Heat pump system with integrated pcm thermal buffer and ota-controlled fallback flow logic

Abstract

A thermal management system comprises a mono-block heat pump and a phase change material (PCM) storage. A heat exchanger routes thermal energy from the heat pump to either the phase change material st

Description

Title 1. A thermal management system comprising a mono-block refrigerant heat pump, integrated or modular phase change material (PCM) storage of compact capacity suitable to buffer startup delay and support passive defrost, wherein each PCM module includes sensors and digital identifiers, a dual-path heat exchanger configured to route thermal energy to either domestic hot water (DHW) output or the PCM module, a shared circulation pump, and a control system with predictive logic and over-the-air (OTA) firmware update capability, the system being operable to deliver DHW without a storage cylinder and to assist in maintaining heating continuity during defrost. Overview 2. An intelligent thermal management system comprising a mono-block refrigerant heat pump and an integrated or close-coupled external modular phase change material (PCM) unit, thermally connected via a dual-path heat exchanger. The system improves thermal efficiency through predictive control logic, supports thermal continuity during defrost events by releasing stored PCM heat, and delivers domestic hot water without a traditional storage cylinder. The control system supports fallback thermal routing in case of module fault or flow disruption and includes over-the-air (OTA) firmware update capability to adapt heating, defrost, and hot water functions dynamically. This configuration enables compact installation, reduces component bulk, and enhances operational resilience. Technical Field 3. The system of claim 1, wherein the PCM modules are compact and externally mounted adjacent to the heat pump, thereby eliminating the need for conventional domestic hot water cylinders, buffer tanks, and large-volume internal PCM storage, simplifying installation and reducing system footprint. Background 4. The system of any preceding claim, wherein the predictive control logic is further configured to adapt to user hot water usage patterns, occupancy detection, and off-peak tariff schedules through OTA-updated profile learning. Summary of the Invention 5. This invention addresses these challenges by integrating PCM storage directly with predictive control logic and fallback thermal routing. It eliminates the need for traditional DHW cylinders and buffer tanks, while also supporting thermal continuity during defrost events without interfering with refrigerant-based defrost operation. The system provides instantaneous domestic hot water, indoor thermal buffering during defrosts, and OTA-enabled adaptability. Together, these features streamline installation, reduce system complexity, lower energy consumption, and enhance user comfort and system resilience. Additionally, the invention leverages a micro-sized PCM module rather than a full-scale thermal store, which provides all the functional benefits of conventional PCM integration—such as buffering during heat pump ramp-up and enabling passive defrost— while dramatically reducing footprint and cost. This targeted capacity optimises the design for compact installation and affordability without compromising performance. Unlike conventional smart tanks, which passively store heated water and respond only to binary temperature thresholds, the system described herein can accept partially heated fluid from the heat pump during ramp-up. By actively detecting the thermal delta across the PCM module and blending sub-threshold fluid with stored latent heat, the system delivers a usable hot water output even before full thermal charge is reached. This real-time thermal management function, governed by OTA-adjustable logic, is not achievable with standard storage cylinders or smart tank controls, which lack both the physical PCM integration and the dynamic routing logic described herein. Description of Embodiments 6. The control-optimised PCM system comprises a refrigerant-based mono-block heat pump integrated with modular PCM storage units. Each PCM unit includes embedded temperature sensors and digital identifiers enabling precise monitoring, control, and diagnostics. A dual-path heat exchanger allows routing of thermal energy either directly to DHW circuits or to the PCM module. Predictive algorithms analyse usage history, occupancy patterns, and energy tariff schedules to optimise charge / discharge cycles. 7. The system of any preceding claim, wherein the PCM module is dimensioned as a micro-capacity unit sized proportionally to the thermal output of the heat pump, sufficient to buffer startup delay and / or provide passive defrost energy, thereby reducing space requirements and manufacturing costs compared to conventional high-volume thermal stores. 8. The system of any preceding claim, wherein solar or auxiliary input is incorporated into the PCM charge cycle only under OTA-governed energy priority rules, ensuring thermal contribution is optimally timed and managed. The PCM module is intentionally designed as a micro unit—approximately 50-60L in volume— sufficient to deliver up to 120L of domestic hot water at 50 °C within 10-12 minutes when combined with OTA blending logic and high-temperature heat pump output. This sizing has been validated against independent lab-tested R290 heat pump data, ensuring recharge within 20-35 minutes during typical seasonal conditions. This approach enables simpler installation, faster response, and lower production and operating costs compared to traditional large-scale PCM thermal batteries or hot water cylinders. In one embodiment, the PCM module is integrated into a low-profile thermal platform that serves either as a plinth beneath the heat pump unit or as a lower structural section of the cabinet itself. This arrangement allows the heat pump to retain a compact, vertically slim profile while incorporating enhanced thermal storage functionality without requiring an external cylinder or buffer tank.

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