the art as a heating, ventilating and air conditioning (HVAC) system. The HVAC system conditions air flowing therethrough and distributes the conditioned air throughout the passenger compartment.

Typically, a compressor of a refrigeration system provides a flow of a fluid having a desired temperature to an evaporator disposed in the HVAC system to condition the air. The compressor is generally driven by a fuel-powered engine of the vehicle. However, in recent years, vehicles having improved fuel economy over the fuel-powered engine and other vehicles are quickly becoming more popular as a cost of traditional fuel increases. The improved fuel economy is due to known technologies such as regenerative braking, electric motor assist, and engine-off operation. Although the technologies improve fuel economy, accessories powered by the fuel-powered engine no longer operate when the fuel-powered engine is not in operation. One major accessory that does not operate is the compressor of the refrigeration system. Therefore, without the use of the compressor, the evaporator disposed in the HVAC system does not condition the air flowing therethrough and the temperature of the passenger compartment increases to a point above a desired temperature.

Accordingly, vehicle manufacturers have used a thermal energy exchanger disposed in the HVAC system to condition the air flowing therethrough when the fuel-powered engine is not in operation. One such thermal energy exchanger, also referred to as a cold accumulator, is described in U.S. Pat. No. 6,854,513 entitled VEHICLE AIR CONDITIONING SYSTEM WITH COLD ACCUMULATOR, hereby incorporated herein by reference in its entirety. The cold accumulator includes a phase change material, also referred to as a cold accumulating material, disposed therein. The cold accumulating material absorbs heat from the air when the fuel-powered engine is not in operation. The cold accumulating material is then recharged by the conditioned air flowing from the cooling heat exchanger when the fuel-powered engine is in operation.

In U.S. Pat. No. 6,691,527 entitled AIR-CONDITIONER FOR A MOTOR VEHICLE, hereby incorporated herein by reference in its entirety, a thermal energy exchanger is disclosed having a phase change material disposed therein. The phase change material of the thermal energy exchanger conditions a flow of air through the HVAC system when the fuel-powered engine of the vehicle is not in operation. The phase change material is charged by a flow of a fluid from the refrigeration system therethrough.

While the prior art HVAC systems perform adequately, it is desirable to produce a thermal energy exchanger having a phase change material disposed therein for an HVAC system, wherein an effectiveness and efficiency thereof are maximized.

SUMMARY OF THE INVENTION

In concordance and agreement with the present invention, a thermal energy exchanger having a phase change material disposed therein for an HVAC system, wherein an effectiveness and efficiency thereof are maximized, has surprisingly been discovered.

In one embodiment, the thermal energy exchanger for a heating, ventilating, and air conditioning system comprises a main housing having a hollow interior; a plurality of tubes disposed in the hollow interior of the housing; and a phase change material disposed in the tubes, wherein the phase change material is at least one of encapsulated with a thermally conductive material and impregnated with a thermally conductive material.

In another embodiment, the thermal energy exchanger for a heating, ventilating, and air conditioning system comprises a hollow main housing including a first inlet and a first outlet, wherein the first inlet and the first outlet are in fluid communication with a source of cooled fluid, the housing further including a second inlet and a second outlet, wherein the second inlet and the second outlet are in fluid communication with a heat exchanger disposed in a control module of a heating, ventilating, and air conditioning system, and wherein each of the inlets and the outlets perform as a diffuser; a plurality of tubes disposed in the housing forming open areas therebetween, wherein at least one of the tubes is adapted to receive one of a fluid from the source of cooled fluid and a fluid from the heat exchanger therethrough; and a phase change material disposed in the open areas of the housing.

In another embodiment, the thermal energy exchanger for a heating, ventilating, and air conditioning system comprises a main housing having a hollow interior; a fluid disposed in the housing, the fluid adapted to circulate through a conduit to a heat exchanger disposed in an HVAC module of a heating, ventilating, and air conditioning system; and a phase change material disposed in the fluid, wherein the phase change material is at least one of encapsulated with a thermally conductive material and impregnated with a thermally conductive material.

BRIEF DESCRIPTION OF THE DRAWINGS

The above, as well as other objects and advantages of the invention, will become readily apparent to those skilled in the art from reading the following detailed description of various embodiments of the invention when considered in the light of the accompanying drawings in which:

FIG. 1 is a schematic flow diagram of an HVAC system including a fragmentary sectional view of an HVAC module having a thermal energy exchanger disposed therein according to an embodiment of the invention;

FIG. 2 is a fragmentary cross-sectional view of the thermal energy exchanger illustrated inFIG. 1, wherein the thermal energy exchanger includes a phase change material impregnated with a thermally conductive material;

FIG. 3 is a schematic flow diagram of the HVAC system illustrated inFIG. 1, wherein the thermal energy exchanger is in fluid communication with a source of cooled fluid;

FIG. 4 is a fragmentary cross-sectional view of the thermal energy exchanger illustrated inFIG. 3, wherein the thermal energy exchanger includes an encapsulated phase change material;

FIG. 5 is a fragmentary cross-sectional view of the thermal energy exchanger illustrated inFIG. 3, wherein the thermal energy exchanger includes an encapsulated phase change material impregnated with a thermally conductive material;

FIG. 6 is a schematic flow diagram of an HVAC system including a cross-sectional view of a thermal energy exchanger having a phase change material disposed therein according to another embodiment of the invention;

FIG. 7 is an enlarged sectional view of the phase change material disposed in the thermal energy exchanger illustrated inFIG. 6 within circle7, wherein the phase change material is encapsulated;

FIG. 8 is an enlarged sectional view of the phase change material disposed in the thermal energy exchanger illustrated inFIG. 6 within circle8, wherein the phase change material having a thermally conductive material disposed therein is encapsulated;

FIG. 9 is a schematic flow diagram of an HVAC system including a cross-sectional view of a thermal energy exchanger having a phase change material disposed therein according to another embodiment of the invention;

FIG. 10 a schematic flow diagram of the HVAC system illustrated inFIG. 9, wherein the thermal energy exchanger includes interleaved tubes;

FIG. 11 a schematic flow diagram of an HVAC system including a cross-sectional view of a thermal energy exchanger having a phase change material disposed therein according to another embodiment of the invention;

FIG. 12 is an enlarged sectional view of the phase change material disposed in the thermal energy exchanger illustrated inFIG. 11 withincircle12, wherein the phase change material is encapsulated; and

FIG. 13 is an enlarged sectional view of the phase change material disposed in the thermal energy exchanger illustrated inFIG. 11 within circle13, wherein the phase change material having a thermally conductive material disposed therein is encapsulated.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The following detailed description and appended drawings describe and illustrate various exemplary embodiments of the invention. The description and drawings serve to enable one skilled in the art to make and use the invention, and are not intended to limit the scope of the invention in any manner.

FIGS. 1 and 3 show a heating, ventilating, and air conditioning (HVAC)system10 according to an embodiment of the invention. TheHVAC system10 typically provides heating, ventilation, and air conditioning for a passenger compartment of a vehicle (not shown) TheHVAC system10 includes acontrol module12 to control at least a temperature of the passenger compartment.

Themodule12 illustrated includes a hollowmain housing14 with anair flow conduit15 formed therein. Thehousing14 includes aninlet section16, a mixing andconditioning section18, and an outlet and distribution section (not shown). In the embodiment shown, anair inlet22 is formed in theinlet section16. Theair inlet22 is in fluid communication with a supply of air (not shown). The supply of air can be provided from outside of the vehicle, recirculated from the passenger compartment of the vehicle, or a mixture of the two, for example. Theinlet section16 is adapted to receive a blower wheel (not shown) therein to cause air to flow through theair inlet22. A filter (not shown) can be provided upstream or downstream of theinlet section16 if desired.

The mixing andconditioning section18 of thehousing14 is adapted to receive anevaporator core24, athermal energy exchanger26, and aheater core28 therein. In the embodiment shown, thethermal energy exchanger26 and theheater core28 are disposed downstream of ablend door29. Theblend door29 is adapted to selectively permit a flow of air through thethermal energy exchanger26 and theheater core28 when theHVAC system10 is not operating in a pull-down mode. A filter (not shown) can also be provided upstream of theevaporator core24, if desired. Theevaporator core24 is in fluid communication with a source of cooledfluid30 such as a refrigeration system, for example, through aconduit36. The source of cooledfluid30 includes afluid37, shown inFIGS. 4 and 5, circulating therein. Thefluid37 absorbs thermal energy and conditions the air flowing through theHVAC module12.

As illustrated inFIGS. 2,4, and5, thethermal energy exchanger26 is a louvered-fin heat exchanger. It is understood that thethermal energy exchanger26 can be any conventional thermal energy exchanger as desired. Thethermal energy exchanger26 is adapted to absorb thermal energy and cool the air flowing therethrough when a fuel-powered engine of the vehicle is not in operation. As shown, thethermal energy exchanger26 includes a plurality oftubes46 withlouvered fins48 formed thereon. Each of thefins48 abuts an outer surface of thetubes46 for enhancing thermal energy transfer of thethermal energy exchanger26. Thefins48 include a plurality ofcrests50 formed thereon. Thecrests50 are formed substantially parallel to each other and at a substantially 90 degree angle to thetubes46. It is understood that thecrests50 can be formed at any angle to thetubes46 if desired. Each of thecrests50 define anair space52 extending between thetubes46 and thefins48.

Thetubes46 include aphase change material56 disposed therein. Thephase change material56 is any material that melts and solidifies at certain temperatures and is capable of storing and releasing thermal energy such as a paraffin wax, an alcohol, water, and any combination thereof, for example. As illustrated inFIGS. 2 and 5, thephase change material56 can be impregnated with a thermallyconductive material58 to further enhance the transfer of thermal energy. It is understood that the thermallyconductive material58 can be any conventional material such as a graphite powder, for example. Thephase change material56 is adapted to absorb thermal energy from the air flowing through thethermal energy exchanger26 when the fuel-powered engine is not in operation. Accordingly, when the fuel-powered engine of the vehicle is in operation, thephase change material56 is adapted to release thermal energy into conditioned air from theevaporator24 flowing therethrough.

As illustrated inFIG. 3, thethermal energy exchanger26 can also be in fluid communication with the source of cooled fluid30 through aconduit38. Avalve39 can be disposed in theconduit38 to militate against a flow of the fluid37 therethrough. Thethermal energy exchanger26 is adapted to absorb thermal energy and cool the air flowing therethrough when a fuel-powered engine of the vehicle is not in operation. Thethermal energy exchanger26 is adapted to receive the fluid37 from the source of cooled fluid30 therethrough. As shown inFIGS. 4 and 5, thephase change material56 can be encapsulated in a thermallyconductive casing60a,or coated with a thermallyconductive coating60b.Thecasing60aand thecoating60bcan be produced from any conventional material such as a polyethylene, for example. In the embodiment shown, thecasing60aand thecoating60bpermit thephase change material56 to be disposed in the fluid37 circulating through thetubes46 of thethermal energy exchanger26. The encapsulatedphase change material56 is adapted to absorb thermal energy from the air flowing through thethermal energy exchanger26 when the fuel-powered engine is not in operation, and release thermal energy into the fluid37 when the fuel-powered engine is in operation.

As illustrated inFIG. 5, thetubes46 of thethermal energy exchanger26 can further include a plurality ofinternal fins66 formed on an inner surface thereof, and a plurality ofscreens68 disposed therein. Theinternal fins66 are adapted to further enhance the transfer of thermal energy of thethermal energy exchanger26. Thescreens68 are disposed in aninlet70 and anoutlet72 of each of thetubes46 and extend across an inner diameter thereof. Thescreens68 are adapted to permit the flow of the fluid37 therethrough while militating against the flow of the encapsulatedphase change material56 from thethermal energy exchanger26. As shown, the encapsulatedphase change material56 can include the thermallyconductive material58 disposed therein.

Theheater core28 and a source ofheated fluid74 are fluidly connected by aconduit76. The source ofheated fluid74 can be any conventional source of heated fluid such as the fuel-powered engine of the vehicle, for example, and the heated fluid can be any conventional fluid such as an engine coolant, for example. Avalve75 can be disposed in theconduit76 to selectively militate against a flow of heated fluid therethrough. Theheater core28 is adapted to release thermal energy and heat the air flowing therethrough when the fuel-powered engine of the vehicle is in operation.

In operation, theHVAC system10 conditions air by heating or cooling the air, and providing the conditioned air to the passenger compartment of the vehicle. Air flows through thehousing14 of themodule12. Air from the supply of air is received in theinlet section16 of thehousing14 in theair inlet22.

When the fuel-powered engine of the vehicle is in operation, the fluid37 from the source of cooledfluid30 circulates through theconduit36. Accordingly, the fluid37 circulates through theevaporator core24, as shown inFIG. 1. The air from theinlet section16 flows into theevaporator core24 where the air is cooled to a desired temperature by a transfer of thermal energy from the air to the fluid37 from the source of cooledfluid30. The conditioned air stream then exits theevaporator core24. When theHVAC system10 is not operating in the pull-down mode, the air from theevaporator core24 is selectively permitted by theblend door29 to flow into thethermal energy exchanger26.

In thethermal energy exchanger26, the conditioned air flows through theair spaces52 defined by thelouvered fins48 and thetubes46 of thethermal energy exchanger26. The conditioned air absorbs thermal energy from thephase change material56 disposed in thetubes46. The transfer of thermal energy from thephase change material56 to the conditioned air cools and solidifies thephase change material56. It is understood that the fluid37 from the source of cooled fluid30 can also circulate through theconduit38 and thethermal energy exchanger26, as shown inFIG. 3. The fluid37 flows from the source of cooled fluid30 through thetubes46 to absorb thermal energy from thephase change material56 disposed therein. Accordingly, the transfer of thermal energy to the fluid37 further cools and solidifies thephase change material56.

When the fuel-powered engine of the vehicle is not in operation, the fluid37 from the source of cooledfluid30 does not circulate through the

conduits

36,38. Accordingly, the fluid37 does not circulate through theevaporator core24 or thethermal energy exchanger26. The air from theinlet section16 flows into and through theevaporator core24 where a temperature thereof is unchanged. The air stream then exits theevaporator core24 and is selectively permitted by theblend door29 to flow into thethermal energy exchanger29.

In thethermal energy exchanger26, the air flows through theair spaces52 defined by thelouvered fins48 and thetubes46 of thethermal energy exchanger26. The air is cooled to a desired temperature by a transfer of thermal energy from thephase change material56 disposed therein to the air. Accordingly, thephase change material56 is caused to melt. The conditioned cooled air then exits thethermal energy exchanger26 and flows through theheater core28, which is not in operation, and into the outlet and distribution section.

FIG. 6 shows an HVAC system according to another embodiment of the invention. Reference numerals for similar structure in respect of the description ofFIGS. 1 thru5 are repeated inFIGS. 6 thru8 with a prime (′) symbol. AnHVAC system10′ includes acontrol module12′ to control at least a temperature of the passenger compartment. Themodule12′ illustrated includes a hollowmain housing14′ with anair flow conduit15′ formed therein. Thehousing14′ includes aninlet section16′, a mixing andconditioning section18′, and an outlet and distribution section (not shown). In the embodiment shown, anair inlet22′ is formed in theinlet section16′. Theair inlet22′ is in fluid communication with a supply of air (not shown). The supply of air can be provided from outside of the vehicle, recirculated from the passenger compartment of the vehicle, or a mixture of the two, for example. Theinlet section16′ is adapted to receive a blower wheel (not shown) therein to cause air to flow through theair inlet22′. A filter (not shown) can also be provided upstream or downstream of theinlet section16′ if desired.

The mixing andconditioning section18′ of thehousing14′ is adapted to receive anevaporator core24′, and at least one of aheat exchanger80 and aheater core28′ therein. In the embodiment shown, theheat exchanger80 and theheater core28′ are disposed downstream of ablend door29′. Theblend door29′ is adapted to selectively permit a flow of air through theheat exchanger80 and theheater core28′ when theHVAC system10′ is not operating in a pull-down mode. A filter (not shown) can be provided upstream of theevaporator core24′, if desired.

Theevaporator core24′ is in fluid communication with a source of cooled fluid30′ such as a refrigeration system, for example, through aconduit36′. Theevaporator core24′ is adapted to absorb thermal energy and cool the air flowing therethrough when a fuel-powered engine of the vehicle is in operation. Theheat exchanger80 is in fluid communication with athermal energy exchanger82 through aconduit84. Theconduit84 includes apump88 adapted to cause a fluid90 disposed therein to circulate. It is understood that the fluid90 can be any conventional fluid such as a coolant, for example. The fluid90 is adapted to absorb thermal energy and cool the air flowing through theheat exchanger80 when a fuel-powered engine of the vehicle is not in operation. Thethermal energy exchanger82 is also in fluid communication with the source of cooled fluid30′ through aconduit86. Theconduit86 can include avalve87 disposed therein to selectively militate against a flow of the fluid37′ therethrough. In the embodiment shown, theheater core28′ is in fluid communication with a source ofheated fluid74′ through aconduit76′. The source ofheated fluid74′ can be any conventional source of heated fluid such as the fuel-powered engine of the vehicle, for example, and the heated fluid can be any conventional fluid such as an engine coolant, for example. Avalve75′ can be disposed in theconduit76′ to selectively militate against a flow of heated fluid therethrough. It is understood that theheat exchanger80 can be in fluid communication with the source ofheated fluid74′ as desired without departing from the scope and spirit of the invention.

In the embodiment shown, thethermal energy exchanger82 includes amain housing92 having a hollow interior. Themain housing92 may be made of conventional materials such as polypropylene, for example. In the embodiment shown, themain housing92 is generally rectangular in shape. It is understood that themain housing92 can have other shapes as desired. Themain housing92 includes afirst inlet94, asecond inlet96, afirst outlet98, and asecond outlet100 formed thereon. The

inlets

94,96 and the

outlets

98,100 are formed to extend laterally outwardly from themain housing92. Thefirst inlet94 and thefirst outlet98 are in fluid communication with the source of cooled fluid30′ through theconduit86. Thesecond inlet96 and thesecond outlet100 are in fluid communication with theheat exchanger80 through theconduit84. The

inlets

94,96 and the

outlets

98,100 each perform as a diffuser to decrease a flow velocity of therespective fluids37′,90 circulated therethrough. An insulatingmaterial102 can be disposed on an outer surface of themain housing92 to militate against a dissipation of thermal energy therefrom.

Thefirst inlet94 and thefirst outlet98 are fluidly connected by a plurality oftubes104. Thetubes104 are disposed in the hollow interior of thethermal energy exchanger82 and are adapted to receive the fluid37′ therethrough. Thetubes104 include a plurality of spaced apartfins106 extending radially outwardly therefrom. Thefins106 enhance a transfer of thermal energy between thefluids37′,90. Thetubes104 and thefins106 are produced from a thermally conductive material such as copper, for example. Thetubes104 are substantially parallel in relation to each other and are spaced apart to define a series ofopen areas108 therebetween. Theopen areas108 permit a flow of the fluid90 therethrough.

The fluid90 includes aphase change material56′ disposed therein. Thephase change material56′ is any material that melts and solidifies at certain temperatures and is capable of storing and releasing thermal energy such as a paraffin wax, an alcohol, water, and any combination thereof, for example. As shown inFIGS. 7 and 8, thephase change material56′ is encapsulated in a thermallyconductive casing60a′, or coated with a thermallyconductive coating60b′. Thecasing60a′ and thecoating60b′ can be produced from any conventional material such as a polyethylene, for example. Thecasing60a′ and thecoating60b′ permit thephase change material56′ to be disposed in the fluid90 circulating through theopen areas108. The encapsulatedphase change material56′ is adapted to absorb thermal energy of the fluid90 flowing through theheat exchanger80 when the fuel-powered engine is not in operation, and release thermal energy into the fluid37′ when the fuel-powered engine is in operation. As illustrated inFIG. 8, the encapsulatedphase change material56′ can include a thermallyconductive material58′ disposed therein to further enhance the transfer of thermal energy, if desired.

Thesecond inlet96 and thesecond outlet100 are fluidly connected by theopen areas108. As shown, each of thesecond inlet96 and thesecond outlet100 can include ascreen110 extending across a diameter thereof. Thescreen110 is adapted to permit the flow of the fluid90 therethrough, while militating against the flow of the encapsulatedphase change material56′ from thethermal energy exchanger82. It is understood that thefirst inlet94 and thefirst outlet98 can be fluidly connected by open areas and thesecond inlet96 and thesecond outlet100 fluid connected by tubes, if desired.

In use, when the fuel-powered engine of the vehicle is in operation, the fluid37′ from the source of cooled fluid30′ circulates through theconduits36′,86. Accordingly, the fluid37′ circulates through theevaporator core24′ and thethermal energy exchanger82. The air from theinlet section16′ flows into theevaporator core24′ where the air is cooled to a desired temperature by a transfer of thermal energy from the air to the fluid37′ from the source of cooled fluid30′. The conditioned air stream then exits theevaporator core24′. When theHVAC system10′ is not operating in the pull-down mode, the air from theevaporator core24′ is selectively permitted by theblend door29′ to flow through theheat exchanger80 and theheater core28′, which is not in operation, and into the outlet and distribution section. The fluid37′ circulating through theconduit86 flows into and through thetubes104 of thethermal energy exchanger82. The fluid37′ absorbs thermal energy from the fluid90 flowing through theopen areas108 and thephase change material56′ disposed therein. The transfer of thermal energy cools and solidifies thephase change material56′.

When the fuel-powered engine of the vehicle is not in operation, the fluid37′ from the source of cooled fluid30′ does not circulate through theconduits36′,86. Accordingly, the fluid37′ does not circulate through theevaporator core24′ or thethermal energy exchanger82. Thepump88 causes the fluid90 to circulate through theconduit84, thethermal energy exchanger82, and theheat exchanger80. The air from theinlet section16′ flows into theevaporator core24′ where a temperature thereof is unchanged. The air then exits theevaporator core24′ and is selectively permitted by theblend door29′ to flow into theheat exchanger80.

In theheat exchanger80 the air is cooled to a desired temperature by a transfer of thermal energy from the air to the fluid90 circulating therethrough. The fluid90 absorbs and transfers the thermal energy from the air to thephase change material56′ disposed therein, causing thephase change material56′ to melt. The conditioned cooled air then exits theheat exchanger80 and flows through theheater core28′, which is not in operation, and into the outlet and distribution section.

FIGS. 9 and 10 show an HVAC system according to another embodiment of the invention. Reference numerals for similar structure in respect of the description ofFIGS. 1 thru8 are repeated inFIGS. 9 and 10 with a prime (″) symbol. AnHVAC system10″ includes acontrol module12″ to control at least a temperature of the passenger compartment. Themodule12″ illustrated includes a hollowmain housing14″ with anair flow conduit15″ formed therein. Thehousing14″ includes aninlet section16″, a mixing andconditioning section18″, and an outlet and distribution section (not shown). In the embodiment shown, anair inlet22″ is formed in theinlet section16″. Theair inlet22″ is in fluid communication with a supply of air (not shown). The supply of air can be provided from outside of the vehicle, recirculated from the passenger compartment of the vehicle, or a mixture of the two, for example. Theinlet section16″ is adapted to receive a blower wheel (not shown) therein to cause air to flow through theair inlet22″. A filter (not shown) can be provided upstream or downstream of theinlet section16″ if desired.

The mixing andconditioning section18″ of thehousing14″ is adapted to receive anevaporator core24″, and at least one of aheat exchanger80″ and a heater core (not shown) therein. In the embodiment shown, theheat exchanger80″ is disposed downstream of ablend door29″. Theblend door29″ is adapted to selectively permit a flow of air through theheat exchanger80″ when theHVAC system10″ is not operating in a pull-down mode. A filter (not shown) can also be provided upstream of theevaporator core24″, if desired.

Theevaporator core24″ is in fluid communication with a source of cooled fluid30″ such as a refrigeration system, for example, through aconduit36″. Theevaporator core24″ is adapted to absorb thermal energy and cool the air flowing therethrough when a fuel-powered engine of the vehicle is in operation. Theheat exchanger80″ is in fluid communication with athermal energy exchanger82″ through aconduit84″. Theconduit84″ includes apump88″ and avalve89 disposed therein. Thepump88″ is adapted to cause a fluid (not shown) disposed therein to circulate. Thevalve89 selectively militates against a flow of the fluid therethrough. It is understood that the fluid can be any conventional fluid such as an engine coolant, for example. The fluid is adapted to absorb thermal energy and cool the air flowing through theheat exchanger80″ when the fuel-powered engine of the vehicle is not in operation. Thethermal energy exchanger82″ is also in fluid communication with the source of cooled fluid30″ through aconduit86″. Theconduit86″ can include avalve87″ disposed therein to selectively militate against a flow of the fluid therethrough. In the embodiment shown, theheat exchanger80″ is also in fluid communication with a source ofheated fluid74″ through aconduit76″. The source ofheated fluid74″ can be any conventional source of heated fluid such as the fuel-powered engine of the vehicle, for example, and the heated fluid can be any conventional fluid such as an engine coolant, for example. Avalve75″ may be disposed in theconduit76″ to selectively militate against a flow of heated fluid therethrough. Theheat exchanger80″ is adapted to release thermal energy and heat the air flowing therethrough when the fuel-powered engine of the vehicle is in operation. It is understood that the source ofheated fluid74″ can be in fluid communication with a heater core as desired without departing from the scope and spirit of the invention.

In the embodiment shown, thethermal energy exchanger82″ includes amain housing92″ having a hollow interior. Themain housing92″ may be made of conventional materials such as polypropylene, for example. In the embodiment shown, themain housing92″ is generally rectangular in shape. It is understood that themain housing92″ can have other shapes as desired. Themain housing92″ includes afirst inlet94″, asecond inlet96″, afirst outlet98″, and asecond outlet100″ formed thereon. Theinlets94″,96″ and theoutlets98″,100″ are formed to extend laterally outwardly from themain housing92″. Thefirst inlet94″ and thefirst outlet98″ are in fluid communication with the source of cooled fluid30″ through theconduit86″. Thesecond inlet96″ and thesecond outlet100″ are in fluid communication with theheat exchanger80″ through theconduit84″. Theinlets94″,96″ and theoutlets98″,100″ each perform as a diffuser to decrease a flow velocity of the fluids circulated therethrough. An insulatingmaterial102″ can be disposed on an outer surface of themain housing92″ to militate against a dissipation of thermal energy therefrom.

Thefirst inlet94″ and thefirst outlet98″ are fluidly connected by a plurality oftubes104″. Thetubes104″ are disposed in the hollow interior of thethermal energy exchanger82″ and are adapted to receive the fluid from the source of cooled fluid30″ therethrough. Thetubes104″ include a plurality of spaced apartfins106″ extending radially outwardly therefrom. Thefins106″ enhance a transfer of thermal energy between the fluid from the source of cooled fluid30″ and fluid from theheat exchanger80′. Thetubes104″ and thefins106″ are produced from a thermally conductive material such as copper, for example. Thetubes104″ are substantially parallel in relation to each other and are spaced apart to define a series ofopen areas108″ therebetween.

As illustrated inFIG. 9 and 10, thesecond inlet96″ and thesecond outlet100″ can also be fluidly connected by a plurality oftubes112. Thetubes112 are disposed in the hollow interior of thethermal energy exchanger82″ and are adapted to receive the fluid from theheat exchanger80″ therethrough. Thetubes112 include a plurality of spaced apartfins114 extending radially outwardly therefrom. Thefins114 enhance a transfer of thermal energy between the fluids. Thetubes112 and thefins114 are produced from a thermally conductive material such as copper, for example. Thetubes112 are substantially parallel in relation to each other and are spaced apart to define a series ofopen areas116 therebetween. It is understood that thetubes112 can be interleaved with thetubes104″, as shown inFIG. 10, to further enhance the transfer of thermal energy between the fluids, if desired. It is further understood that thetubes112 can include a plurality of spaced apart fins (not shown) extending radially inwardly and an encapsulated phase change material (not shown) disposed therein, if desired, to further enhance the transfer of thermal energy.

Theopen areas116 formed between thetubes112 are in fluid communication with theopen areas108″ formed between thetubes104″. Theopen areas108″,116 include aphase change material56″ disposed therein. Thephase change material56″ is any material that melts and solidifies at certain temperatures and is capable of storing and releasing thermal energy such as a paraffin wax, an alcohol, water, and any combination thereof, for example. In the embodiment shown, thephase change material56″ is adapted to absorb thermal energy of the fluid flowing through thetubes112 when the fuel-powered engine is not in operation, and release thermal energy to the fluid flowing through thetubes108″ when the fuel-powered engine is in operation. As illustrated inFIGS. 9 and 10, thephase change material56″ can include a thermallyconductive material58″ disposed therein to further enhance the transfer of thermal energy. A pocket ofair118 is disposed inside the interior of thethermal energy exchanger82″ to permit thephase change material56″ disposed therein to expand when releasing thermal energy to the fluid from the source of cooled fluid30″.

In use, when the fuel-powered engine of the vehicle is in operation, the fluid from the source of cooled fluid30″ circulates through theconduits36″,86″. Accordingly, the fluid from the source of cooled fluid30″ circulates through theevaporator core24″ and thethermal energy exchanger82″. The air from theinlet section16″ flows into theevaporator core24″ where the air is cooled to a desired temperature by a transfer of thermal energy from the air to the fluid from the source of cooled fluid30″. The conditioned air stream then exits theevaporator core24″. When theHVAC system10″ is not operating in the pull-down mode, the air from theevaporator core24″ is selectively permitted by theblend door29″ to flow through theheat exchanger80″ and into the outlet and distribution section. The fluid circulating through theconduit86″ flows into and through thetubes104″ of thethermal energy exchanger82″. The fluid absorbs thermal energy from thephase change material56″ disposed in theopen areas108″,116. The transfer of thermal energy cools and solidifies thephase change material56″. Additionally, thephase change material56″ cools the fluid circulating throughconduit84″ and theheat exchanger80″ by absorbing thermal energy therefrom. The thermal energy absorbed by thephase change material56″ is then transferred to the fluid from the source of cooled fluid30″.

When the fuel-powered engine of the vehicle is not in operation, the fluid from the source of cooled fluid30″ does not circulate through theconduits36″,86″. Accordingly, the fluid does not circulate through theevaporator core24″ or thethermal energy exchanger82″. Thepump88″ causes the fluid disposed in theheat exchanger80″ to circulate through theconduit84″ and thethermal energy exchanger82″. The fluid flows into and through thetubes112 of thethermal energy exchanger82″, releasing thermal energy to thephase change material56″ disposed in theopen areas108″,116 thereof. Accordingly, the fluid is cooled by thephase change material56″. The air from theinlet section16″ flows into and through theevaporator core24″ where a temperature thereof is unchanged. The air then exits theevaporator core24″ and is selectively permitted to flow through theheat exchanger80″.

In theheat exchanger80″, the air is cooled to a desired temperature by a transfer of thermal energy from the air to the fluid circulating therethrough. The fluid absorbs and transfers the thermal energy from the air to thephase change material56″ disposed in theopen areas108″,116 of thethermal energy exchanger82″ Thus, thephase change material56″ is caused to melt. The conditioned cooled air then exits theheat exchanger80″ and flows into the outlet and distribution section.

FIG. 11 shows an HVAC system according to another embodiment of the invention. Reference numerals for similar structure in respect of the description ofFIGS. 1 thru10 are repeated inFIG. 11 with a prime (′″) symbol. AnHVAC system10′″ includes acontrol module12′″ to control at least a temperature of the passenger compartment. Themodule12′″ illustrated includes a hollowmain housing14′″ with anair flow conduit15′″ formed therein. Thehousing14′″ includes aninlet section16′″, a mixing andconditioning section18′″, and an outlet and distribution section (not shown). In the embodiment shown, anair inlet22′″ is formed in theinlet section16′″. Theair inlet22′″ is in fluid communication with a supply of air (not shown). The supply of air can be provided from outside of the vehicle, recirculated from the passenger compartment of the vehicle, or a mixture of the two, for example. Theinlet section16′″ is adapted to receive a blower wheel (not shown) therein to cause air to flow through theair inlet22′″ A filter (not shown) can be provided upstream or downstream of theinlet section16′″ if desired.

The mixing andconditioning section18′″ of thehousing14′″ is adapted to receive anevaporator core24′″, aheat exchanger80′″, and aheater core28′″ therein. In the embodiment shown, theheat exchanger80′″ and theheater core28′″ are disposed downstream of ablend door29′″. Theblend door29′″ is adapted to selectively permit a flow of air through theheat exchanger80′″ and theheater core28′″ when theHVAC system10′″ is not operating in a pull-down mode. A filter (not shown) can be provided upstream of theevaporator core24′″, if desired. Theevaporator core24′″ is in fluid communication with a source of cooled fluid30′″ such as a refrigeration system, for example, through aconduit36′″. Theevaporator core24′″ is adapted to absorb thermal energy and cool the air flowing therethrough when a fuel-powered engine of the vehicle is in operation. Theheat exchanger80′″ is in fluid communication with athermal energy exchanger120 through aconduit84′″. Theconduit84′″ includes apump88′″ adapted to cause a fluid90′″ disposed therein to circulate. It is understood that the fluid90′″ can be any conventional fluid such as a coolant, for example. The fluid90″ is adapted to absorb thermal energy and cool the air flowing through theheat exchanger80′″ when the fuel-powered engine of the vehicle is not in operation. In the embodiment shown, theheater core28′″ is in fluid communication with a source ofheated fluid74′″ through aconduit76′″. The source ofheated fluid74′″ can be any conventional source of heated fluid such as the fuel-powered engine of the vehicle, for example, and the heated fluid can be any conventional fluid such as an engine coolant, for example. Avalve75′″ may be disposed in theconduit76″ to selectively militate against a flow of heated fluid therethrough. It is understood that theheat exchanger80′″ can be in fluid communication with the source ofheated fluid74′″ as desired without departing from the scope and spirit of the invention.

In the embodiment shown, thethermal energy exchanger120 includes amain housing122 having a hollow interior. Themain housing122 may be made of conventional materials such as polypropylene, for example. In the embodiment shown, themain housing122 is generally rectangular in shape. It is understood that themain housing122 can have other shapes as desired. Themain housing122 includes afirst aperture124 and asecond aperture126. The

apertures

124,126 are adapted to receive aninlet end128 and anoutlet end130 of theconduit84′″ therethrough. Theinlet end128 and theoutlet end130 extend through the

respective apertures

124,126 and into the fluid90′″.

The fluid90′″ includes aphase change material56′″ disposed therein. Thephase change material56′″ is any material that melts and solidifies at certain temperatures and is capable of storing and releasing thermal energy such as a paraffin wax, an alcohol, water, and any combination thereof, for example. As shown inFIGS. 12 and 13, thephase change material56′″ is encapsulated in a thermallyconductive casing60a′″, or coated with a thermallyconductive coating60b′″. Thecasing60a′″ and thecoating60b′″ can be produced from any conventional material such as a polyethylene, for example. Thecasing60a′″ and thecoating60b′″ permit thephase change material56′″ to be disposed in the fluid90 circulating through theconduit84′″ and theheat exchanger80′″. The encapsulatedphase change material56′″ is adapted to absorb thermal energy of the fluid90′″ flowing through theheat exchanger80′″ when the fuel-powered engine is not in operation. As illustrated inFIG. 13, the encapsulatedphase change material56′″ can include a thermallyconductive material58′″ disposed therein to further enhance the transfer of thermal energy if desired. It is understood that theinlet end128 and theoutlet end130 of theconduit84′″ can include a screen adapted to permit the flow of the fluid90′″ therethrough, while militating against the flow of the encapsulatedphase change material56′″ from thethermal energy exchanger120, if desired.

In use, when the fuel-powered engine of the vehicle is in operation, the fluid from the source of cooled fluid30′″ circulates through theconduit36′″. Accordingly, the fluid circulates through theevaporator core24′″. The air from theinlet section16′″ flows into theevaporator core24′″ where the air is cooled to a desired temperature by a transfer of thermal energy from the air to the fluid from the source of cooled fluid30′″. The conditioned air stream then exits theevaporator core24′″. When theHVAC system10′″ is not operating in the pull-down mode, the air from theevaporator core24′″ is selectively permitted by theblend door29′″ to flow into and through theheat exchanger80′″. In theheat exchanger80′″, the conditioned air absorbs thermal energy from the fluid90′″ circulating therein. The transfer of thermal energy from the fluid90′″ cools the fluid90′″. Accordingly, the fluid90′″ absorbs thermal energy from thephase change material56′″ disposed therein. The transfer of thermal energy from thephase change material56′″ to the fluid90′″ cools and solidifies thephase change material56′″. The conditioned air stream then flows through theheater core28′″, which is not in operation, and into the outlet and distribution section.

When the fuel-powered engine of the vehicle is not in operation, the fluid from the source of cooled fluid30′″ does not circulate through theconduit36′″. Accordingly, the fluid does not circulate through theevaporator core24′″. The air from theinlet section16′″ flows into and through theevaporator core24′″ where a temperature thereof is unchanged. The air then exits theevaporator core24′″ and is selectively permitted by theblend door29′″ to flow into theheat exchanger80′″.

In theheat exchanger80′″ the air is cooled to a desired temperature by a transfer of thermal energy from the air to the fluid90′″ circulating therethrough. Thepump88′″ causes the fluid90′″ to circulate through theconduit84′″ and thethermal energy exchanger120. The fluid90′″ absorbs and transfers the thermal energy from the air to thephase change material56′″ disposed therein. Thus, thephase change material56′″ is caused to melt. The conditioned cooled air then exits theheat exchanger80′″ and flows through theheater core28′″, which is not in operation, and into the outlet and distribution section.

From the foregoing description, one ordinarily skilled in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, can make various changes and modifications to the invention to adapt it to various usages and conditions.

Claims

1. A thermal energy exchanger for a heating, ventilating, and air conditioning system comprising:

a main housing having a hollow interior;

a plurality of tubes disposed in the hollow interior of the housing; and

a phase change material disposed in the tubes, wherein the phase change material is at least one of encapsulated with a thermally conductive material and impregnated with a thermally conductive material.

2. The thermal energy exchanger according toclaim 1, wherein the tubes include a plurality of internal fins.

3. The thermal energy exchanger according toclaim 1, wherein the tubes include at least one screen adapted to militate against a flow of the phase change material therefrom.

4. The thermal energy exchanger according toclaim 1, wherein the tubes are in fluid communication with a source of cooled fluid.

5. The thermal energy exchanger according toclaim 4, wherein the phase change material is cooled and solidified by at least one of a fluid from the source of cooled fluid and a flow of air therethrough.

6. A thermal energy exchanger for a heating, ventilating, and air conditioning system comprising:

a hollow main housing including a first inlet and a first outlet, wherein the first inlet and the first outlet are in fluid communication with a source of cooled fluid, the housing further including a second inlet and a second outlet, wherein the second inlet and the second outlet are in fluid communication with a heat exchanger disposed in a control module of a heating, ventilating, and air conditioning system, and wherein each of the inlets and the outlets perform as a diffuser;

a plurality of tubes disposed in the housing forming open areas therebetween, wherein at least one of the tubes is adapted to receive one of a fluid from the source of cooled fluid and a fluid from the heat exchanger therethrough; and

a phase change material disposed in the open areas of the housing.

7. The thermal energy exchanger according toclaim 6, wherein the phase change material is at least one of encapsulated with a thermally conductive material and impregnated with a thermally conductive material.

8. The thermal energy exchanger according toclaim 6, wherein the phase change material is cooled and solidified by a fluid from the source of cooled fluid.

9. The thermal energy exchanger according toclaim 6, wherein the phase change material is disposed in one of the fluid from the source of cooled fluid and the fluid from the heat exchanger.

10. The thermal energy exchanger according toclaim 6, wherein at least one of the inlets and the outlets includes a screen to militate against a flow of the phase change material therefrom.

11. The thermal energy exchanger according toclaim 6, wherein the tubes include radially outwardly extending fins formed thereon.

12. The thermal energy exchanger according toclaim 6, wherein the tubes include radially inwardly extending fins formed thereon.

13. The thermal energy exchanger according toclaim 6, wherein one of the tubes fluidly connects the first inlet and the first outlet.

14. The thermal energy exchanger according toclaim 6, wherein one of the tubes fluidly connects the first inlet and the first outlet.

15. The thermal energy exchanger according toclaim 6, wherein one of the tubes fluidly connects the second inlet and the second outlet.

16. The thermal energy exchanger according toclaim 6, wherein the tubes are interleaved.

17. A thermal energy exchanger for a heating, ventilating, and air conditioning system comprising:

a main housing having a hollow interior;

a fluid disposed in the housing, the fluid adapted to circulate through a conduit to a heat exchanger disposed in an HVAC module of a heating, ventilating, and air conditioning system; and

a phase change material disposed in the fluid, wherein the phase change material is at least one of encapsulated with a thermally conductive material and impregnated with a thermally conductive material.

18. The thermal energy exchanger according toclaim 17, wherein the conduit includes an inlet end and an outlet end disposed in the housing.

19. The thermal energy exchanger according toclaim 17, wherein each of the inlet end and the outlet end of the conduit includes a screen disposed therein to militate against a flow of the phase change material from the housing.

20. The thermal energy exchanger according toclaim 17, wherein the phase change material is cooled and solidified by at least one of the fluid and a flow of air through the heat exchanger.