Ultra-Low Profile HVAC Apparatus with Multi-Zone Heat Exchange
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Solution Overview
Problem
HVAC apparatuses with large profile heights provide more cooling power and energy efficiency but reduce valuable head height and visibility, while ultra-low profile designs struggle to deliver sufficient cooling power, especially in vehicle cabins with long air ducts.
Innovation Solution
An ultra-low profile HVAC apparatus with a plate-shaped housing containing a fan unit and heat exchanger unit, featuring multiple cooling regions with different working temperatures controlled by a temperature control unit, including thermal expansion valves and heat pipes, to optimize energy efficiency and reduce overall dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a large profile height is used for the HVAC apparatus, then cooling power and energy efficiency are improved, but head height and visibility in the vehicle cabin are reduced
Solution Approach 1:
The patent transitions from a conventional vertical stacking arrangement to a horizontal planar layout within a plate-shaped housing. The fan unit, heat exchanger unit, and temperature control unit are arranged side-by-side in the horizontal plane rather than stacked vertically, enabling the apparatus to achieve sufficient cooling capacity without increasing profile height. This dimensional reorganization allows integration into vehicle roofs with limited vertical space while maintaining adequate cooling performance.
Solution Approach 2:
The heat exchanger unit incorporates multiple cooling regions with different working temperatures (first cooling region with higher temperature, second cooling region with lower temperature) to optimize heat transfer efficiency for different air flow requirements. This localized temperature differentiation enables effective cooling across the entire heat exchanger surface area, compensating for the reduced overall profile height.
2Loss of energy
If a large profile height is used for the HVAC apparatus, then energy efficiency is improved, but vehicle aerodynamic drag and roof structure thickness increase
Solution Approach 1:
The patent reorganizes the HVAC apparatus from a vertical configuration to a horizontal planar layout within a plate-shaped housing. This dimensional change reduces the profile height to less than 80 mm, enabling integration into the vehicle roof structure without increasing aerodynamic drag or requiring roof thickening, while maintaining adequate energy efficiency through optimized heat exchanger design.
Solution Approach 2:
The temperature control unit adjusts the working temperatures of different cooling regions independently to optimize the equilibrium temperature gradient between the air stream and heat transfer surface. This parameter optimization maximizes heat transfer efficiency within the constrained profile height, ensuring energy efficiency is maintained despite the compact form factor.
3Length of stationary object
If a low profile height is used for the HVAC apparatus, then head height and visibility are improved, but cooling power and fan capacity are reduced
Solution Approach 1:
The patent achieves sufficient cooling power with a low profile height by transitioning to a horizontal planar arrangement. The plate-shaped housing with dimensions including a profile height of less than 80 mm accommodates expanded surface area heat exchangers and adequate fan capacity in the horizontal plane, demonstrating that cooling performance can be maintained through dimensional reorganization rather than vertical scaling.
Solution Approach 2:
The heat exchanger unit features multiple cooling regions with different working temperatures optimized for their specific functions. The first cooling region operates at a higher temperature while the second cooling region operates at a lower temperature, allowing each region to function at optimal efficiency. This localized optimization ensures sufficient overall cooling power is achieved despite the compact profile height.
4Length of stationary object
If a low profile height is used for the HVAC apparatus, then vehicle aerodynamic drag is reduced, but cooling power for long air ducts is insufficient
Solution Approach 1:
The patent reorganizes the HVAC apparatus into a horizontal planar layout within a plate-shaped housing, reducing profile height to less than 80 mm. This configuration provides sufficient cooling power for long air ducts by expanding the heat exchanger surface area and optimizing air flow paths in the horizontal plane, maintaining effective cooling performance without the aerodynamic penalties of a taller profile.
Solution Approach 2:
The temperature control unit independently adjusts the working temperatures of different cooling regions to optimize the equilibrium temperature gradient. This parameter optimization maximizes heat transfer efficiency across the entire heat exchanger surface, ensuring adequate cooling power is delivered through long air ducts despite the compact profile height of the apparatus.
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 solution achieves high energy efficiency and sufficient cooling power while maintaining an ultra-low profile height, allowing integration into vehicle roofs without thickening, with an overall profile height of less than 80 mm, optimizing the equilibrium temperature gradient for enhanced heat transfer.
Implementation Method 1
the heat exchanger unit comprises a heat exchanger having at least two different cooling regions with different working temperatures through which received air flows consecutively
Implementation Method 2
The optimized equilibrium temperature gradient increases the provided energy efficiency at a given cooling power
Implementation Method 3
The temperature control unit may comprise at least two thermal expansion valves with different refrigerant flow rates at a given condition
Implementation Method 4
The temperature control unit may comprise at least two heat pipes with different evaporation points, wherein the at least two heat pipes are connected to different cooling regions of the heat exchanger
Implementation Method 5
at least two heat pipes with different evaporation points
Data Source
AI summary
A HVAC apparatus for a vehicle having a fan unit with at least one impeller driven by a motor; a heat exchanger unit forming an air duct receiving air from the fan unit, wherein the heat exchanger unit comprises a heat exchanger having at least two different cooling regions with different working temperatures through which received air flows consecutively; and wherein the different working temperatures are controlled by a temperature control unit; and a plate-shaped housing accommodating the fan unit and the heat exchanger unit.