Abstract: A heat storage heat pump heater (HSHPH) incorporated into a heating, ventilation, and air conditioning (HVAC) system that provides heat to maintain the temperature in a compartment (e.g., a cabin of an electric vehicle) during both a heating cycle and defrosting cycle. This HSHPH contains a heat exchanger having an inlet and an outlet located in one or more manifolds and a core that includes one or more refrigerant tubes through which a refrigerant flows and a plurality of fins that extend between the tubes, the one or more refrigerant tubes being in fluid communication with the inlet and the outlet; and a phase change material (PCM) configured to store heat transferred from the refrigerant during a heating cycle and to transfer heat to the refrigerant during a defrosting cycle. The PCM changes phase at a temperature that is greater than or equal to 24° C.

Abstract: An evaporator for an air conditioning system includes a plurality of clamshell plates stacked in series along a longitudinal axis and a plurality of core tubes coupled with the stacked clamshell plates. In an upper region of the evaporator, the stacked clamshell plates form an inlet tank and an outlet tank hydraulically communicated with the core tubes for a refrigerant flow. Each of the clamshell plates includes a pooling ridge on a first surface of the clamshell plate for pooling a liquid refrigerant by gravity such that the liquid refrigerant is evenly distributed to inlet core tubes disposed along the longitudinal axis.

Abstract: An HVAC module having a reconfigurable bi-level duct system is disclosed. The air duct includes an air duct inlet in fluid communication with the HVAC module, an interior wall dividing the air duct into first and second air passageways, a bypass port enabling fluid communication between the first air and second air passageways. A downstream control valve disposed adjacent the bypass port and is configured to selectively direct air flow from one of the first and second air passageways to the other of the first and second air passageways. An upstream flow control valve is disposed adjacent to the inlet of the air duct, wherein the upstream flow control valve is configured to selectively direct air flow from the hot and cold chambers of the HVAC module to the first and second air passageways of the air duct.

Abstract: A method controls the discharge of temperature-conditioned air from a plurality of zone outlets of an automotive HVAC system via an open architecture multi-zone HVAC unit having a single blower fan, an evaporator downstream of the blower and a heater downstream of the evaporator, wherein each zone in the module includes a temperature mix door for proportioning hot and cold air, which is controlled by a separate Discharge Temperature Maintenance control (DTM control), and an output valve for controlling a zonal output flow rate. The output valve of each zone outlet is placed in an output valve position associated with a target resistance; and the single blower fan is operated at a minimum voltage required for generating a total requested blower output flowrate.

Abstract: A heat exchanger includes a header, a plurality of tubes, and a distributor. The header is configured to contain refrigerant and define an opening proximate to a termination end of the header. The plurality of tubes extends away from and is fluidicly coupled to the header. The plurality of tubes includes a first group of adjacent tubes characterized as located further away from the opening than a second group of adjacent tubes. The distributor is located within the header and spaced apart from the opening such that a first portion of the refrigerant in the first group of tubes does flow through the distributor, and a second portion of the refrigerant in the first group of tubes does not flow through the distributor.

Abstract: The disclosure presents a heat exchanger assembly having a first manifold, a second manifold spaced from the first manifold, a plurality of refrigerant tubes extending between and in hydraulic communication with the first and second manifolds, a plurality of corrugated fins inserted between the plurality of refrigerant tubes, and a condensate extractor having a comb baffle portion with fingers inserted between the plurality of refrigerant tubes and a conveyance portion. The comb baffle portion is configured to extract condensate from between the plurality of refrigerant tubes and the conveyance portion is configured to convey condensate away from the heat exchanger assembly.

Abstract: HVAC module has an air inlet, an evaporator downstream of the blower and a heater downstream of the evaporator, and a rear mixing zone downstream of the evaporator and the heater, wherein a control valve prevents cold air from flowing back towards the hot air by regulating the pressure of the cold air. A method is devised to control anti-backflow control valve of such an HVAC module by the steps of reading pressure and temperatures at various points in the HVAC module; setting air flow and temperature discharge targets; calculating the resistance of the control valve and a bland valve; determining corresponding control valve and blend valve positions; and moving the control valve and blend valve to those corresponding positions.

Abstract: A heat pump cooling and heating system for an electric vehicle includes a range extending PCM heat exchanger (24), with a single acting phase change material with a melt temperature between the two comfort temperatures associated with cooling and heating, respectively. In a charging mode, as the vehicle batteries are charged, the same exterior current source runs the compressor (10), charging the PCM exchanger (24) with heat or “cold.” During an initial range extending mode, the PCM exchanger/reservoir (24) serves as the heat source or heat sink. The PCM material does not directly heat or cool the air, as is conventional, allowing a single reservoir material to be used in both heating and cooling modes.

Abstract: HVAC unit has a single blower fan, an evaporator downstream of the blower and a heater downstream of the evaporator, wherein each zone outlet includes a temperature mixing door for controlling portions of hot and cold air and an output valve for controlling a zonal output flow rate. A method is devised to control the discharge of temperature-conditioned air from a plurality of zone outlets of an automotive HVAC system via such an HVAC unit by the steps of reading an operator-requested zonal discharge blower level for each of the zone outlets; converting each zonal discharge blower level request to a zonal flowrate request; calculating a total requested output flowrate as a summation of all zonal flowrate requests; and adjusting a blower voltage to a minimum voltage required for generating the total requested output flowrate.

Abstract: A heat pump heat exchanger includes a first manifold, a second manifold spaced from the first manifold, a plurality of refrigerant tubes hydraulically connecting the manifolds, and a distribution tube disposed in the first manifold. The distribution tube includes an inlet end, a distal end opposite the inlet end, a plurality of orifices between the inlet end and the distal end. The distribution tube also includes a terminal aperture immediately adjacent the distal end, wherein the terminal aperture includes an open aperture area greater than any one of the open orifice area. The open aperture area is large enough to provide a uniform refrigerant collection with acceptable minimal pressure drop in evaporative mode, but small enough to prevent vapor overflow to an area of the manifold adjacent to the distal end in condenser mode. The length of the distribution tube is less than ¾ the length of the first manifold.

Abstract: An HVAC module having a reconfigurable bi-level duct system is disclosed. The air duct includes an air duct inlet in fluid communication with the HVAC module, an interior wall dividing the air duct into first and second air passageways, a bypass port enabling fluid communication between the first air and second air passageways. A downstream control valve disposed adjacent the bypass port and is configured to selectively direct air flow from one of the first and second air passageways to the other of the first and second air passageways. An upstream flow control valve is disposed adjacent to the inlet of the air duct, wherein the upstream flow control valve is configured to selectively direct air flow from the hot and cold chambers of the HVAC module to the first and second air passageways of the air duct.

Abstract: HVAC module has an air inlet, an evaporator downstream of the blower and a heater downstream of the evaporator, and a rear mixing zone downstream of the evaporator and the heater, wherein a control valve prevents cold air from flowing back towards the hot air by regulating the pressure of the cold air. A method is devised to control anti-backflow control valve of such an HVAC module by the steps of reading pressure and temperatures at various points in the HVAC module; setting air flow and temperature discharge targets; calculating the resistance of the control valve and a bland valve; determining corresponding control valve and blend valve positions; and moving the control valve and blend valve to those corresponding positions.

Abstract: A heat pump cooling and heating system for an electric vehicle includes a range extending PCM heat exchanger (24), with a single acting phase change material with a melt temperature between the two comfort temperatures associated with cooling and heating, respectively. In a charging mode, as the vehicle batteries are charged, the same exterior current source runs the compressor (10), charging the PCM exchanger (24) with heat or “cold.” During an initial range extending mode, the PCM exchanger/reservoir (24) serves as the heat source or heat sink. The PCM material does not directly heat or cool the air, as is conventional, allowing a single reservoir material to be used in both heating and cooling modes.

Abstract: A method controls the discharge of temperature-conditioned air from a plurality of zone outlets of an automotive HVAC system via an open architecture multi-zone HVAC unit having a single blower fan, an evaporator downstream of the blower and a heater downstream of the evaporator, wherein each zone in the module includes a temperature mix door for proportioning hot and cold air, which is controlled by a separate Discharge Temperature Maintenance control (DTM control), and an output valve for controlling a zonal output flow rate. The output valve of each zone outlet is placed in an output valve position associated with a target resistance; and the single blower fan is operated at a minimum voltage required for generating a total requested blower output flowrate.

Abstract: HVAC unit has a single blower fan, an evaporator downstream of the blower and a heater downstream of the evaporator, wherein each zone outlet includes a temperature mixing door for controlling portions of hot and cold air and an output valve for controlling a zonal output flow rate. A method is devised to control the discharge of temperature-conditioned air from a plurality of zone outlets of an automotive HVAC system via such an HVAC unit by the steps of reading an operator-requested zonal discharge blower level for each of the zone outlets; converting each zonal discharge blower level request to a zonal flowrate request; calculating a total requested output flowrate as a summation of all zonal flowrate requests; and adjusting a blower voltage to a minimum voltage required for generating the total requested output flowrate.

Abstract: A heat pump heat exchanger includes a first manifold, a second manifold spaced from the first manifold, a plurality of refrigerant tubes hydraulically connecting the manifolds, and a distribution tube disposed in the first manifold. The distribution tube includes an inlet end, a distal end opposite the inlet end, a plurality of orifices between the inlet end and the distal end. The distribution tube also includes a terminal aperture immediately adjacent the distal end, wherein the terminal aperture includes an open aperture area greater than any one of the open orifice area. The open aperture area is large enough to provide a uniform refrigerant collection with acceptable minimal pressure drop in evaporative mode, but small enough to prevent vapor overflow to an area of the manifold adjacent to the distal end in condenser mode. The length of the distribution tube is less than 3/4 the length of the first manifold.

Abstract: The disclosure presents a heat exchanger assembly having a first manifold, a second manifold spaced from the first manifold, a plurality of refrigerant tubes extending between and in hydraulic communication with the first and second manifolds, a plurality of corrugated fins inserted between the plurality of refrigerant tubes, and a condensate extractor having a comb baffle portion with fingers inserted between the plurality of refrigerant tubes and a conveyance portion. The comb baffle portion is configured to extract condensate from between the plurality of refrigerant tubes and the conveyance portion is configured to convey condensate away from the heat exchanger assembly.

Abstract: A heat exchanger assembly having an inlet header, an outlet header spaced from the inlet header, a plurality of refrigerant tubes hydraulically connecting the inlet header with the outlet header. A distributor tube having a plurality of orifices disposed in the inlet header, wherein the orifices are arranged along the distributor tube such that at least one orifice is oriented in the liquid phase of the refrigerant pressed against the internal surface of the distributor tube regardless of orientation of the evaporator. The orifices may be arranged in a random order about the distributor tube, positioned in groups of at least two at predetermined locations, or spiraled along the distributor tube.

Abstract: An improved heat exchanger assembly having an inlet header in hydraulic communication with an outlet header via a plurality of multi-channel flat refrigerant tubes, in which the multi-channel flat refrigerant tubes are substantially perpendicular to the headers. Interconnecting the refrigerant tubes are corrugated fins. The plurality of refrigerant tubes together with the fins defines the core of the heat exchanger assembly. The heat exchanger assembly also includes a distributor tube disposed in the inlet header cavity and a collector tube disposed in the outlet header cavity. The distributor tube and collector tube have cooperating features for archiving uniform refrigerant distribution through the refrigerant tubes.

Abstract: A heat exchanger assembly having an inlet header, an outlet header spaced apart from and substantially parallel the inlet header, and a plurality of refrigerant tubes each extending between and in hydraulic communication with the inlet header and outlet header. Contained within the outlet header is a refrigerant collector conduit adapted to provide a predetermined pressure drop (?P) and having a cross-section area Acollector. The refrigerant collector includes a plurality of orifices having a cumulative orifice area (nAorifice) that are substantially equally spaced along the refrigerant collector. The collector conduit is in fluid communication with the outlet header for transferring the vapor phase of a two refrigerant. The collector conduit cross sectional area (Acollector) and cumulative orifice area (nAorifice) is described by the following equation: ? ? ? p = m dot 2 ? ? [ 467.892 ? ( 1 A collector 2 - 1 n 2 ? A orifice 2 ) + 51.