Thermal control system
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Thermal control systems face challenges in efficiently managing heat in cold environments, particularly with high power consumption and energy expenditure due to the need for high current levels when using positive-temperature coefficient (PTC) heaters, and limited excess or waste heat from internal combustion engines in hybrid or electric vehicles.
Innovation Solution
A heat-pump-based thermal control system that incorporates heat reclamation by positioning a heat exchanger in the exhaust flow path to recover heat from exhaust airflow, reducing energy consumption and eliminating the need for icing-and-defrost cycles, while also dehumidifying and reheating air for improved efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If PTC heaters are used to heat air in cold environments, then heating capability is improved, but power consumption increases significantly
Solution Approach 1:
The patent recovers waste heat from the exhaust airflow and uses it to preheat the intake airflow, converting previously wasted thermal energy into a useful heating resource. This reduces the energy burden on the PTC heater while maintaining effective cabin heating in cold environments.
Solution Approach 2:
The exhaust airflow is used to preheat the intake airflow before it enters the cabin, performing a preliminary heating action that reduces the subsequent heating load required by the PTC heater or heat pump system.
2Temperature
If heat pump systems operate in cold environments, then heating is provided, but icing occurs on heat exchangers requiring defrost cycles
Solution Approach 1:
The patent uses the warm exhaust airflow to prevent icing on the heat exchanger by routing it through or near the evaporator, converting the exhaust heat into a protective anti-icing mechanism that eliminates the need for separate defrost cycles.
Solution Approach 2:
The exhaust airflow automatically serves to prevent icing on the heat exchanger, providing a self-service anti-icing function without requiring additional heating elements or complex control systems.
3Use of energy by moving object
If exhaust heat is reclaimed through heat exchangers, then power consumption is reduced, but system complexity increases due to additional components
Solution Approach 1:
The heat exchanger is designed to serve multiple functions: cooling the intake airflow during hot conditions, heating the intake airflow during cold conditions, and preventing icing on the evaporator. This multi-functionality reduces the need for separate components while maintaining energy efficiency.
Solution Approach 2:
The system dynamically routes exhaust airflow through different paths using controllable doors based on operating conditions, allowing the same heat exchanger to adapt its function for cooling, heating, or anti-icing without requiring multiple fixed components.
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
The system achieves reduced power consumption, especially in cold temperatures, by reclaiming heat from exhaust airflow, maintaining even cabin temperatures, and controlling humidity, thus enhancing the thermal control system's performance and durability in cold environments.
Implementation Method 1
a first heat exchanger configured to heat the working fluid and a second heat exchanger configured to cool the working fluid
Implementation Method 2
The second heat exchanger is positioned downstream of the first heat exchanger in the intake flow path and is configured to heat the intake airflow that passes through the second heat exchanger
Implementation Method 3
positioning a heat exchanger in the exhaust flow path to recover heat from exhaust airflow
Data Source
AI summary
A thermal control system includes a housing defining an intake flow path for travel of intake airflow and an exhaust flow path for travel of exhaust airflow. An intake door is disposed along the intake flow path and has first and second positions blocking and allowing intake airflow through the intake door. An exhaust door is disposed along the exhaust flow path and has first and second positions blocking and allowing exhaust airflow through the exhaust door. A mode door is disposed in the housing between the intake flow path and the exhaust flow path with a first position blocking the intake airflow and allowing the exhaust airflow to pass through a heat exchanger, a second position blocking the exhaust airflow and allowing the intake airflow to pass through the heat exchanger, and a third position allowing the intake airflow and the exhaust airflow to pass through the heat exchanger.