VASCULAR STRUCTURES AND METHODS FOR THERMAL CONTROL

Abstract

Thermal control system comprising: a component (20) having vascular channels (38) integrated into a network (22) within the component (20), the component (20) being configured as part of a manufactured environment configured for occupants; a fluid circuit (320) connected to the vascular channels (38) and configured to circulate a fluid through the component (20); wherein the fluid changes a thermal state of the component (20); wherein the vascular channels (38) have a diameter between 100 micrometers and one millimeter; further comprising a heat exchanger (316), wherein the fluid circuit (320) includes the heat exchanger (316); a heating, ventilation, and air conditioning (HVAC) system (318) configured to circulate a second fluid, the second fluid circulating through the heat exchanger (316); a coolant circuit (306) of the HVAC system (318), wherein the second fluid comprises engine coolant; a second heat exchanger (332), wherein the fluid circuit (320) includes the second heat exchanger (332); and an air conditioning system (324) configured to circulate a third fluid, wherein the third fluid circulates through the second heat exchanger (332).

Description

INTRODUCTION

[0001] The present disclosure relates generally to structures and methods for thermal control via vascular channels, and more particularly to heating or cooling via vascular channels formed in internal components.

[0002] Assembled structures can include components of different shapes and materials. Individual components can conduct heat, radiate heat, and / or extract heat from other objects. When components define a manufacturing space occupied by people, the space is generally conditioned by a heating, ventilation, and air conditioning (HVAC) system. Providing an HVAC system allows a comfortable environment to be maintained for occupants by adding or removing heat from the space. The HVAC system therefore works against unwanted heat or cold. When components are the source of the heat or cold, the HVAC system only addresses these sources indirectly by conditioning the indoor air. In certain applications, an HVAC system may have limited capacity. In other applications, it is desirable to reduce the energy consumption of an HVAC system.

[0003] DE 10 2014 011 684 A1 describes a vehicle, preferably a bus, with a device for cooling and heating a passenger compartment of the vehicle. The device for cooling and heating a passenger compartment of the vehicle comprises a conduit arrangement arranged on an interior surface of the passenger compartment and through which a liquid energy carrier can flow for cooling or heating the interior surface; and an energy carrier circuit configured to selectively heat or cool the liquid energy carrier. The conduit arrangement is configured as part of the energy carrier circuit. The energy carrier circuit can be coupled to a heating circuit via a liquid / liquid heat exchanger for heating the energy carrier and to a refrigerant circuit via an evaporator for cooling the energy carrier.

[0004] CN 1 06 515 383 A describes an automotive window glass. The automotive window glass comprises an inner glass layer, an outer glass layer, and a ventilation structure, wherein the ventilation structure comprises a ventilation bend tube, a valve, and an air heater embedded between the inner glass layer and the outer glass layer.

[0005] DE 10 2007 062 898 A1 describes an air-conditioned interior trim component for a motor vehicle, which has a multi-layer structure, wherein an intermediate layer through which a cooling medium flows is arranged between a cover layer and a carrier.

[0006] CN 1 02 211 511 A describes a motor vehicle in which a plurality of cavity layers are arranged around a base cabin. The plurality of cavity layers form a cavity system, wherein each cavity of the plurality of cavities in the cavity system is interconnected by a connecting pipe. An outlet pipe of a cooling device is connected to an inlet opening of the cavity system, and an inlet pipe of the cooling device is connected to an outlet opening of the cavity system.

[0007] WO 2012 / 118956 A2 describes a bio-inspired window created by applying one or more heat exchange layers to one or more surfaces of a window of a building, boat, vehicle, or other structure. The heat exchange layer may comprise an interconnected network or array of channels or microchannels that can be used to flow a fluid across the surface of the window. The fluid can be used to heat or cool the surface of the window to control heat flow across the window and reduce heating or cooling energy requirements.

[0008] It is desirable to provide structures and methods that efficiently and effectively provide heat and / or cooling for a wide range of applications. Furthermore, other desirable features and characteristics of the thermal control structures and methods will become apparent from the following detailed description and the appended claims, taken in conjunction with the accompanying drawings and the foregoing technical field and background. SUMMARY

[0009] Systems and methods for thermal control using vascular channels are provided. According to the invention, vascular channels are integrated into a network within a component. The component is part of a manufactured environment configured for occupants. A fluid circuit is connected to the vascular channels and circulates a fluid through the component to alter a thermal state of the component.

[0010] In further embodiments, the manufacturing environment includes a cabin of a vehicle and the component includes an interior panel of the vehicle.

[0011] In additional embodiments, the fluid circuit includes a heat exchanger. An HVAC system is configured to circulate a second fluid through the heat exchanger.

[0012] In additional embodiments, the component includes a vehicle dashboard.

[0013] In additional embodiments, the component includes a windshield.

[0014] According to the invention, the vascular channels have a diameter between 100 micrometers and one millimeter.

[0015] In additional embodiments, the vascular channels include tubes embedded in the component.

[0016] In additional embodiments, the network includes a manifold connected to the vascular channels.

[0017] In additional embodiments, the component consists of a fiber material incorporated into a polymer matrix. According to the invention, the fluid circuit includes a heat exchanger. A heating, ventilation, and air conditioning (HVAC) system is configured to circulate a second fluid, wherein the second fluid circulates through the heat exchanger. A coolant circuit of the HVAC system is provided, wherein the second fluid comprises engine coolant. A second heat exchanger is provided, wherein the fluid circuit includes the second heat exchanger, and an air conditioning system is configured to circulate a third fluid, wherein the third fluid circulates through the second heat exchanger.

[0018] The invention further includes a method for thermal control of a component, comprising incorporating vascular channels into a network within the component. The component is mounted as part of a manufactured environment configured for the occupants. A fluid circuit is connected to the vascular channels. A fluid circulates through the component and alters the thermal state of the component.

[0019] In additional embodiments, the method includes configuring the manufactured environment as a cabin of a vehicle. The component may be configured as an interior panel of the vehicle.

[0020] According to the invention, the method includes connecting a heat exchanger in the fluid circuit. A heating, ventilation, and air conditioning (HVAC) system is configured to circulate a second fluid, wherein the second fluid circulates through the heat exchanger. A coolant circuit of the HVAC system is provided, wherein the second fluid comprises engine coolant. A second heat exchanger is provided, wherein the fluid circuit includes the second heat exchanger, and an air conditioning system is configured to circulate a third fluid, wherein the third fluid circulates through the second heat exchanger.

[0021] In additional embodiments, the method includes configuring the component as a vehicle instrument panel.

[0022] In additional embodiments, the method includes configuring the component as a vehicle windshield.

[0023] According to the invention, the method involves forming the vascular channels with a diameter between 100 micrometers and one millimeter.

[0024] In additional embodiments, the method includes forming the vascular channels as tubes and embedding the tubes in the component.

[0025] In additional embodiments, the method includes connecting a manifold to the vascular channels and integrating the manifold into the component.

[0026] In additional embodiments, the method includes forming the component of a fiber material incorporated into a polymer matrix.

[0027] Further exemplary embodiments include a thermal control system for a vehicle cabin. A component of the vehicle defines an interior portion of the cabin. A fluid circuit circulates a fluid. A vascular channel in the component is connected to the fluid circuit to conduct the fluid through the component. A heat exchanger is carried by the vehicle and is incorporated into the fluid circuit. The cabin is configured to support an occupant, and the fluid is configured to alter a thermal state of the component to increase or decrease a temperature sensed by the occupant. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The exemplary embodiments are described below in conjunction with the following drawings, wherein like reference numerals designate like elements, and wherein: Fig. 1 is a schematic representation of a component with vascular channels according to one embodiment; Fig. Figure 2 is a graph of temperature versus time for the component of the embodiment of Fig. 1; Fig. Figure 3 is a graph of temperature over time for a cabin incorporating the component of the embodiment of Fig. 1 contains; Fig. 4 is a schematic cross-sectional view of a component according to one embodiment; Fig. Figure 5 is a schematic cross-sectional view of the component of Fig. 4 with an applied die, according to an embodiment; Fig. Figure 6 is a schematic cross-sectional view of the component of Fig. 4 with formed vascular channels, according to one embodiment; Fig. 7 is a schematic illustration of a plate application method for a component according to an embodiment; Fig. Figure 8 is a schematic cross-sectional view taken generally along line 8-8 of Fig. 7 according to one embodiment; Fig. 9 is a schematic representation of a component and a die according to an embodiment; Fig. 10 is a schematic representation of a component with vascular channels according to one embodiment; Fig. 11 is a schematic cross-sectional view of an element of a component according to an embodiment; Fig. 12 is a schematic cross-sectional view of the component of Fig. 11, formed with vascular channels, according to one embodiment; Fig. 13 is a schematic cross-sectional illustration of a component heating process according to various embodiments; Fig. 14 is a schematic representation of the component of Fig. 13, formed with vascular channels, according to one embodiment; Fig. 15 is a schematic representation of an element of a component according to an embodiment; Fig. 16 is a schematic representation of an element of the component of Fig. 15 according to one embodiment; Fig. 17 is a schematic illustration of the tube application to a component according to one embodiment; Fig. 18 is a schematic illustration of a tube application method for a component according to one embodiment; Fig. 19 is a schematic cross-sectional view of the component of Fig. 18 with integrated tubes according to one embodiment; Fig. 20 is a schematic perspective view of a laminated component according to one embodiment; Fig. 21 is a schematic cross-sectional view of a component according to one embodiment; Fig. 22 is a schematic cross-sectional view of the component of Fig. 21 with applied channel structures according to an embodiment; Fig. 23 is a schematic cross-sectional view of the component of Fig. 21, formed with vascular channels, according to one embodiment; Fig. 24 is a schematic cross-sectional view of a mold with applied channel structures according to one embodiment; Fig. Figure 25 is a schematic cross-sectional view of a component corresponding to the channel structures and mold of Fig. 24 was added according to one embodiment; Fig. 26 is a schematic cross-sectional view of the component of Fig. 25, formed with vascular channels, according to one embodiment; Fig. 27 is a schematic cross-sectional view of an element of a component according to an embodiment; Fig. Figure 28 is a schematic cross-sectional view of the element of Fig. 27 with applied traces of sacrificial materials according to one embodiment; Fig. 29 is a schematic cross-sectional view of the element of Fig. 27 with applied traces of sacrificial materials and another element forming a component, according to an embodiment; Fig. 30 is a schematic cross-sectional view of the component of Fig. 29, formed with vascular channels, according to one embodiment; Fig. 31 is a schematic illustration of a sacrificial material formed in traces connected to sacrificial manifolds according to one embodiment; Fig. 32 is a schematic cross-sectional view of the tracks of Fig. 31 with a trained component; Fig. 33 is a schematic cross-sectional view of the component of Fig. 32 formed with vascular channels, according to one embodiment; Fig. 34 is a schematic cross-sectional view of a blow molding process according to one embodiment; Fig. 35 is a schematic cross-sectional view of a vascular conduit preform according to one embodiment; Fig. 36 is a schematic cross-sectional view of the preform of Fig. 35, which is integrated into a component according to one embodiment; Fig. 37 is a schematic illustration of a vascular channel fluid system of a vehicle according to an embodiment; Fig. 38 is a schematic illustration of a vascular channel fluid system of a vehicle according to an embodiment; Fig. 39 is a schematic representation of a vascular channel fluid system of a vehicle according to one embodiment; and Fig. 40 is a schematic diagram of a vascular channel fluid system of a vehicle according to an embodiment. DETAILED DESCRIPTION

[0029] The following detailed description is provided for illustrative purposes only and is not intended to limit the application and use in any way. Furthermore, there is no intention to be bound by any theory expressed or implied in this introduction, summary, or the following detailed description.

[0030] According to the preferred embodiments described herein, the sensed temperature of a manufactured environment is controlled by integrating vascular channel fluid circulation systems and methods for specific components. In manufactured environments, such as the cabin of an automobile, heat sinks and thermal loads, such as from conductive and radiant sources, affect the temperatures experienced by an occupant. To economically improve the thermal comfort of occupants, the temperature of components is varied by circulating fluids through vascular channels. The size of the vascular channels depends on the application and the manufacturing method chosen to form a component. Heat can be added or removed via the vascular channels.Excess heat, such as from solar radiation, propulsion systems, battery systems, electronics, and various vehicle systems, can be dissipated and released into the environment. Heat can be supplied through integrated vascular channels to warm cold components, such as seating surfaces or other occupant interface surfaces, windows, or other components. Heating and cooling vascular channels can be used as a complement to an HVAC system, allowing the size of energy-consuming HVAC components to be reduced, thus improving efficiency. Size and weight reductions are also possible for various systems used for heat removal, such as an engine cooling radiator, an air conditioning condenser, a transmission cooler, and a battery cooler. These aspects are useful in all applications, including electric vehicle applications.

[0031] Accordingly, the following description relates to vascular structures, systems, and methods for thermal control. The structures, systems, and methods may be described in the context of a vehicle application for demonstrating examples. A vehicle is only one type of environment in which heating and / or cooling of the vascular conduit may be implemented. The present disclosure is not limited to vehicle applications but also encompasses all applications where thermal control is desired and where components for the application of vascular conduits are present. Accordingly, the teachings of the present disclosure may be applied, optionally, to vehicles or to other applications.

[0032] In an exemplary embodiment, for example, in a vehicle cabin, an occupant's comfort is influenced not only by the air temperature within the vehicle, but also by a variety of radiating and conductive sources. Radiating sources are those surrounding the occupant, such as the windshield / windows, sun visor, dashboard, door panels, seats, floor coverings, and others. Conductive sources are those the occupant touches, such as the seat surfaces, steering wheel, armrests, and others. These sources increase the occupant's heat load on a hot day, and conductive sources, in particular, affect the occupant's heat loss on a cold day. Accordingly, the occupant experience is improved by varying the temperature of various component sources by heating and / or cooling the vascular channel.

[0033] In an example, as in Fig. 1, a component in the form of an instrument panel for an automobile includes the network 22, which is a vascular conduit network. The network 22 is integrated into the component, such as by one of the methods described below. The component is sized and shaped to meet the packaging and functional requirements of the automobile and has a contoured surface 24. It should be understood that the network 22 is shown for descriptive purposes, but in application may be embedded beneath the surface 24 and thus not visible. The component also includes features such as speaker openings 26, 28, vent openings 30, 32, 34, and a sensor opening 36. Within the limitations of the component shape and its characteristics, the network 22 is designed to utilize the available space.The network 22 includes a number of channels 38, which in this embodiment generally run from the front 40 to the back 42 of the component. The channels 38 are connected to a manifold 44 that runs near the front 40 of the component and another manifold 46 that runs near the back 42 of the component. In the exemplary embodiment, the channels 38 are spaced 20 millimeters apart and have a diameter of 0.8 millimeters. A fluid can circulate through the network 22, for example, by being pumped into the manifold 46 at an inlet 48. From the inlet 48, the fluid flows through the manifold 46, the channels 38, and the manifold 44, exiting at the outlet 50. The fluid can be heated or cooled to change the temperature of the component.Since the component in this embodiment is an instrument panel, the radiant heat load of a vehicle occupant is changed by the circulation of the fluid through the network 22.

[0034] With reference to Fig. 2 is a graph illustrating instrument panel temperature in degrees Celsius on the vertical axis 52 and time in minutes on the horizontal axis 54. In the exemplary embodiment, the fluid is circulated at a rate of 100 milliliters per minute at a temperature of ten degrees Celsius. Curve 56 demonstrates the temperature reduction of component 20 resulting solely from cooling of the vehicle's HVAC system. Curve 58 demonstrates the temperature reduction of the component as a result of cooling of the vehicle's HVAC system along with cooling via network 22. The higher heat reduction rate achieved by the additional cooling via network 22 results in a lower heat load on the occupants due to the reduced radiant heat from component 20. The effect is that occupant comfort is achieved more quickly. This effect is also illustrated by graph 60 of Fig. 3, which shows the time it takes for a vehicle's cabin to reach a comfortable temperature on a very cold day. Graph 60 shows the cabin temperature in degrees Celsius on the vertical axis 62 and the time in minutes on the horizontal axis 64. Curve 66 shows the time to reach cabin temperature using only the vehicle's air conditioning heating system. Curve 68 shows the cabin temperature resulting from the vehicle's HVAC heating system combined with heating via network 22. The greater temperature increase achieved by adding heat via network 22 means a ten percent time saving to reach a comfortable temperature between curves 68 and 66. Accordingly, occupants experience a comfortable level of comfort more quickly.

[0035] A number of embodiments involve the fabrication of vascular channels by direct formation of channels in a multilayer component with selective local binding. With reference to Fig. 4-6, two layers lie against each other. One of the layers may take the form of a component 102 for which heating or cooling is desired. For example, the component 102 may be an interior panel of a cabin, a seating surface, a portion of a floor, wall, or ceiling, or another type of component. The component 102 may be formed from a variety of materials, including metal, polymer, composite, or others. Generally, the component 102 is formed in its final shape at this stage; in some embodiments, the component 102 may undergo further shape changes at a later time. The second layer may take the form of a deformable plate 104. As shown in Fig. 4, the component 102 and the deformable plate 104 are placed together with a surface 106 of the component 102 against a surface 108 of the deformable plate 104. The deformable plate 104 may cover the entire surface 106 or only a portion of the surface 106. In several embodiments, the component 102 may have a thickness 110 that is consistent. In further embodiments, the thickness 110 varies across the area of ​​the component 102. The deformable plate 104 generally has a uniform thickness 112 that is less than the thickness 110 of the component.

[0036] As in Fig. 5, a tool, in this example in the form of a die 111, is brought into contact with the deformable plate 104. The die 111 has raised areas 114 which press the contacted areas of the deformable plate 104 against the component 102 using a force 116. In the interface areas 120 corresponding to the positions of the raised areas 114, the surface 108 is pressed against the surface 106. The interface areas 120 can optionally be covered with an adhesive on the surface 108 and / or the surface 106. The application of the force 116 secures the deformable plate 104 to the component 102 at the interface areas 120. In further embodiments, the die 111 is heated and the deformable plate 104 is fused to the component 102 at the interface areas 120. The die 111 includes a series of recesses 122 between the raised areas 114.The pattern of recesses 122 defines the channels formed by the mated component 102 and the deformable plate 104. Referring to FIG. Fig. 6, a pressure 124 is applied between surfaces 106 and 108 to open passages between interface regions 120, which form channels 126. The deformable plate 104 can be plastically deformed under the action of the pressure 124, leaving the channels 126 open. In further embodiments, the channels 126 are filled with fluid while the pressure 124 is applied, and the fluid remains in the channels 126 without plastically deforming the deformable plate 104. In still further embodiments, the deformable plate 104 is elastic, and the channels 126 are inflated when a fluid circulates through them in use.

[0037] In an exemplary embodiment, as shown in the Fig. 7-8, the deformable sheet 104 is applied to the component 102 by a rolling action. The deformable sheet 104 is guided onto the component 102 by a roller 128. A roller 130 presses the deformable sheet 104 against the component 102 at the interface regions 120. The roller has a raised area 114 with recesses 122 formed therebetween. The surface 108 is affixed to the surface 106 at the interface regions 120 by an adhesive or by heat from the roller 130. In several embodiments, the deformable sheet 104 is preformed with ribs 132 that fit into the recesses 122, eliminating the need for compression forming.

[0038] In an exemplary embodiment, as in Fig. 9, the die 111 includes integrated heaters 136 in the raised areas 114. The die 111 also includes ports 137 that correspond with the recesses 122. A vacuum can be drawn through the ports 137, pulling the adjacent portions of the deformable plate 104 into the recesses 122. The deformable plate 104 and the component 102 are brought together using force 116, and the interface areas 120 are secured by fusing under the applied heat during the vacuum. In further embodiments, the deformable plate is plastically deformed using the vacuum, the vacuum is released, and the component 102 and the deformable plate 104 are then joined to the already deformable plate to form the channels 126.

[0039] In an exemplary embodiment, as in Fig. As illustrated in Figure 10, an assembly 138 of component 102 and deformable plate 104 is formed with channels in a plurality of different flow paths 140, 142. The flow paths 140, 142 may be formed in independent networks each having a plurality of paths, may have a countercurrent configuration, may carry different fluids, may carry fluids at different temperatures, may be controlled at different or varying flow rates, and may vary in other ways. In some embodiments, regions of the assembly 138 are covered with channels of different densities to allow for localized variations in heating or cooling. The flow paths 140, 142 may take various shapes, such as straight, curved, serpentine, etc.

[0040] In an exemplary embodiment, as shown in the Fig. 11-12, the component 102 is covered with an adhesive layer 144, such as a spray applicator 146. The coverage may be uniform over the entire surface 106, or the adhesive may be applied to selected areas. As shown in Fig. 12, the deformable plate 104 may be pre-deformed and is applied against the adhesive layer 144 under an applied pressure 117. The deformable plate 104 is attached to the component 102 with the adhesive layer 144 and the channels 126 are defined. In a number of embodiments, as shown in the Fig. 13-14, instead of the adhesive layer 144, the surfaces 106, 108 are heated, for example by an infrared radiator 147. The infrared radiator 147 is withdrawn and the pre-deformed, deformable plate 104 is brought against the component 102 under the action of the force 116, whereby both are fused together and define the channels 126.

[0041] In an exemplary embodiment, as shown in the Fig. 15-16, an assembly of two elements 150, 152 is formed. Element 150 is formed with depressions 154 between raised areas 156. Element 150 is contoured with a curved surface 158. Element 150 may be formed in a variety of ways and, in the current embodiment, is manufactured by injection molding. Element 152 may also be formed in a variety of ways. Element 152 may be a flexible sheet or a rigid part. In some embodiments, element 152 is manufactured by injection molding. Element 152 has a contour 160 that corresponds to the contour of the curved surface 158 that it may be formed into or that it may adopt when applied to element 150. Elements 150, 152 may be brought together as described above and secured with an adhesive or thermally.In the current embodiment, either surface 162 or surface 164 may be the exposed surface visible during assembly in its application. This is because the injection-molded elements 150, 152 are formed without viewing the channels through both surfaces 162, 164.

[0042] A number of embodiments involve the manufacture of products with vascular channels by incorporating tubes into a component. With reference to Fig. 17, a plurality of tubes 166 are arranged in a desired pattern for the desired heating or cooling effect. The tubes 166 can be any size to meet the requirements of the application. In a number of embodiments, the tubes 166 range from about 0.5 millimeters to about 5.0 millimeters in diameter. The tubes are placed in a mold 168, and a component 170 is formed around the tubes 166. In some embodiments, as in Fig. 18, the tubes 166 are drawn off a roller 172 and placed in the mold 168. The resulting component 170 with the incorporated tubes 166 can take on any desired shape, such as non-linear surfaces, as in Fig. 19 shown.

[0043] In an exemplary embodiment, as in Fig. 20, a laminated component is formed from a tube-containing layer 174 disposed between a pair of outer layers 176 and 178. In one example, the component is a window, such as the windshield 177 of an automobile. The outer layers 176 and 178 are formed from glass, and the tubes 180 and the tube-containing layer 174 are formed from a transparent polymer such as polyvinyl butyral, ethylene-vinyl acetate, polycarbonate, thermoplastic polyurethane, poly(methyl methacrylate), or another polymer. The tube-containing layer 174 contains an index-matching material having a refractive index very close to that of the outer layers 176, 178. In the example of the windshield 177, which can transfer significant radiant heat into the vehicle cabin, a chilled fluid is passed through the tubes 180 for cooling purposes.In further embodiments, the fluid is heated, for example for dehumidification or thawing.

[0044] A number of embodiments involve the manufacture of products with vascular channels through the use of sacrificial materials. The use of sacrificial materials enables the formation of channels with very small diameters. For example, diameters of up to 100 micrometers can be formed. With reference to Fig. 21, in an exemplary embodiment, a component 182 is formed by various methods, such as injection molding. The component 182 may be formed in any shape and has a surface 184, which may be an optical surface (Class A surface) that is visible when the component 182 is assembled into a product. As shown in Fig. As shown in Figure 22, channel structures 186 are created with a stable outer wall 188 and a sacrificial core 190. The channel structures 186 are placed and glued or applied to a surface 192.

[0045] The surface 192 is located in an unexposed area when the component 182 is assembled into a product. In one example, the channel structures 186 are printed onto the surface 192, which encapsulate sacrificial fibers as the sacrificial core 190. The sacrificial core 190 is applied to the surface 192 as a sacrificial framework, with the outer wall 188 being deposited layer by layer and built up to a thickness structurally sufficient for the pressures occurring in the formed channels. As shown in Fig. As shown in Figure 23, the sacrificial core 190 is depleted, and the walls 188 form the channels 194. The material of the sacrificial core 190 can be removed thermally, chemically, electrically, ultraviolet, or by other means, depending on the material used. In one example, the sacrificial cores 190 are formed from catalyst-impregnated polylactide and removed by evaporation at an elevated temperature.

[0046] In an exemplary embodiment, as in Fig. 24, the outer walls 188 are printed on a surface 196 of a mold 198 which encapsulates the sacrificial cores 190. As in Fig. 25, a component 200 is formed on the mold 198, for example, by injection molding over the outer walls 188. The component 200 is formed around the sacrificial cores 190 and the outer walls 188. As shown in Fig. 26, the sacrificial cores 190 are exhausted and the channels 202 are formed in the component 200. The outer walls 188 may be formed from the same material as the component 200 and become an integral part thereof.

[0047] In an exemplary embodiment, as in Fig. 27, an element 204 of a component 206 is formed from a variety of methods. In this example, the element 204 is formed by injection molding. A series of traces 208 of the sacrificial material are printed on a surface 210 of the element 204, as shown in Fig. 28. Another element 212 of the component 206 is formed on the element 204 overmolded on the tracks 208, as shown in Fig. 29. In the current example, the element 212 is formed by injection molding. The traces 208 of the sacrificial material are formed as shown in Fig. 30, for example, thermally, chemically, electrically, ultravioletly, or otherwise, depending on the material used. The channels 214 are formed in the component 206 by removing the traces 208 of the sacrificial material.

[0048] A number of embodiments involve the manufacture of products with manifolds to connect the vascular channels through the use of sacrificial materials. In an exemplary embodiment, as in Fig. 31, a series of traces 216 are formed from sacrificial material by one of the methods described above, including injection molding, 3D printing, and other methods. The traces 216 are connected to a pair of elbows 218 and 220. The elbow 218 is connected to each end of the traces 216, and the elbow 220 is connected to the opposite ends of the traces 216. In this embodiment, the traces 216 and the elbows 218, 220 are formed into a component 222, as shown in Fig. 32. The component 222 can be formed by any of the methods described above, including injection molding. The ends 224, 226 of the manifolds 218, 220, respectively, are accessible for connection to a fluid circulation system. The component is treated to deplete the sacrificial material of the traces 216, for example, by thermal, chemical, electrical, ultraviolet, or other means. The removal of the sacrificial material traces 216 leaves channels 228 in the component 222, as shown in Fig. 33 shown.

[0049] A number of embodiments involve the manufacture of products with elbows to connect the vascular channels by preforming the elbows. As in Fig. 34, a network 230 is formed by one of the methods described above, including injection molding, 3D printing, and other methods. In an exemplary embodiment, the network 230 is formed by blow molding. A heated polymer material 232 is injected into a mold 234 having the network configuration in its interior surfaces 236, 238. Air is blown into the mold 234, forming cavities 240 in the polymer material 232. The mold 234 is opened, and the network 230 is removed and molded as shown in Fig. 35. The network 230 includes a series of blow-molded tubular elements 242 connected to a pair of elbows 244 and 246. The network 230 is closed except for the ends 254, 256 of the respective elbows 244, 246. The elbow 244 is connected to one end of each tubular element 242, and the elbow 246 is connected to the opposite ends of the tubular elements 242. The tubular elements 242 and the elbows 244, 246 are formed into a component 252, as shown in Fig. 36. Component 252 may be formed by any of the methods described above, including injection molding. The ends 254, 256 of manifolds 244, 246, respectively, are accessible for connection to a fluid circulation system. Network 230 may be formed in any configuration required for circulating one or more fluids through component 252.

[0050] In various examples, the components described above are formed from materials such as metals, polymers, and / or compounds. In various examples, components are formed from a metal such as steel, aluminum alloys, magnesium alloys, or others. In various examples, a polymer such as a thermoset or thermoplastic is used. Examples of polymers include, but are not limited to: Acrylonitrile Butadiene Styrene (ABS), Polymethyl Methacrylate (PMMA), Celluloid, Cellulose Acetate, Cycloolefin Copolymer (COC), Benzoxazine, Bis-Maleimide (BMI), Cyanate Esters, Epoxy, Ethylene Vinyl Acetate (EVA), Ethylene Vinyl Alcohol (EVOH), Fluoroplastics (including PTFE, FEP, PFA, CTFE, ECTFE, ETFE), Phenioc (PF), Polyacetal (POM or Acetal), Polyacrylates (Acrylic), Polyacrylonitrile (PAN or Acrylonitrile), Polyamide (PA or Nylon), Polyamide-Imide (PAI), Polyaryletherketone (PAEK or Ketone), Polybutadiene (PBD),Polybutylene (PB), polybutylene terephthalate (PBT), polycaprolactone (PCL), polychlorotrifluoroethylene (PCTFE), polyethylene terephthalate (PET), polycyclohexylenedimethylene terephthalate (PCT), polycarbonate (PC), polyhydroxyalkanoates (PHAs), polyketone (PK), polyester, polyetheretheretherketone (PEEK), polyetherketoneketone (PEKK), polyetherimide (PEI), polyethersulfone (PES), polysulfone, polyethylene chlorinates (PEC), polyimide (PI), polylactic acid (PLA), polymethylpentene (PMP), polyphenylene oxide (PPO), polyphenylene sulfide (PPS), polyphthalamide (PPA), polystyrene (PS), polysulfone (PSU), polytrimethylene terephthalate (PTT), polyurethane (PU), polyvinyl acetate (PVA), Polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), styrene-acrylonitrile (SAN), Polycarbonate+acrylonitrile-butadiene-styrene mixture (ABS+PC), polypropylene (PP), polyethylene (PE), unsaturated polyester, polyurethane (PUR), vinyl ester, silicone or combinations or mixtures in any amount thereof,or another type. In various examples, compounds are used with a fibrous material incorporated into a polymer matrix material. Fibers can be carbon, glass, para-aramid, meta-aramid, basalt, polyethylene, combinations thereof, or another material. The components are formed by any process suitable for the chosen materials.

[0051] In a number of embodiments, as in Fig. 37, a vehicle 300 includes a vascular duct fluid system 302. The instrument panel-shaped component includes the network 22 with an inlet 48 and an outlet 50. The vehicle 300 includes an engine 304 with a coolant circuit 306. Generally, the coolant is circulated by a branch 308 from the engine 304 through the radiator 310 to dissipate heat. The coolant is circulated by another branch 312 from the engine 304 through a heater core 314 and a heat exchanger 316. The heater core 314 is part of the HVAC system 318, and the heat exchanger 316 is part of the vascular duct fluid system 302. The HVAC system includes a blower 319 for moving air. The vascular channel fluid system 302 includes a fluid circuit 320, which includes a pump 322 for circulating fluid through the network 22 and the heat exchanger 316. The pump 322 may be a small, efficient device, such as a 20-watt pump.To increase the temperature of the component, coolant heated by the engine 304 is passed through branch 312, which heats the heat exchanger 316. Heat can be simultaneously utilized in the HVAC system 318 because the coolant flows through the heater core 314 in series with the heat exchanger 316. A control mechanism 323, which may include an auxiliary pump, valves, or other flow control components, can be integrated into branch 312 to control the flow. As the heat exchanger 316 is heated by the coolant, the fluid is moved through the network 22 by the pump 322, which heats the component.

[0052] The vehicle 300 also includes an air conditioning system 324. Refrigerant is circulated by a compressor 326, a condenser 328, an evaporator 330, and a heat exchanger 332. The condenser 328 is part of the HVAC system 318, and the heat exchanger 332 is part of the vascular channel fluid system 302. The heat exchangers 316, 332 are arranged in series in the vascular channel fluid system 302. To lower the temperature of the component 20, still-cooling refrigerant from the evaporator 330 is circulated through the heat exchanger 332, which provides cooling. The cooling can be used simultaneously in the HVAC system 318 because the refrigerant is expanded by the evaporator 330. When the heat exchanger 332 is cooled by the refrigerant, the fluid is moved through the network 22 by the pump 322, which cools the component. Accordingly, the vascular channels enable an efficient form of thermal control of the component 20.

[0053] In a number of embodiments, as in Fig. 38 illustrates, portions of a vascular channel fluid system 334 are integrated into an HVAC module 336. The HVAC module 336 includes the blower 319, the evaporator 330, and the heater core 314. A fluid circuit 338 circulates the fluid through the network 22 and through a heat exchanger 340 by means of selective operation of the pump 322. The heat exchanger 340 is included in the HVAC module 336 in a common channel 342 with the evaporator 330 and the heater core 314. The blower 319 moves air through the channel 342 over the evaporator 330, the heater core 314, and the heat exchanger 340, which are connected in series. The air is then directed into the cabin 344 of the vehicle 300. The air flowing through duct 342 is cooled by evaporator 330 when HVAC system 318 is operating in air conditioning mode and heated when the HVAC system is operating in heating mode. The cooled or heated air moves across heat exchanger 340, acting either as a cooling or heating element.The fluid in fluid circuit 338 is circulated through heat exchanger 340, which absorbs heat when HVAC system 318 is operating in heating mode and releases heat when HVAC system 318 is operating in air conditioning mode. The heated or cooled fluid in fluid circuit 338 is then circulated through network 22 to either heat or cool the component.

[0054] In a number of embodiments, as in Fig. 39, the network 22 is part of a fluid circuit 345, which includes a cooler-like heat exchanger 346 and the pump 322. A fan 347 moves ambient air 348 through the heat exchanger 346 and provides a heating or cooling effect depending on the temperature of the ambient air 348 and the component. For example, if the cabin 344 has an elevated temperature, for example due to sunlight when the vehicle 300 is parked, the fluid circuit 345 is used to cool the component. The fluid circulated by the pump 322 through the fluid circuit 345 absorbs the heat in the network 22 and releases it to the ambient air 348 via the heat exchanger 346. The heat exchanger 346 is located in the front area 350 of the vehicle 300 and is provided for the supply of ambient air 348.

[0055] In a number of embodiments, as in Fig.As illustrated in Figure 40, the network 22 is selectively connected to the coolant circuit 306 or the air conditioning system 324. The network 22 is divided into two separate fluid circuits 352, 354 to maintain the separation between coolant and refrigerant. The fluid circuits 352, 354 can be located in separate areas of the component or can be separate but distributed over the same area. A valve 356 controls the flow of coolant into the fluid circuit 352. The coolant heated by the motor 304 flows through the heater core 314, and when opened, the valve 356 directs it into the fluid circuit 352 to heat the component. A valve 358 controls the flow of refrigerant into the fluid circuit 354. The refrigerant compressed by the compressor 326 flows through the evaporator 330 and, when open, through the valve 358 into the fluid circuit 354 to cool the component 20.

[0056] Through the aforementioned structures, systems, and methods, vascular conduits enable an efficient form of thermal control. While some exemplary embodiments have been presented in the foregoing detailed description, it should be understood that numerous variations exist. It should also be understood that the exemplary embodiment(s) are merely examples and are not intended to limit the scope, applicability, or configuration of this disclosure in any way. Rather, the foregoing detailed description provides those skilled in the art with a convenient roadmap for implementing the exemplary embodiment(s).It is understood that various changes may be made in the function and arrangement of elements without departing from the scope of the disclosure as set forth in the appended claims and their legal equivalents.

Claims

[1] Thermal control system comprising: a component (20) having vascular channels (38) integrated into a network (22) within the component (20), the component (20) being configured as part of a manufactured environment configured for occupants; a fluid circuit (320) connected to the vascular channels (38) and configured to circulate a fluid through the component (20); wherein the fluid changes a thermal state of the component (20); wherein the vascular channels (38) have a diameter between 100 micrometers and one millimeter; further comprising a heat exchanger (316), wherein the fluid circuit (320) includes the heat exchanger (316); a heating, ventilation, and air conditioning (HVAC) system (318) configured to circulate a second fluid, the second fluid circulating through the heat exchanger (316); a coolant circuit (306) of the HVAC system (318), wherein the second fluid comprises engine coolant; a second heat exchanger (332), wherein the fluid circuit (320) includes the second heat exchanger (332); and an air conditioning system (324) configured to circulate a third fluid, wherein the third fluid circulates through the second heat exchanger (332). [2] The thermal control system of claim 1, wherein the manufactured environment comprises a cabin (344) of a vehicle (300) and the component (20) is an interior panel of the vehicle (300). [3] A thermal control system according to claim 1, wherein the component (20) is a vehicle windshield (177) includes. [4] A method for thermally controlling a component (20), comprising: Incorporating vascular channels (38) into a network (22) within the component (20); Forming the vascular channels (38) with a diameter between 100 micrometers and one millimeter; Mounting the component (20) as part of a manufactured vehicle configured for the occupants Vicinity; Connecting a fluid circuit (320) to the vascular channels (38); and Circulating a fluid through the component (20), wherein the fluid changes a thermal state of the component (20); wherein the fluid circuit (320) includes a heat exchanger (316); wherein a heating, ventilation, and air conditioning (HVAC) system (318) is configured to circulate a second fluid, the second fluid circulating through the heat exchanger (316); wherein a coolant circuit (306) of the HVAC system (318) is provided, wherein the second fluid comprises engine coolant; wherein the fluid circuit (320) includes a second heat exchanger (332); and wherein an air conditioning system (324) is configured to circulate a third fluid, the third fluid circulating through the second heat exchanger (332). [5] A method according to claim 4, comprising: Configuring the manufactured environment as a vehicle cabin; and Configuring the component (20) as interior panel of the vehicle (300). [6] A method according to claim 5, comprising: Connecting a heat exchanger (316) in the fluid circuit (320); and Circulating a second fluid through the heat exchanger (316) and through a heating, ventilation and air conditioning (HVAC) system (318).

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