THERMAL ENERGY STORAGE SYSTEM WITH HEAT PUMP, REDUCED HEATER CORE, AND INTEGRATED BATTERY COOLING AND HEATING

Abstract

A control module for a heating, ventilating, and air conditioning system includes a housing having an air flow conduit formed therein. An evaporator core is disposed in the air flow conduit, wherein at least a portion of the evaporator is configured to receive a fluid from a fluid source therein. An internal thermal energy exchanger is disposed in the air flow conduit downstream of at least a portion of the evaporator core and upstream of a blend door disposed in the air flow conduit. The internal thermal energy exchanger is configured to receive another fluid from at least another fluid source therein to provide a heating and cooling thereto.

Description

FIELD OF THE INVENTION

The invention relates to a climate control system for a vehicle and more particularly to a heating, ventilating, and air conditioning system of a vehicle having a thermal energy storage system.

BACKGROUND OF THE INVENTION

A vehicle typically includes a climate control system which maintains a temperature within a passenger compartment of the vehicle at a comfortable level by providing heating, cooling, and ventilation. Comfort is maintained in the passenger compartment by an integrated mechanism referred to in the art as a heating, ventilating and air conditioning (HVAC) system. The HVAC system conditions air flowing therethrough and distributes the conditioned air throughout the passenger compartment.

Typically, a compressor of a refrigeration system provides a flow of a fluid having a desired temperature to an evaporator disposed in the HVAC system to condition the air. The compressor is generally driven by a fuel-powered engine of the vehicle. However, in recent years, vehicles having improved fuel economy over the fuel-powered engine and other vehicles are quickly becoming more popular as a cost of traditional fuel increases. The improved fuel economy is due to known technologies such as regenerative braking, electric motor assist, and engine-off operation. Although the technologies improve fuel economy, accessories powered by the fuel-powered engine no longer operate when the fuel-powered engine is not in operation. One major accessory that does not operate is the compressor of the refrigeration system. Therefore, without the use of the compressor, the evaporator disposed in the HVAC system does not condition the air flowing therethrough and the temperature of the passenger compartment increases to a point above a desired temperature.

Accordingly, vehicle manufacturers have used a thermal energy exchanger disposed in the HVAC system to condition the air flowing therethrough when the fuel-powered engine is not in operation. One such thermal energy exchanger, also referred to as a cold accumulator, is described in U.S. Pat. No. 6,854,513 entitled VEHICLE AIR CONDITIONING SYSTEM WITH COLD ACCUMULATOR, hereby incorporated herein by reference in its entirety. The cold accumulator includes a phase change material, also referred to as a cold accumulating material, disposed therein. The cold accumulating material absorbs heat from the air when the fuel-powered engine is not in operation. The cold accumulating material is then recharged by the conditioned air flowing from the cooling heat exchanger when the fuel-powered engine is in operation.

In U.S. Pat. No. 6,691,527 entitled AIR-CONDITIONER FOR A MOTOR VEHICLE, hereby incorporated herein by reference in its entirety, a thermal energy exchanger is disclosed having a phase change material disposed therein. The phase change material of the thermal energy exchanger conditions a flow of air through the HVAC system when the fuel-powered engine of the vehicle is not in operation. The phase change material is charged by a flow of a fluid from the refrigeration system therethrough.

While the prior art HVAC systems perform adequately, it is desirable to produce a thermal energy storage system for an HVAC system, wherein an effectiveness and efficiency thereof are maximized.

SUMMARY OF THE INVENTION

In concordance and agreement with the present invention, a thermal energy storage system for an HVAC system, wherein an effectiveness and efficiency thereof are maximized, has surprisingly been discovered.

In one embodiment, a heating, ventilating, and air conditioning (HVAC) system for a vehicle, comprises: a control module including a housing having an air flow conduit formed therein, the air flow conduit in fluid communication with a passenger compartment of the vehicle; an evaporator core disposed in the air flow conduit, at least a portion of the evaporator core configured to receive a first fluid from a first fluid source; and a thermal energy exchanger disposed in the air flow conduit downstream of the at least a portion the evaporator core, the thermal energy exchanger configured to receive a second fluid from a second fluid source and at least one of a third fluid from a third fluid source and a fourth fluid from a fourth fluid source, wherein the first fluid and the second fluid are different fluid types.

In another embodiment, a heating, ventilating, and air conditioning (HVAC) system for a vehicle, comprises: a control module including a housing having an air flow conduit formed therein, the air flow conduit in fluid communication with a passenger compartment of the vehicle; and an evaporator core having a plurality of layers disposed in the air flow conduit, wherein at least one of the layers is configured to receive a first fluid from a first fluid source therein, and at least another one of the layers is configured to receive a second fluid from a second fluid source and at least one of a third fluid from a third fluid source and a fourth fluid from a fourth fluid source, and wherein the first fluid and the second fluid are different fluid types.

In yet another embodiment, a heating, ventilating, and air conditioning (HVAC) system for a vehicle, comprises: a control module including a housing having an air flow conduit formed therein; an evaporator core disposed in the air flow conduit, the evaporator core configured to receive a first fluid from a first fluid source therein; a thermal energy exchanger disposed in the air flow conduit, the thermal energy exchanger configured to receive a second fluid from a second fluid source therein, wherein the first fluid and the second fluid are different fluid types; and a condenser disposed in the air flow conduit downstream of the thermal energy exchanger, wherein the condenser is configured to receive a working fluid from a heat pump system of the vehicle.

BRIEF DESCRIPTION OF THE DRAWINGS

The above, as well as other objects and advantages of the invention, will become readily apparent to those skilled in the art from reading the following detailed description of various embodiments of the invention when considered in the light of the accompanying drawings in which:

FIG. 1 is a schematic flow diagram of an HVAC system including a fragmentary sectional view of an HVAC module having an evaporator core and an internal thermal energy exchanger disposed therein according to an embodiment of the invention and showing the evaporator core in fluid communication with a first fluid source and the internal thermal energy exchanger in fluid communication with a second fluid source and a third fluid source;

FIG. 2 is a schematic perspective view of the evaporator core illustrated in FIG. 1 showing a portion of two layers of the evaporator core cutaway;

FIG. 3 is a schematic flow diagram of an HVAC system including a fragmentary sectional view of an HVAC module having an evaporator core, an internal thermal energy exchanger, and a heater core disposed therein according to another embodiment of the invention and showing the evaporator core in fluid communication with a first fluid source, the internal thermal energy exchanger in fluid communication with a second fluid source and a fourth fluid source, and the heater core in fluid communication with a third fluid source;

FIG. 4 is a schematic flow diagram of an HVAC system including a fragmentary sectional view of an HVAC module having an evaporator core, an internal thermal energy exchanger, and a heater core disposed therein according to another embodiment of the invention and showing the evaporator core in fluid communication with a first fluid source, the internal thermal energy exchanger in fluid communication with a second fluid source and a fourth fluid source, and the heater core in fluid communication with a third fluid source, wherein the heater core and the third fluid source are in thermal energy exchange relationship with the fourth fluid source; and

FIG. 5 is a schematic flow diagram of an HVAC system including a fragmentary sectional view of an HVAC module having an evaporator core, an internal thermal energy exchanger, and a heater core disposed therein according to another embodiment of the invention and showing the evaporator core in fluid communication with a first fluid source, the internal thermal energy exchanger in fluid communication with a second fluid source, a third fluid source, and a fourth fluid source, and the heater core in fluid communication with the second fluid source and the third fluid source, wherein the heater core and the third fluid source are in thermal energy exchange relationship with the fourth fluid source; and

FIG. 6 is a schematic flow diagram of an HVAC system including a fragmentary sectional view of an HVAC module having an evaporator core, an internal thermal energy exchanger, and a condenser of a heat pump system disposed therein according to another embodiment of the invention and showing the evaporator core in fluid communication with a first fluid source and the internal thermal energy exchanger in fluid communication with a second fluid source, a third fluid source, and a fourth fluid source, wherein the condenser is in thermal energy exchange relationship with the third fluid source in a chiller of the heat pump system.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The following detailed description and appended drawings describe and illustrate various exemplary embodiments of the invention. The description and drawings serve to enable one skilled in the art to make and use the invention, and are not intended to limit the scope of the invention in any manner.

FIG. 1 shows a heating, ventilating, and air conditioning (HVAC) system 10 according to an embodiment of the invention. The HVAC system 10 typically provides heating, ventilation, and air conditioning for a passenger compartment of a vehicle (not shown). The HVAC system 10 includes a control module 12 to control at least a temperature of the passenger compartment.

The module 12 illustrated includes a hollow main housing 14 with an air flow conduit 15 formed therein. The housing 14 includes an inlet section 16, a mixing and conditioning section 18, and an outlet and distribution section (not shown). In the embodiment shown, an air inlet 22 is formed in the inlet section 16. The air inlet 22 is in fluid communication with a supply of air (not shown). The supply of air can be provided from outside of the vehicle, recirculated from the passenger compartment of the vehicle, or a mixture of the two, for example. The inlet section 16 is adapted to receive a blower wheel (not shown) therein to cause air to flow through the air inlet 22. A filter (not shown) can be provided upstream, in, or downstream of the inlet section 16 in respect of a direction of flow through the module 12 if desired.

The mixing and conditioning section 18 of the housing 14 is configured to receive an evaporator core 24 and a heater core 28 therein. As shown, at least a portion of the mixing and conditioning section 18 is divided into a first passage 30 and a second passage 32. In particular embodiments, the evaporator core 24 is disposed upstream of a selectively positionable blend door 34 in respect of the direction of flow through the module 12 and the heater core 28 is disposed in the second passage 32 downstream of the blend door 34 in respect of the direction of flow through the module 12. A filter (not shown) can also be provided upstream of the evaporator core 24 in respect of the direction of flow through the module 12, if desired.

The evaporator core 24 of the present invention, shown in FIGS. 1-2, is a multi-layer louvered-fin thermal energy exchanger. In a non-limiting example, the evaporator core 24 has a first layer 40, a second layer 42, and a third layer 44 arranged substantially perpendicular to the direction of flow through the module 12. Additional or fewer layers than shown can be employed as desired. The layers 40, 42, 44 are arranged so the second layer 42 is disposed downstream of the first layer 40 and upstream of the third layer 44 in respect of the direction of flow through the module 12. It is understood, however, that the layers 40, 42, 44 can be arranged as desired. The layers 40, 42, 44 can be bonded together by any suitable method as desired such as brazing and welding, for example.

Each of the layers 40, 42, 44 of the evaporator core 24 includes an upper first fluid manifold 46, 48, 50 and a lower second fluid manifold 52, 54, 56, respectively. A plurality of first tubes 58 extends between the fluid manifolds 46, 52 of the first layer 40. A plurality of second tubes 60 extends between the fluid manifolds 48, 54 of the second layer 42. A plurality of third tubes 62 extends between the fluid manifolds 50, 56 of the third layer 44. In particular embodiments, each of the first upper fluid manifolds 46, 48, 50 is an inlet manifold which distributes the fluid into at least a portion of the respective tubes 58, 60, 62 and each of the second lower fluid manifolds 52, 54, 56 is an outlet manifold which collects the fluid from at least a portion of the respective tubes 58, 60, 62.

Each of the tubes 58, 60, 62 is provided with louvered fins 64 disposed therebetween. The fins 64 abut an outer surface of the tubes 58, 60, 62 for enhancing thermal energy transfer of the evaporator core 24. Each of the fins 64 defines an air space 68 extending between the tubes 58, 60, 62. The tubes 58, 60, 62 of the evaporator core 24 can further include a plurality of internal fins (not shown) formed on an inner surface thereof. The internal fins further enhance the transfer of thermal energy of the evaporator core 24. It is understood, however, that the evaporator core 24 can be constructed as a finless thermal energy exchanger if desired.

In a particular embodiment, the layers 40, 42 of the evaporator core 24, shown in FIG. 1, are in fluid communication with a first fluid source 70 via a conduit 72. It is understood, however, that any of the layers 40, 42, 44, alone or in combination, may be in fluid communication with the first fluid source 70 via the conduit 72 and configured to receive the flow of the first fluid therein. The first fluid source 70 includes a prime mover 74 such as a pump or a compressor, for example, to cause a first fluid to circulate therein. Each of the layers 40, 42 shown is configured to receive a flow of the first fluid from the first fluid source 70 therein. The first fluid absorbs thermal energy to condition the air flowing through the module 12 when a fuel-powered engine of the vehicle, and thereby the prime mover 74, is in operation. As a non-limiting example, the first fluid source 70 is a refrigeration circuit, and the first fluid is a refrigerant such as R134a, HFO-1234yf, AC-5, AC-6, and CO₂, for example. A valve 76 can be disposed in the conduit 72 to selectively militate against the flow of the first fluid therethrough.

The HVAC system 10 of the present invention further includes an internal thermal energy exchanger 78 in fluid communication with a second fluid source 80 via a conduit 82. The second fluid source 80 includes a prime mover 84 (e.g. an electrical pump) to cause a second fluid to circulate through the internal thermal energy exchanger 78. As illustrated, the internal thermal energy exchanger 78 is the third layer 44 of the evaporator core 24. It is understood, however, that the internal thermal energy exchanger 78 may be any of the layers 42, 44 of the evaporator core 24, alone or in combination, in fluid communication with the second fluid source 80 via the conduit 82 and configured to receive the flow of the second fluid from the second fluid source 80 therein. In another particular embodiment, the internal thermal energy exchanger 78 is a separate thermal energy exchanger disposed downstream and spaced apart from the evaporator core 24 and upstream of the blend door 34. It is understood that the internal thermal energy exchanger 78 can be any conventional thermal energy exchanger as desired.

The second fluid absorbs or releases thermal energy to condition the air flowing through the module 12. A valve 86 can be disposed in the conduit 82 to selectively militate against the flow of the second fluid therethrough. As a non-limiting example, the second fluid source 80 is a fluid reservoir containing a phase change material (PCM) therein. Those skilled in the art will appreciate that the phase change material can be any suitable material that melts and solidifies at predetermined temperatures and is capable of storing and releasing thermal energy such as organic, inorganic, eutectic and ionic liquids (e.g. a paraffin, a paraffin wax, an alcohol, water, a polyglycol, a glycol), and the like, or any combination thereof, for example. The phase change material can also be impregnated with a thermally conductive material such as graphite powder, for example, to further enhance the transfer of thermal energy. As another non-limiting example, the second fluid source 80 is a fluid reservoir containing a coolant therein. As another non-limiting example, the second fluid source 80 is a fluid reservoir containing a phase change material coolant such as CryoSolplus, for example, therein. As yet another non-limiting example, the second fluid source 80 is an external thermal energy exchanger (e.g. a shell and tube heat exchanger, a chiller, etc.) which includes a phase change material disposed therein and/or is in fluid communication with at least one other vehicle system.

As shown, the heater core 28 is in fluid communication with a third fluid source 94 via a conduit 96. The heater core 28 is configured to receive a flow of a third fluid from the third fluid source 94 therein. The third fluid source 94 can be any conventional source of heated fluid such as the fuel-powered engine of the vehicle, for example, and the third fluid can be any fluid such as a phase change material, a coolant, and a phase change material coolant, for example. A valve 97 can be disposed in the conduit 96 to selectively militate against the flow of the third fluid therethrough. The heater core 28 is configured to facilitate a release of thermal energy from the third fluid to heat the air flowing therethrough when the fuel-powered engine of the vehicle is in operation.

In certain embodiments, the heater core 28 and the third fluid source 94 are also in fluid communication with the internal thermal energy exchanger 78 via a conduit 98. The internal thermal energy exchanger 78 is configured to facilitate a release of thermal energy from the third fluid to heat the air flowing therethrough. Accordingly, a size and capacity of the heater core 28 may be decreased, which may cause a decrease in air side pressure drop during heating modes of the HVAC system 10, as well as an increase in available package space within the control module 12. A valve 99 can be disposed in the conduit 98 to selectively militate against the flow of the third fluid therethrough. As a non-limiting example, the second fluid from the second fluid source 80 and the third fluid from the third fluid source 94 are the same fluid types. It is understood, however, that the second fluid from the second fluid source 80 and the third fluid from the third fluid source 94 may be different fluid types if desired.

In operation, the HVAC system 10 conditions air by heating or cooling the air, and providing the conditioned air to the passenger compartment of the vehicle. Air from the supply of air is received in housing 14 and flows through the module 12.

In a cooling mode or an engine-off cooling mode of the HVAC system 10, the blend door 34 is positioned in one of a first position permitting air from the evaporator core 24 and the internal thermal energy exchanger 78 to only flow into the first passage 30, a second position permitting the air from the evaporator core 24 and the internal thermal energy exchanger 78 to only flow into the second passage 32, and an intermediate position permitting the air from the evaporator core 24 and the internal thermal energy exchanger 78 to flow through both the first passage 30 and the second passage 32. In a heating mode or an engine-off heating mode of the HVAC system 10, the blend door 34 is positioned either in the second position permitting the air from the evaporator core 24 and the internal thermal energy exchanger 78 to only flow into the second passage 32 and through the heater core 28 or in the intermediate position permitting the air from the evaporator core 24 and the internal thermal energy exchanger 78 to flow through the first passage 30 and the second passage 32 and through the heater core 28. In a thermal energy charge mode or a recirculation heating mode of the HVAC system 10, the blend door 34 is positioned in one of the first position permitting the air from the evaporator core 24 and the internal thermal energy exchanger 78 to only flow into the first passage 30, the second position permitting the air from the evaporator core 24 and the internal thermal energy exchanger 78 to only flow into the second passage 32, and the intermediate position permitting the air from the evaporator core 24 and the internal thermal energy exchanger 78 to flow through both the first passage 30 and/or the second passage 32.

When the fuel-powered engine of the vehicle is in operation and the HVAC system 10 is in either the cooling mode or the cold thermal energy charge mode, the first fluid from the first fluid source 70 circulates through the conduit 72 to the layers 40, 42 of the evaporator core 24. Additionally, the second fluid from the second fluid source 80 circulates through the conduit 82 to the internal thermal energy exchanger 78 (e.g. the third layer 44 of the evaporator core 24). However, the valves 97, 99 are closed to militate against the circulation of the third fluid from the third fluid source 94 through the respective conduits 96, 98 to the heater core 28 and the internal thermal energy exchanger 78. Accordingly, the air from the inlet section 16 flows into the evaporator core 24 where the air is cooled to a desired temperature by a transfer of thermal energy from the air to the first fluid from the first fluid source 70. The conditioned air then flows from the evaporator core 24 to the internal thermal energy exchanger 78. As the conditioned air flows through the internal thermal energy exchanger 78, the conditioned air absorbs thermal energy from the second fluid. The transfer of thermal energy from the second fluid to the conditioned air cools the second fluid. The second fluid then flows to the second fluid source 80 and absorbs thermal energy to cool or charge the phase change material, the coolant, the phase change material coolant, or any combination thereof contained in the second fluid source 80. The conditioned air then exits the internal thermal energy exchanger 78 and is selectively permitted by the blend door 34 to flow through the first passage 30 and/or the second passage 32. It is understood, however, that in other embodiments the valve 97 is open, permitting the third fluid from the third fluid source 94 to circulate through the conduit 96 to the heater core 28, and thereby demist the conditioned air flowing through the second passage 32.

In other certain embodiments, when the fuel-powered engine of the vehicle is in operation and the HVAC system 10 is operating in the cooling mode, the first fluid from the first fluid source 70 circulates through the conduit 72 to the layers 40, 42 of the evaporator core 24. However, the valve 86 is closed to militate against the circulation of the second fluid from the second fluid source 80 through the conduit 82 to the internal thermal energy exchanger 78. Additionally, the valves 97, 99 are closed to militate against the circulation of the third fluid from the third fluid source 94 through the respective conduits 96, 98 to the heater core 28 and the internal thermal energy exchanger 78. Accordingly, the air from the inlet section 16 flows into the evaporator core 24 where the air is cooled to a desired temperature by a transfer of thermal energy from the air to the first fluid from the first fluid source 70. The conditioned air then flows from the evaporator core 24 to the internal thermal energy exchanger 78. As the conditioned air flows through the internal thermal energy exchanger 78, the temperature of the conditioned air is relatively unaffected. The conditioned air then exits the internal thermal energy exchanger 78 and is selectively permitted by the blend door 34 to flow through the first passage 30 and/or the second passage 32. It is understood, however, that in other embodiments the valve 97 is open, permitting the third fluid from the third fluid source 94 to circulate through the conduit 96 to the heater core 28, and thereby demist the conditioned air flowing through the second passage 32.

When the fuel-powered engine of the vehicle is not in operation and the HVAC system 10 is in the engine-off cooling mode, the first fluid from the first fluid source 70 does not circulate through the conduit 72 to the layers 40, 42 of the evaporator core 24. However, the second fluid from the second fluid source 80 circulates through the conduit 82 to the internal thermal energy exchanger 78. Additionally, the third fluid from the third fluid source 94 does not circulate through the conduits 96, 98 to the heater core 28 and the internal thermal energy exchanger 78. Accordingly, the air from the inlet section 16 flows through the evaporator core 24 where a temperature of the air is relatively unaffected. The air then flows from the evaporator core 24 to the internal thermal energy exchanger 78. As the air flows through the internal thermal energy exchanger 78, the air is cooled to a desired temperature by a transfer of thermal energy from the air to the second fluid from the second fluid source 80. The conditioned air then exits the thermal energy exchanger 78 and is selectively permitted by the blend door 34 to flow through the first passage 30 and/or the second passage 32.

When the fuel-powered engine of the vehicle is in operation and the HVAC system 10 is in the heating mode, the first fluid from the first fluid source 70 does not circulate through the conduit 72 to the layers 40, 42 of the evaporator core 24. Similarly, the valve 86 is closed to militate against the circulation of the second fluid from the second fluid source 80 through the conduit 82 to the internal thermal energy exchanger 78. Additionally, the third fluid from the third fluid source 94 circulates through the conduit 96 to the heater core 28. Accordingly, the air from the inlet section 16 flows through the evaporator core 24 and the internal thermal energy exchanger 78 where a temperature of the air is relatively unaffected. The unconditioned air then exits the evaporator core 24 and the internal thermal energy exchanger 78 and is selectively permitted by the blend door 34 to flow through the first passage 30 and/or the second passage 32 through the heater core 28 to be heated to a desired temperature.

In other certain embodiments, when the fuel-powered engine of the vehicle is in operation and the HVAC system 10 is in the heating mode, the first fluid from the first fluid source 70 does not circulate through the conduit 72 to the layers 40, 42 of the evaporator core 24. However, the second fluid from the second fluid source 80 circulates through the conduit 82 to the internal thermal energy exchanger 78. Additionally, the third fluid from the third fluid source 94 circulates through the conduit 96 to the heater core 28. Accordingly, the air from the inlet section 16 flows through the evaporator core 24 where a temperature of the air is relatively unaffected. The air then flows from the evaporator core 24 to the internal thermal energy exchanger 78. As the air flows through the internal thermal energy exchanger 78, the air is heated to a desired temperature by a transfer of thermal energy from the second fluid from the second fluid source 80 to the air flowing through the internal thermal energy exchanger 78. The conditioned air then exits the internal thermal energy exchanger 78 and is selectively permitted by the blend door 34 to flow through the first passage 30 and/or the second passage 32 through the heater core 28 to be further heated to a desired temperature.

In other certain embodiments, when the fuel-powered engine of the vehicle is in operation and the HVAC system 10 is in the heating mode, the first fluid from the first fluid source 70 does not circulate through the conduit 72 to the layers 40, 42 of the evaporator core 24. Similarly, the valve 86 is closed to militate against the circulation of the second fluid from the second fluid source 80 through the conduit 82 to the internal thermal energy exchanger 78. Additionally, the third fluid from the third fluid source 94 circulates through the conduit 96 to the heater core 28 and through the conduit 98 to the internal thermal energy exchanger 78. Accordingly, the air from the inlet section 16 flows through the evaporator core 24 where a temperature of the air is relatively unaffected. The air then flows from the evaporator core 24 to the internal thermal energy exchanger 78. As the air flows through the internal thermal energy exchanger 78, the air is heated to a desired temperature by a transfer of thermal energy from the third fluid from the third fluid source 94 to the air flowing through the internal thermal energy exchanger 78. The conditioned air then exits the internal thermal energy exchanger 78 and is selectively permitted by the blend door 34 to flow through the first passage 30 and/or the second passage 32 through the heater core 28 to be further heated to a desired temperature.

In yet other certain embodiments, when the fuel-powered engine of the vehicle is in operation and the HVAC system 10 is in either the heating mode or the hot thermal energy charge mode, the first fluid from the first fluid source 70 does not circulate through the conduit 72 to the layers 40, 42 of the evaporator core 24. However, the second fluid from the second fluid source 80 circulates through the conduit 82 to the internal thermal energy exchanger 78. Additionally, the third fluid from the third fluid source 94 circulates through the conduit 96 to the heater core 28 and through the conduit 98 to the internal thermal energy exchanger 78. The second fluid mixes with the third fluid before, in, or after flowing through the internal thermal energy exchanger 78. Accordingly, the air from the inlet section 16 flows through the evaporator core 24 where a temperature of the air is relatively unaffected. The air then flows from the evaporator core 24 to the internal thermal energy exchanger 78. As the air flows through the internal thermal energy exchanger 78, the air is heated to a desired temperature by a transfer of thermal energy from the mixture of the second fluid and the third fluid to the air flowing through the internal thermal energy exchanger 78. The mixture of the second fluid and the third fluid then flows to the second fluid source 80 and the third fluid source 94. In the second fluid source 80, the mixture of the second fluid and the third fluid releases thermal energy to heat or charge the phase change material, the coolant, the phase change material coolant, or any combination thereof contained in the second fluid source 80. The conditioned air then exits the internal thermal energy exchanger 78 and is selectively permitted by the blend door 34 to flow through the first passage 30 and/or the second passage 32 through the heater core 28 to be further heated to a desired temperature.

In other certain embodiments, when the fuel-powered engine of the vehicle is not in operation and the HVAC system 10 is in the engine-off heating mode, the first fluid from the first fluid source 70 does not circulate through the conduit 72 to the layers 40, 42 of the evaporator core 24. The second fluid from the second fluid source 80 circulates through the conduit 82 to the internal thermal energy exchanger 78. However, the valves 97, 99 are closed to militate against the circulation of the third fluid from the third fluid source 94 through the respective conduits 96, 98 to the heater core 28 and the internal thermal energy exchanger 78. Accordingly, the air from the inlet section 16 flows through the evaporator core 24 where a temperature of the air is relatively unaffected. The air then flows from the evaporator core 24 to the internal thermal energy exchanger 78. As the air flows through the internal thermal energy exchanger 78, the air is heated to a desired temperature by a transfer of thermal energy from the second fluid from the second fluid source 80 to the air flowing through the internal thermal energy exchanger 78. The conditioned air then exits the internal thermal energy exchanger 78 and is selectively permitted by the blend door 34 to flow through the first passage 30 and/or the second passage 32.

When the fuel-powered engine of the vehicle is in operation and the HVAC system 10 is in either the recirculation heating mode or another hot thermal energy charge mode, the first fluid from the first fluid source 70 does not circulate through the conduit 72 to the layers 40, 42 of the evaporator core 24. The second fluid from the second fluid source 80 circulates through the conduit 82 to the internal thermal energy exchanger 78. However, the valves 97, 99 are closed to militate against the circulation of the third fluid from the third fluid source 94 through the respective conduits 96, 98 to the heater core 28 and the internal thermal energy exchanger 78. Accordingly, a re-circulated air from a passenger compartment of the vehicle flow through the inlet section 16 and into the evaporator core 24 where a temperature of the air is relatively unaffected. The re-circulated air then flows from the evaporator core 24 to the internal thermal energy exchanger 78. As the air flows through the internal thermal energy exchanger 78, the re-circulated air transfers thermal energy to the second fluid to heat the second fluid. The second fluid then flows to the second fluid source 80 and releases thermal energy to heat or charge the phase change material, the coolant, the phase change material coolant, or any combination thereof contained in the second fluid source 80. The re-circulated air then exits the internal thermal energy exchanger 78 and is selectively permitted by the blend door 34 to flow through the first passage 30 and/or the second passage 32.

FIG. 3 shows an alternative embodiment of the HVAC system 10 illustrated in FIG. 1. Structure similar to that illustrated in FIGS. 1-2 includes the same reference numeral and a prime (′) symbol for clarity. In FIG. 3, the HVAC system 10′ is substantially similar to the HVAC system 10, except the internal thermal energy exchanger 78′ is in fluid communication with the second fluid source 80′ and a fourth fluid source 102 instead of the third fluid source 94′.

The evaporator core 24′ of the present invention, shown in FIG. 3, is a multi-layer louvered-fin thermal energy exchanger. In a non-limiting example, the evaporator core 24′ has a first layer 40′, a second layer 42′, and a third layer 44′ arranged substantially perpendicular to the direction of flow through a module 12′. Additional or fewer layers than shown can be employed as desired. The layers 40′, 42′, 44′ are arranged so the second layer 42′ is disposed downstream of the first layer 40′ and upstream of the third layer 44′ in respect of the direction of flow through the module 12′. It is understood, however, that the layers 40′, 42′, 44′ can be arranged as desired. The layers 40′, 42′, 44′ can be bonded together by any suitable method as desired such as brazing and welding, for example.

The layers 40′, 42′ of the evaporator core 24′, shown in FIG. 3, are in fluid communication with a first fluid source 70′ via a conduit 72′. It is understood, however, that any of the layers 40′, 42′, 44′, alone or in combination, may be in fluid communication with the first fluid source 70′ via the conduit 72′ and configured to receive the flow of the first fluid therein. The first fluid source 70′ includes a prime mover 74′ such as a pump or a compressor, for example, to cause a first fluid to circulate therein. Each of the layers 40′, 42′ shown is configured to receive a flow of the first fluid from the first fluid source 70′ therein. The first fluid absorbs thermal energy to condition the air flowing through the module 12′ when a fuel-powered engine of the vehicle, and thereby the prime mover 74′, is in operation. As a non-limiting example, the first fluid source 70′ is a refrigeration circuit, and the first fluid is a refrigerant such as R134a, HFO-1234yf, AC-5, AC-6, and CO₂, for example. A valve 76′ can be disposed in the conduit 72′ to selectively militate against the flow of the first fluid therethrough.

The HVAC system 10′ of the present invention further includes an internal thermal energy exchanger 78′ in fluid communication with a second fluid source 80′ via a conduit 82′. The second fluid source 80′ includes a prime mover 84′ (e.g. an electrical pump) to cause a second fluid to circulate through the internal thermal energy exchanger 78′. As illustrated, the internal thermal energy exchanger 78′ is the third layer 44′ of the evaporator core 24′. It is understood, however, that the internal thermal energy exchanger 78′ may be any of the layers 42′, 44′ of the evaporator core 24′, alone or in combination, in fluid communication with the second fluid source 80′ via the conduit 82′ and configured to receive the flow of the second fluid from the second fluid source 80′ therein. In another particular embodiment, the internal thermal energy exchanger 78′ is a separate thermal energy exchanger disposed downstream and spaced apart from the evaporator core 24′ and upstream of the blend door 34′. It is understood that the internal thermal energy exchanger 78′ can be any conventional thermal energy exchanger as desired.

The second fluid absorbs or releases thermal energy to condition the air flowing through the module 12′. A valve 86′ can be disposed in the conduit 82′ to selectively militate against the flow of the second fluid therethrough. As a non-limiting example, the second fluid source 80′ is a fluid reservoir containing a phase change material (PCM) therein. Those skilled in the art will appreciate that the phase change material can be any suitable material that melts and solidifies at predetermined temperatures and is capable of storing and releasing thermal energy such as organic, inorganic, eutectic and ionic liquids (e.g. a paraffin, a paraffin wax, an alcohol, water, a polyglycol, a glycol), and the like, or any combination thereof, for example. The phase change material can also be impregnated with a thermally conductive material such as graphite powder, for example, to further enhance the transfer of thermal energy. As another non-limiting example, the second fluid source 80′ is a fluid reservoir containing a coolant therein. As another non-limiting example, the second fluid source 80′ is a fluid reservoir containing a phase change material coolant such as CryoSolplus, for example, therein. As yet another non-limiting example, the second fluid source 80′ is an external thermal energy exchanger (e.g. a shell and tube heat exchanger, a chiller, etc.) which includes a phase change material disposed therein and/or is in fluid communication with at least one other vehicle system.

As shown, the heater core 28′ is in fluid communication with a third fluid source 94′ via a conduit 96′. The heater core 28′ is configured to receive a flow of a third fluid from the third fluid source 94′ therein. The third fluid source 94′ can be any conventional source of heated fluid such as the fuel-powered engine of the vehicle, for example, and the third fluid can be any fluid such as a phase change material, a coolant, and a phase change material coolant, for example. A valve 97′ can be disposed in the conduit 96′ to selectively militate against the flow of the third fluid therethrough. The heater core 28′ is configured to facilitate a release of thermal energy from the third fluid to heat the air flowing therethrough when the fuel-powered engine of the vehicle is in operation.

As shown, the HVAC system 10′ further includes the fourth fluid source 102. The internal thermal energy exchanger 78′ is in fluid communication with the fourth fluid source 102 via a conduit 104. The fourth fluid source 102 can be any conventional vehicle system such as a battery system of the vehicle, for example, and the fourth fluid can be any fluid such as a phase change material, a coolant, and a phase change material coolant, for example. The fourth fluid source 102 is configured to receive a flow of the fourth fluid therein. In certain embodiments, the fourth fluid flowing through the fourth fluid source 102 absorbs thermal energy to cool at least a portion of the fourth fluid source 102 (e.g. a battery cell). Accordingly, the internal thermal energy exchanger 78′ is configured to facilitate an absorption of thermal energy from the fourth fluid by the air flowing therethrough to cool the fourth fluid. In other embodiments, the fourth fluid flowing through the fourth fluid source 102 releases thermal energy to heat at least a portion of the fourth fluid source 102 (e.g. a battery cell). As such, the internal thermal energy exchanger 78′ is configured to facilitate a release of thermal energy from the air flowing therethrough to heat the fourth fluid. A valve 106 can be disposed in the conduit 104 to selectively militate against the flow of the fourth fluid therethrough. As a non-limiting example, the second fluid from the second fluid source 80′ and the fourth fluid from the fourth fluid source 102 are the same fluid types. It is understood, however, that the second fluid from the second fluid source 80′ and the fourth fluid from the fourth fluid source 102 may be different fluid types if desired.

In operation, the HVAC system 10′ conditions air by heating or cooling the air, and providing the conditioned air to the passenger compartment of the vehicle. Air from the supply of air is received in housing 14′ and flows through the module 12′.

In a cooling mode or an engine-off cooling mode of the HVAC system 10′, the blend door 34′ is positioned in one of a first position permitting air from the evaporator core 24′ and the internal thermal energy exchanger 78′ to only flow into the first passage 30′, a second position permitting the air from the evaporator core 24′ and the internal thermal energy exchanger 78′ to only flow into the second passage 32′, and an intermediate position permitting the air from the evaporator core 24′ and the internal thermal energy exchanger 78′ to flow through both the first passage 30′ and the second passage 32′. In a heating mode or an engine-off heating mode of the HVAC system 10′, the blend door 34′ is positioned either in the second position permitting the air from the evaporator core 24′ and the internal thermal energy exchanger 78′ to only flow into the second passage 32′ and through the heater core 28′ or in the intermediate position permitting the air from the evaporator core 24′ and the internal thermal energy exchanger 78′ to flow through the first passage 30′ and the second passage 32′ and through the heater core 28′. In a thermal energy charge mode or a recirculation heating mode of the HVAC system 10′, the blend door 34′ is positioned in one of the first position permitting the air from the evaporator core 24′ and the internal thermal energy exchanger 78′ to only flow into the first passage 30′, the second position permitting the air from the evaporator core 24′ and the internal thermal energy exchanger 78′ to only flow into the second passage 32′, and the intermediate position permitting the air from the evaporator core 24′ and the internal thermal energy exchanger 78′ to flow through both the first passage 30′ and/or the second passage 32′.

When the fuel-powered engine of the vehicle is in operation and the HVAC system 10′ is in either the cooling mode or the cold thermal energy charge mode, the first fluid from the first fluid source 70′ circulates through the conduit 72′ to the layers 40′, 42′ of the evaporator core 24′. Additionally, the second fluid from the second fluid source 80′ circulates through the conduit 82′ to the internal thermal energy exchanger 78′ (e.g. the third layer 44′ of the evaporator core 24′). However, the valve 97′ is closed to militate against the circulation of the third fluid from the third fluid source 94′ through the conduit 96′ to the heater core 28′ and the valve 106 is closed to militate against the circulation of the fourth fluid from the fourth fluid source 102 through the conduit 104 to the internal thermal energy exchanger 78′. Accordingly, the air from the inlet section 16′ flows into the evaporator core 24′ where the air is cooled to a desired temperature by a transfer of thermal energy from the air to the first fluid from the first fluid source 70′. The conditioned air then flows from the evaporator core 24′ to the internal thermal energy exchanger 78′. As the conditioned air flows through the internal thermal energy exchanger 78′, the conditioned air absorbs thermal energy from the second fluid. The transfer of thermal energy from the second fluid to the conditioned air cools the second fluid. The second fluid then flows to the second fluid source 80′ and absorbs thermal energy to cool or charge the phase change material, the coolant, the phase change material coolant, or any combination thereof contained in the second fluid source 80′. The conditioned air then exits the internal thermal energy exchanger 78′ and is selectively permitted by the blend door 34′ to flow through the first passage 30′ and/or the second passage 32′. It is understood, however, that in other embodiments the valve 97′ is open, permitting the third fluid from the third fluid source 94′ to circulate through the conduit 96′ to the heater core 28′, and thereby demist the conditioned air flowing through the second passage 32′.

In other certain embodiments, when the fuel-powered engine of the vehicle is in operation and the HVAC system 10′ is operating in the cooling mode, the first fluid from the first fluid source 70′ circulates through the conduit 72′ to the layers 40′, 42′ of the evaporator core 24′. However, the valve 86′ is closed to militate against the circulation of the second fluid from the second fluid source 80′ through the conduit 82′ to the internal thermal energy exchanger 78′. Additionally, the valve 97′ is closed to militate against the circulation of the third fluid from the third fluid source 94′ through the conduit 96′ to the heater core 28′ and the valve 106 is closed to militate against the circulation of the fourth fluid from the fourth fluid source 102 through the conduit 104 to the internal thermal energy exchanger 78′. Accordingly, the air from the inlet section 16′ flows into the evaporator core 24′ where the air is cooled to a desired temperature by a transfer of thermal energy from the air to the first fluid from the first fluid source 70′. The conditioned air then flows from the evaporator core 24′ to the internal thermal energy exchanger 78′. As the conditioned air flows through the internal thermal energy exchanger 78′, the temperature of the conditioned air is relatively unaffected. The conditioned air then exits the internal thermal energy exchanger 78′ and is selectively permitted by the blend door 34′ to flow through the first passage 30′ and/or the second passage 32′. It is understood, however, that in other embodiments the valve 97′ is open, permitting the third fluid from the third fluid source 94′ to circulate through the conduit 96′ to the heater core 28′, and thereby demist the conditioned air flowing through the second passage 32′.

When the fuel-powered engine of the vehicle is not in operation and the HVAC system 10′ is in the engine-off cooling mode, the first fluid from the first fluid source 70′ does not circulate through the conduit 72′ to the layers 40′, 42′ of the evaporator core 24′. However, the second fluid from the second fluid source 80′ circulates through the conduit 82′ to the internal thermal energy exchanger 78′. Additionally, the valve 97′ is closed to militate against the circulation of the third fluid from the third fluid source 94′ through the conduit 96′ to the heater core 28′ and the valve 106 is closed to militate against the circulation of the fourth fluid from the fourth fluid source 102 through the conduit 104 to the internal thermal energy exchanger 78′. Accordingly, the air from the inlet section 16′ flows through the evaporator core 24′ where a temperature of the air is relatively unaffected. The air then flows from the evaporator core 24′ to the internal thermal energy exchanger 78′. As the air flows through the internal thermal energy exchanger 78′, the air is cooled to a desired temperature by a transfer of thermal energy from the air to the second fluid from the second fluid source 80′. The conditioned air then exits the thermal energy exchanger 78′ and is selectively permitted by the blend door 34′ to flow through the first passage 30′ and/or the second passage 32′.

When the fuel-powered engine of the vehicle is in operation and the HVAC system 10′ is in the heating mode, the first fluid from the first fluid source 70′ does not circulate through the conduit 72′ to the layers 40′, 42′ of the evaporator care 24′. Similarly, the valve 86′ is closed to militate against the circulation of the second fluid from the second fluid source 80′ through the conduit 82′ to the internal thermal energy exchanger 78′. Additionally, the third fluid from the third fluid source 94′ circulates through the conduit 96′ to the heater core 28′. However, the valve 106 is closed to militate against the circulation of the fourth fluid from the fourth fluid source 102 through the conduit 104 to the internal thermal energy exchanger 78′. Accordingly, the air from the inlet section 16′ flows through the evaporator core 24′ and the internal thermal energy exchanger 78′ where a temperature of the air is relatively unaffected. The unconditioned air then exits the evaporator core 24′ and the internal thermal energy exchanger 78′ and is selectively permitted by the blend door 34′ to flow through the first passage 30′ and/or the second passage 32′ through the heater core 28′ to be heated to a desired temperature.

In other certain embodiments, when the fuel-powered engine of the vehicle is in operation and the HVAC system 10′ is in the heating mode, the first fluid from the first fluid source 70′ does not circulate through the conduit 72′ to the layers 40′, 42′ of the evaporator core 24′. The second fluid from the second fluid source 80′ circulates through the conduit 82′ to the internal thermal energy exchanger 78′. Additionally, the third fluid from the third fluid source 94′ circulates through the conduit 96′ to the heater core 28′. However, the valve 106 is closed to militate against the circulation of the fourth fluid from the fourth fluid source 102 through the conduit 104 to the internal thermal energy exchanger 78′. Accordingly, the air from the inlet section 16′ flows through the evaporator core 24′ where a temperature of the air is relatively unaffected. The air then flows from the evaporator core 24′ to the internal thermal energy exchanger 78′. As the air flows through the internal thermal energy exchanger 78′, the air is heated to a desired temperature by a transfer of thermal energy from the second fluid from the second fluid source 80′ to the air flowing through the internal thermal energy exchanger 78′. The conditioned air then exits the internal thermal energy exchanger 78′ and is selectively permitted by the blend door 34′ to flow through the first passage 30′ and/or the second passage 32′ through the heater core 28′ to be further heated to a desired temperature.

In other certain embodiments, when the fuel-powered engine of the vehicle is in operation and the HVAC system 10′ is in the heating mode, the first fluid from the first fluid source 70′ does not circulate through the conduit 72′ to the layers 40′, 42′ of the evaporator core 24′. However, the valve 86′ is closed to militate against the circulation of the second fluid from the second fluid source 80′ through the conduit 82′ to the internal thermal energy exchanger 78′. Additionally, the third fluid from the third fluid source 94′ circulates through the conduit 96′ to the heater core 28′. The fourth fluid from the fourth fluid source 102 circulates through the conduit 104 to the internal thermal energy exchanger 78′. Accordingly, the air from the inlet section 16′ flows through the evaporator core 24′ where a temperature of the air is relatively unaffected. The air then flows from the evaporator core 24′ to the internal thermal energy exchanger 78′. As the air flows through the internal thermal energy exchanger 78′, the air is heated to a desired temperature by a transfer of thermal energy from the fourth fluid from the fourth fluid source 102 to the air flowing through the internal thermal energy exchanger 78′. The fourth fluid then flows to the fourth fluid source 102. In the fourth fluid source 102, the fourth fluid absorbs thermal energy to cool the fourth fluid source 102. The conditioned air then exits the internal thermal energy exchanger 78′ and is selectively permitted by the blend door 34′ to flow through the first passage 30′ and/or the second passage 32′ through the heater core 28′ to be further heated to a desired temperature.

In yet other certain embodiments, when the fuel-powered engine of the vehicle is in operation and the HVAC system 10′ is in either the heating mode or the hot thermal energy charge mode, the first fluid from the first fluid source 70′ does not circulate through the conduit 72′ to the layers 40′, 42′ of the evaporator core 24′. However, the second fluid from the second fluid source 80′ circulates through the conduit 82′ to the internal thermal energy exchanger 78′. Additionally, the third fluid from the third fluid source 94′ circulates through the conduit 96′ to the heater core 28′ and the fourth fluid from the fourth fluid source 102 circulates through the conduit 104 to the internal thermal energy exchanger 78′. The fourth fluid mixes with the second fluid before, in, or after flowing through the internal thermal energy exchanger 78′. Accordingly, the air from the inlet section 16′ flows through the evaporator core 24′ where a temperature of the air is relatively unaffected. The air then flows from the evaporator core 24′ to the internal thermal energy exchanger 78′. As the air flows through the internal thermal energy exchanger 78′, the air is heated to a desired temperature by a transfer of thermal energy from the mixture of the second fluid and the fourth fluid to the air flowing through the internal thermal energy exchanger 78′. The mixture of the second fluid and the fourth fluid then flows to the second fluid source 80′ and the fourth fluid source 102. In the second fluid source 80′, the mixture of the second fluid and the fourth fluid releases thermal energy to heat or charge the phase change material, the coolant, the phase change material coolant, or any combination thereof contained in the second fluid source 80′. In the fourth fluid source 102, the mixture of the second fluid and the fourth fluid absorbs thermal energy to cool the fourth fluid source 102. The conditioned air then exits the internal thermal energy exchanger 78′ and is selectively permitted by the blend door 34′ to flow through the first passage 30′ and/or the second passage 32′ through the heater core 28′ to be further heated to a desired temperature.

In other certain embodiments, when the fuel-powered engine of the vehicle is not in operation and the HVAC system 10′ is in the engine-off heating mode, the first fluid from the first fluid source 70′ does not circulate through the conduit 72′ to the layers 40′, 42′ of the evaporator core 24′. The second fluid from the second fluid source 80′ and/or the fourth fluid from the fourth fluid source 102 circulates through the respective conduits 82′, 104 to the internal thermal energy exchanger 78′. However, the valve 97′ is closed to militate against the circulation of the third fluid from the third fluid source 94′ through the conduit 96′ to the heater core 28′. Accordingly, the air from the inlet section 16′ flows through the evaporator core 24′ where a temperature of the air is relatively unaffected. The air then flows from the evaporator core 24′ to the internal thermal energy exchanger 78′. As the air flows through the internal thermal energy exchanger 78′, the air is heated to a desired temperature by a transfer of thermal energy from the second fluid and/or the fourth fluid to the air flowing through the internal thermal energy exchanger 78′. The conditioned air then exits the internal thermal energy exchanger 78′ and is selectively permitted by the blend door 34′ to flow through the first passage 30′ and/or the second passage 32′.

When the fuel-powered engine of the vehicle is in operation and the HVAC system 10′ is in either the recirculation heating mode or another hot thermal energy charge mode, the first fluid from the first fluid source 70′ does not circulate through the conduit 72′ to the layers 40′, 42′ of the evaporator core 24′. The second fluid from the second fluid source 80′ circulates through the conduit 82′ to the internal thermal energy exchanger 78′. However, the valve 97′ is closed to militate against the circulation of the third fluid from the third fluid source 94′ through the conduit 96′ to the heater core 28′ and the valve 106 is closed to militate against the circulation of the fourth fluid from the fourth fluid source 102 to the internal thermal energy exchanger 78′. Accordingly, a re-circulated air from a passenger compartment of the vehicle flow through the inlet section 16′ and into the evaporator core 24′ where a temperature of the air is relatively unaffected. The re-circulated air then flows from the evaporator core 24′ to the internal thermal energy exchanger 78′. As the air flows through the internal thermal energy exchanger 78′, the re-circulated air transfers thermal energy to the second fluid′. The transfer of thermal energy from the re-circulated air to the second fluid heats the second fluid. The second fluid then flows to the second fluid source 80′ and releases thermal energy to heat or charge the phase change material, the coolant, the phase change material coolant, or any combination thereof contained in the second fluid source 80′. The re-circulated air then exits the internal thermal energy exchanger 78′ and is selectively permitted by the blend door 34′ to flow through the first passage 30′ and/or the second passage 32′.

FIG. 4 shows another alternative embodiment of the HVAC system 10, 10′ illustrated in FIGS. 1 and 3. Structure similar to that illustrated in FIGS. 1-3 includes the same reference numeral and a double prime (″) symbol for clarity. In FIG. 4, the HVAC system 10″ is substantially similar to the HVAC systems 10, 10′ except an internal thermal energy exchanger 78″ is in fluid communication with both a second fluid source 80″ and a fourth fluid source 102″ and a third fluid source 94″ is in thermal energy exchange relationship with a fourth fluid source 102″.

The evaporator core 24″ of the present invention, shown in FIG. 4, is a multi-layer louvered-fin thermal energy exchanger. In a non-limiting example, the evaporator core 24″ has a first layer 40″, a second layer 42″, and a third layer 44″ arranged substantially perpendicular to the direction of flow through a module 12″. Additional or fewer layers than shown can be employed as desired. The layers 40″, 42″, 44″ are arranged so the second layer 42″ is disposed downstream of the first layer 40″ and upstream of the third layer 44″ in respect of the direction of flow through the module 12″. It is understood, however, that the layers 40″, 42″, 44″ can be arranged as desired. The layers 40″, 42″, 44″ can be bonded together by any suitable method as desired such as brazing and welding, for example.

The layers 40″, 42″ of the evaporator core 24″, shown in FIG. 4, are in fluid communication with a first fluid source 70″ via a conduit 72″. It is understood, however, that any of the layers 40″, 42″, 44″, alone or in combination, may be in fluid communication with the first fluid source 70″ via the conduit 72″ and configured to receive the flow of the first fluid therein. The first fluid source 70″ includes a prime mover 74″ such as a pump or a compressor, for example, to cause a first fluid to circulate therein. Each of the layers 40″, 42″, shown is configured to receive a flow of the first fluid from the first fluid source 70″ therein. The first fluid absorbs thermal energy to condition the air flowing through the module 12″ when a fuel-powered engine of the vehicle, and thereby the prime mover 74″, is in operation. As a non-limiting example, the first fluid source 70″ is a refrigeration circuit, and the first fluid is a refrigerant such as R134a, HFO-1234yf, AC-5, AC-6, and CO₂, for example. A valve 76″ can be disposed in the conduit 72″ to selectively militate against the flow of the first fluid therethrough.

The HVAC system 10″ of the present invention further includes an internal thermal energy exchanger 78″ in fluid communication with a second fluid source 80″ via a conduit 82″. The second fluid source 80″ includes a prime mover 84″ (e.g. an electrical pump) to cause a second fluid to circulate through the internal thermal energy exchanger 78″. As illustrated, the internal thermal energy exchanger 78″ is the third layer 44″ of the evaporator core 24″. It is understood, however, that the thermal energy exchanger may be any of the layers 42″, 44″ of the evaporator core 24″, alone or in combination, in fluid communication with the second fluid source 80″ via the conduit 82″ and configured to receive the flow of the second fluid from the second fluid source 80″ therein. In another particular embodiment, the internal thermal energy exchanger 78″ is a separate thermal energy exchanger disposed downstream and spaced apart from the evaporator core 24″ and upstream of the blend door 34″. It is understood that the internal thermal energy exchanger 78″ can be any conventional thermal energy exchanger as desired.

The second fluid absorbs or releases thermal energy to condition the air flowing through the module 12″. A valve 86″ can be disposed in the conduit 82″ to selectively militate against the flow of the second fluid therethrough. As a non-limiting example, the second fluid source 80″ is a fluid reservoir containing a phase change material (PCM) therein. Those skilled in the art will appreciate that the phase change material can be any suitable material that melts and solidifies at predetermined temperatures and is capable of storing and releasing thermal energy such as organic, inorganic, eutectic and ionic liquids (e.g. a paraffin, a paraffin wax, an alcohol, water, a polyglycol, a glycol), and the like, or any combination thereof, for example. The phase change material can also be impregnated with a thermally conductive material such as graphite powder, for example, to further enhance the transfer of thermal energy. As another non-limiting example, the second fluid source 80″ is a fluid reservoir containing a coolant therein. As another non-limiting example, the second fluid source 80″ is a fluid reservoir containing a phase change material coolant such as CryoSolplus, for example, therein. As yet another non-limiting example, the second fluid source 80″ is an external thermal energy exchanger (e.g. a shell and tube heat exchanger, a chiller, etc.) which includes a phase change material disposed therein and/or is in fluid communication with at least one other vehicle system.

As shown, the heater core 28″ is in fluid communication with a third fluid source 94″ via a conduit 96″. The heater core 28″ is configured to receive a flow of a third fluid from the third fluid source 94″ therein. The third fluid source 94″ can be any conventional source of heated fluid such as the fuel-powered engine of the vehicle, for example, and the third fluid can be any fluid such as a phase change material, a coolant, and a phase change material coolant, for example. A valve 97″ can be disposed in the conduit 96″ to selectively militate against the flow of the third fluid therethrough. The heater core 28″ is configured to facilitate a release of thermal energy from the third fluid to heat the air flowing therethrough when the fuel-powered engine of the vehicle is in operation.

The HVAC system 10″ of the present invention further includes the fourth fluid source 102″. The internal thermal energy exchanger 78″ is in fluid communication with the fourth fluid source 102″ via a conduit 104″. The fourth fluid source 102″ can be any conventional vehicle system such as a battery system of the vehicle, for example, and the fourth fluid can be any fluid such as a phase change material, a coolant, and a phase change material coolant, for example. The fourth fluid source 102″ is configured to receive a flow of a fourth fluid therein. In certain embodiments, the fourth fluid flowing through the fourth fluid source 102″ absorbs thermal energy to cool at least a portion of the fourth fluid source 102″ (e.g. a battery cell). Accordingly, the internal thermal energy exchanger 78″ is configured to facilitate an absorption of thermal energy by the air flowing therethrough to cool the fourth fluid. In other embodiments, the fourth fluid flowing through the fourth fluid source 102″ releases thermal energy to heat at least a portion the fourth fluid source 102″. As such, the internal thermal energy exchanger 78″ is configured to facilitate a release of thermal energy by the air flowing therethrough to heat the fourth fluid. A valve 106″ can be disposed in the conduit 104″ to selectively militate against the flow of the fourth fluid therethrough. As a non-limiting example, the second fluid from the second fluid source 80″ and the fourth fluid from the fourth fluid source 102″ are the same fluid types. It is understood, however, that the second fluid from the second fluid source 80″ and the fourth fluid from the fourth fluid source 102″ may be different fluid types if desired.

As illustrated, the fourth fluid source 102″ is also in thermal energy exchange relationship with the heater core 28″ and the third fluid source 94″ via a conduit 202. The fourth fluid source 102″ is either disposed adjacent to a flow of the third fluid from the heater core 28″ to the third fluid source 94″ or configured to receive the flow of the third fluid from the heater core 28″ to the third fluid source 94″. In certain embodiments, the third fluid flowing through or adjacent to the fourth fluid source 102″ absorbs thermal energy to cool at least a portion of the fourth fluid source 102″ (e.g. a battery cell) to a desired temperature. In other embodiments, the third fluid flowing through or adjacent to the fourth fluid source 102″ releases thermal energy to heat at least a portion the fourth fluid source 102″ (e.g. a battery cell). A valve 204 can be disposed in the conduit 202 to selectively militate against the flow of the third fluid therethrough.

In operation, the HVAC system 10″ conditions air by heating or cooling the air, and providing the conditioned air to the passenger compartment of the vehicle. Air from the supply of air is received in housing 14″ and flows through the module 12″.

In a cooling mode or an engine-off cooling mode of the HVAC system 10″, the blend door 34″ is positioned in one of a first position permitting air from the evaporator core 24″ and the internal thermal energy exchanger 78″ to only flow into the first passage 30″, a second position permitting the air from the evaporator core 24″ and the internal thermal energy exchanger 78″ to only flow into the second passage 32″, and an intermediate position permitting the air from the evaporator core 24″ and the internal thermal energy exchanger 78″ to flow through both the first passage 30″ and the second passage 32″. In a heating mode or an engine-off heating mode of the HVAC system 10″, the blend door 34″ is positioned either in the second position permitting the air from the evaporator core 24″ and the internal thermal energy exchanger 78″ to only flow into the second passage 32″ and through the heater core 28″ or in the intermediate position permitting the air from the evaporator core 24″ and the internal thermal energy exchanger 78″ to flow through the first passage 30″ and the second passage 32″ and through the heater core 28″. In a thermal energy charge mode or a recirculation heating mode of the HVAC system 10″, the blend door 34″ is positioned in one of the first position permitting the air from the evaporator core 24″ and the internal thermal energy exchanger 78″ to only flow into the first passage 30″, the second position permitting the air from the evaporator core 24″ and the internal thermal energy exchanger 78″ to only flow into the second passage 32″, and the intermediate position permitting the air from the evaporator core 24″ and the internal thermal energy exchanger 78″ to flow through both the first passage 30″ and/or the second passage 32″.

When the fuel-powered engine of the vehicle is in operation and the HVAC system 10″ is in either the cooling mode or the cold thermal energy charge mode, the first fluid from the first fluid source 70″ circulates through the conduit 72″ to the layers 40″, 42″ of the evaporator core 24″. Additionally, the second fluid from the second fluid source 80″ circulates through the conduit 82″ to the internal thermal energy exchanger 78″ (e.g. the third layer 44″ of the evaporator core 24″). However, the valve 97″ is closed to militate against the circulation of the third fluid from the third fluid source 94″ through the conduit 96″ to the heater core 28″, the valve 204 is closed to militate against the circulation of the third fluid from the third fluid source 94″ through the conduit 202 to the fourth fluid source 102″, and the valve 106″ is closed to militate against the circulation of the fourth fluid from the fourth fluid source 102″ through the conduit 104″ to the internal thermal energy exchanger 78″. Accordingly, the air from the inlet section 16″ flows into the evaporator core 24″ where the air is cooled to a desired temperature by a transfer of thermal energy from the air to the first fluid from the first fluid source 70″. The conditioned air then flows from the evaporator core 24″ to the internal thermal energy exchanger 78″. As the conditioned air flows through the internal thermal energy exchanger 78″, the conditioned air absorbs thermal energy from the second fluid. The transfer of thermal energy from the second fluid to the conditioned air cools the second fluid. The second fluid then flows to the second fluid source 80″ and absorbs thermal energy to cool or charge the phase change material, the coolant, the phase change material coolant, or any combination thereof contained in the second fluid source 80″. The conditioned air then exits the internal thermal energy exchanger 78″ and is selectively permitted by the blend door 34″ to flow through the first passage 30″ and/or the second passage 32″. It is understood, however, that in other embodiments the valve 97″ is open, permitting the third fluid from the third fluid source 94″ to circulate through the conduit 96″ to the heater core 28″, and thereby demist the conditioned air flowing through the second passage 32″.

In other certain embodiments, when the fuel-powered engine of the vehicle is in operation and the HVAC system 10″ is operating in the cooling mode, the first fluid from the first fluid source 70″ circulates through the conduit 72″ to the layers 40″, 42″ of the evaporator core 24″. However, the valve 86″ is closed to militate against the circulation of the second fluid from the second fluid source 80″ through the conduit 82″ to the internal thermal energy exchanger 78″. Additionally, the valve 97″ is closed to militate against the circulation of the third fluid from the third fluid source 94″ through the conduit 96″ to the heater core 28″, the valve 204 is closed to militate against the circulation of the third fluid from the third fluid source 94″ through the conduit 202 to the fourth fluid source 102″, and the valve 106″ is closed to militate against the circulation of the fourth fluid from the fourth fluid source 102″ through the conduit 104″ to the internal thermal energy exchanger 78″. Accordingly, the air from the inlet section 16″ flows into the evaporator core 24″ where the air is cooled to a desired temperature by a transfer of thermal energy from the air to the first fluid from the first fluid source 70″. The conditioned air then flows from the evaporator core 24″ to the internal thermal energy exchanger 78″. As the conditioned air flows through the internal thermal energy exchanger 78″, the temperature of the conditioned air is relatively unaffected. The conditioned air then exits the internal thermal energy exchanger 78″ and is selectively permitted by the blend door 34″ to flow through the first passage 30″ and/or the second passage 32″. It is understood, however, that in other embodiments the valve 97″ is open, permitting the third fluid from the third fluid source 94″ to circulate through the conduit 96″ to the heater core 28″, and thereby demist the conditioned air flowing through the second passage 32″.

In other certain embodiments, when the fuel-powered engine of the vehicle is in operation and the HVAC system 10 is operating in an alternative cooling mode, the first fluid from the first fluid source 70″ circulates through the conduit 72″ to the layers 40″, 42″ of the evaporator core 24″. The fourth fluid from the fourth fluid source 102″ circulates through the conduit 104″ to the internal thermal energy exchanger 78″. However, the valve 86″ is closed to militate against the circulation of the second fluid from the second fluid source 80″ through the conduit 82″ to the internal thermal energy exchanger 78″. Additionally, the valve 97″ is closed to militate against the circulation of the third fluid from the third fluid source 94″ through the conduit 96″ to the heater core 28″ and the valve 204 is closed to militate against the circulation of the third fluid from the third fluid source 94″ through the conduit 202 to the fourth fluid source 102″. Accordingly, the air from the inlet section 16″ flows into the evaporator core 24″ where the air is cooled to a desired temperature by a transfer of thermal energy from the air to the first fluid from the first fluid source 70″. The conditioned air then flows from the evaporator core 24″ to the internal thermal energy exchanger 78″. As the conditioned air flows through the internal thermal energy exchanger 78″, the air flowing through the internal thermal energy exchanger 78″ absorbs thermal energy from the fourth fluid to cool the fourth fluid. The fourth fluid then flows to the fourth fluid source 102″. In the fourth fluid source 102″, the fourth fluid absorbs thermal energy to cool the fourth fluid source 102″. The conditioned air then exits the internal thermal energy exchanger 78″ and is selectively permitted by the blend door 34″ to flow through the first passage 30″ and/or the second passage 32″. It is understood, however, that in other embodiments the valve 86″ is open, permitting the second fluid from the second fluid source 80″ to circulate through the conduit 82″ to the internal thermal energy exchanger 78″, and thereby absorb thermal energy from the fourth fluid to further cool the fourth fluid. It is further understood, however, that in other embodiments the valve 97″ is open, permitting the third fluid from the third fluid source 94″ to circulate through the conduit 96″ to the heater core 28″, and thereby demist the conditioned air flowing through the second passage 32″.

When the fuel-powered engine of the vehicle is not in operation and the HVAC system 10″ is in the engine-off cooling mode, the first fluid from the first fluid source 70″ does not circulate through the conduit 72″ to the layers 40″, 42″ of the evaporator core 24″. However, the second fluid from the second fluid source 80″ circulates through the conduit 82″ to the internal thermal energy exchanger 78″. Additionally, the valve 97″ is closed to militate against the circulation of the third fluid from the third fluid source 94″ through the conduit 96″ to the heater core 28″, the valve 204 is closed to militate against the circulation of the third fluid from the third fluid source 94″ through the conduit 202 to the fourth fluid source 102″, and the valve 106″ is closed to militate against the circulation of the fourth fluid from the fourth fluid source 102″ through the conduit 104″ to the internal thermal energy exchanger 78″. Accordingly, the air from the inlet section 16″ flows through the evaporator core 24″ where a temperature of the air is relatively unaffected. The air then flows from the evaporator core 24″ to the internal thermal energy exchanger 78″. As the air flows through the internal thermal energy exchanger 78″, the air is cooled to a desired temperature by a transfer of thermal energy from the air to the second fluid from the second fluid source 80″. The conditioned air then exits the thermal energy exchanger 78″ and is selectively permitted by the blend door 34″ to flow through the first passage 30″ and/or the second passage 32″.

When the fuel-powered engine of the vehicle is in operation and the HVAC system 10″ is in the heating mode, the first fluid from the first fluid source 70″ does not circulate through the conduit 72″ to the layers 40″, 42″ of the evaporator core 24″. Similarly, the valve 86″ is closed to militate against the circulation of the second fluid from the second fluid source 80″ through the conduit 82″ to the internal thermal energy exchanger 78″. Additionally, the third fluid from the third fluid source 94″ circulates through the conduit 96″ to the heater core 28″. However, the valve 204 is closed to militate against the circulation of the third fluid from the third fluid source 94″ through the conduit 202 to the fourth fluid source 102″ and the valve 106″ is closed to militate against the circulation of the fourth fluid from the fourth fluid source 102″ through the conduit 104″ to the internal thermal energy exchanger 78″. Accordingly, the air from the inlet section 16″ flows through the evaporator core 24″ and the internal thermal energy exchanger 78″ where a temperature of the air is relatively unaffected. The unconditioned air then exits the evaporator 24″ and the internal thermal energy exchanger 78″ and is selectively permitted by the blend door 34″ to flow through the first passage 30″ and/or the second passage 32″ through the heater core 28″ to be heated to a desired temperature. It is understood, however, that in other embodiments the valve 204 is open, permitting the third fluid from the third fluid source 94″ to circulate through the conduit 202 to the fourth fluid source 102″, and thereby release thermal energy to heat the fourth fluid source 102″.

In other certain embodiments, when the fuel-powered engine of the vehicle is in operation and the HVAC system 10″ is in the heating mode, the first fluid from the first fluid source 70″ does not circulate through the conduit 72″ to the layers 40″, 42″ of the evaporator core 24″. The second fluid from the second fluid source 80″ circulates through the conduit 82″ to the internal thermal energy exchanger 78″. Additionally, the third fluid from the third fluid source 94″ circulates through the conduit 96″ to the heater core 28″. However, the valve 204 is closed to militate against the circulation of the third fluid from the third fluid source 94″ through the conduit 202 to the fourth fluid source 102″ and the valve 106″ is closed to militate against the circulation of the fourth fluid from the fourth fluid source 102″ through the conduit 104″ to the internal thermal energy exchanger 78″. Accordingly, the air from the inlet section 16″ flows through the evaporator core 24″ where a temperature of the air is relatively unaffected. The air then flows from the evaporator core 24″ to the internal thermal energy exchanger 78″. As the air flows through the internal thermal energy exchanger 78″, the air is heated to a desired temperature by a transfer of thermal energy from the second fluid from the second fluid source 80″ to the air flowing through the internal thermal energy exchanger 78″. The conditioned air then exits the internal thermal energy exchanger 78″ and is selectively permitted by the blend door 34″ to flow through the first passage 30″ and/or the second passage 32″ through the heater core 28″ to be further heated to a desired temperature. It is understood, however, that in other embodiments the valve 204 is open, permitting the third fluid from the third fluid source 94″ to circulate through the conduit 202 to the fourth fluid source 102″, and thereby release thermal energy to heat the fourth fluid source 102″.

In other certain embodiments, when the fuel-powered engine of the vehicle is in operation and the HVAC system 10″ is in the heating mode, the first fluid from the first fluid source 70″ does not circulate through the conduit 72″ to the layers 40″, 42″ of the evaporator core 24″. The fourth fluid from the fourth fluid source 102″ circulates through the conduit 104″ to the internal thermal energy exchanger 78″. However, the valve 86″ is closed to militate against the circulation of the second fluid from the second fluid source 80″ through the conduit 82″ to the internal thermal energy exchanger 78″. Additionally, the third fluid from the third fluid source 94″ circulates through the conduit 96″ to the heater core 28″. However, the valve 204 is closed to militate against the circulation of the third fluid from the third fluid source 94″ through the conduit 202 to the fourth fluid source 102″. Accordingly, the air from the inlet section 16″ flows through the evaporator core 24″ where a temperature of the air is relatively unaffected. The air then flows from the evaporator core 24″ to the internal thermal energy exchanger 78″. As the air flows through the internal thermal energy exchanger 78″, the air is heated to a desired temperature by a transfer of thermal energy from the fourth fluid from the fourth fluid source 80″ to the air flowing through the internal thermal energy exchanger 78″. The fourth fluid then flows to the fourth fluid source 102″. In the fourth fluid source 102″, the fourth fluid absorbs thermal energy to cool the fourth fluid source 102″. The conditioned air then exits the internal thermal energy exchanger 78″ and is selectively permitted by the blend door 34″ to flow through the first passage 30″ and/or the second passage 32″ through the heater core 28″ to be further heated to a desired temperature.

In yet other certain embodiments, when the fuel-powered engine of the vehicle is in operation and the HVAC system 10″ is in either the heating mode or the hot thermal energy charge mode, the first fluid from the first fluid source 70″ does not circulate through the conduit 72″ to the layers 40″, 42″ of the evaporator core 24″. However, the second fluid from the second fluid source 80″ circulates through the conduit 82″ to the internal thermal energy exchanger 78″. Additionally, the third fluid from the third fluid source 94″ circulates through the conduit 96″ to the heater core 28″ and the fourth fluid from the fourth fluid source 102″ circulates through the conduit 104″ to the internal thermal energy exchanger 78″. The fourth fluid mixes with the second fluid before, in, or after flowing through the internal thermal energy exchanger 78″. Accordingly, the air from the inlet section 16″ flows through the evaporator core 24″ where a temperature of the air is relatively unaffected. The air then flows from the evaporator core 24″ to the internal thermal energy exchanger 78″. As the air flows through the internal thermal energy exchanger 78″, the air is heated to a desired temperature by a transfer of thermal energy from the mixture of the second fluid and the fourth fluid to the air flowing through the internal thermal energy exchanger 78″. The mixture of the second fluid and the fourth fluid then flows to the second fluid source 80″ and the fourth fluid source 102″. In the second fluid source 80″, the mixture of the second fluid and the fourth fluid releases thermal energy to heat or charge the phase change material, the coolant, the phase change material coolant, or any combination thereof contained in the second fluid source 80″. In the fourth fluid source 102″, the mixture of the second fluid and the fourth fluid absorbs thermal energy to cool the fourth fluid source 102″. The conditioned air then exits the internal thermal energy exchanger 78″ and is selectively permitted by the blend door 34″ to flow through the first passage 30″ and/or the second passage 32″ through the heater core 28″ to be further heated to a desired temperature.

In other certain embodiments, when the fuel-powered engine of the vehicle is not in operation and the HVAC system 10″ is in the engine-off heating mode, the first fluid from the first fluid source 70″ does not circulate through the conduit 72″ to the layers 40″, 42″ of the evaporator core 24″. The second fluid from the second fluid source 80″ and/or the fourth fluid from the fourth fluid source 102″ circulates through the respective conduits 82″, 104″ to the internal thermal energy exchanger 78″. However, the valve 97″ is closed to militate against the circulation of the third fluid from the third fluid source 94″ through the conduit 96″ to the heater core 28″ and the valve 204 is closed to militate against the circulation of the third fluid from the third fluid source 94″ through the conduit 202 to the fourth fluid source 102″. Accordingly, the air from the inlet section 16″ flows through the evaporator core 24″ where a temperature of the air is relatively unaffected. The air then flows from the evaporator core 24″ to the internal thermal energy exchanger 78″. As the air flows through the internal thermal energy exchanger 78″, the air is heated to a desired temperature by a transfer of thermal energy from the second fluid and/or the fourth fluid to the air flowing through the internal thermal energy exchanger 78″. The conditioned air then exits the internal thermal energy exchanger 78″ and is selectively permitted by the blend door 34″ to flow through the first passage 30″ and/or the second passage 32″.

When the fuel-powered engine of the vehicle is in operation and the HVAC system 10″ is in either the recirculation heating mode or another hot thermal energy charge mode, the first fluid from the first fluid source 70″ does not circulate through the conduit 72″ to the layers 40″, 42″ of the evaporator core 24″. The second fluid from the second fluid source 80″ circulates through the conduit 82″ to the internal thermal energy exchanger 78″. However, the valve 97″ is closed to militate against the circulation of the third fluid from the third fluid source 94″ through the conduit 96″ to the heater core 28″, the valve 204 is closed to militate against the circulation of the third fluid from the third fluid source 94″ through the conduit 202 to the fourth fluid source 102″, and the valve 106″ is closed to militate against the circulation of the fourth fluid from the fourth fluid source 102″ to the internal thermal energy exchanger 78″. Accordingly, a re-circulated air from a passenger compartment of the vehicle flow through the inlet section 16″ and into the evaporator core 24″ where a temperature of the air is relatively unaffected. The re-circulated air then flows from the evaporator core 24″ to the internal thermal energy exchanger 78″. As the air flows through the internal thermal energy exchanger 78″, the re-circulated air transfers thermal energy to the second fluid″. The transfer of thermal energy from the re-circulated air to the second fluid heats the second fluid. The second fluid then flows to the second fluid source 80″ and releases thermal energy to heat or charge the phase change material, the coolant, the phase change material coolant, or any combination thereof contained in the second fluid source 80″. The re-circulated air then exits the internal thermal energy exchanger 78″ and is selectively permitted by the blend door 34″ to flow through the first passage 30″ and/or the second passage 32″.

FIG. 5 shows another alternative embodiment of the HVAC system 10, 10′, 10″ illustrated in FIGS. 1 and 3-4. Structure similar to that illustrated in FIGS. 1-4 includes the same reference numeral and a triple prime (′″) symbol for clarity. In FIG. 5, the HVAC system 10′″ is substantially similar to the HVAC systems 10, 10′, 10″ except the internal thermal energy exchanger 78′″ is in fluid communication with the third fluid source 94′″ and in thermal energy exchange relationship with the fourth fluid source 102′″.

The evaporator core 24′″ of the present invention, shown in FIG. 5, is a multi-layer louvered-fin thermal energy exchanger. In a non-limiting example, the evaporator core 24′″ has a first layer 40′″, a second layer 42′″, and a third layer 44′″ arranged substantially perpendicular to the direction of flow through a module 12′″. Additional or fewer layers than shown can be employed as desired. The layers 40′″, 42′″, 44′″ are arranged so the second layer 42′″ is disposed downstream of the first layer 40′″ and upstream of the third layer 44′″ in respect of the direction of flow through the module 12′″. It is understood, however, that the layers 40′″, 42′″, 44′″ can be arranged as desired. The layers 40′″, 42′″, 44′″ can be bonded together by any suitable method as desired such as brazing and welding, for example.

The layers 40′″, 42′″ of the evaporator core 24′″, shown in FIG. 5, are in fluid communication with a first fluid source 70′″ via a conduit 72′″. It is understood, however, that any of the layers 40′″, 42′″, 44′″, alone or in combination, may be in fluid communication with the first fluid source 70′″ via the conduit 72′″ and configured to receive the flow of the first fluid therein. The first fluid source 70′″ includes a prime mover 74′″ such as a pump or a compressor, for example, to cause a first fluid to circulate therein. Each of the layers 40′″, 42′″ shown is configured to receive a flow of the first fluid from the first fluid source 70′″ therein. The first fluid absorbs thermal energy to condition the air flowing through the module 12′″ when a fuel-powered engine of the vehicle, and thereby the prime mover 74′″, is in operation. As a non-limiting example, the first fluid source 70′″ is a refrigeration circuit, and the first fluid is a refrigerant such as R134a, HFO-1234yf, AC-5, AC-6, and CO₂, for example. A valve 76′″ can be disposed in the conduit 72′″ to selectively militate against the flow of the first fluid therethrough.

The HVAC system 10′″ of the present invention further includes an internal thermal energy exchanger 78′″ in fluid communication with a second fluid source 80′″ via a conduit 82′″. The second fluid source 80′″ includes a prime mover 84′″ (e.g. an electrical pump) to cause a second fluid to circulate through the internal thermal energy exchanger 78′″. As illustrated, the internal thermal energy exchanger 78′″ is the third layer 44′″ of the evaporator core 24′″. It is understood, however, that the thermal energy exchanger may be any of the layers 42′″, 44′″ of the evaporator core 24′″, alone or in combination, in fluid communication with the second fluid source 80′″ via the conduit 82′″ and configured to receive the flow of the second fluid from the second fluid source 80′″ therein. In another particular embodiment, the internal thermal energy exchanger 78′″ is a separate thermal energy exchanger disposed downstream and spaced apart from the evaporator core 24′″ and upstream of the blend door 34′″. It is understood that the internal thermal energy exchanger 78′″ can be any conventional thermal energy exchanger as desired.

The second fluid absorbs or releases thermal energy to condition the air flowing through the module 12′″. A valve 86′″ can be disposed in the conduit 82′″ to selectively militate against the flow of the second fluid therethrough. As a non-limiting example, the second fluid source 80′″ is a fluid reservoir containing a phase change material (PCM) therein. Those skilled in the art will appreciate that the phase change material can be any suitable material that melts and solidifies at predetermined temperatures and is capable of storing and releasing thermal energy such as organic, inorganic, eutectic and ionic liquids (e.g. a paraffin, a paraffin wax, an alcohol, water, a polyglycol, a glycol), and the like, or any combination thereof, for example. The phase change material can also be impregnated with a thermally conductive material such as graphite powder, for example, to further enhance the transfer of thermal energy. As another non-limiting example, the second fluid source 80′″ is a fluid reservoir containing a coolant therein. As another non-limiting example, the second fluid source 80′″ is a fluid reservoir containing a phase change material coolant such as CryoSolplus, for example, therein. As yet another non-limiting example, the second fluid source 80′″ is an external thermal energy exchanger (e.g. a shell and tube heat exchanger, a chiller, etc.) which includes a phase change material disposed therein and/or is in fluid communication with at least one other vehicle system.

As shown, the heater core 28′″ is in fluid communication with a third fluid source 94′″ via a conduit 96′″. The heater core 28′″ is configured to receive a flow of a third fluid from the third fluid source 94′″ therein via a conduit 302. The third fluid source 94′″ can be any conventional source of heated fluid such as the fuel-powered engine of the vehicle, for example, and the third fluid can be any fluid such as a phase change material, a coolant, and a phase change material coolant, for example. A valve 97′″ can be disposed in the conduit 96′″ to selectively militate against the flow of the third fluid therethrough. The heater core 28′″ is configured to facilitate a release of thermal energy from the third fluid to heat the air flowing therethrough when the fuel-powered engine of the vehicle is in operation.

In certain embodiments, the heater core 28′″ and the third fluid source 94′″ are also in fluid communication with the internal thermal energy exchanger 78′″ via a conduit 98′″ and a conduit 304. The internal thermal energy exchanger 78′″ is configured to facilitate a release of thermal energy from the third fluid to heat the air flowing therethrough. Accordingly, a size and capacity of the heater core 28′″ may be decreased, which may cause a decrease in air side pressure drop during heating modes of the HVAC system 10′″, as well as an increase in available package space within the control module 12′″. A valve 99′″ can be disposed in the conduit 98′″ and a valve 306 can be disposed in the conduit 304 to selectively militate against the flow of the third fluid therethrough.

An external thermal energy exchanger 308 may be disposed in the conduit 302. The external thermal energy exchanger 308 is disposed downstream of the third fluid source 94′″ and upstream of the heater core 28′″. The external thermal energy exchanger 308 shown is a liquid-to-liquid condenser of a heat pump system. It is understood, however, that the external thermal energy exchanger 308 can be any conventional thermal energy exchanger such as a shell and tube heat exchanger, a chiller, and the like, for example. As illustrated, the external thermal energy exchanger 308 is configured to receive a flow of the third fluid from the third fluid source 94′″ and a flow of a working fluid from another vehicle system therein via a conduit 310. In certain embodiments, the working fluid is the first fluid (e.g. refrigerant) from the first fluid source 70′″ (e.g. the refrigerant circuit) which has been discharged by the prime mover 74′″. The external thermal energy exchanger 308 is configured to facilitate an absorption of thermal energy by the third fluid to cool the working fluid flowing therethrough when the fuel-powered engine of the vehicle is in operation.

The HVAC system 10′″ of the present invention further includes the fourth fluid source 102′″. The internal thermal energy exchanger 78′″ is in fluid communication with the fourth fluid source 102′″ via a conduit 104′″. The fourth fluid source 102′″ can be any conventional vehicle system such as a battery system of the vehicle, for example, and the fourth fluid can be any fluid such as a phase change material, a coolant, and a phase change material coolant, for example. In certain embodiments, the fourth fluid flowing through the fourth fluid source 102′″ absorbs thermal energy to cool at least a portion of the fourth fluid source 102′″ (e.g. a battery cell). Accordingly, the internal thermal energy exchanger 78′″ is configured to facilitate an absorption of thermal energy by the air flowing therethrough to cool the fourth fluid. In other embodiments, the fourth fluid flowing through the fourth fluid source 102′″ releases thermal energy to heat at least a portion of the fourth fluid source 102′″ (e.g. a battery cell). As such, the internal thermal energy exchanger 78′″ is configured to facilitate a release of thermal energy by the air flowing therethrough to heat the fourth fluid. A valve 106′″ can be disposed in the conduit 104′″ to selectively militate against the flow of the fourth fluid therethrough.

As illustrated, the fourth fluid source 102′″ can also be in thermal energy exchange relationship with the third fluid source 94′″ through the heater core 28′″ and the internal thermal energy exchanger 78′″. The fourth fluid source 102′″ is either disposed adjacent to a flow of the third fluid from the internal thermal energy exchanger 78′″ or configured to receive the flow of the third fluid from the internal thermal energy exchanger 78′″. In certain embodiments, the third fluid flowing through or adjacent to the fourth fluid source 102′″ absorbs thermal energy to cool at least a portion of the fourth fluid source 102′″ (e.g. a battery cell) to a desired temperature. In other embodiments, the third fluid flowing through or adjacent to the fourth fluid source 102′″ releases thermal energy to heat at least a portion of the fourth fluid source 102′″ (e.g. a battery cell). The valves 99′″, 106′″ disposed in the respective conduits 98′″, 104′″ selectively militate against the flow of the third fluid through or adjacent to the fourth fluid source 102′″. As a non-limiting example, the second fluid from the second fluid source 80′″, the third fluid from the third fluid source 94′″, and the fourth fluid from the fourth fluid source 102′″ are the same fluid types. It is understood, however, that any of the second fluid from the second fluid source 80′″, the third fluid from the third fluid source 94′″, and the fourth fluid from the fourth fluid source 102′″ can be a different fluid type if desired.

In operation, the HVAC system 10′″ conditions air by heating or cooling the air, and providing the conditioned air to the passenger compartment of the vehicle. Air from the supply of air is received in housing 14′″ and flows through the module 12′″.

In a cooling mode or an engine-off cooling mode of the HVAC system 10′″, the blend door 34′″ is positioned in one of a first position permitting air from the evaporator core 24′″ and the internal thermal energy exchanger 78′″ to only flow into the first passage 30′″, a second position permitting the air from the evaporator core 24′″ and the internal thermal energy exchanger 78′″ to only flow into the second passage 32′″, and an intermediate position permitting the air from the evaporator core 24′″ and the internal thermal energy exchanger 78′″ to flow through both the first passage 30′″ and the second passage 32′″. In a heating mode or an engine-off heating mode of the HVAC system 10′″, the blend door 34′″ is positioned either in the second position permitting the air from the evaporator core 24′″ and the internal thermal energy exchanger 78′″ to only flow into the second passage 32′″ and through the heater core 28′″ or in the intermediate position permitting the air from the evaporator core 24′″ and the internal thermal energy exchanger 78′″ to flow through the first passage 30′″ and the second passage 32′″ and through the heater core 28′″. In a thermal energy charge mode or a recirculation heating mode of the HVAC system 10′″, the blend door 34′″ is positioned in one of the first position permitting the air from the evaporator core 24′″ and the internal thermal energy exchanger 78′″ to only flow into the first passage 30′″, the second position permitting the air from the evaporator core 24′″ and the internal thermal energy exchanger 78′″ to only flow into the second passage 32′″, and the intermediate position permitting the air from the evaporator core 24′″ and the internal thermal energy exchanger 78′″ to flow through both the first passage 30′″ and/or the second passage 32′″.

When the fuel-powered engine of the vehicle is in operation and the HVAC system 10′″ is in either the cooling mode or the cold thermal energy charge mode, the first fluid from the first fluid source 70′″ circulates through the conduit 72′″ to the layers 40′″, 42′″ of the evaporator core 24′″. Additionally, the second fluid from the second fluid source 80′″ circulates through the conduit 82′″ to the internal thermal energy exchanger 78′″ (e.g. the third layer 44′″ of the evaporator core 24′″). However, the valve 97′″ is closed to militate against the circulation of the third fluid from the third fluid source 94′″ through the conduit 96′″ to the heater core 28′″, the valve 99′″ is closed to militate against the circulation of the third fluid through the conduit 96′″ to the internal thermal energy exchanger 78′″, the valve 306 is closed to militate against the circulation of the second fluid to the fourth fluid source 102′″, and the valve 106′″ is closed to militate against the circulation of the fourth fluid from the fourth fluid source 102′″ through the conduit 104′″ to the internal thermal energy exchanger 78′″. Accordingly, the air from the inlet section 16′″ flows into the evaporator core 24′″ where the air is cooled to a desired temperature by a transfer of thermal energy from the air to the first fluid from the first fluid source 70′″. The conditioned air then flows from the evaporator core 24′″ to the internal thermal energy exchanger 78′″. As the conditioned air flows through the internal thermal energy exchanger 78′″, the conditioned air absorbs thermal energy from the second fluid. The transfer of thermal energy from the second fluid to the conditioned air cools the second fluid. The second fluid then flows to the second fluid source 80′″ and absorbs thermal energy to cool or charge the phase change material, the coolant, the phase change material coolant, or any combination thereof contained in the second fluid source 80′″. The conditioned air then exits the internal thermal energy exchanger 78′″ and is selectively permitted by the blend door 34′″ to flow through the first passage 30′″ and/or the second passage 32′″. It is understood, however, that in other embodiments the valve 97′″ is open, permitting the third fluid from the third fluid source 94′″ to circulate through the conduit 96′″ to the heater core 28′″, and thereby demist the conditioned air flowing through the second passage 32′″.

In other certain embodiments, when the fuel-powered engine of the vehicle is in operation and the HVAC system 10′″ is operating in the cooling mode, the first fluid from the first fluid source 70′″ circulates through the conduit 72′″ to the layers 40′″, 42′″ of the evaporator core 24′″. However, the valve 86′″ is closed to militate against the circulation of the second fluid from the second fluid source 80′″ through the conduit 82′″ to the internal thermal energy exchanger 78′″. Additionally, the valve 97′″ is closed to militate against the circulation of the third fluid from the third fluid source 94′″ through the conduit 96′″ to the heater core 28′″, the valve 99′″ is closed to militate against the circulation of the third fluid through the conduit 96′″ to the internal thermal energy exchanger 78′″, the valve 306 is closed to militate against the circulation of the second fluid to the fourth fluid source 102′″, and the valve 106′″ is closed to militate against the circulation of the fourth fluid from the fourth fluid source 102′″ through the conduit 104′″ to the internal thermal energy exchanger 78′″. Accordingly, the air from the inlet section 16′″ flows into the evaporator core 24′″ where the air is cooled to a desired temperature by a transfer of thermal energy from the air to the first fluid from the first fluid source 70′″. The conditioned air then flows from the evaporator core 24′″ to the internal thermal energy exchanger 78′″. As the conditioned air flows through the internal thermal energy exchanger 78′″, the temperature of the conditioned air is relatively unaffected. The conditioned air then exits the internal thermal energy exchanger 78′″ and is selectively permitted by the blend door 34′″ to flow through the first passage 30′″ and/or the second passage 32′″. It is understood, however, that in other embodiments the valve 97′″ is open, permitting the third fluid from the third fluid source 94′″ to circulate through the conduit 96′″ to the heater core 28′″, and thereby demist the conditioned air flowing through the second passage 32′″.

In other certain embodiments, when the fuel-powered engine of the vehicle is in operation and the HVAC system 10′″ is operating in an alternative cooling mode, the first fluid from the first fluid source 70′″ circulates through the conduit 72′″ to the layers 40′″, 42′″ of the evaporator core 24′″. The fourth fluid from the fourth fluid source 102′″ circulates through the conduit 104′″ to the internal thermal energy exchanger 78′″. However, the valve 86′″ is closed to militate against the circulation of the second fluid from the second fluid source 80′″ through the conduit 82′″ to the internal thermal energy exchanger 78′″, the valve 97′″ is closed to militate against the circulation of the third fluid from the third fluid source 94′″ through the conduit 96′″ to the heater core 28′″, and the valve 99′″ is closed to militate against the circulation of the third fluid through the conduit 98′″ to the internal thermal energy exchanger 78′″. Accordingly, the air from the inlet section 16′″ flows into the evaporator core 24′″ where the air is cooled to a desired temperature by a transfer of thermal energy from the air to the first fluid from the first fluid source 70′″. The conditioned air then flows from the evaporator core 24′″ to the internal thermal energy exchanger 78′″. As the conditioned air flows through the internal thermal energy exchanger 78′″, the air flowing through the internal thermal energy exchanger 78′″ absorbs thermal energy from the fourth fluid to cool the fourth fluid. The fourth fluid then flows to the fourth fluid source 102′″. In the fourth fluid source 102′″, the fourth fluid absorbs thermal energy to cool the fourth fluid source 102′″. The conditioned air then exits the internal thermal energy exchanger 78′″ and is selectively permitted by the blend door 34′″ to flow through the first passage 30′″ and/or the second passage 32′″. It is understood, however, that in other embodiments the valve 86′″ is open, permitting the second fluid from the second fluid source 80′″ to circulate through the conduit 82′″ to the internal thermal energy exchanger 78′″, and thereby absorb thermal energy from the fourth fluid to further cool the fourth fluid. It is further understood, that in yet other embodiments the valve 97′″ is open, permitting the third fluid from the third fluid source 94′″ to circulate through the conduit 96′″ to the heater core 28′″, and thereby demist the conditioned air flowing through the second passage 32′″.

When the fuel-powered engine of the vehicle is not in operation and the HVAC system 10′″ is in the engine-off cooling mode, the first fluid from the first fluid source 70′″ does not circulate through the conduit 72′″ to the layers 40′″, 42′″ of the evaporator core 24′″. However, the second fluid from the second fluid source 80′″ circulates through the conduit 82′″ to the internal thermal energy exchanger 78′″. Additionally, the valve 97′″ is closed to militate against the circulation of the third fluid from the third fluid source 94′″ through the conduit 96′″ to the heater core 28′″, the valve 99′″ is closed to militate against the circulation of the third fluid through the conduit 98′″ to the internal thermal energy exchanger 78′″, the valve 306 is closed to militate against the circulation of the second fluid to the fourth fluid source 102′″, and the valve 106′″ is closed to militate against the circulation of the fourth fluid from the fourth fluid source 102′″ through the conduit 104′″ to the internal thermal energy exchanger 78′″. Accordingly, the air from the inlet section 16′″ flows through the evaporator core 24′″ where a temperature of the air is relatively unaffected. The air then flows from the evaporator core 24′″ to the internal thermal energy exchanger 78′″. As the air flows through the internal thermal energy exchanger 78′″, the air is cooled to a desired temperature by a transfer of thermal energy from the air to the second fluid from the second fluid source 80′″. The conditioned air then exits the thermal energy exchanger 78′″ and is selectively permitted by the blend door 34′″ to flow through the first passage 30′″ and/or the second passage 32′″.

When the fuel-powered engine of the vehicle is in operation and the HVAC system 10′″ is in the heating mode, the first fluid from the first fluid source 70′″ does not circulate through the conduit 72′″ to the layers 40′″, 42′″ of the evaporator core 24′″. Similarly, the valve 86′″ is closed to militate against the circulation of the second fluid from the second fluid source 80′″ through the conduit 82′″ to the internal thermal energy exchanger 78′″. However, the third fluid from the third fluid source 94′″ circulates through the conduits 96′″, 302 and through the external thermal energy exchanger 308 to the heater core 28′″. Within the external thermal energy exchanger 308, the third fluid absorbs thermal energy from the working fluid flowing therethrough. As such, the third fluid is heated before flowing into the heater core 28′″. Additionally, the valve 99′″ is closed to militate against the circulation of the third fluid through the conduit 98′″ to the internal thermal energy exchanger 78′″, the valve 306 is closed to militate against the circulation of the second fluid to the fourth fluid source 102′″, and the valve 106′″ is closed to militate against the circulation of the fourth fluid from the fourth fluid source 102′″ through the conduit 104′″ to the internal thermal energy exchanger 78′″. Accordingly, the air from the inlet section 16′″ flows through the evaporator core 24′″ and the internal thermal energy exchanger 78′″ where a temperature of the air is relatively unaffected. The unconditioned air then exits the evaporator core 24′″ and the internal thermal energy exchanger 78′″ and is selectively permitted by the blend door 34′″ to flow through the first passage 30′″ and/or the second passage 32′″ through the heater core 28′″ to be heated to a desired temperature.

In other certain embodiments, when the fuel-powered engine of the vehicle is in operation and the HVAC system 10′″ is in the heating mode, the first fluid from the first fluid source 70′″ does not circulate through the conduit 72′″ to the layers 40′″, 42′″ of the evaporator core 24′″. The second fluid from the second fluid source 80′″ circulates through the conduit 82′″ to the internal thermal energy exchanger 78′″. The third fluid from the third fluid source 94′″ circulates through the conduits 96′″, 302 and through the external thermal energy exchanger 308 to the heater core 28′″. Within the external thermal energy exchanger 308, the third fluid absorbs thermal energy from the working fluid flowing therethrough. As such, the third fluid is desirably heated before flowing into the heater core 28′″. Additionally, the valve 99′″ is closed to militate against the circulation of the third fluid through the conduit 98′″ to the internal thermal energy exchanger 78′″, the valve 306 is closed to militate against the circulation of the second fluid to the fourth fluid source 102′″, and the valve 106′″ is closed to militate against the circulation of the fourth fluid from the fourth fluid source 102′″ through the conduit 104′″ to the internal thermal energy exchanger 78′″. Accordingly, the air from the inlet section 16′″ flows through the evaporator core 24′″ where a temperature of the air is relatively unaffected. The air then flows from the evaporator core 24′″ to the internal thermal energy exchanger 78′″. As the air flows through the internal thermal energy exchanger 78′″, the air is heated to a desired temperature by a transfer of thermal energy from the second fluid to the air flowing through the internal thermal energy exchanger 78′″. The conditioned air then exits the internal thermal energy exchanger 78′″ and is selectively permitted by the blend door 34′″ to flow through the first passage 30′″ and/or the second passage 32′″ through the heater core 28′″ to be further heated to a desired temperature.

In other certain embodiments, when the fuel-powered engine of the vehicle is in operation and the HVAC system 10′″ is in the heating mode, the first fluid from the first fluid source 70′″ does not circulate through the conduit 72′″ to the layers 40′″, 42′″ of the evaporator core 24′″. The valve 86′″ is closed to militate against the circulation of the second fluid from the second fluid source 80′″ through the conduit 82′″ to the internal thermal energy exchanger 78′″ and the valve 106′″ is closed to militate against the circulation of the fourth fluid from the fourth fluid source 102′″ to the internal thermal energy exchanger 78′″. However, the third fluid from the third fluid source 94′″ circulates through the conduit 96′″, through the external thermal energy exchanger 308 to the heater core 28′″, through the conduit 99′″ to the internal thermal energy exchanger 78′″, and through the conduit 304 to return to the third fluid source 94′″. Within the external thermal energy exchanger 308, the third fluid absorbs thermal energy from the working fluid flowing therethrough. As such, the third fluid is desirably heated before flowing into the heater core 28′″. Accordingly, the air from the inlet section 16′″ flows through the evaporator core 24′″ where a temperature of the air is relatively unaffected. The air then flows from the evaporator core 24′″ to the internal thermal energy exchanger 78′″. As the air flows through the internal thermal energy exchanger 78′″, the air is heated to a desired temperature by a transfer of thermal energy from the third fluid to the air flowing through the internal thermal energy exchanger 78′″. The conditioned air then exits the internal thermal energy exchanger 78′″ and is selectively permitted by the blend door 34′″ to flow through the first passage 30′″ and/or the second passage 32′″ through the heater core 28′″ to be further heated to a desired temperature.

In yet other certain embodiments, when the fuel-powered engine of the vehicle is in operation and the HVAC system 10′″ is in either the heating mode or the hot thermal energy charge mode, the first fluid from the first fluid source 70′″ does not circulate through the conduit 72′″ to the layers 40′″, 42′″ of the evaporator core 24′″. However, the second fluid from the second fluid source 80′″ circulates through the conduit 82′″ to the internal thermal energy exchanger 78′″. The third fluid from the third fluid source 94′″ circulates through the conduit 96′″ and through the external thermal energy exchanger 308 to the heater core 28′″. Within the external thermal energy exchanger 308, the third fluid absorbs thermal energy from the working fluid flowing therethrough. As such, the third fluid is desirably heated before flowing into the heater core 28′″. Additionally, at least one of the fourth fluid circulates through the conduit 104′″ and the third fluid circulates through the conduit 99′″ to the internal thermal energy exchanger 78′″. The second fluid mixes with at least one of the third fluid and the fourth fluid before, in, or after flowing through the internal thermal energy exchanger 78′″. Accordingly, the air from the inlet section 16′″ flows through the evaporator core 24′″ where a temperature of the air is relatively unaffected. The air then flows from the evaporator core 24′″ to the internal thermal energy exchanger 78′″. As the air flows through the internal thermal energy exchanger 78′″, the air is heated to a desired temperature by a transfer of thermal energy from the mixture of the second fluid and at least one of the third fluid and the fourth fluid to the air flowing through the internal thermal energy exchanger 78′″. The mixture of the fluids then flows through the conduit 82′″ to the second fluid source 80′″ and through the conduit 304 to return to the respective fluid source 94′″, 102′″. In the second fluid source 80′″, the mixture of the fluids releases thermal energy to heat or charge the phase change material, the coolant, the phase change material coolant, or any combination thereof contained in the second fluid source 80′″. In each of the third fluid source 94′″ and the fourth fluid source 102′″, the mixture of the fluids absorbs thermal energy to cool the respective fluid sources 94′″, 102′″. The conditioned air then exits the internal thermal energy exchanger 78′″ and is selectively permitted by the blend door 34′″ to flow through the first passage 30′″ and/or the second passage 32′″ through the heater core 28′″ to be further heated to a desired temperature.

In other certain embodiments, when the fuel-powered engine of the vehicle is not in operation and the HVAC system 10′″ is in the engine-off heating mode, the first fluid from the first fluid source 70′″ does not circulate through the conduit 72′″ to the layers 40′″, 42′″ of the evaporator core 24′″. The second fluid from the second fluid source 80′″ and/or the fourth fluid from the fourth fluid source 102′″ to circulate through the respective conduits 82′″, 104′″ to the internal thermal energy exchanger 78′″. The fourth fluid may also circulate through the conduit 304 and return to the fourth fluid source 102′″. However, the valve 97′″ is closed to militate against the circulation of the third fluid from the third fluid source 94′″ through the conduit 96′″ to the heater core 28′″ and the valve 99′″ is closed to militate against the circulation of the third fluid to the internal thermal energy exchanger 78′″. Accordingly, the air from the inlet section 16′″ flows through the evaporator core 24′″ where a temperature of the air is relatively unaffected. The air then flows from the evaporator core 24′″ to the internal thermal energy exchanger 78′″. As the air flows through the internal thermal energy exchanger 78′″, the air is heated to a desired temperature by a transfer of thermal energy from the second fluid and/or the fourth fluid to the air flowing through the internal thermal energy exchanger 78′″. The fourth fluid then returns to the fourth fluid source 102′″. In the fourth fluid source 102′″, the fourth fluid absorbs thermal energy to cool the fourth fluid source 102′″. The conditioned air then exits the internal thermal energy exchanger 78′″ and is selectively permitted by the blend door 34′″ to flow through the first passage 30′″ and/or the second passage 32′″.

When the fuel-powered engine of the vehicle is in operation and the HVAC system 10′″ is in either the recirculation heating mode or another hot thermal energy charge mode, the first fluid from the first fluid source 70′″ does not circulate through the conduit 72′″ to the layers 40′″, 42′″ of the evaporator core 24′″. The second fluid from the second fluid source 80′″ circulates through the conduit 82′″ to the internal thermal energy exchanger 78′″. However, the valve 97′″ is closed to militate against the circulation of the third fluid from the third fluid source 94′″ through the conduit 96′″ to the heater core 28′″, the valve 99′″ is closed to militate against the circulation of the third fluid through the conduit 98′″ to the internal thermal energy exchanger 78′″, the valve 106′″ is closed to militate against the circulation of the fourth fluid from the fourth fluid source 102′″ through the conduit 104′″ to the internal thermal energy exchanger 78′″, and the valve 306 is closed to militate against the circulation of at least one of the third fluid and the fourth fluid through the conduit 304 to the respective fluid sources 94′″, 102′″. Accordingly, a re-circulated air from a passenger compartment of the vehicle flow through the inlet section 16′″ and into the evaporator core 24′″ where a temperature of the air is relatively unaffected. The re-circulated air then flows from the evaporator core 24′″ to the internal thermal energy exchanger 78′″. As the air flows through the internal thermal energy exchanger 78′″, the re-circulated air transfers thermal energy to the second fluid. The transfer of thermal energy from the re-circulated air to the second fluid heats the second fluid. The second fluid then flows to the second fluid source 80′″ and releases thermal energy to heat or charge the phase change material, the coolant, the phase change material coolant, or any combination thereof contained in the second fluid source 80′″. The re-circulated air then exits the internal thermal energy exchanger 78′″ and is selectively permitted by the blend door 34′″ to flow through the first passage 30′″ and/or the second passage 32′″.

FIG. 6 shows another alternative embodiment of the HVAC system 10, 10′, 10″, 10′″ illustrated in FIGS. 1 and 3-5. Structure similar to that illustrated in FIGS. 1-5 includes the same reference numeral and a quadruple prime (″″) symbol for clarity. In FIG. 6, the HVAC system 10″″ is substantially similar to the HVAC systems 10, 10′, 10″, 10′″ except a condenser 402 of a heat pump system is disposed in the air flow conduit 15″″ instead of a heater core.

The evaporator core 24″″ of the present invention, shown in FIG. 6, is a multi-layer louvered-fin thermal energy exchanger. In a non-limiting example, the evaporator core 24″″ has a first layer 40″″, a second layer 42″″, and a third layer 44″″ arranged substantially perpendicular to the direction of flow through a module 12″″. Additional or fewer layers than shown can be employed as desired. The layers 40″″, 42″″, 44″″ are arranged so the second layer 42″″ is disposed downstream of the first layer 40″″ and upstream of the third layer 44″″ in respect of the direction of flow through the module 12″″. It is understood, however, that the layers 40″″, 42″″, 44″″ can be arranged as desired. The layers 40″″, 42″″, 44″″ can be bonded together by any suitable method as desired such as brazing and welding, for example.

The layers 40″″, 42″″ of the evaporator core 24″″ shown are in fluid communication with a first fluid source 70″″ via a conduit 72″″. It is understood, however, that any of the layers 40″″, 42″″, 44″″, alone or in combination, may be in fluid communication with the first fluid source 70″″ via the conduit 72″″ and configured to receive the flow of the first fluid therein. The first fluid source 70″″ includes a prime mover 74″″ such as a pump or a compressor, for example, to cause a first fluid to circulate therein. Each of the layers 40″″, 42″″ shown is configured to receive a flow of the first fluid from the first fluid source 70″″ therein. The first fluid absorbs thermal energy to condition the air flowing through the module 12″″ when a fuel-powered engine of the vehicle, and thereby the prime mover 74″″, is in operation. As a non-limiting example, the first fluid source 70″″ is a refrigeration circuit, and the first fluid is a refrigerant such as R134a, HFO-1234yf, AC-5, AC-6, and CO₂, for example. A valve 76″″ can be disposed in the conduit 72″″ to selectively militate against the flow of the first fluid therethrough.

The HVAC system 10″″ of the present invention further includes an internal thermal energy exchanger 78″″ in fluid communication with a second fluid source 80″″ via a conduit 82″″. The second fluid source 80″″ includes a prime mover 84″″ (e.g. an electrical pump) to cause a second fluid to circulate through the internal thermal energy exchanger 78″″. As illustrated, the internal thermal energy exchanger 78″″ is the third layer 44″″ of the evaporator core 24″″. It is understood, however, that the thermal energy exchanger may be any of the layers 42″″, 44″″ of the evaporator core 24″″, alone or in combination, in fluid communication with the second fluid source 80″″ via the conduit 82″″ and configured to receive the flow of the second fluid from the second fluid source 80″″ therein. In another particular embodiment, the internal thermal energy exchanger 78″″ is a separate thermal energy exchanger disposed downstream and spaced apart from the evaporator core 24″″ and upstream of the blend door 34″″. It is understood that the internal thermal energy exchanger 78″″ can be any conventional thermal energy exchanger as desired.

The second fluid absorbs or releases thermal energy to condition the air flowing through the module 12″″. A valve 86″″ can be disposed in the conduit 82″″ to selectively militate against the flow of the second fluid therethrough. As a non-limiting example, the second fluid source 80″″ is a fluid reservoir containing a phase change material (PCM) therein. Those skilled in the art will appreciate that the phase change material can be any suitable material that melts and solidifies at predetermined temperatures and is capable of storing and releasing thermal energy such as organic, inorganic, eutectic and ionic liquids (e.g. a paraffin, a paraffin wax, an alcohol, water, a polyglycol, a glycol), and the like, or any combination thereof, for example. The phase change material can also be impregnated with a thermally conductive material such as graphite powder, for example, to further enhance the transfer of thermal energy. As another non-limiting example, the second fluid source 80″″ is a fluid reservoir containing a coolant therein. As another non-limiting example, the second fluid source 80″″ is a fluid reservoir containing a phase change material coolant such as CryoSolplus, for example, therein. As yet another non-limiting example, the second fluid source 80″″ is an external thermal energy exchanger (e.g. a shell and tube heat exchanger, a chiller, etc.) which includes a phase change material disposed therein and/or is in fluid communication with at least one other vehicle system.

As shown, a third fluid source 94″″ is in fluid communication with an external thermal energy exchanger 404 via a conduit 96″″. The external thermal energy exchanger 404 is configured to receive a flow of a third fluid from the third fluid source 94″″ therein. The third fluid source 94″″ can be any conventional source of heated fluid such as the fuel-powered engine of the vehicle, for example, and the third fluid can be any fluid such as a phase change material, a coolant, and a phase change material coolant, for example. A valve 97″″ can be disposed in the conduit 96″″ to selectively militate against the flow of the third fluid therethrough. In certain embodiments, the external thermal energy exchanger 404 is a chiller of a heat pump system. It is understood, however, that the external thermal energy exchanger 404 can be any conventional thermal energy exchanger such as a shell and tube heat exchanger, a condenser, a chiller, and the like, for example. As illustrated, the external thermal energy exchanger 404 is configured to receive the flow of the third fluid from the third fluid source 94″″ counter to a flow of a working fluid from another vehicle system therein through the condenser 402 of a heat pump system disposed in the air flow conduit 15″″ via a conduit 406. In certain embodiments, the working fluid is the first fluid (e.g. refrigerant) from the first fluid source 70″″ (e.g. the refrigerant circuit) which has been discharged by the prime mover 74″″. The external thermal energy exchanger 404 is configured to facilitate an absorption of thermal energy by the third fluid to cool the working fluid flowing therethrough when the fuel-powered engine of the vehicle is in operation.

The third fluid source 94″″ is also in fluid communication with the internal thermal energy exchanger 78″″ via a conduit 98″″. The internal thermal energy exchanger 78″″ is configured to receive a flow of the third fluid from the third fluid source 94″″. The internal thermal energy exchanger 78″″ is configured to facilitate a release of thermal energy from the third fluid to heat the air flowing therethrough when the fuel-powered engine of the vehicle is in operation. Accordingly, a size and capacity of the condenser 402 may be decreased, which may cause a decrease in air side pressure drop during heating modes of the HVAC system 10″″, as well as an increase in available package space within the control module 12″″. A valve 99″″ can be disposed in the conduit 98″″ and a valve 306″″ can be disposed in the conduit 304″″ to selectively militate against the flow of the third fluid therethrough.

The HVAC system 10″″ of the present invention further includes the fourth fluid source 102″″. The internal thermal energy exchanger 78″″ is in fluid communication with the fourth fluid source 102″″ via a conduit 104″″. The fourth fluid source 102″″ can be any conventional vehicle system such as a battery system of the vehicle, for example, and the fourth fluid can be any fluid such as a phase change material, a coolant, and a phase change material coolant, for example. In certain embodiments, the fourth fluid flowing through the fourth fluid source 102″″ absorbs thermal energy to cool at least a portion of the fourth fluid source 102″″ (e.g. a battery cell). Accordingly, the internal thermal energy exchanger 78″″ is configured to facilitate an absorption of thermal energy by the air flowing therethrough to cool the fourth fluid. In other embodiments, the fourth fluid flowing through the fourth fluid source 102″″ releases thermal energy to heat at least a portion of the fourth fluid source 102″″ (e.g. a battery cell). As such, the internal thermal energy exchanger 78″″ is configured to facilitate a release of thermal energy by the air flowing therethrough to heat the fourth fluid. A valve 106″″ can be disposed in the conduit 104″″ to selectively militate against the flow of the fourth fluid therethrough.

As illustrated, the fourth fluid source 102″″ can also be in thermal energy exchange relationship with the third fluid source 94″″ through the internal thermal energy exchanger 78″″. The fourth fluid source 102″″ is either disposed adjacent to a flow of the third fluid from the internal thermal energy exchanger 78″″ or configured to receive the flow of the third fluid from the internal thermal energy exchanger 78″″. In certain embodiments, the third fluid flowing through or adjacent to the fourth fluid source 102″″ absorbs thermal energy to cool at least a portion of the fourth fluid source 102″″ (e.g. a battery cell) to a desired temperature. In other embodiments, the third fluid flowing through or adjacent to the fourth fluid source 102″″ releases thermal energy to heat at least a portion of the fourth fluid source 102″″ (e.g. a battery cell). The valves 99″″, 106″″ disposed in the respective conduits 98″″, 104″″ selectively militate against the flow of the third fluid through or adjacent to the fourth fluid source 102″″. As a non-limiting example, the second fluid from the second fluid source 80″″, the third fluid from the third fluid source 94″″, and the fourth fluid from the fourth fluid source 102″″ are the same fluid types. It is understood, however, that any of the second fluid from the second fluid source 80″″, the third fluid from the third fluid source 94″″, and the fourth fluid from the fourth fluid source 102″″ can be a different fluid type if desired.

In operation, the HVAC system 10″″ conditions air by heating or cooling the air, and providing the conditioned air to the passenger compartment of the vehicle. Air from the supply of air is received in housing 14″″ and flows through the module 12″″.

In a cooling mode or an engine-off cooling mode of the HVAC system 10″″, the blend door 34″″ is positioned in one of a first position permitting air from the evaporator core 24″″ and the internal thermal energy exchanger 78″″ to only flow into the first passage 30″″, a second position permitting the air from the evaporator core 24″″ and the internal thermal energy exchanger 78″″ to only flow into the second passage 32″″, and an intermediate position permitting the air from the evaporator core 24″″ and the internal thermal energy exchanger 78″″ to flow through both the first passage 30″″ and the second passage 32″″. In a heating mode or an engine-off heating mode of the HVAC system 10″″, the blend door 34″″ is positioned either in the second position permitting the air from the evaporator core 24″″ and the internal thermal energy exchanger 78″″ to only flow into the second passage 32″″ and through the condenser 402 or in the intermediate position permitting the air from the evaporator core 24″″ and the internal thermal energy exchanger 78″″ to flow through the first passage 30″″ and the second passage 32″″ and through the condenser 402. In a thermal energy charge mode or a recirculation heating mode of the HVAC system 10″″, the blend door 34″″ is positioned in one of the first position permitting the air from the evaporator core 24″″ and the internal thermal energy exchanger 78″″ to only flow into the first passage 30″″, the second position permitting the air from the evaporator core 24″″ and the internal thermal energy exchanger 78″″ to only flow into the second passage 32″″, and the intermediate position permitting the air from the evaporator core 24″″ and the internal thermal energy exchanger 78″″ to flow through both the first passage 30″″ and/or the second passage 32″″.

When the fuel-powered engine of the vehicle is in operation and the HVAC system 10″″ is in either the cooling mode or the cold thermal energy charge mode, the first fluid from the first fluid source 70″″ circulates through the conduit 72″″ to the layers 40″″, 42″″ of the evaporator core 24″″. Additionally, the second fluid from the second fluid source 80″″ circulates through the conduit 82″″ to the internal thermal energy exchanger 78″″ (e.g. the third layer 44″″ of the evaporator core 24″″). However, the valve 97″″ is closed to militate against the circulation of the third fluid from the third fluid source 94″″ through the conduit 96″″ to the external thermal energy exchanger 404, the valve 99″″ is closed to militate against the circulation of the third fluid through the conduit 98″″ to the internal thermal energy exchanger 78″″, the valve 306″″ is closed to militate against the circulation of the second fluid to the fourth fluid source 102″″, and the valve 106″″ is closed to militate against the circulation of the fourth fluid from the fourth fluid source 102″″ through the conduit 104″″ to the internal thermal energy exchanger 78″″. Additionally, the working fluid is not permitted to circulate through the condenser 402 and the external thermal energy exchanger 404 via the conduit 406. Accordingly, the air from the inlet section 16″″ flows into the evaporator core 24″″ where the air is cooled to a desired temperature by a transfer of thermal energy from the air to the first fluid from the first fluid source 70″″. The conditioned air then flows from the evaporator core 24″″ to the internal thermal energy exchanger 78″″. As the conditioned air flows through the internal thermal energy exchanger 78″″, the conditioned air absorbs thermal energy from the second fluid. The transfer of thermal energy from the second fluid to the conditioned air cools the second fluid. The second fluid then flows to the second fluid source 80″″ and absorbs thermal energy to cool or charge the phase change material, the coolant, the phase change material coolant, or any combination thereof contained in the second fluid source 80″″. The conditioned air then exits the internal thermal energy exchanger 78″″ and is selectively permitted by the blend door 34″″ to flow through the first passage 30″″ and/or the second passage 32″″. It is understood, however, that in other embodiments the working fluid is permitted to circulate through the conduit 406 and through the condenser 402 to demist the conditioned air flowing through the second passage 32″″.

In other certain embodiments, when the fuel-powered engine of the vehicle is in operation and the HVAC system 10″″ is operating in the cooling mode, the first fluid from the first fluid source 70″″ circulates through the conduit 72″″ to the layers 40″″, 42″″ of the evaporator core 24″″. However, the valve 86″″ is closed to militate against the circulation of the second fluid from the second fluid source 80″″ through the conduit 82″″ to the internal thermal energy exchanger 78″″. Additionally, the valve 97″″ is closed to militate against the circulation of the third fluid from the third fluid source 94″″ through the conduit 96″″ to the external thermal energy exchanger 404, the valve 99″″ is closed to militate against the circulation of the third fluid through the conduit 96″″ to the internal thermal energy exchanger 78″″, the valve 306″″ is closed to militate against the circulation of the second fluid to the fourth fluid source 102″″, and the valve 106″″ is closed to militate against the circulation of the fourth fluid from the fourth fluid source 102″″ through the conduit 104″″ to the internal thermal energy exchanger 78″″. Additionally, the working fluid is not permitted to circulate through the condenser 402 and the external thermal energy exchanger 404 via the conduit 406. Accordingly, the air from the inlet section 16″″ flows into the evaporator core 24″″ where the air is cooled to a desired temperature by a transfer of thermal energy from the air to the first fluid from the first fluid source 70″″. The conditioned air then flows from the evaporator core 24″″ to the internal thermal energy exchanger 78″″. As the conditioned air flows through the internal thermal energy exchanger 78″″, the temperature of the conditioned air is relatively unaffected. The conditioned air then exits the internal thermal energy exchanger 78″″ and is selectively permitted by the blend door 34″″ to flow through the first passage 30″″ and/or the second passage 32″″. It is understood, however, that in other embodiments the valve 97″″ is open, permitting the third fluid from the third fluid source 94″″ to circulate through the conduit 96″″ to the condenser 402, and thereby demist the conditioned air flowing through the second passage 32″″. It is understood, however, that in other embodiments the working fluid is permitted to circulate through the conduit 406 and through the condenser 402 to demist the conditioned air flowing through the second passage 32″″.

In other certain embodiments, when the fuel-powered engine of the vehicle is in operation and the HVAC system 10″″ is operating in an alternative cooling mode, the first fluid from the first fluid source 70″″ circulates through the conduit 72″″ to the layers 40″″, 42″″ of the evaporator core 24″″. The fourth fluid from the fourth fluid source 102″″ circulates through the conduit 104″″ to the internal thermal energy exchanger 78″″. However, the valve 86″″ is closed to militate against the circulation of the second fluid from the second fluid source 80″″ through the conduit 82″″ to the internal thermal energy exchanger 78″″, the valve 97″″ is closed to militate against the circulation of the third fluid from the third fluid source 94″″ through the conduit 96″″ to the external thermal energy exchanger 404, and the valve 99″″ is closed to militate against the circulation of the third fluid through the conduit 98″″ to the internal thermal energy exchanger 78″″. Additionally, the working fluid is not permitted to circulate through the condenser 402 and the external thermal energy exchanger 404 via the conduit 406. Accordingly, the air from the inlet section 16″″ flows into the evaporator core 24″″ where the air is cooled to a desired temperature by a transfer of thermal energy from the air to the first fluid from the first fluid source 70″″. The conditioned air then flows from the evaporator core 24″″ to the internal thermal energy exchanger 78″″. As the conditioned air flows through the internal thermal energy exchanger 78″″, the air flowing through the internal thermal energy exchanger 78″″ absorbs thermal energy from the fourth fluid to cool the fourth fluid. The fourth fluid then flows to the fourth fluid source 102″″. In the fourth fluid source 102″″, the fourth fluid absorbs thermal energy to cool the fourth fluid source 102″″. The conditioned air then exits the internal thermal energy exchanger 78″″ and is selectively permitted by the blend door 34″″ to flow through the first passage 30″″ and/or the second passage 32″″. It is understood, however, that in other embodiments the valve 86″″ is open, permitting the second fluid from the second fluid source 80″″ to circulate through the conduit 82″″ to the internal thermal energy exchanger 78″″, and thereby absorb thermal energy from the fourth fluid to further cool the fourth fluid. It is further understood, that in yet other embodiments the working fluid is permitted to circulate through the conduit 406 and through the condenser 402 to demist the conditioned air flowing through the second passage 32″″.

When the fuel-powered engine of the vehicle is not in operation and the HVAC system 10″″ is in the engine-off cooling mode, the first fluid from the first fluid source 70″″ does not circulate through the conduit 72″″ to the layers 40″″, 42″″ of the evaporator core 24″″. However, the second fluid from the second fluid source 80″″ circulates through the conduit 82″″ to the internal thermal energy exchanger 78″″. Additionally, the valve 97″″ is closed to militate against the circulation of the third fluid from the third fluid source 94″″ through the conduit 96″″ to the external thermal energy exchanger 404, the valve 99″″ is closed to militate against the circulation of the third fluid through the conduit 98″″ to the internal thermal energy exchanger 78″″, the valve 306″″ is closed to militate against the circulation of the second fluid to the fourth fluid source 102″″, and the valve 106″″ is closed to militate against the circulation of the fourth fluid from the fourth fluid source 102″″ through the conduit 104″″ to the internal thermal energy exchanger 78″″. Accordingly, the air from the inlet section 16″″ flows through the evaporator core 24″″ where a temperature of the air is relatively unaffected. The air then flows from the evaporator core 24″″ to the internal thermal energy exchanger 78″″. As the air flows through the internal thermal energy exchanger 78″″, the air is cooled to a desired temperature by a transfer of thermal energy from the air to the second fluid from the second fluid source 80″″. The conditioned air then exits the thermal energy exchanger 78″″ and is selectively permitted by the blend door 34″″ to flow through the first passage 30″″ and/or the second passage 32″″.

When the fuel-powered engine of the vehicle is in operation and the HVAC system 10″″ is in the heating mode, the first fluid from the first fluid source 70″″ does not circulate through the conduit 72″″ to the layers 40″″, 42″″ of the evaporator core 24″″. Similarly, the valve 86″″ is closed to militate against the circulation of the second fluid from the second fluid source 80″″ through the conduit 82″″ to the internal thermal energy exchanger 78″″. However, the third fluid from the third fluid source 94″″ circulates through the conduit 96″″ and through the external thermal energy exchanger 404 and the working fluid circulates through the condenser 402 and the external thermal energy exchanger 404 via the conduit 406. Within the external thermal energy exchanger 404, the third fluid absorbs thermal energy from the working fluid flowing therethrough. Additionally, the valve 99″″ is closed to militate against the circulation of the third fluid through the conduit 98″″ to the internal thermal energy exchanger 78″″, the valve 306″″ is closed to militate against the circulation of the second fluid to the fourth fluid source 102″″, and the valve 106″″ is closed to militate against the circulation of the fourth fluid from the fourth fluid source 102″″ through the conduit 104″″ to the internal thermal energy exchanger 78″″. Accordingly, the air from the inlet section 16″″ flows through the evaporator core 24″″ and the internal thermal energy exchanger 78″″ where a temperature of the air is relatively unaffected. The unconditioned air then exits the evaporator core 24″″ and the internal thermal energy exchanger 78″″ and is selectively permitted by the blend door 34″″ to flow through the first passage 30″″ and/or the second passage 32″″ through the condenser 402 to be heated to a desired temperature.

In other certain embodiments, when the fuel-powered engine of the vehicle is in operation and the HVAC system 10″″ is in the heating mode, the first fluid from the first fluid source 70″″ does not circulate through the conduit 72″″ to the layers 40″″, 42″″ of the evaporator core 24″″. The second fluid from the second fluid source 80″″ circulates through the conduit 82″″ to the internal thermal energy exchanger 78″″. The third fluid from the third fluid source 94″″ circulates through the conduit 96″″ and through the external thermal energy exchanger 404 and the working fluid circulates through the condenser 402 and the external thermal energy exchanger 404 via the conduit 406. Within the external thermal energy exchanger 404, the third fluid absorbs thermal energy from the working fluid flowing therethrough. Additionally, the valve 99″″ is closed to militate against the circulation of the third fluid through the conduit 98″″ to the internal thermal energy exchanger 78″″, the valve 306″″ is closed to militate against the circulation of the second fluid to the fourth fluid source 102″″, and the valve 106″″ is closed to militate against the circulation of the fourth fluid from the fourth fluid source 102″″ through the conduit 104″″ to the internal thermal energy exchanger 78″″. Accordingly, the air from the inlet section 16″″ flows through the evaporator core 24″″ where a temperature of the air is relatively unaffected. The air then flows from the evaporator core 24″″ to the internal thermal energy exchanger 78″″. As the air flows through the internal thermal energy exchanger 78″″, the air is heated to a desired temperature by a transfer of thermal energy from the second fluid to the air flowing through the internal thermal energy exchanger 78″″. The conditioned air then exits the internal thermal energy exchanger 78″″ and is selectively permitted by the blend door 34″″ to flow through the first passage 30″″ and/or the second passage 32″″ through the condenser 402 to be further heated to a desired temperature.

In other certain embodiments, when the fuel-powered engine of the vehicle is in operation and the HVAC system 10″″ is in the heating mode, the first fluid from the first fluid source 70″″ does not circulate through the conduit 72″″ to the layers 40″″, 42″″ of the evaporator core 24″″. The valve 86″″ is closed to militate against the circulation of the second fluid from the second fluid source 80″″ through the conduit 82″″ to the internal thermal energy exchanger 78″″ and the valve 106″″ is closed to militate against the circulation of the fourth fluid from the fourth fluid source 102″″ to the internal thermal energy exchanger 78″″. However, the third fluid from the third fluid source 94″″ circulates through the conduit 96″″, through the external thermal energy exchanger 404, through the conduit 98″″ to the internal thermal energy exchanger 78″″, and through the conduit 304″″ to return to the third fluid source 94″″. Within the external thermal energy exchanger 404, the third fluid absorbs thermal energy from the working fluid flowing therethrough. As such, the third fluid is desirably heated before flowing into the internal thermal energy exchanger 78″″. Accordingly, the air from the inlet section 16″″ flows through the evaporator core 24″″ where a temperature of the air is relatively unaffected. The air then flows from the evaporator core 24″″ to the internal thermal energy exchanger 78″″. As the air flows through the internal thermal energy exchanger 78″″, the air is heated to a desired temperature by a transfer of thermal energy from the third fluid to the air flowing through the internal thermal energy exchanger 78″″. The conditioned air then exits the internal thermal energy exchanger 78″″ and is selectively permitted by the blend door 34″″ to flow through the first passage 30″″ and/or the second passage 32″″ through the condenser 402 to be further heated to a desired temperature.

In yet other certain embodiments, when the fuel-powered engine of the vehicle is in operation and the HVAC system 10″″ is in either the heating mode or the hot thermal energy charge mode, the first fluid from the first fluid source 70″″ does not circulate through the conduit 72″″ to the layers 40″″, 42″″ of the evaporator core 24″″. However, the second fluid from the second fluid source 80″″ circulates through the conduit 82″″ to the internal thermal energy exchanger 78″″. The third fluid from the third fluid source 94″″ circulates through the conduit 96″″ and through the external thermal energy exchanger 404. Within the external thermal energy exchanger 404, the third fluid absorbs thermal energy from the working fluid flowing therethrough. Additionally, at least one of the fourth fluid circulates through the conduit 104″″ and the third fluid circulates through the conduit 98″″ to the internal thermal energy exchanger 78″″. The second fluid mixes with at least one of the third fluid and the fourth fluid before, in, or after flowing through the internal thermal energy exchanger 78″″. Accordingly, the air from the inlet section 16″″ flows through the evaporator core 24″″ where a temperature of the air is relatively unaffected. The air then flows from the evaporator core 24″″ to the internal thermal energy exchanger 78″″. As the air flows through the internal thermal energy exchanger 78″″, the air is heated to a desired temperature by a transfer of thermal energy from the mixture of the second fluid and at least one of the third fluid and the fourth fluid to the air flowing through the internal thermal energy exchanger 78″″. The mixture of the fluids then flows through the conduit 82″″ to the second fluid source 80″″ and through the conduit 304″″ to return to the respective fluid sources 94″″, 102″″. In the second fluid source 80″″, the mixture of the fluids releases thermal energy to heat or charge the phase change material, the coolant, the phase change material coolant, or any combination thereof contained in the second fluid source 80″″. In each of the third fluid source 94″″ and the fourth fluid source 102″″, the mixture of the fluids absorbs thermal energy to cool the respective fluid sources 94″″, 102″″. The conditioned air then exits the internal thermal energy exchanger 78″″ and is selectively permitted by the blend door 34″″ to flow through the first passage 30″″ and/or the second passage 32″″ through the condenser 402 to be further heated to a desired temperature.

In other certain embodiments, when the fuel-powered engine of the vehicle is not in operation and the HVAC system 10″″ is in the engine-off heating mode, the first fluid from the first fluid source 70″″ does not circulate through the conduit 72″″ to the layers 40″″, 42″″ of the evaporator core 24″″. The second fluid from the second fluid source 80″″ and/or the fourth fluid from the fourth fluid source 102″″ circulates through the respective conduits 82″″, 104″″ to the internal thermal energy exchanger 78″″. The fourth fluid may also circulate through the conduit 304″″ and return to the fourth fluid source 102″″. However, the valve 97″″ is closed to militate against the circulation of the third fluid from the third fluid source 94″″ through the conduit 96″″ to the external thermal energy exchanger 404 and the valve 99″″ is closed to militate against the circulation of the third fluid to the internal thermal energy exchanger 78″″. Additionally, the working fluid is not permitted to circulate through the condenser 402 and the external thermal energy exchanger 404 via the conduit 406. Accordingly, the air from the inlet section 16″″ flows through the evaporator core 24″″ where a temperature of the air is relatively unaffected. The air then flows from the evaporator core 24″″ to the internal thermal energy exchanger 78″″. As the air flows through the internal thermal energy exchanger 78″″, the air is heated to a desired temperature by a transfer of thermal energy from the second fluid and/or the fourth fluid to the air flowing through the internal thermal energy exchanger 78″″. The fourth fluid then returns to the fourth fluid source 102″″. In the fourth fluid source 102″″, the fourth fluid absorbs thermal energy to cool the fourth fluid source 102″″. The conditioned air then exits the internal thermal energy exchanger 78″″ and is selectively permitted by the blend door 34″″ to flow through the first passage 30″″ and/or the second passage 32″″.

When the fuel-powered engine of the vehicle is in operation and the HVAC system 10″″ is in either the recirculation heating mode or another hot thermal energy charge mode, the first fluid from the first fluid source 70″″ does not circulate through the conduit 72″″ to the layers 40″″, 42″″ of the evaporator core 24″″. The second fluid from the second fluid source 80″″ circulates through the conduit 82″″ to the internal thermal energy exchanger 78″″. However, the valve 97″″ is closed to militate against the circulation of the third fluid from the third fluid source 94″″ through the conduit 96″″ to the external thermal energy exchanger 404, the valve 99″″ is closed to militate against the circulation of the third fluid through the conduit 98″″ to the internal thermal energy exchanger 78″″, the valve 106″″ is closed to militate against the circulation of the fourth fluid from the fourth fluid source 102″″ through the conduit 104″″ to the internal thermal energy exchanger 78″″, and the valve 306″″ is closed to militate against the circulation of at least one of the third fluid and the fourth fluid through the conduit 304″″ to the respective fluid sources 94″″, 102″″. Accordingly, a re-circulated air from a passenger compartment of the vehicle flow through the inlet section 16″″ and into the evaporator core 24″″ where a temperature of the air is relatively unaffected. The re-circulated air then flows from the evaporator core 24″″ to the internal thermal energy exchanger 78″″. As the air flows through the internal thermal energy exchanger 78″″, the re-circulated air transfers thermal energy to the second fluid″″. The transfer of thermal energy from the re-circulated air to the second fluid heats the second fluid. The second fluid then flows to the second fluid source 80″″ and releases thermal energy to heat or charge the phase change material, the coolant, the phase change material coolant, or any combination thereof contained in the second fluid source 80″″. The re-circulated air then exits the internal thermal energy exchanger 78″″ and is selectively permitted by the blend door 34″″ to flow through the first passage 30″″ and/or the second passage 32″″.

From the foregoing description, one ordinarily skilled in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, can make various changes and modifications to the invention to adapt it to various usages and conditions.

Claims

1. A heating, ventilating, and air conditioning (HVAC) system for a vehicle, comprising:

a control module including a housing having an air flow conduit formed therein, the air flow conduit in fluid communication with a passenger compartment of the vehicle;

an evaporator core disposed in the air flow conduit, at least a portion of the evaporator core configured to receive a first fluid from a first fluid source; and

a thermal energy exchanger disposed in the air flow conduit downstream of the at least a portion the evaporator core, the thermal energy exchanger configured to receive a second fluid from a second fluid source and at least one of a third fluid from a third fluid source and a fourth fluid from a fourth fluid source, wherein the first fluid and the second fluid are different fluid types.

2. The HVAC system of claim 1, wherein the thermal energy exchanger is one of another portion of the evaporator core and a thermal energy exchanger separate from the evaporator core.

3. The HVAC system of claim 1, wherein the first fluid source is a refrigerant circuit of the vehicle.

4. The HVAC system of claim 1, wherein the second fluid source is one of an external thermal energy exchanger and a fluid reservoir containing at least one of a phase change material, a coolant, and a phase change material coolant.

5. The HVAC system of claim 1, wherein the third fluid source is a fuel-powered engine of the vehicle.

6. The HVAC system of claim 1, wherein the fourth fluid source is a battery system of the vehicle.

7. The HVAC system of claim 1, further comprising a heater core disposed in the air flow conduit, wherein the heater core is in fluid communication with the third fluid source.

8. The HVAC system of claim 7, wherein the heater core is in thermal energy exchange relationship with the fourth fluid source.

9. The HVAC system of claim 8, further comprising an external thermal energy exchanger in fluid communication with at least one of the heater core, the thermal energy exchanger, and the third fluid source.

10. The HVAC system of claim 9, wherein the thermal energy exchanger is in fluid communication with at least one of the heater core and the external thermal energy exchanger.

11. The HVAC system of claim 10, further comprising a condenser disposed in the air flow conduit.

12. The HVAC system of claim 11, wherein the condenser is in fluid communication with the external thermal energy exchanger.

13. A heating, ventilating, and air conditioning (HVAC) system for a vehicle, comprising:

a control module including a housing having an air flow conduit formed therein, the air flow conduit in fluid communication with a passenger compartment of the vehicle; and

an evaporator core having a plurality of layers disposed in the air flow conduit, wherein at least one of the layers is configured to receive a first fluid from a first fluid source therein, and at least another one of the layers is configured to receive a second fluid from a second fluid source and at least one of a third fluid from a third fluid source and a fourth fluid from a fourth fluid source, and wherein the first fluid and the second fluid are different fluid types.

14. The HVAC system of claim 13, wherein the at least another one of the layers of the evaporator core configured to receive the second fluid therein is disposed downstream from the at least one layer of the evaporator core configured to receive the first fluid therein.

15. The HVAC system of claim 13, wherein the at least another one of the layers of the evaporator core configured to receive the second fluid therein is disposed between a plurality of the layers of the evaporator core configured to receive the first fluid therein.

16. The HVAC system of claim 13, wherein the least another one of the layers of the evaporator core configured to receive the second fluid therein is disposed downstream of and spaced apart from the at least one layer of the evaporator core configured to receive the first fluid therein.

17. A heating, ventilating, and air conditioning (HVAC) system of a vehicle, comprising:

a control module including a housing having an air flow conduit formed therein;

an evaporator core disposed in the air flow conduit, the evaporator core configured to receive a first fluid from a first fluid source therein;

a thermal energy exchanger disposed in the air flow conduit, the thermal energy exchanger configured to receive a second fluid from a second fluid source therein, wherein the first fluid and the second fluid are different fluid types; and

a condenser disposed in the air flow conduit downstream of the thermal energy exchanger, wherein the condenser is configured to receive a working fluid from a heat pump system of the vehicle.

18. The HVAC system of claim 17, further comprising an external thermal energy exchanger configured to receive at least one of a third fluid from a third fluid source and the working fluid from the heat pump system of the vehicle.

19. The HVAC system of claim 18, wherein the thermal energy exchanger is in fluid communication with at least one of the external thermal energy exchanger and a fourth fluid source.

20. The HVAC system of claim 18, wherein the external thermal energy exchanger is a chiller of the heat pump system of the vehicle.