Heating module with heat pump and electric heater, as well as vehicle, household appliance and building heating system

Abstract

A heating module (1) is disclosed, comprising: a heat pump (2) configured to extract heat from a reservoir (6) by expending technical work and supplying it as usable heat to a heating circuit (8), and an electric heater (4) configured to supply usable heat to the heating circuit (8). The heating module (1) is configured such that it can be integrated into or connected to the heating circuit (8). Furthermore, a vehicle, a household appliance, and a building heating system incorporating the heating module (1) are disclosed.

Description

[0001] A heating module comprising a heat pump and an electric heater is disclosed. The heat pump and the electric heater are designed to supply usable heat to a heating circuit. The heating module is designed such that it can be integrated into or connected to the heating circuit. Furthermore, a vehicle, a household appliance, and a building heating system comprising the heating module are disclosed.

[0002] Due to their comparatively high energy efficiency, heat pumps are used in various applications to provide usable heat. For example, heat pumps are used in electric vehicles to increase their range through improved energy efficiency. Another example is their use in household appliances to achieve a higher energy efficiency rating. Heat pumps are also typically used in building heating systems.

[0003] Despite their good energy efficiency, heat pumps also have disadvantages regarding responsiveness and efficiency under certain environmental conditions, such as a low temperature of the reservoir from which the heat pump extracts heat by expending mechanical work. To mitigate these disadvantages, a heat pump can be combined with an electric heater.

[0004] Based on this, the revealed task is to provide an improved solution for the combined use of a heat pump with an electric heater.

[0005] This problem is solved by the items according to the independent claims. Advantageous embodiments are specified in the dependent claims as well as in the following description and / or the figures.

[0006] A heating module as disclosed comprises a heat pump and an electric heater. The heat pump is designed to extract heat from a reservoir by expending technical work and supply it to a heating circuit as usable heat. The reservoir can be waste heat from another component, e.g., from a vehicle's engine (internal combustion engine or electric motor) and / or battery pack, ambient heat (ambient air or another fluid), or another heat source (e.g., solar collectors, geothermal energy, etc.). The electric heater is designed to supply usable heat to the heating circuit. Furthermore, the electric heater may preferably have a faster response time than the heat pump. The heating module is designed such that it can be integrated into or connected to the heating circuit. This means that the heating circuit, or at least a section of it, is part of the heating module.Therefore, the heat pump and the electric heating circuit can be integrated into or connected to the heating circuit. Consequently, a simple and space-saving integration of the heat pump and the electric heater into the heating circuit is possible.

[0007] The heating module can have or share common connections for connection to the heating circuit. This means that the heat pump and the electric heater can have a common inlet and outlet. The heating module can therefore be easily connected to or integrated into the heating circuit by connecting the common connections to the corresponding connections of the heating circuit, thus achieving simple integration.

[0008] Furthermore, the heating module can have a housing that accommodates the heat pump and the electric heater. The common connections described above can then be located on the outside of the housing, for example, exiting the housing to connect to the corresponding connections of the heating circuit. The housing shape can be adapted to the intended installation space in which the heating module is to be installed. Consequently, the heating module can be integrated within the available space.

[0009] The electric heater can be arranged in or on a pipe leading to a heat exchanger designed to transfer usable heat emitted by a heat pump's condenser into the heating circuit. The electric heater can be a section of the pipe leading to the heat exchanger. Alternatively, the electric heater can be located inside the pipe and surrounded by a fluid flowing in the heating circuit. The electric heater can also be attached to the outside of the pipe, with at least one section of the pipe serving as a heat sink. This heat sink can be formed, for example, by constructing the pipe, or at least a section of it, from a thermally conductive material, such as metal. Furthermore, the heat sink can be integrated into the pipe or be designed to be integrated into it. In this way, a series arrangement of the heat pump, i.e.,The heat exchanger, which is connected to the heat pump's condenser in a heat-transferring manner, and the electric heater are obtained. The heating module can thus be easily constructed and integrated into or connected to the heating circuit.

[0010] Alternatively or additionally, a bypass can be installed parallel to the heat exchanger, which is connected to the heat pump's condenser in a heat-transferring manner. The electric heater can then be located in or on the bypass. The electric heater can be arranged similarly to the line described above. Fluid flow through the line to the heat exchanger or through the bypass can be controlled by valves or a flow diverter. The fluid flow can also be split between the line to the heat exchanger and the bypass. The supply of usable heat to the heating circuit via the heat pump or the electric heater can then be controlled, among other things, by directing the fluid flow accordingly through the line to the heat exchanger or through the bypass.

[0011] The heating module can include a control unit designed to manage the operation of both the heat pump and the electric heater, i.e., the heating module itself. The control unit can be housed within the enclosure. In this case, one or more connectors, such as plugs and / or sockets, can be provided on the outside of the enclosure for connecting the control unit to a data interface and / or an electrical power supply. The control unit can manage the operation of both the heat pump and the electric heater. Alternatively, the control unit can be located outside the enclosure and transmit control signals to the heat pump or the electric heater via one or more connectors. This allows for better coordination of the operation of the two units. Furthermore, sensors required for controlling the heat pump and the electric heater, such as...A temperature sensor for measuring the flow temperature in the heating circuit and / or a temperature sensor for measuring the ambient temperature can be used together. This allows for savings in components and consequently costs.

[0012] The control unit can be configured to manage the operation of the heat pump and electric heater according to a preset mode from a selection of multiple modes. This mode can be set by the user according to a user's preference. Alternatively, the mode can be set based on the operation of a higher-level system in which the heating module is used. For example, an energy-saving mode can be selected in an electric vehicle when its range is low, and a corresponding mode can then be set in the heating module's control unit. In this way, the operation of the heating module can be adapted to the operation of the higher-level system, i.e., the electric vehicle, the household appliance, or the building's heating system.

[0013] The control unit can be configured to operate the heat pump in an efficiency mode at a predetermined output. This predetermined output can essentially be the nominal output of the heat pump. Preferably, the electric heater is not operated. Consequently, high efficiency is achieved in supplying the usable heat to the heating circuit.

[0014] The control unit can be configured to operate the heat pump at essentially its rated output in a maximum power mode and to operate the electric heater to provide additional power. Consequently, a heat pump can be designed for a lower rated output, and additional power can be provided by the electric heater in special situations, e.g., low reservoir temperature.

[0015] The control unit can be configured to operate the heat pump in a lifetime optimization mode, at a power output that is expected to extend its service life. Preferably, the heat pump can be operated continuously at this power output. This power output can preferably be 60 to 80% of the rated power output. More preferably, it can be 70% of the rated power output. The control unit can also be configured to operate the electric heater to provide additional power when needed. Preferably, the heater can be operated at its rated power output. Such operation extends the service life of the heat pump. Furthermore, operating the heat pump at a constant power output avoids frequent load changes. Peak loads can be absorbed by appropriately operating the electric heater.

[0016] The control unit can be configured to operate the heat pump at a constant power output and the electric heater at a predetermined power output in a constant power mode, so that power peaks and dips can be compensated for by adjusting the operation of the electric heater. Consequently, load changes during heat pump operation are avoided.

[0017] The control unit can be configured to operate the electric heater at a predetermined power level in a quick-start mode, while simultaneously operating the heat pump to gradually provide that same power. This ensures a rapid initial supply of usable heat, allowing the heat pump to ramp up gently.

[0018] The control unit can be configured to operate the electric heater in an emergency mode to at least partially compensate for a heat pump failure. This heat pump failure can be complete or partial. Consequently, the heat pump can no longer supply the required usable heat to the heating circuit. In this case, the electric heater can then be used to provide usable heat. Therefore, even in the event of a heat pump failure, the heating circuit can still receive the required usable heat, or at least a portion of it.

[0019] The electric heater can be based on either a constant or a variable resistance characteristic. For example, a PTC heater with a variable resistance profile, a stratified charge heater, a heater with tubular heating elements, or a circuit board heater with constant resistance are all possible. Such heaters offer a fast response time and can be easily integrated into a fluid line.

[0020] A vehicle as disclosed has the heating module according to one of the preceding aspects. In particular, the vehicle is a hybrid vehicle or an electric vehicle. Therefore, a heat pump and an electric heater can be easily integrated into a heating circuit of the vehicle.

[0021] A household appliance as described in the disclosure has a heating module according to one of the preceding aspects. The household appliance could be, for example, a clothes dryer, a washing machine, or a dishwasher. Therefore, a heat pump and an electric heater can be easily integrated into a heating circuit of the household appliance.

[0022] A building heating system as disclosed has the heating module according to one of the preceding aspects. Therefore, a heat pump and an electric heater can be easily integrated into a heating circuit of the building heating system.

[0023] The following is a description of the revelation with reference to the accompanying figures. They show: Fig. 1 a heating module according to an embodiment of the present disclosure in which an electric heater is arranged in or on a line to a heat exchanger provided on a condenser of a heat pump; Fig. 2 a heating module according to a further embodiment of the present disclosure, in which an electric heater is arranged in or on a bypass which is formed parallel to the heat exchanger which is provided on the condenser of the heat pump; and Fig. 3 a heating module according to another embodiment of the present disclosure, in which an electric heater is arranged in or on the line to the heat exchanger and another electric heater is arranged in or on the bypass.

[0024] Embodiments of the present disclosure are described below with reference to the figures. It should be noted that the description of the embodiment is not to be considered exhaustive.

[0025] Fig. Figure 1 shows a heating module 1 according to one embodiment. The heating module 1 comprises a heat pump 2 and an electric heater 4.

[0026] The heat pump 2 is designed to extract heat from a reservoir 6 by expending technical work and supply it as usable heat to a heating circuit 8. For this purpose, the heat pump 2 comprises an evaporator 10, which is connected to the reservoir 6 by means of a heat exchanger 12, a compressor 14, a condenser 16, which can supply usable heat to the heating circuit 8 via a heat exchanger 18, and an expansion valve 20. The evaporator 10, the compressor 14, the condenser 16, and the expansion valve 20 are connected to each other via a refrigeration circuit 22, in which refrigerant flows cyclically during operation of the heat pump 2.

[0027] The evaporator 10 extracts heat from the reservoir 6 using the heat exchanger 12. Various heat sources can be used as the reservoir 6. Examples include waste heat from a motor, such as an internal combustion engine and / or an electric motor, waste heat from a battery pack, ambient air, or another heat source, such as solar collectors or geothermal energy. The heat can be supplied to the heat exchanger 12, i.e., the evaporator 10, via a fluid circuit or a fluid channel.

[0028] The refrigerant located in the evaporator 10 absorbs the heat supplied by the heat exchanger 12 and evaporates, thereby transferring heat to the refrigerant. This process takes place at low pressure and low temperature.

[0029] After the refrigerant has evaporated in the evaporator 10, it is directed to the compressor 14. The compressor 14 draws in the refrigerant during the compression process, thus ensuring a cyclical flow of the refrigerant in the refrigeration circuit 22. In the compressor 14, the refrigerant is compressed, thereby increasing its pressure and temperature.

[0030] In the condenser 16, the compressed, gaseous refrigerant is condensed and converted back into a liquid state. This occurs by transferring the heat absorbed by the refrigerant to the heating circuit 8 via the heat exchanger 18.

[0031] The expansion valve 20 controls the refrigerant pressure by creating a pressure difference between a high-pressure area upstream of the expansion valve 20 and a low-pressure area downstream of the expansion valve 20. Consequently, the expansion valve 20 reduces the refrigerant pressure as it transitions from the high-pressure to the low-pressure area. This lowers the refrigerant temperature, allowing it to absorb heat again in the evaporator 10.

[0032] The electric heater 4 is designed to supply usable heat to the heating circuit 8. The electric heater 4 preferably has a faster response time than the heat pump 2. Electric heaters 4 with either constant or variable resistance characteristics can be used. For example, a PTC heater with variable resistance, a stratified charge heater, a heater with tubular heating elements, or a circuit board heater with constant resistance are all possible. The electric heater 4 can be arranged in or on a (fluid) conduit, e.g., a pipe.

[0033] As in Fig. As can be seen in Figure 1, the heating module 1 is designed such that it can be integrated into or connected to the heating circuit 8. For example, the heating circuit 8, or at least a section of it, can be formed by the heating module 1. If the heating module 1 is designed to be connectable to the heating circuit 8, connections 24 and 26 can be provided for connecting the heating module 1 to corresponding connections of the heating circuit 8. Consequently, the heat pump 2 and the electric heater 4 can be connected to the heating circuit 8 through a single connection process.

[0034] Furthermore, the heat pump 2 and the electric heater 4 can be housed in a casing 28, thus further simplifying the integration or connection of the heating module 1 with the heating circuit 8. The casing 28 can also be a casing specifically designed for the heat pump 2. Preferably, the casing 28 can be adapted to a designated installation space, enabling suitable integration into a higher-level system, such as a vehicle, a household appliance, or a building heating system.

[0035] In the Fig. In the embodiment shown in Figure 1, the electric heater 4 is arranged in or on a line 30 leading to the heat exchanger 18. This means that the heat exchanger 18, i.e., the condenser 16 of the heat pump 2, and the electric heater 4 are arranged in series. Due to the series arrangement, the combined output of the heat pump 2 and the electric heater 4 can be easily adjusted.

[0036] A control unit 32 is provided for controlling the operation of the heating module 1; this unit is designed to control the operation of the heat pump 2 and the electric heater 4. In the Fig. In the embodiment shown in Figure 1, the control unit 32 is also housed within the casing 28. To facilitate easy connection to a control unit of a higher-level system, a connector 34 is provided on the outside of the casing 28. The connector 34 can be configured as a socket or a plug. Naturally, the connector 34 can also supply electrical power to the heating module 1, i.e., the control unit 32, the heat pump 2, and the electric heater 4. The control unit 32 can have an integrated or separate power supply unit (not shown) to provide electrical power to the heat pump 2 and the electric heater 4. Of course, additional connectors can also be provided on the casing 28. Furthermore, the control unit 32 can also be located outside the casing 28.Control signals can then be transmitted to the heat pump 2 and the electric heater 4 via connector 34. In this modification, the power supply unit can still be housed in the casing 28. In all cases, however, the advantage is achieved that the heat pump 2 and the electric heater 4 are controlled by a single control unit 32.

[0037] Furthermore, the heating module 1 can have one or more sensors for controlling the heat pump 2 and the electric heater 4. For example, a temperature sensor 36 can measure the flow temperature of the heating circuit 8. The temperature sensor 36 can be a thermocouple, an NTC resistor, or a platinum measuring resistor. Consequently, by using a single control unit 32 to control the operation of the heat pump 2 and the electric heater 4, the number of required sensors can also be reduced.

[0038] The control unit 32 can be configured to control the operation of the heat pump 2 and the electric heater 4 according to a selected mode from a plurality of modes. The mode can be set by a user according to a predefined setting. Alternatively or additionally, the mode can also be predefined by a setting of the higher-level system. Individual modes are described below.

[0039] In an efficiency mode, the control unit 32 can operate the heat pump 2 at a predefined power output. This predefined power output can, in particular, be essentially set to the nominal power output of the heat pump 2. Preferably, the electric heater 4 will then not operate. Consequently, high efficiency in the provision of usable heat can be achieved.

[0040] In maximum power mode, the control unit 32 can operate the heat pump 2 at essentially its rated power. It can also operate the electric heater 4 to provide additional power. The power of the electric heater 4 can be set up to essentially its rated power. Consequently, a high total power output can be provided. This mode should be selected when a rapid heating process is desired or when the heat pump's performance is limited, for example, due to low temperatures in the reservoir 6.

[0041] In a lifetime optimization mode, the heat pump 2 can be operated by the control unit 32 at a power output at which a longer service life of the heat pump 2 is expected. Preferably, the power output is kept constant to avoid load changes of the heat pump 2. The power output at which the longer service life is expected lies in the range between 60 and 80%, preferably 70%, of the rated power of the heat pump 2. If a higher power output is required to heat the heating circuit 8, this can be provided by operating the electric heater 4. Consequently, the service life of the heat pump 2 can be extended.

[0042] In constant power mode, the control unit 32 can operate the heat pump 2 at a constant output. This output can be set to 60 to 80%, preferably 70%, of the rated output of the heat pump 2. However, a higher or lower output can also be selected. In constant power mode, the electric heater 4 operates at a predetermined output, and power peaks and dips are compensated for by adjusting the operation of the electric heater 4. Consequently, the heat pump 2 can be operated at a constant, predetermined output, thus avoiding load changes. A dynamic power profile can still be provided by appropriately adjusting the operation of the electric heater 4.

[0043] In a quick-start mode, the control unit 32 can operate the electric heater 4 at a preset power output. The heat pump 2 is operated in such a way that it progressively provides the preset power output. This means that the heat pump 2 is continuously ramped up to the preset power output. At the same time, the power output of the electric heater is reduced accordingly. Consequently, the mechanical components of the heat pump 2 can be put into operation in a gentle manner.

[0044] In emergency mode, the control unit 32 can operate the electric heater 4 to compensate for a (partial) failure of the heat pump 2. The failure of the heat pump 2 can be complete or partial. Consequently, the heat pump 2 can no longer supply the required usable heat to the heating circuit 8. In this case, the electric heater 4 can then be used to provide usable heat. Therefore, even in the event of a failure of the heat pump 2, the heating circuit 8 can still be supplied with the required usable heat, or a portion thereof.

[0045] As mentioned previously, the individual modes can be set according to a setting of the higher-level system in which the heating module 1 is installed or used. For example, the efficiency mode can be set when the range of an electric vehicle is low, i.e., when the range falls below a predefined threshold. The lifespan optimization mode can be set when a gentle mode is activated. The quick-start mode or the maximum power mode can be selected for rapid heating.

[0046] Fig. Figure 2 shows a further embodiment of the heating module 1, in which an electric heater 40 is arranged in a bypass 42 that is parallel to the line 30 leading to the heat exchanger 18. In this embodiment, no electric heater is arranged in the line 30.

[0047] The flow of fluid through line 30 or bypass 42 is controlled by the corresponding position of valves 44 and 46. The control unit 32 can operate valves 44 and 46. Alternatively, a flow diverter valve can be used instead of the two valves 44 and 46 shown.

[0048] The other components of heating module 1 are made of Fig. 2 correspond to those of the in Fig. 1 heating module 1 shown, so that reference is made to its description for the above embodiment.

[0049] Fig. Figure 3 shows another embodiment of the heating module 1, in which the electric heater 4 is arranged in the line 30 and the electric heater 40 is arranged in the bypass 42.

[0050] The flow of fluid through line 30 or bypass 42 is controlled by the corresponding position of valves 44 and 46. Valves 44 and 46 are operated by the control unit 32. Alternatively, a flow diverter can be used instead of the two valves 44 and 46 shown.

[0051] The other components of heating module 1 are made of Fig. 3 correspond to those of the in Fig. 1 heating module 1 shown, so that reference is made to its description for the above embodiment.

[0052] The heating modules 1 described above can be used in a vehicle, e.g., a hybrid vehicle or an electric vehicle. Waste heat from other components, e.g., from an engine (internal combustion engine or electric motor) in the vehicle and / or from a battery pack in the vehicle, ambient heat (ambient air or another fluid), or another heat source (e.g., solar collectors) can be used as a reservoir.

[0053] The heating modules 1 described above can also be used in a household appliance, e.g., a dishwasher, washing machine, or tumble dryer. Ambient heat (ambient air or another fluid) or another heat source (e.g., solar collectors) can be used as the reservoir 6.

[0054] Furthermore, the heating modules described above can be used in a building heating system. Ambient heat (outside air or geothermal energy) can be used as reservoir 6. However, another heat source (e.g., solar collectors) can also be used. Reference symbol list 1 heating module 2 Heat pump 4 electric heaters 6 Reservoir 8 heating circuits 10 evaporators 12 heat exchangers 14 Compressor 16 Capacitor 18 heat exchangers 20 Expansion valve 22 Refrigeration cycle 24 connection 26 connection 28 cases 30 lines 32 Control unit 34 connectors 36 Temperature sensor 40 electric heaters 42 Bypass 44 valve 46 valve

Claims

[1] Heating module (1) comprising: a heat pump (2) designed to extract heat from a reservoir (6) by expending technical work and to supply it as usable heat to a heating circuit (8), and an electric heater (4) designed to supply useful heat to the heating circuit (8) and preferably having a faster response time than the heat pump (2), characterized by , that the heating module (1) is designed in such a way that it can be integrated into or connected to the heating circuit (8). [2] Heating module (1) according to claim 1, characterized by , that the heating module (1) forms or has common connections (24, 26) for connecting to the heating circuit (8). [3] Heating module (1) according to one of claims 1 or 2, characterized by a housing (28) in which the heat pump (2) and the electric heater (4) are housed. [4] Heating module (1) according to one of claims 1 to 3, characterized by, that the electric heater (4) is arranged in or on a line (30) to a heat exchanger (18) which is designed to transfer useful heat emitted by a condenser (16) of the heat pump (2) into the heating circuit (8). [5] Heating module (1) according to any one of claims 1 to 4, characterized by , that the electric heater (4) is arranged in or on a bypass (42) which is formed parallel to the line (30) to the heat exchanger (18). [6] Heating module (1) according to any one of claims 1 to 5, characterized by a control unit (32) designed to control the operation of the heat pump (2) and the electric heater (4). [7] Heating module (1) according to claim 6, characterized by , that the control unit (32) is designed to control the operation of the heat pump (2) and the electric heater (4) according to a set mode from a plurality of modes. [8] Heating module (1) according to claim 7, characterized by, that the control unit (32) is configured to operate the heat pump (2) in an efficiency mode with a predetermined power output, preferably its rated power output, and preferably not to operate the electric heater (4). [9] Heating module (1) according to one of claims 7 or 8, characterized by , that the control unit (32) is configured to operate the heat pump (2) in a maximum power mode at substantially its rated power and to operate the electric heater (4) to provide additional power. [10] Heating module (1) according to any one of claims 7 to 9, characterized by , that the control unit (32) is configured to operate the heat pump (2), preferably at a constant power output, in a lifetime optimization mode, at a power output at which a longer lifetime is expected, and to operate the electric heater (4) to provide additional power when needed. [11] Heating module (1) according to any one of claims 7 to 10, characterized by , that the control unit (32) is designed to operate the heat pump (2) at constant power and the electric heater (4) at a predetermined power in a constant power mode, so that power peaks and dips can be compensated by adjusting the operation of the electric heater (4). [12] Heating module (1) according to one of claims 7 to 11, characterized by , that the control unit (32) is designed to operate the electric heater (4) with a predetermined power in a quick-start mode and to operate the heat pump (2) in such a way that it progressively takes over the provision of the predetermined power. [13] Heating module (1) according to any one of claims 7 to 12, characterized by, that the control unit (32) is designed to operate the electric heater (4) in an emergency operating mode in order to at least partially compensate for a failure of the heat pump (2). [14] Heating module (1) according to any one of claims 1 to 13, characterized by , that the electric heater (4) has a constant or a variable resistance behavior, and is preferably a PTC heater with variable resistance behavior or a layer heater, a heater with tubular heating elements or a circuit board heater with constant resistance behavior. [15] Vehicle comprising the heating module (1) according to any one of claims 1 to 14. [16] Household appliance comprising the heating module (1) according to any one of claims 1 to 14. [17] Building heating system comprising the heating module (1) according to any one of claims 1 to 14.

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