HVAC Heater Coolant Flow Control for Compact Module Design
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Solution Overview
Problem
Conventional HVAC systems for vehicles are larger than desired due to the need for a blend door and mixing chamber, and they continuously pump hot coolant through the heater core regardless of heating needs, leading to inefficiencies.
Innovation Solution
The method involves flowing all air through the evaporator through the heater core and using a flow control valve to periodically introduce and stop hot coolant from the engine, determining its temperature to refill the heater core when cooled, eliminating the need for a blend door and mixing chamber by ensuring uniform temperature control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a blend door and mixing chamber are used to control air temperature, then air temperature uniformity is improved, but the HVAC module size increases
Solution Approach 1:
The patent removes the blend door and mixing chamber from the HVAC system, extracting these components entirely. Instead, it uses a heater core with controlled coolant flow to heat all air passing through the evaporator, eliminating the need for separate mixing mechanisms and reducing overall module size.
Solution Approach 2:
The heater core serves multiple functions: it heats all air passing through the evaporator and replaces the need for both the blend door (for temperature control) and mixing chamber (for uniformity). By making the heater core the primary temperature control element, the system achieves multi-functionality with fewer components.
2Power
If hot coolant is continuously pumped through the heater core, then heating capacity is maintained, but energy efficiency deteriorates when heating is not needed
Solution Approach 1:
The patent implements periodic action by using a control valve to intermittently supply hot coolant to the heater core based on actual heating demands. The valve opens when heating is needed and closes when not needed, converting continuous coolant flow into periodic flow to match operational requirements and reduce energy waste.
Solution Approach 2:
The system uses feedback control where the control valve responds to heating demands (temperature sensors detecting cabin or component heating needs) to regulate coolant flow to the heater core. This closed-loop control ensures coolant is supplied only when heating is actually required, improving energy efficiency while maintaining heating capacity when needed.
3Volume of moving object
If the HVAC module is reduced in size by eliminating components, then packaging space is improved, but system complexity in achieving temperature control increases
Solution Approach 1:
The patent extracts and removes the blend door and mixing chamber components, simplifying the physical structure. The temperature control function is achieved through a different mechanism (controlled coolant flow to heater core) that requires fewer mechanical parts, thereby reducing overall system complexity despite the functional requirements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces the size of the HVAC module by eliminating the blend door and mixing chamber, allowing for efficient air temperature control and minimizing packaging space, particularly beneficial in small vehicles.
Implementation Method 1
heating the air in such HVAC systems... flowing essentially all of the air flowing through the evaporator through a heater core... flow of hot coolant from an engine into the heater core
Data Source
AI summary
An air conditioning system and a method of heating air flowing through a heater core of a HVAC module is disclosed. The method includes flowing essentially all of the air flowing through an evaporator through a heater core for all HVAC operating conditions. A flow control valve is opened long enough to allow a flow of hot coolant from an engine into the heater core. The valve is then closed to stop the flow of the hot coolant. When the temperature of the hot coolant is determined to have cooled to a predetermined temperature threshold, the flow control valve is then opened again to allow hot coolant to flow into the heater core.