U.S. patent application number 09/847856 was filed with the patent office on 2002-02-14 for thermoelectric heat exchanger.
Invention is credited to Bell, Lon E..
Application Number | 20020017102 09/847856 |
Document ID | / |
Family ID | 22132523 |
Filed Date | 2002-02-14 |
United States Patent
Application |
20020017102 |
Kind Code |
A1 |
Bell, Lon E. |
February 14, 2002 |
Thermoelectric heat exchanger
Abstract
Disclosed is a system for thermally conditioning and pumping a
fluid having use as a ventilation system for vehicle seats and
other applications. The system includes a thermoelectric heat
exchanger having a thermoelectric element configured to pump heat
from one body to another body. A pair of heat exchanger elements
comprising rotor units are coupled to the thermoelectric element
for both transferring heat to and from the thermoelectric element
and generating a fluid flow across the thermoelectric element. The
conditioned fluid may be placed in thermal communication with a
variety of objects, one of which is a vehicle seat to provide
localized heating and cooling of a person sitting on the seat.
Inventors: |
Bell, Lon E.; (Pasadena,
CA) |
Correspondence
Address: |
KNOBBE MARTENS OLSON & BEAR LLP
620 NEWPORT CENTER DRIVE
SIXTEENTH FLOOR
NEWPORT BEACH
CA
92660
US
|
Family ID: |
22132523 |
Appl. No.: |
09/847856 |
Filed: |
May 1, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09847856 |
May 1, 2001 |
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09428018 |
Oct 27, 1999 |
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6223539 |
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09428018 |
Oct 27, 1999 |
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09076518 |
May 12, 1998 |
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6119463 |
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Current U.S.
Class: |
62/3.7 |
Current CPC
Class: |
B60H 1/00478 20130101;
F04D 29/4246 20130101; H01L 35/30 20130101; B60N 2/5657 20130101;
B60N 2/5635 20130101; B60N 2/5692 20130101; B60H 1/00471 20130101;
F04D 25/166 20130101; B60N 2/5685 20130101; F04D 29/5826 20130101;
F04D 17/162 20130101; B60H 1/2225 20130101; B60N 2/5678 20130101;
F25B 21/04 20130101; F25B 2321/0251 20130101 |
Class at
Publication: |
62/3.7 |
International
Class: |
F25B 021/02 |
Claims
What is claimed is:
1. A temperature controlled ventilation system for a seat,
comprising: a supply side heat exchanger forming a hole therein
about an axis of rotation and configured to allow air to pass
outward from said axis of rotation; a waste side heat exchanger
forming a hole therein about said axis of rotation and configured
to allow air to pass outward from said axis of rotation; a
thermoelectric device having opposing surfaces that generate
elevated temperatures on one surface and reduced temperatures on
the opposing surface depending on the electrical potential applied
to the thermoelectric device, one opposing surface being connected
to and in thermal communication with the supply side heat exchanger
and the other opposing surface being connected to and in thermal
communication with the waste side heat exchanger; a motor drivingly
connected to at least one of the heat exchangers or thermoelectric
device to rotate the heat exchangers about the axis of rotation to
cause air to enter at least one of the holes and pass outward
through the heat exchanger; a housing containing at least the
supply heat exchanger and forming an outlet through which air exits
after passing through the supply heat exchanger; a seat of a motor
vehicle having a surface against which a person rests, the surface
having passages therethrough in at least a portion of the surface
where the person rests, the surface being in fluid communication
with the outlet of the supply heat exchanger, the heat exchanger
and motor rotation cooperating so air from the heat exchanger is
forced through the surface to provide conditioned air in the area
where the passenger rests against the surface.
2. A system as defined in claim 1, wherein the housing encloses
both heat exchangers and further comprising an insulating layer
between the first and second heat exchangers that extends radially
outward toward the housing to form an insulated barrier between the
supply and waste heat exchangers
3. A system as defined in claim 1, additionally comprising a
wicking material being connected to at least a portion of the
housing and having a first portion in contact with air exiting the
supply heat exchanger and having a second portion in contact with
air exiting the waste heat exchanger so that if one of the heat
exchangers generates moisture the wicking material conducts the
moisture away from the heat exchanger producing the moisture.
4. A system as defined in claim 1, wherein the combined height of
the heat exchangers and thermoelectric device is less than about 30
mm when measured along the rotational axis.
5. A system as defined in claim 1, wherein the housing encloses
both heat exchangers and further comprising an insulating layer
between the first and second heat exchangers that extends radially
outward toward the housing to form an insulated barrier between the
supply and waste heat exchangers.
6. A system as defined in claim 1, wherein the heat exchangers
comprise annular heat exchangers forming annular holes, with the
motor nesting into at least one of said annular holes.
7. A system as defined in claim 6, further comprising a wicking
material connected to at least a portion of the housing and having
a first portion in contact with air exiting the supply heat
exchanger and having a second portion in contact with air exiting
the waste heat exchanger so that if one of the heat exchangers
generates moisture the wicking material conducts the moisture away
from the heat exchanger producing the moisture.
8. A system as defined in claim 7, wherein the housing further
encloses the waste side heat exchanger and has a waste side outlet
in fluid communication with a passage that exhausts the air from
the waste side of the heat exchanger.
9. A system for use with a seat having a surface in fluid
communication with a heat exchanger, comprising: a first heat
exchanger having an outlet in fluid communication with the surface
of the seat, the first heat exchanger comprising: an electronic
element selected to generate heat in response to an electrical
current; a heat exchanger connected to and in thermal communication
with the electronic element, the heat exchanger comprising a first
series of heat exchange surfaces rotatable about a rotational axis
and configured to transfer a temperature differential from the
electronic element, the electronic element and the heat exchanger
being connected to rotate about the rotational axis so that the
first series of heat exchange surfaces generates a fluid flow
across the heat exchange surfaces.
10. The system of claim 9, wherein the electronic element comprises
a thermoelectric device that has opposing surfaces comprising a
first junction on one surface and a second junction on an opposing
surface, with the first junction being at a higher temperature than
the second junction when electrical current is applied to the
thermoelectric element in a first direction, and with the first
junction being at a lower temperature than the second junction when
the electrical current is applied to the electronic element in a
second direction.
11. The system of claim 9, wherein the heat exchanger additionally
comprises a second heat exchanger connected to and in thermal
communication with the second junction of the thermoelectric
element, the second heat exchanger comprising a second series of
heat exchange surfaces rotatable about a rotational axis and
configured to transfer a temperature differential from the second
junction, the second heat exchanger being connected to rotate about
the rotational axis with the first heat exchanger so that the
second series of heat exchange surfaces generates a fluid flow
across the second series of heat exchange surfaces.
12. The system of claim 11, wherein at least one of the first and
second series of heat exchange surfaces form substantially flat
sheets extending outward from the rotational axis and define a
series of spaces between the blades.
13. The system of 11, wherein the fluid comprises a gas and at
least one of the first and second series of heat exchange surfaces
are separated by a distance in the range of approximately 0.5-2
mm.
14. The system of 12, wherein the fluid comprises a gas and at
least one of the first and second series of heat exchange surfaces
are separated by a distance in the range of approximately 0.5-2
mm.
15. The system of 11, wherein the fluid comprises a gas, the heat
exchangers comprise annular heat exchangers and the combined height
of the heat exchangers and thermoelectric element is less than
about 30 mm measured along the rotational axis.
16. The system of 12, wherein the fluid comprises a gas, the heat
exchangers comprise annular heat exchangers and the combined height
of the heat exchangers and the thermoelectric element is less than
about 30 mm measured along the rotational axis.
17. The system of claim 13, wherein the fluid comprises a gas and
at least one of the first and second series of heat exchange
surfaces are of thermally conductive material and have a thickness
in the range of approximately 0.05-0.2 mm.
18. The system of claim 14, wherein the fluid comprises a gas and
at least one of the first and second series of heat exchange
surfaces are of thermally conductive material and have a thickness
in the range of approximately 0.05-0.2 mm.
19. The system of claim 15, wherein the fluid comprises a gas and
at least one of the first and second series of heat exchange
surfaces are of thermally conductive material and have a thickness
in the range of approximately 0.05-0.2 mm.
20. A system for providing conditioned fluid to a seat, comprising:
an electronic device selected to convert electrical energy into
thermal energy producing a temperature change in response to an
electrical current being applied thereto, the electronic device
being mounted to rotate about a rotational axis; a heat transfer
device having an outlet in fluid communication with the seat, the
heat transfer device comprising: a rotatable flow generating device
configured to produce a fluid flow in response to rotation thereof
about the axis, the flow generating device further being in
conductive thermal communication with the electronic device so that
the airflow generating device conducts the temperature change
generated by the heat transfer device to transfer the temperature
change to the fluid flowing across the heat transfer device.
21. The system of claim 20, wherein the electronic device comprises
a thermoelectric device.
22. The system of claim 20, wherein the flow generating device
comprises a series of radially-extending heat exchange surfaces
connected to a first surface of a thermoelectric device.
23. The system of claim 21, wherein the flow generating device
comprises a first series of outwardly-extending heat exchange
surfaces connected to and in thermal communication with a first
surface of the thermoelectric device, and a second series of
outwardly-extending heat exchange surfaces connected to an
opposing, second surface of the thermoelectric device.
24. A temperature controlled ventilation system for a seat,
comprising: means for producing a temperature differential; and
supply side heat exchanger means for conducting said temperature
change, said heat exchanger means further comprising fluid flow
generating means for causing fluid to flow across said heat
exchanger means, said supply side heat exchanger means being in
fluid communication with the seat.
25. A temperature controlled ventilation system for a seat having a
fluid distribution system in fluid communication with the seat,
comprising: a first fan rotating about a rotational axis and having
a first plurality of heat exchange elements configured to generate
a fluid flow through the heat exchange elements when rotated and in
conductive thermal communication with an electronic device that
converts electrical energy into a temperature change, the fan being
enclosed in a housing that has an outlet in fluid communication
with the fluid distribution system.
26. A system as defined in claim 25, wherein the electronic device
comprises a thermoelectric device having a first side in thermal
communication with said fan, and further comprising a second fan
having a second plurality of heat exchange elements in conductive
thermal communication with a second side of the thermoelectric
device to conduct a temperature differential from said second side
of the thermoelectric device, the second fan being enclosed in a
housing that has an outlet in fluid communication with an exhaust
port.
27. The system of claim 26, wherein at least one of the first and
second plurality of heat exchange elements form substantially flat
sheets extending radially outward from the rotational axis and
define a series of spaces between the blades.
28. The system of claim 26, wherein the fluid comprises a gas and
at least one of the first and second plurality of heat exchange
elements are separated by a distance in the range of approximately
0.5-2 mm.
29. The system of claim 26, wherein the fluid comprises a gas and
the height of the fans and thermoelectric device is less than about
30 mm measured along the rotational axis.
30. The system of claim 26, wherein the fluid comprises a gas and
at least one of the first and second plurality of heat exchange
elements are of a high thermal conductivity material and have a
thickness in the range of approximately 0.05-0.2 mm.
31. A system of claim 26, further comprising a wicking material
having a first portion in contact with a gas exiting the first
plurality of heat exchange elements and having a second portion in
contact with a gas exiting the second plurality of heat exchange
elements to conduct any moisture away from the housing in which the
moisture is produced.
32. A method for providing temperature controlled ventilation to a
seat having a seat surface, comprising the steps of: forming a
supply side heat exchanger rotating about an axis of rotation and
configuring the heat exchanger to allow fluid to pass therethrough;
forming a waste side heat exchanger rotating about said axis of
rotation and configuring the waste side heat exchanger to allow
fluid to pass therethrough; providing a thermoelectric device
having opposing surfaces that generate elevated temperatures on one
surface and reduced temperatures on the opposing surface depending
on the electrical potential applied to the thermoelectric device,
and conductively connecting one opposing surface of the
thermoelectric device to the supply side heat exchanger and
conductively connecting the other opposing surface to the waste
side heat exchanger; rotating at the heat exchangers and
thermoelectric device about the axis of rotation to cause fluid to
pass through the heat exchanger; enclosing the supply heat
exchanger and forming an outlet through which fluid exits after
passing through the supply heat exchanger; and placing the seat
surface in fluid communication with the outlet of the supply heat
exchanger.
33. A method as defined in claim 32, comprising the further step of
enclosing both heat exchangers and insulating the first and second
heat exchangers from each other.
34. A method for use with a seat having an exterior surface where a
person rests, comprising the steps of: placing a first heat
exchanger having a fluid outlet in fluid communication with the
exterior surface of the seat and mounting the heat exchanger to
rotate about a rotational axis; placing the first heat exchanger in
conductive thermal communication with an electrical device that is
selected to generate a temperature change when an electrical
current is applied to the electrical device; and rotating the first
heat exchanger about the axis to force fluid through the heat
exchanger while conditioning the temperature of the fluid passing
over the heat exchanger.
35. The method of claim 34, wherein the step of placing the heat
exchanger in thermal communication with an electrical device
comprises the step of placing the first heat exchanger in thermal
communication with a first surface of a rotating thermoelectric
device.
36. The method of claim 35, comprising the further steps of:
placing a second heat exchanger in conductive thermal communication
with a second surface of the thermoelectric device; and rotating
the second heat exchanger about the axis with the first heat
exchanger to force fluid through the second heat exchanger while
conditioning the fluid passing through the second heat
exchanger;
37. The method of claim 36, comprising the further step of forming
at least one of the first and second heat exchangers to have a
series of heat exchange elements formed of substantially flat
sheets extending radially outward from the rotational axis and
define a series of spaces between the blades.
38. The method of claim 37, comprising the further step of
separating said series of heat exchange elements by a distance in
the range of approximately 0.5-2 mm.
39. The method of claim 36, comprising the further step of forming
the first and second series of heat exchange elements and the
thermoelectric device to have an annular shape and a combined
height that is less than about 30 mm measured along the rotational
axis.
40. The method of claim 36, comprising the further step of forming
the series of heat exchange elements of a thermally conductive
material with a thickness in the range of approximately 0.05-0.2
mm.
41. The method of claim 36, comprising the further step of placing
the heat exchangers inside the seat.
42. A method of providing temperature controlled ventilation to an
seat, comprising the steps of: producing a temperature
differential; and conducting said temperature differential to a
heat exchanger to condition a fluid flowing across the heat
exchanger; rotating said heat exchanger to cause the fluid to flow
across the heat exchanger; placing fluid from the heat exchanger in
fluid communication with the seat.
43. A method for providing temperature controlled ventilation to an
seat having an fluid distribution system in fluid communication
with the seat, comprising the steps of: generating a temperature
differential by an electronic device that is selected to convert
electrical energy into a temperature change; placing a first
plurality of heat exchange surfaces of a first fan in conductive
thermal communication with the electronic device to conduct the
temperature differential through the heat exchange surfaces;
rotating the first fan about a rotational axis to cause the fluid
to pass over the heat exchange surfaces to condition the fluid;
enclosing the fan in a housing that has an outlet; and placing the
outlet in fluid communication with the fluid distribution
system.
44. A method defined in claim 43, wherein the electronic device
comprises a thermoelectric device having a first side in thermal
communication with said fan, and further comprising the steps of
providing a second fan having a second plurality of heat exchange
surfaces placed in conductive thermal communication with a second
side of the thermoelectric device to conduct a temperature
differential from said second side of the thermoelectric device,
and rotating the second fan with the first fan, and enclosing the
second fan in a housing that has an outlet in fluid communication
with an exhaust port.
45. An apparatus for thermally conditioning a fluid, comprising: an
electronic device selected to convert electrical energy into
thermal energy producing a temperature change in response to an
electrical current being applied thereto, the electronic device
being mounted to rotate about a rotational axis; a heat transfer
device in conductive thermal communication with the electronic
device and being mounted to rotate about the axis, the heat
transfer device having thermally radiating surfaces arranged to
produce a fluid flow across the surfaces when rotated about the
axis.
46. The system of claim 45, wherein the electronic device comprises
a thermoelectric device.
47. The apparatus of claim 45, wherein the heat transfer device
comprises a first series of outwardly-extending thermally radiating
surfaces connected to a first surface of the electric device.
48. The apparatus of claim 46, wherein the heat transfer device
comprises a first series of thermally radiating surfaces connected
to a first surface of the thermoelectric device, and a second
series of thermally radiating surfaces connected to an opposing,
second surface of the thermoelectric device.
49. The apparatus of claim 48, wherein the heat transfer device is
contained in a housing having at least one outlet in fluid
communication with a seat.
50. An apparatus for thermally conditioning a fluid, comprising:
means for producing a temperature change; and rotating supply side
heat exchanger means for conducting said temperature change, said
heat exchanger means further comprising fluid flow generating means
for causing fluid to flow across said heat exchanger means.
51. The apparatus defined of claim 50, wherein said fluid comprises
a gas and said supply side heat exchanger means is in fluid
communication with a seat to provide gas from the heat exchanger
means to the seat.
52. A temperature conditioning fluid moving device, comprising: a
first fan rotating about a rotational axis and having a first
plurality of heat exchange surfaces in conductive thermal
communication with an electronic device that converts electrical
energy into a temperature change, the fan being enclosed in a
housing that has an outlet.
53. A device as defined in claim 52, wherein the electronic device
comprises a thermoelectric device having a first side in thermal
communication with said fan, and further comprising a second fan
having a second plurality of heat exchange surfaces in conductive
thermal communication with a second side of the thermoelectric
device to conduct a temperature change from said second side of the
thermoelectric device, the second fan being enclosed in a housing
that has an outlet.
54. A device as defined in claim 53, wherein at least one of the
outlets is in fluid communication with a seat.
55. A device as defined in claim 53, wherein at least some of the
heat exchange surfaces form substantially flat sheets extending
outward from the rotational axis and define a series of spaces
between the sheets.
56. A device as defined in claim 53, wherein the at least one of
the first and second series of heat exchange surfaces are separated
by a distance in the range of approximately 0.5-2 mm.
57. A device as defined in claim 53, wherein the fans have an
annular shape and the height of the fans and thermoelectric device
is less than about 30 mm measured along the rotational axis.
58. A device as defined in claim 53, wherein at least one of the
first and second plurality of heat exchange surfaces are of a
thermally conductive material and have a thickness in the range of
approximately 0.05-0.2 mm.
59. A method for thermally conditioning a fluid, comprising the
steps of: forming a supply side heat exchanger rotating about an
axis of rotation and configuring that heat exchanger to pass
therethrough; forming a waste side heat exchanger rotating about
said axis of rotation and configuring the waste side heat exchanger
to allow gas to pass through; providing a thermoelectric device
having opposing surfaces that generate elevated temperatures on one
surface and reduced temperatures on the opposing surface depending
on the electrical potential applied to the thermoelectric device,
and conductively connecting one opposing surface of the
thermoelectric device to the supply side heat exchanger and
conductively connecting the other opposing surface to the waste
side heat exchanger; rotating the heat exchangers and
thermoelectric device about the axis of rotation to cause gas to
pass through the heat exchangers; and enclosing the supply heat
exchanger and forming an outlet through which gas exits after
passing through the supply heat exchanger.
60. A method as defined in claim 59 wherein the step of forming the
supply side heat exchanger comprises forming the heat exchanger
with a hole therein about said axis of rotation and configuring
that heat exchanger to allow gas to pass outward from said axis of
rotation; and wherein said step of forming a waste side heat
exchanger comprises the step of forming a hole therein about said
axis of rotation and configuring the waste side heat exchanger to
allow gas to pass outward from said axis of rotation; and wherein
said step of rotating the heat exchangers and thermoelectric device
about the axis of rotation causes fluid to enter at least one of
the holes and pass outward through the heat exchanger.
61. A method as defined in claim 59, comprising the further steps
of: placing a seat in fluid communication with the outlet of the
supply side heat exchanger.
62. A method for thermally conditioning and moving a fluid,
comprising the steps of: forming a first heat exchanger having
radiative surfaces aligned to allow the passage of gas outward from
an axis about which the heat exchanger rotates; placing the first
heat exchanger in conductive thermal communication with an
electrical device that generates a temperature change when an
electrical current is applied to the electrical device; and
rotating the first heat exchanger about the axis.
63. The method of claim 62, wherein the step of placing the heat
exchanger in thermal communication with an electrical device
comprises the step of placing the first heat exchanger in thermal
communication with a first surface of a thermoelectric device.
64. The method of claim 63, comprising the further step of placing
the heat exchanger inside a seat.
65. A method of providing temperature controlled fluid, comprising
the steps of: producing a temperature change by an electronic
device; and conducting said temperature change to a heat exchanger
having radiative surfaces; and rotating said heat exchanger to
cause fluid to flow across the radiative surfaces of the heat
exchanger.
66. A method as defined in claim 65, comprising the further step of
placing fluid from the heat exchanger in thermal communication with
a seat.
67. A method as defined in claim 65, comprising the further step of
circulating fluid conditioned by at least a portion of the heat
exchanger to the interior of a chamber.
68. A method as defined in claim 67, comprising the further step of
thermally insulating the chamber and providing an closable opening
to allow access to the interior of the chamber.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to temperature control
devices. More particularly, the present invention relates to a
thermoelectric heat exchanger that is particularly useful for
controlling the temperature of a seat, such as an automobile
seat.
[0003] 2. Description of the Related Art
[0004] Modern automobile seats may be equipped with temperature
control systems that allow the occupant to vary the temperature of
the seat by flowing temperature-controlled air through the seat
covering. One type of system comprises a seat having a heat
transfer system mounted therein, such as a thermoelectric element
configured to heat or cool air that is moved over the element using
a separate fan unit that is also mounted within the seat. The
conditioned air is distributed to the occupant by passing the air
through the seat surface via a series of air ducts within the
seat.
[0005] The amount of space available within, below and around the
seat for such temperature control systems is severely limited. In
some cars, to save weight or increase passenger room, the seats are
a few inches thick and abut the adjacent structure of the car, such
as the floorboard or the back of the car. Further, automobile
manufacturers are increasingly mounting various devices, such as
electronic components or variable lumbar supports, within, below
and around the seat. Additionally, the size of the seat,
particularly the seat back, needs to be as small as possible to
reduce the amount of cabin space consumed by the seat.
[0006] Present temperature control systems are often too large to
be mounted within, below or around vehicle seats. Conventional
systems may have a squirrel cage fan five or six inches in diameter
generating an air flow that passes through a duct to reach a heat
exchanger that adjusts the temperature of the air. The heat
exchanger is several inches wide and long, and at least an inch or
so thick. From the heat exchanger the air is transported through
ducts to the bottom of the seat cushion and to the back of the seat
cushion. Such systems are bulky and difficult to fit underneath or
inside car seats. Using thermoelectric devices to heat and cool the
heat exchanger helps reduce the size of unit, but still requires a
large volume for the combined heating and cooling system.
[0007] The ducting used with these systems is also bulky and
difficult to use if the duct must go from a seat bottom to a seat
back that is allowed to pivot or rotate. These ducts not only use
additional space within the seat, but also resist air flow and thus
require a larger fan to provide the air flow, and the larger fan
requires additional space or else runs at greater speeds and
generates more noise. Noise is undesirable inside motor vehicles.
Further, the ducting affects the temperature of the passing air and
either heats cool air, or cools heated air, with the result of
often requiring larger fans or heat exchangers.
[0008] In light of these drawbacks, there is a need for a more
compact and energy efficient heating and cooling system for
automobile seats, and preferably a quieter system.
SUMMARY OF THE INVENTION
[0009] This device uses air flow generators, such as fan blades,
that act as both a heat exchanger to transfer a thermal
differential from a thermoelectric device and thereby condition air
passing over the heat exchanger, and that act as an air pump. The
heat exchanger rotates and provides aerodynamic and centrifugal
force to the air passing through the heat exchanger to generate
pressurized air for distribution, such as to the seat of a motor
vehicle.
[0010] In more detail, one embodiment of this device comprises at
least one annular thermoelectric device (e.g., Peltier device)
that, depending on the voltage applied, heats one surface and cools
the opposing surface of the annular, thermoelectric device. Annular
heat exchangers are placed in thermal communication with the
opposing sides of the annular thermoelectric device by mounting
them directly to the thermoelectric device so that each heat
exchanger conducts the heat or cold from the surface of the device
to which the heat exchanger is mounted. A resistive heating element
may also be used to generate heat.
[0011] In one embodiment, the annular heat exchangers are formed
with radial slots extending through the heat exchanger, and form an
annular cavity inside the heat exchangers when assembled. A motor
nests inside the annular cavity formed on the inside of the
assembled annular heat exchangers and annular, thermoelectric
device, but spaced apart from the heat exchangers and
thermoelectric device by an amount sufficient to allow air to flow
along the exterior of the motor. The motor is drivingly connected
to one of the heat exchangers and thermoelectric device to rotate
them. The rotating heat exchangers act as a fan, drawing air into
the annular cavity and expelling the air through the radial slots
of the heat exchangers at a higher pressure. The volume of
compressed air created is determined by the motor size, the fan
blade shape, the rotational speed, and the overall geometry of the
assembly.
[0012] This arrangement allows the heat exchanger to be directly
coupled to the thermoelectric device, and to act as a fan to not
only generate the air pressure that distributes the conditioned air
to passenger seats, but to condition the air as the air passes
through the fan blades/heat exchanger. This reduces ducting and
associated pressure losses, reduces the size of the system, and
increases the overall efficiency of the system which in turn allows
a reduction in fan size and power requirements. The compact
arrangement allows the system to be placed underneath, and
preferably inside most automobile seats, which further reduces
ducting and associated pressure losses, and allows further
reductions in motor size and power. The result of the various
reductions is some combination of a smaller system volume, less
power consumption, smaller size, and generation of less noise, than
previously available.
[0013] Advantageously, a seal separates the opposing sides of the
rotating, annular heat exchangers to form a main, or supply side
and a waste side. Air enters the assembly near the axis of
rotation, which advantageously is aligned with the motor's
rotational axis. The air exits radially or axially outward into a
housing enclosing the majority of the annular fan/heat exchanger.
An outlet in fluid communication with the main (or supply) side is
in fluid communication with the seat of a passenger vehicle. An
outlet in fluid communication with the waste side is also in fluid
communication with an outlet at a location that will not degrade
performance by allowing the waste air to be recirculated to the air
entry portion. The thermoelectric creates a temperature
differential between the supply side air and the waste side air.
Layers of thermal insulation between the waste side and the supply
side help maintain that temperature differential in portions of the
assembly.
[0014] Power is supplied to the thermoelectric device by brush and
slip ring assemblies on the rotational axis of the motor. When
appropriate voltages and currents are applied to the thermoelectric
and the motor, a flow of either cold or hot air is provided to the
supply side by the heat exchanger that conducts the temperature
differential throughout the heat exchanger, and heats or cools the
air passing over the heat exchanger/fan blades by conduction and
convection. Voltage adjustments to the motor and thermoelectric
control the pressure, temperature and flow rate.
[0015] Advantageously, around a portion of the inside of the
housing enclosing the annular fans, a wicking material is placed so
that the material extends from the supply side to the waste side.
If moisture condenses on one rotating fan, it is urged against the
wicking material by centrifugal force from the rotating fan/heat
exchanger. The wicking material absorbs the moisture, and
transports the moisture to the opposing side where heated air
evaporates the moisture and carries the moisture out of the
system.
[0016] There is thus advantageously provided a system for thermally
conditioning a fluid passing over a rotating heat exchanger that
also causes movement of the fluid. The system comprises an
electronic device selected to convert electrical energy into
thermal energy producing a temperature change in response to an
electrical current being applied thereto. The electronic device is
mounted to rotate about a rotational axis. A heat transfer device
is placed in conductive thermal communication with the electronic
device and is mounted to rotate about the axis. The heat transfer
device has thermally radiating surfaces arranged to produce a fluid
flow across the surfaces when rotated about the axis. The
electronic device can comprise a heating resistor, or a
thermoelectric device that can heat or cool the fluid.
Advantageously, the heat transfer device comprises a first series
of outwardly-extending thermally radiating surfaces connected to a
first surface of the electric device. A second series of thermally
radiating surfaces may be connected to an opposing, second surface
of the thermoelectric device. In a preferred embodiment, the heat
transfer device is contained in a housing having at least one
outlet in fluid communication with a seat.
[0017] The present invention also includes a means for producing a
temperature change and a rotating supply side heat exchanger means
for conducting the temperature change. The heat exchanger means
further comprises fluid flow generating means for causing fluid to
flow across said heat exchanger means. The fluid advantageously
comprises a gas and the supply side heat exchanger means is
advantageously in fluid communication with a seat to provide gas
from the heat exchanger means to the seat.
[0018] The apparatus also comprises a device for thermally
conditioning a fluid having a first fan rotating about a rotational
axis and having a first plurality of heat exchange surfaces in
conductive thermal communication with an electronic device that
converts electrical energy into a temperature change. The fan is
advantageously enclosed in a housing that has an outlet.
[0019] The present invention also comprises a method for thermally
conditioning a fluid comprising the steps of producing a
temperature change by an electronic device, conducting that
temperature change to a heat exchanger having radiative surfaces,
and rotating the radiative surfaces to cause fluid to flow across
the radiative surfaces. Advantageously fluid from the heat
exchanger is placed in thermal communication with a seat, and the
fluid comprises a gas, preferably air. Alternatively, the thermally
conditioned fluid is circulated to the interior of a chamber which
may comprise a gas plenum, or circulated to a thermally insulated
chamber provided with a closable opening to allow access to the
interior of the chamber--such as a cooler.
[0020] One method for producing a very compact form of the
invention is to form a first heat exchanger having radiative
surfaces aligned to allow the passage of air outward from an axis
about which the heat exchanger rotates. The first heat exchanger is
placed in conductive thermal communication with an electrical
device that generates a temperature change when an electrical
current is applied to the electrical device. The first heat
exchanger is then rotated about the axis. Advantageously the
electrical device comprises a thermoelectric device, and when
placed inside a vehicle seat, provides a compact unit for
ventilating the seat.
[0021] The present invention further comprises means for producing
a temperature differential and supply side heat exchanger means for
conducting said temperature change, where the heat exchanger means
further comprises fluid flow generating means for causing fluid to
flow across said heat exchanger means. Advantageously, the supply
side heat exchanger means is in fluid communication with a vehicle
seat.
[0022] A further version of the invention comprises a first fan
rotating about a rotational axis and having a first plurality of
heat exchange elements configured to generate a fluid flow through
the heat exchange elements when rotated and in conductive thermal
communication with an electronic device that converts electrical
energy into a temperature change. The fan is advantageously
enclosed in a housing that has an outlet in fluid communication
with a fluid distribution system, and preferably the electronic
device comprises a thermoelectric device.
[0023] There is thus provided a system for thermally conditioning
and pumping a fluid having use as a ventilation system for vehicle
seats and other applications, in which an electrical resistor or
thermoelectric device generates a temperature change that is
conducted to a heat exchanger which forms an impeller to cause
fluid to flow across the heat exchanger and thermally condition the
fluid. The thermally conditioned fluid may be placed in thermal
communication with a variety of objects, one of which is a vehicle
seat to provide localized heating and cooling of a person sitting
on the seat.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] These and other features of the invention will now be
described with reference to the drawings of an embodiment in which
like number indicate like parts throughout, and which are intended
to illustrate and not to limit the invention, and in which:
[0025] FIG. 1 is a perspective view of the heat exchanger of the
present invention;
[0026] FIG. 2 is a perspective view of a rotary assembly of the
heat exchanger of FIG. 1;
[0027] FIG. 3 is a cross-sectional view of the heat exchanger along
line 3-3 of FIG. 1;
[0028] FIG. 4 is an enlarged cross-sectional view of a portion of
the heat exchanger;
[0029] FIG. 5 is a top view of a rotor used with the heat
exchanger;
[0030] FIG. 6 is a side view of the rotor of FIG. 4;
[0031] FIG. 7 is a schematic view of a seat temperature control
system incorporating the heat exchanger of the present
invention;
[0032] FIG. 8 is a perspective view of a cooler box that
incorporates the heat exchanger;
[0033] FIG. 9 is a cross-sectional side view of a lid of the cooler
box of FIG. 8;
[0034] FIG. 10 is a side view of a fan unit incorporating the heat
exchanger of the present invention;
[0035] FIG. 11 is a side cross-sectional view of the fan unit of
FIG. 10; and
[0036] FIG. 12 is a perspective view of another embodiment of the
heat exchanger.
DETAILED DESCRIPTION
[0037] As shown in FIG. 1, the heat exchanger unit 28 of the
present invention includes an outer housing 32 that defines an
interior cavity 29 (FIG. 3) in which a rotor assembly 30 (FIGS. 2
and 3) is rotatably mounted for producing a conditioned airflow
into and out of the outer housing 32. While other shapes are
suitable, the outer housing 32 is shown as resembling a generally
flat disc with a first surface or first wall 31 that corresponds to
an upper or top surface if the housing 32 is placed in a seat
bottom generally parallel to the ground. As used herein, up or
upper will refer to a direction away from the ground. Down, lower
or bottom will refer to a direction toward the ground. The relative
direction of parts would alter if the entire orientation of housing
32 were changed, as may occur in actual use. A second wall 33,
corresponding to a bottom surface, is opposite the first wall 31.
The generally circular peripheries of walls 31, 33 are joined by
side wall 35 to form an enclosure.
[0038] A first outlet 34 extends outwardly from the side wall 35
adjacent the first or upper wall 31 of the outer housing 32. A
second outlet 36 extends outwardly from the side wall 35 adjacent
the second, or lower wall 33. Advantageously the outlets 34, 36
extend generally tangential from the periphery of the housing 32.
The outlets 34, 36 are shown extending in generally opposite
directions, about 180.degree. relative to each other. But depending
on the particular direction the air needs to flow, the outlets 34,
36 could be located at other angles relative to each other, with
60.degree., 90.degree. on either side of the housing 32, being the
most likely relative positions. The outlets 34, 36 could exit in
the same direction if desired, but then it would be advantageous to
have insulation between the outlets to help maintain the
temperature differential between the outlets.
[0039] A set of apertures 38 are centrally formed in the first or
top wall 31 of the outer housing 32 to form a first inlet 38 that
communicates with the interior cavity 29 formed and enclosed by the
outer housing 32. Although not necessary, a second inlet 40 (FIG.
3) may also be located on the second or bottom wall 33 of the outer
housing 32 opposite the first inlet 38.
[0040] Referring to FIGS. 2 and 3, the rotor assembly 30 generally
comprises a plurality of components including an annular first
rotor 42, an annular second rotor 44 disposed below the first rotor
42, and at least one annular thermoelectric device 46 interposed
between, and in thermal communication with, the first rotor 42 and
the second rotor 44. The thermoelectric device is also known as a
Peltier device which comprises at least one pair of dissimilar
materials connected electrically in series and thermally in
parallel, and typically comprises a series of n-type and p-type
semiconductor elements connected electrically in series and
thermally in parallel. Depending on the direction of current
passing through the thermoelectric device 46, one surface will be
heated and the opposing surface will be cooled. The thermoelectric
device 46 generates a temperature differential that causes heat to
transfer by conduction through the rotors 42, 44. The greater the
temperature differential, the greater the rate of heat transfer.
Current thermoelectric devices can generate a temperature
differential of 70.degree. C. across the opposing surfaces of the
thermoelectric device, and if the devices are stacked, temperature
differentials of 130.degree. C. are currently possible. The
temperature differentials and efficiencies are expected to increase
as the technology improves.
[0041] The rotors 42, 44 comprise annular heat exchangers in direct
thermal communication with the thermoelectric device 46 to conduct
heat throughout the rotors 42, 44, primarily by thermal conduction
to thereby form a short thermal path length between the rotors 42,
44 and the thermoelectric device 46. Depending on the material and
construction of the rotors 42, 44, the rate of thermal conduction
will vary. The rotors 42, 44 also allow air to pass outward, such
as in a radial direction, through the heat exchanger, and further
comprise blades of fans that cause the air to pass outward through
the rotors 42, 44. The heat exchanger thus forms the fan that
causes the air to flow through the heat exchanger. Alternatively
phrased, the fan that generates the air flow also forms the heat
exchanger. In one embodiment, the fins of the heat exchanger
comprise the blades or airfoils of the fan generating the air flow.
Alternately, the heat exchanger could comprise a series of heat
exchange surfaces that are configured to generate an airflow when
the surfaces are rotated.
[0042] The rotors 42, 44 are advantageously formed by taking a
length of heat exchanger of aluminum or copper that is formed from
a flat strip of metal having corrugated or accordion-like pleats
folded so heat sinks and sources can be connected at the ends of
the pleats where the metal folds to change direction. The pleats
are orientated so air can flow along the corrugations of the heat
exchanger. The opposing ends of that length of heat exchanger are
curved toward each other, and then overlapped and fastened together
either mechanically or by thermal or adhesive bonding. This bending
forms the previously straight length into a circle so the air flows
radially through what is now a circular heat exchanger. In this
annular configuration the heat exchanger can effectively act as the
blades of a squirrel cage fan or a circular fan. This method is
advantageously used to form both the first rotor 42 and the second
rotor 44.
[0043] In the illustrated embodiment, the first rotor 42 is located
on the supply side of the heat exchanger that supplies conditioned
air to a user, and has an outer diameter that is smaller than the
diameter of the second rotor 44. The second rotor 44 is located on
the waste side of the system and exhausts conditioned air,
advantageously to a location that does not direct air to the supply
side or that otherwise directs air to a location that could affect
the user. Each of the components are axially aligned to rotate
about a central axis aligned with a drive shaft or axle 52 of motor
50. A disc-shaped connector 51 having a central aperture is
disposed on top of the first rotor 42 and the motor 50. The motor
50 may be directly coupled to the axle 52 or could be indirectly
coupled, such as via a gear assembly.
[0044] The connector 51 mechanically couples at least one of the
shaft 52 or motor 50 to the first rotor 42 so that the motor 50 is
configured to rotatably drive the first rotor 42, the
thermoelectric device 46, and the second rotor 44 about a common
axis, as described in more detail below. The interior diameter of
rotors 42, 44 is advantageously large enough to allow motor 50 to
be inserted inside the space formed inside the annular rotors 42,
44, to minimize the height of the unit along the longitudinal axis
about which rotors 42, 44 rotate.
[0045] As shown in FIG. 3, the rotor assembly 30 is mounted within
the outer housing 32 on a drive axle 52 that, in the illustrated
embodiment, is journaled at opposing ends of the axle on shaft
bearings 54 which are advantageously mounted to walls 31, 33. The
drive axle 52 of the rotor assembly 30 is axially aligned with the
first and second inlets 38 and 40 of the outer housing 32. -The
outer housing 32 could also be equipped with only a single inlet or
with more than two inlets.
[0046] The plane of the thermoelectric device 46 defines a boundary
line 56 that divides the interior cavity 29 into an upper portion
or supply side 58 and a lower portion or waste side 60. The first
rotor 42 is located within the upper portion or supply side 58 and
the second rotor 44 is located within the lower portion or waste
side 60.
[0047] As best shown in FIG. 3, the rotor assembly 30 further
includes a first annular plate 63 that is disposed between a top
edge of the thermoelectric device 46 and a bottom edge of the first
rotor 42. A second annular plate 65 is disposed between a bottom
edge of the thermoelectric device 46 and the top of the second
rotor 44 so that the thermoelectric device 46 is interposed between
the first and second plates 63 and 65. The first and second plates
63 and 65 are preferably manufactured of a material that is
thermally conductive but is electrically insulative, such as, for
example, alumina. In one embodiment, a heat-resistant,
thermally-conductive adhesive, such as silver-filled silicon
adhesive, is used to mount the first rotor 42 to the first plate 63
and the second rotor 44 to the second plate 65. Alternately, plates
63 and 65 may be omitted and the first and second rotors 42 and 44
may be directly attached to the thermoelectric device 46.
[0048] An annular, disc-like insulation member 64 of thermally
insulated material extends from between the rotors 42, 44, radially
outward and ends before it hits the inside of the side walls 35.
Advantageously the member 64 is positioned on top of the second
annular plate 65 adjacent the inner and outer periphery of the
thermoelectric device 46 and is placed generally in the plane
containing boundary line 56. The insulation member 64 is
dimensioned to extend radially inward and outward from the
thermoelectric device toward the motor 50 along the boundary line
56. A gap 66 is defined between the outer periphery of the
insulation disc 64 and the interior surface of the outer housing
32, with the gap 66 forming an air bearing to reduce the passage of
air across the gap 66.
[0049] As shown in FIGS. 3 and 4, a thin and flexible annular seal
70 of thermally insulated material is positioned so as to extend
radially inward from the interior surface of the outer housing 32
generally along the boundary line 56. The annular seal 70 is
preferably sized so that it overlaps, but does not contact the
adjacent surface of the insulation member 64. The annular seal 70
cooperates with the insulation member 64 to define a labyrinth seal
around the outer periphery of the member 64 that thermally
insulates the upper portion or supply side 58 of the interior
cavity 29 from the lower portion or waste side 60 of the interior
cavity 29. The insulation member 64 and annular seal 70 prevent
significant heat convection between the waste and main sides. The
annular seal 70 can be in the form of an air bearing that
facilitates rotation of the rotor assembly 30. The insulation
member 64 may comprise any of a wide variety of heat resistant,
thermally-insulative materials, such as expanded polypropylene.
[0050] With reference to FIG. 4, at least a portion of the interior
surface of the housing 32 advantageously is coated with a wicking
material 78 that is adapted to absorb and conduct moisture. The
wicking material 78 extends between the upper and lower portions
58, 60, and advantageously comprises a woven cotton fabric that has
been texture coated to prevent microbe growth. The wicking material
78 absorbs condensed moisture expelled by centrifugal force from
whichever rotor 42, 44 produces the condensation, and conducts the
moisture to the other rotor where it is evaporated by the heated
air--in order to avoid accumulation in the interior cavity 33 and
in passages distributing the cooled air. Advantageously the wicking
material 78 absorbs enough moisture to prevent accumulation in the
downstream passages in fluid communication with whichever rotor 42,
44 is cooled prompting a potential for condensation.
[0051] The annular seal 70 must allow the wicking material 78 to
pass. Thus, the seal 70 may be connected to an exterior surface of
the material 78, may extend through the material 78 at intermittent
locations, or may connect to side walls 35 at locates where the
material 78 is absent. The material 70 could also extend outside of
the interior cavity 33.
[0052] Referring to FIG. 3, electrically-conductive wires 80 are
electrically coupled to the thermoelectric device 46 to provide an
electrical potential thereto in a well known manner through brushes
84 that are in electrical communication with the rotating drive
axle 52. Because electrical current must be provided to the
thermoelectric device 46 in a closed circuit, two brushes 84 are in
electrical communication with the axle 52 and thermoelectric 46
through brush and slip-ring assemblies known in the art. Other
electrical connections, such as, for example, an inductive
coupling, can be devised given the present disclosure.
[0053] FIGS. 5 and 6 are top and side views, respectively, of the
first rotor 42. The structure of the second rotor 44 may be
identical to that of the first rotor 42, although the respective
dimensions may differ. The following more detailed description of
the first rotor 42 is therefore equally applicable to that of the
second rotor 44. The first rotor 42 comprises a strip of corrugated
metal having two connected ends so that the first rotor 42 is
annular in shape. The corrugations or accordion-like pleats in the
first rotor 42 form a series of radially-extending fins or blades
91 that define a series of radially-extending chambers or spaces 92
therebetween. Referring further to FIG. 4, the width (i.e., the
circumferential distance between adjacent fins 91) of the chambers
92 gradually increases moving radially outward from a center point
90 of the first rotor 42. Each rotor 42 and 44 has an inner radius
R.sub.1 and an outer radius R.sub.2. The spacing between adjacent
fins 91 is sufficiently wide at the inner radius R.sub.1 to allow
air flow radially outward through the rotor 42.
[0054] In the illustrated embodiment, the blades 91 comprise
generally flat walls that are connected and extend radially outward
from a center point 90 on the rotational axis of the rotor 42. This
design is not believed optimum from the aerodynamic viewpoint of
moving the maximum volume of air through the rotor 42 for a given
rotational speed or rotor size. The blades 91 may also be
aerodynamically configured to provide various airflow profiles. For
example, the blades 91 may be s-shaped, c-shaped, etc. Alternately,
the blades 91 may comprise any type of straight or curved surface
that produces an airflow when the surfaces are rotated.
[0055] The outer radius R.sub.2 preferably ranges from
approximately 12-75 mm when incorporated into a temperature control
system for a motor vehicle seat. The radial length of the blade 91,
the difference between the inner radius R.sub.1 and outer radius
R.sub.2, is approximately 10-40 mm when the heat exchanger 28 is
incorporated into a temperature control system for a motor vehicle
seat, as described below with reference to FIG. 7. The blades 91
may have a height measured along the rotational axis, in the range
of approximately 6-15 mm when used with car seats. Adjacent blades
91 are preferably spaced apart a distance of approximately 0.5-2 mm
for a temperature control system for a seat. The thickness of the
blades 91 when made of copper or aluminum is preferably in the
range of approximately 0.05-0.2 mm when incorporated into a car
seat.
[0056] In an alternative embodiment, the thermoelectric device 46
is replaced by a resistive heating element which converts
electrical energy into heat energy. This resistive heating element
does not have the cooling capability of the thermoelectric device
46, but it does provided heat air which may have wider
applicability in certain climates.
[0057] Referring to FIG. 3, in operation, the motor 50 rotate the
axle 52 by activating the power source through a control, such as a
manual switch or a thermostatically controlled switch. The motor is
in driving communication with the first rotor 42, the second rotor
44, and the thermoelectric device 46 so as to rotate those
components about the rotational axis of drive axle 52. The rotation
of the first rotor 42 creates a pressure differential that draws
air into the supply side 58 of the interior cavity 29 through the
first inlet 38. The air flows into the spaces 92 and radially
outward across the blades 91 of the first rotor 42. The rotation of
the rotor 42 imparts centrifugal force to the air that propels the
air radially outward from rotor 42 so that the air travels out of
the supply side 58 of the interior cavity 29 through the first
outlet 34.
[0058] In a similar manner, the second rotor 44 also rotates and
draws are into the lower portion or waste side 60 of the interior
cavity 29 through the second inlet 40 (or through either inlet 38
or 40 if only one inlet is provided). The air passes through the
spaces 92 between the blades 91 of the second rotor 44, radially
outward across blades 91, and is propelled out of the waste side 60
through the second outlet 36. The divider 64 keeps the air flows
from intermingling, and because it is thermally insulated,
maintains a temperature differential between the supply side 58 and
waste side 60.
[0059] The electrical wires 80 also supply an electrical current to
the thermoelectric device 46, advantageously through shaft 52, so
that the thermoelectric device 46 heats the rotor 42 and cools
rotor 44, or cools rotor 42 and heats rotor 44, depending on which
direction the electrical current flows through the thermoelectric
divide 46. As the air flows across the blades 91 of the first rotor
42 and the second rotor 44, the air is either heated or cooled
through a convective process. That is, on the hot side of the
thermoelectric device 46, heat is transferred to the air from the
heated fins of the rotor as the air flows thereover. On the cooled
side of the thermoelectric device, heat is absorbed from the air as
the air passes over the cooled rotor to thereby cool the air. The
heat exchanger thus produces heated air through one outlet and
cooled air through the other outlet. The heated or cooled air is
then directed to the appropriate location in the seat for heating
or cooling the passenger seat. The air with the undesired
temperature is vented to a location where it will not noticeably
affect the vehicle passengers. Preferably, the waste air is vented
to a location such that the waste air is not drawn back into the
outer housing 32.
[0060] The first rotor 42 and the second rotor 44 simultaneously
function as fan units for generating an airflow at a predetermined
pressure and also as heat exchangers for transferring heat to and
from the airflow and maintaining the airflow at the desired
temperature. By combining the heat exchanger function into the fan
that generates the air flow, several advantages are achieved. By
forming the heat exchanger into an annular fan and nesting the
motor inside the heat exchanger/fan, space and weight savings are
achieved.
[0061] Currently used systems are about 45 mm in height, which is
too big for many motor vehicles. Newly designed systems are about
30 mm in height, but a great number of motor vehicles still have
seats too small to accommodate such fans underneath or around the
seat, and few can accommodate that size within the seat. Fan and
heat exchanger units 28 with a height below about 20-30 mm will
accommodate a majority of automotive seats, and the present
invention can allow such construction. But systems 28 of the
present invention having a height of about 16 mm are believed
possible, which is about half the height of the smallest systems
currently available, and small enough to allow the use of the
heating/cooling system inside a significant majority of seat
bottoms and seat backs currently used in motor vehicles.
[0062] This height reduction represents the distance between walls
31, 33 and associated ducting to carry the air to the location
within the seat. The design of rotors 42, 44 can be used to vary
the dimensions, with the heat exchanger surface area of blades 91
being a compromise between blade height, blade length, and
diameter, and that area must be offset by the change in performance
and rotational speed of the fan. Also, shorter rotors 42, 44 can be
achieved by increasing the diameter of the rotors or by operating
the rotors at higher speeds, which may increase noise.
[0063] Further, the design eliminates the interconnecting ducting
between the fan and the heat exchanger, saving weight, size and
pressure losses in the transmitted air. The small size also allows
placement of heating and cooling systems directly in the seat
bottoms and backs, further reducing the need for ducting, and
especially reducing the need for ducting across the pivoted joints
between seat bottoms and backs. The reduced ducting and its
associated pressure losses and performance degradation, also allows
the use of smaller fans, which use less energy and generate less
noise.
[0064] Moreover, the consolidation of several parts and functions
allows a reduced manufacturing cost and an increase in efficiency
of the system. The drag normally caused by passing the air over the
heat exchanger is significantly reduced because the heat exchanger
forms the fan blades that generate the air flow. Thus, savings of
about 25%-35% of the fan power are believed possible. Further,
adequate heating and cooling of a motor vehicle seat are believed
to use about 1000 watts less than the power needed to provide the
same comfort level to a passenger using the heating and cooling
system of a motor vehicle--which must heat and cool the entire
passenger compartment rather than the localized environment of the
seat on which the passenger sits.
[0065] A further advantage is the reduction of noise because two
small fans can be used. The rotors 42 and 44 preferably operate at
a rotational speed in the range of approximately 2,000-5,000
revolutions per minute, although speeds of about 1000 rpm may be
desirable in some applications, and higher speeds of up to 10,000
revolutions per minute in others. The rate of airflow of the main
side of the heat exchanger is in the range of approximately 2-6
cubic feet per minute at a pressure of about 0.2-1 inches of water,
with a flow rate of about 3-4 cfm being preferred. The rate of
airflow of the waste side of the heat exchanger is in the range of
approximately 2-10 cubic feet per minute, at a pressure of about
0.3-0.4 inches of water. The rotors 42, 44 with the blades acting
as conductive heat exchanger as well as fan blades to move air,
provide these needed air flows. In typical automobile use, 12 volt
motors drive the rotors 42, 44 This fan flow rate and pressure are
smaller than in prior seat systems where the fan had to generate
enough pressure and air flow to provide air to both the bottom and
backrest portions of the seat.
[0066] To further enhance the above advantages, in a further
embodiment the blades 91 may comprise a series of independent walls
mounted on an annular plate where the blades 91 are contoured or
curved to provide a preselected airflow profile when the first
rotor 42 rotates, advantageously a profile that is more efficient
than the straight blades 91 described above while still conducting
heat well and maintaining a low manufacturing cost. Further, the
blades 91 as illustrated and described above are not optimized for
minimizing noise, and noise reduction is an important consideration
for equipment operating inside the passenger compartment of motor
vehicles. A more refined design of the blades 91 could
advantageously reduce noise. It is believed that the level of noise
generated by rotation of the rotors 42 and 44 generally decreases
as the number of blades 91 increases. To accommodate the thermal
transfer use of the rotor blades 91, more blades are likely to be
required than may be desirable for optimum performance if the
rotors 42, 44 were designed solely for use as fans to move
air--without regard to the heat transfer function and noise of the
rotors 42, 44.
[0067] The compact design also reduces the weight of the unit. As
mentioned, the blades 91 are preferably manufactured of a thermally
conductive material, such as pure annealed aluminum, carbon, and
copper, which are known to be highly thermally conductive
materials. Other material may be used as scientific advances in
conductive material are made. While copper is heavier than
aluminum, its increased thermal conduction properties offer
advantages and design options in configuring the rotor blades 91 to
perform both heat transfer and air movement functions. The blades
preferably have a thermal conductivity rate of greater than about
12 w/m.multidot..degree. K.
[0068] The conditioned air that flows out of the first and second
outlets 34 and 36 may be put to any of a wide variety of uses. In
one embodiment, the heat exchanger 28 is incorporated into a
ventilation system for vehicle seats, such as for automobiles, as
described below with reference to FIG. 7. It will be appreciated
that the heat exchanger 28 could also be used in other applications
as well.
[0069] Referring to FIG. 7, an automobile seat temperature control
system 112 comprises at least one seat 114 and a pair of heat
exchangers 28a and 28b (referred to collectively as "heat
exchangers 28") mounted therein. The heat exchangers 28 are of the
type described above with reference to FIGS. 1-6. In the
illustrated embodiment, the first heat exchanger 28a is mounted
within a seat bottom 118 and the second heat exchanger 28b is
mounted within a seat back 120. The heat exchangers may also be
mounted adjacent any portion of the seat 114, such as below or on
the side of the seat 114.
[0070] The seat 114 has a series of channels 116 for the passage of
air. An outer covering 117 of the seat 114 surrounds a padding
layer 119 through which the channels 116 extend. The outer covering
117 is desirably perforated or air-permeable to allow air to flow
therethrough from the channels 116. The seat 114 also includes seat
bottom 118 and seat back 120 extending upwardly therefrom for
supporting a human body in a sitting position. The outer covering
117 may comprise any well known material for covering seats, such
as perforated vinyl, cloth, perforated leather, etc. The padding
layer of the seat 114 may comprise any well-known material for
enhancing user comfort, such as reticulated foam.
[0071] With reference to FIG. 7, the first outlet 34 (FIG. 1) of
the first heat exchanger 28a is attached to channels 116 that
extend through the seat back 114. The first outlet 34 of the second
heat exchanger 28 is attached to the channels 116 that extend
through the seat bottom 118. Each of the heat exchangers 28 is
electrically coupled to a power source via a control switch so that
a user may selectively power the heat exchangers via the power
switch. A control switch is also coupled to the heat exchangers 28
for reversing the polarity of the electrical current applied to the
heat exchangers 28 in a well known manner. The control switch is
used to switch the heat exchangers 28 between a heating and a
cooling mode. In the heating mode, the heat exchangers 28 pump
heated air into the seat 114. In the cooling mode, the heat
exchangers pump cooled air into the seat 114. The heat exchangers
28 may also be coupled to separate power and temperature
controllers for providing independently-controlled conditioned
airflow to the seat back 114 and the seat bottom 120.
[0072] A feedback control system including a temperature sensor,
such as a thermocouple, may also be provided. The system 112 may
also be equipped with a control system for varying the speed of the
rotors 42 and 44 to vary the flow rate. Those skilled in the art
will appreciate that any of a wide variety of control devices may
also be provided.
[0073] The channels 116 may comprise a series of plastic ducts or
pipes that are coupled to at least one of the first and second
outlets 34, 36 of the heat exchangers 28 and disposed within the
seat 114. Advantageously, the ducts may be formed by heat sealing
the plastic foam of which the seat is made, or by coating the duct
with a sealant to reduce air loss through the duct. The channels
could also comprise air gaps within a permeable material, such as
reticulated foam, that allow air to flow therethrough.
Additionally, the channels may comprise any type of passage for the
flow of air, such as ducts, pipes, small holes, etc.
[0074] Preferably, a main duct 137 is connected to the first outlet
34 for routing the cooled or heated air to the seat 114 surface 117
via the channels 116. A waste duct 138 is connected to at least the
second outlet 36 for routing the unwanted "waste" air to the
outside environment away from the passenger occupying seat 114.
[0075] In operation, the power switch is activated to supply an
electrical current to the heat exchangers 28. As discussed above,
the thermoelectric device 46 and the main and second rotors 42 and
44 combine to generate a flow of heated or cooled air which is
routed to the main ducts 137 and throughout the seat 114. The
conditioned air flows out of the channels 116 through the permeable
outer covering 117 to thereby cool or heat the occupant of the seat
114. Desirably, the waste air is routed away from the seats 114
through the waste ducts 138.
[0076] The waste ducts 138 can advantageously vent below the seat
bottom 118 because the heating and cooling system in the passenger
compartment can produce typically over 20 times the amount of heat
or cool air as is exhausted through waste duct 138. As long as the
waste ducts 138 do not vent directly on a passenger, toward a
passenger, or on the inlets 38, 40 the environmental heating and
cooling equipment will amply dissipate the output from waste ducts
138. A waste duct 138 connecting unit 28a located in the back
portion 119 can vent below the seat bottom 118 without having a
duct extend across the pivoted joint between the bottom portion 118
and backrest 119. Because the airflow of waste duct 138 is downward
toward the seat bottom 118, two aligned openings, one at the bottom
of back portion 119, and one in the seat bottom 118, are sufficient
to convey the air to below the seat bottom 118.
[0077] As shown in FIG. 8, in another embodiment, the heat
exchanger 28 is incorporated into a cooler, such as an ice chest
140. In the illustrated embodiment, the ice chest 140 comprises a
rectangular box that includes a base wall 144 and four side walls
146 extending upwardly therefrom. A lid 150 is pivotably mounted on
the four side walls 146 in a well known manner to provide access to
a storage space 152 defined by the walls of the ice chest 140. The
walls of the ice chest are desirably insulated in a well known
manner to maintain the temperature of the storage space 152.
[0078] FIG. 9 is a cross-sectional side view of the lid 150 of the
ice chest 140. At least one heat exchangers 28 of the type
described above with reference to FIGS. 1-6 is disposed within the
lid 150. The heat exchanger 28 is connected to a power source (not
shown), such as a battery of the proper voltage and power, and is
configured to operate in a cooling mode such that it outputs a flow
of cold air at the first fan 42, as described above. The heat
exchanger 28 is rotatably mounted within the lid 150 such that the
waste side of the heat exchanger 28 is positioned between top and
bottom walls 156, 158, respectively, with an insulation member
positioned to thermally separate the main and waste sides. The main
side of the heat exchanger 28 is disposed immediately below the
bottom wall 158. A cover unit 159 is positioned over the main side
of the heat exchanger 28. The cover unit 159 includes a series of
apertures to allow air to flow through the main side of the heat
exchanger 28. The main side of the heat exchanger 28 is positioned
within the storage space 152 of the ice chest 140 when the lid 150
is closed.
[0079] The waste side of the heat exchanger 28 is disposed between
the top and bottom walls 156 and 158 of the lid 150. An inlet 38
extends through the top wall 156 to allow air to flow into and out
of the heat exchanger 28. The lid 150 is preferably filled within
insulative material around heat exchanger 28.
[0080] In operation, the heat exchanger 28 is powered in the
cooling mode so that the first fan 42 generates a flow of cooled
air within the storage space 152 when the lid 150 is closed. In
this manner, the storage space 152 is maintained at a relatively
cool temperature. The heated waste air is routed to the outside
environment such as through an outlet in the top wall 156 of the
lid 150. Any of a wide variety of articles, such as food, may be
stored within the storage space 152.
[0081] With reference to FIG. 10, there is shown a fan unit 200
that is configured to be mounted adjacent or within a standard
desk. The fan unit 200 includes a housing 202 that is pivotably
mounted to base 204. The housing 202 is substantially cylindrical
shaped and includes a conditioned air outlet 206 and one or more
waste air outlets 208 around the periphery of the housing 202. An
air inlet 210 is located in the housing 200 opposite the
conditioned air outlet 206. A control switch 212 and a power cord
214 are coupled to the base 204 for selectively powering the fan
unit 200 and/or the thermoelectric element 232 in a well known
manner.
[0082] FIG. 11 is a cross-sectional view of the fan unit 200. An
annular duct 216 is disposed within the housing 202 and defines the
conditioned air outlet 206. A second duct 218 defines the waste air
outlets 208. A drive axle 220 is rotatably mounted within the
housing so as to be axially-aligned with the conditioned air outlet
206. In the illustrated embodiment, a motor 222 is drivingly
coupled to the drive axle 220 via a drive belt 224. A rotor
assembly 226 is mounted to the drive axle 220 so that the rotor
assembly rotates with the drive axle 220.
[0083] The rotor assembly 220 comprises a main fan 228 adjacent the
conditioned air outlet 206 and an annular waste fan 230 on the side
of the main fan 228 opposite the conditioned air outlet 206. A
thermoelectric element 232, such as a Peltier heat exchanger, is
interposed between the main and waste fans 228 and 230. The main
fan 228 has a circumference that is less than or equal to the
circumference of the conditioned air outlet 206 so that the main
fan is configured to cause air to flow through the conditioned air
outlet 206. The waste fan 230 is positioned so to communicate with
the waste outlet 208. The main and waste fans 228 and 230 may
comprise any type of device that is configured to produce an air
flow upon rotation.
[0084] In one embodiment, the fans comprises flat discs having
louvers 234 punched therethrough. The fans are preferably
manufactured of a highly thermally conductive material.
[0085] In operation, the motor 22 is powered through a power source
(not shown) in a well known manner. The thermoelectric device 232
cools the main fan 228 and heats the waste fan 230 (or vice versa)
in the manner described above with respect to the previous
embodiments. The fans also rotate to produce a flow of conditioned
and waste air through the conditioned air outlet 206 and the waste
air outlet 208, respectively. The air may be routed to cool a
desired location, such as beneath a desk.
[0086] If desired, ducts, hoses and other devices may be connected
to the outlets to further direct the flow of air therefrom.
[0087] FIG. 12 shows another embodiment of a heat exchanger
comprising a fan unit 170 having a plurality of air flow generating
members, such as blades 172, that rotate about an drive axle 174. A
motor 176 is drivingly connected to the axle 174, either directly
or indirectly, such as through a gear mechanism. One or more
electrical heat generating devices, such as electrical resistors
180, are mounted on the blades 172. The resistors may be embedded
within the blades 172 or may be painted thereon, such as with
adhesive.
[0088] In operation, the resistors 180 are heated by applying an
electrical current thereto and the axle 174 is rotated via the
motor 176. The blades 172 generate an airflow, which is heated by
the resistors through a convective process. The fan unit 170 is
thereby used to generate a heated airflow.
[0089] Given the above disclosure, other variations of this
invention will be known to those skilled in the art. For example,
the rotors 42, 44 are shown connected to the rotating shaft 52 by
plate 51 located adjacent the first or upper wall 31. In this
configuration the interior cavity formed by the inner diameters of
rotors 42, 44 are interconnected. It is believed possible to have
the plate 51 contoured to the exterior shape of the top portion of
motor 50 and then extend radially outward at about the plane
containing the thermoelectric 46. That would place a physical
separation between the air flows entering rotors 42 and 44. It is
also believed possible to form the housing of motor 50 with a
radial flange extending radially outward at about the plane
containing boundary line 56, with the motor 50 rotating, and thus
provide a physical separation between the air flows entering the
rotor 42 and 44.
[0090] The above description refers primarily to the use of the
method and apparatus in a vehicle seat. But the method and
apparatus are equally applicable to other seats, including, but not
limited to, theater seats, office seats, airplane seats, seats
found in the home such as sofas and recliners, hospital seats for
patients, hospital beds for bedridden patients, and wheelchairs.
The method and apparatus is especially useful where a localized
flow of conditioned air is desired.
[0091] The above description refers to the passage of air through
the heat exchangers, but the present invention is not limited to
air as other gases may be used with the present apparatus and
method. Indeed, some gases, such as helium, have greater thermal
conductivity than air and are desirable in certain applications,
while other gasses such as oxygen, nitrogen or argon may be more
desirable in other applications. A variety of gases and gas
mixtures can be used as the particular application requires.
[0092] Further, liquids can be used with the present invention by
applying appropriate liquid seals and insulators known in the art
to keep the liquid circulating through the heat exchanger from
making electrical contact with the thermoelectric device and any
other electrical devices. Thus, liquids such as water and
antifreeze are contemplated for use with the present method and
apparatus, as are liquid metals such as liquid sodium. The
particular liquid used will depend upon the application. The
increased thermal conductivity achieved by passing the liquids over
the rotating heat exchanger offer the possibility of increased heat
conduction over less dense and less conductive gases. Whether a
liquid or gas is most advantageous will vary with the particular
application. For ease of reference, the term "fluid" will be used
to refer to a gas, a liquid or both.
[0093] Because the temperature change available from a
thermoelectric can be significant, the rotating heat exchanger of
the present invention has potential applicability to a wide variety
of uses other than the seat, fan and cooler described herein. The
method and apparatus of described herein are generally applicable
to any situation where there is a desire to pump a thermally
conditioned fluid. Such applications include constant temperature
devices, as for example devices using a reference temperature as in
a thermocouple assembly. Constant temperature baths for laboratory
equipment and experiments is another exemplary application, as for
instance growing bacteria cultures or cell cultures. The method and
apparatus described herein are particularly useful where lower flow
rates and/or smaller temperature changes are desired, but the
invention is not so limited and may find application in situations
requiring large flow rates and/or substantial temperature
differences.
[0094] By placing a temperature sensor at a predetermined location,
whether on the heat exchanger, the rotating fan, upstream or
downstream of the heat exchanger, and electronically controlling
the thermoelectric and the fan rotation, a controlled stream of
thermally conditioned fluid can be provided to maintain the
temperature at a predetermined temperature, or to provide
predetermined thermal conditions. Thus, the invention provides
advantages where localized thermal control is desired, as in
vehicle seats, waterbeds, aquariums, water coolers, and cooling of
non-carbonated beverages such as wine and punch. In these
applications the temperature is controlled to a fairly constant
temperature, or controlled within a fairly narrow temperature range
of less than about a 5.degree. F. variation above or below a
predetermined temperature, and more typically within a 1-2.degree.
F. variation on either side of a predetermined temperature. Such
temperature control systems are known to those skilled in the art
and their incorporation and use with the present method and
apparatus are not described in detail herein.
[0095] Further, this device and method find particular application
in situations where a fluid of differing temperature is desired at
various times. The fan portion of the device may be operated with
the thermoelectric heating or cooling aspects being activated only
when desired to thermally condition the fluid flowing through the
fan. Thus a heated, cooled, or neutral temperature fluid can be
provided by the same device and method.
[0096] Although the foregoing description of the preferred
embodiment of the preferred invention has shown, described, and
pointed out certain novel features of the invention, it will be
understood that various omissions, substitutions, and changes in
the form of the detail of the apparatus as illustrated as well as
the uses thereof, may be made by those skilled in the art without
departing from the spirit of the present invention. Consequently,
the scope of the present invention should not be limited by the
foregoing discussion, which is intended to illustrate rather than
limit the scope of the invention.
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