U.S. patent application number 12/178458 was filed with the patent office on 2009-01-29 for radial thermoelectric device assembly.
Invention is credited to JOHN LOFY.
Application Number | 20090026813 12/178458 |
Document ID | / |
Family ID | 40281807 |
Filed Date | 2009-01-29 |
United States Patent
Application |
20090026813 |
Kind Code |
A1 |
LOFY; JOHN |
January 29, 2009 |
RADIAL THERMOELECTRIC DEVICE ASSEMBLY
Abstract
According to some embodiments, a heat exchange device includes a
housing, having at least one inlet, at least one first outlet and
at least one second outlet. The device further includes an impeller
positioned within the housing and configured to receive fluid from
the at least one inlet and transfer it to at least one of the first
outlet and the second outlet. In addition, the device comprises one
or more heat exchange modules configured to receive a volume of
fluid and selectively thermally condition it before said fluid
exits through the first outlet or the second outlet. In one
embodiment, the heat exchange module is partially or completely
positioned within the housing.
Inventors: |
LOFY; JOHN; (Claremont,
CA) |
Correspondence
Address: |
KNOBBE MARTENS OLSON & BEAR LLP
2040 MAIN STREET, FOURTEENTH FLOOR
IRVINE
CA
92614
US
|
Family ID: |
40281807 |
Appl. No.: |
12/178458 |
Filed: |
July 23, 2008 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
60951431 |
Jul 23, 2007 |
|
|
|
Current U.S.
Class: |
297/180.15 ;
165/104.31 |
Current CPC
Class: |
F25B 21/02 20130101;
B60N 2/5635 20130101; B60N 2/5685 20130101; B60N 2/5692
20130101 |
Class at
Publication: |
297/180.15 ;
165/104.31 |
International
Class: |
A47C 31/00 20060101
A47C031/00; F28D 15/00 20060101 F28D015/00 |
Claims
1. A heat exchange device comprising: a housing, having at least
one inlet, at least one first outlet and at least one second
outlet; an impeller positioned within the housing, the impeller
configured to receive fluid from the at least one inlet and
transfer it to at least one of the first outlet and the second
outlet; and at least one heat exchange module configured to receive
a volume of fluid and selectively thermally condition said fluid
before said fluid exits through the first outlet or the second
outlet; wherein the heat exchange module is positioned within the
housing.
2. The device of claim 1, wherein the heat exchange module
comprises a thermoelectric device.
3. The device of claim 2, wherein the thermoelectric device
comprises a Peltier circuit
4. The device of claim 2, wherein the heat exchange module further
comprises heat exchangers, the heat exchangers being in thermal
communication with the thermoelectric device, wherein at least a
portion of the volume of fluid is directed through or near such
heat exchangers.
5. The device of claim 4, wherein the heat exchangers are in
thermal communication with a substrate, the substrate comprising a
thermally conductive and electrically non-conductive material.
6. The device of claim 1, wherein the heat exchange module is
positioned along an outer perimeter portion of the interior of the
housing.
7. The device of claim 6, wherein the heat exchange module extends
along substantially the entire perimeter portion of the
housing.
8. The device of claim 1, wherein the device comprises at least two
separate heat exchange modules.
9. The device of claim 8, wherein the heat exchange modules are
substantially equally spaced apart within the interior of the
housing.
10. The device of claim 8, wherein the heat exchange modules are
electrically connected to each other.
11. The device of claim 10, wherein the heat exchange modules are
electrically connected to each other using end couplings, said end
coupling comprising extensions of a substrate of a thermoelectric
device.
12. The device of claim 4, wherein the heat exchange module
comprises a set of upper heat exchangers in fluid communication
with an upper side of the thermoelectric device and a set of lower
heat exchangers in fluid communication with a lower side of the
thermoelectric device, wherein the at least one first outlet is in
fluid communication with the set of upper heat exchangers and the
at least one second outlet is in fluid communication with the set
of lower heat exchangers.
13. The device of claim 1, wherein the at least first outlet is
located along a sidewall portion of the housing and wherein the at
least second outlet is located along a bottom portion of the
housing.
14. The device of claim 1, wherein the impeller is configured to
substantially deliver an equal volume of fluid to the at least
first outlet and the at least second outlet.
15. The device of claim 4, wherein the heat exchangers are oriented
along a direction that generally coincides with a fluid flow
direction approaching said heat exchangers.
16. The device of claim 1, wherein the device is configured to
supply thermally conditioned fluid to a seat assembly.
17. The device of claim 1, wherein the heat exchange module is
configured to accommodate thermal stresses when in use.
18. The device of claim 17, wherein a substrate of the heat
exchange module comprises at least one expansion joint.
19. A climate controlled seat assembly comprising: a seat bottom
portion; a seat back portion; a heat exchange device comprising: a
housing, having at least one inlet, at least one first outlet and
at least one second outlet; an impeller positioned within the
housing, the impeller configured to receive fluid from the at least
one inlet and transfer it to at least one of the first outlet and
the second outlet; and at least one heat exchange module configured
to receive a volume of fluid and selectively thermally condition
said fluid before said fluid exits through the first outlet or the
second outlet; wherein the heat exchange module is positioned
within the housing; wherein thermally conditioned fluid exiting the
first outlet or the second outlet of the heat exchange device is
configured to be delivered within an opening of at least of the
seat bottom portion and the seat back portion; and wherein the
thermally conditioned fluid is configured to be transferred toward
a occupant of the seat assembly.
20. The assembly of claim 19, wherein the heat exchange device is
mounted to a surface of the seat back portion or the seat bottom
portion.
21. The assembly of claim 19, wherein at least one of the first
outlet and the second outlet is configured to generally align with
and be in fluid communication with the opening of the seat bottom
portion or the seat back portion.
22. A method of thermally conditioning a fluid comprising
positioning at least one heat exchange module within a housing of a
blower; wherein the at least one heat exchange module configured to
receive a volume of fluid and selectively thermally condition said
fluid before said fluid exits through an outlet of the housing; and
selectively heating or cooling said fluid by electrically
energizing said heat exchange module and activating an impeller of
the blower; wherein the heat exchange module comprises a
thermoelectric device.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the priority benefit under 35 U.S.C.
.sctn. 119(e) of U.S. Provisional Application No. 60/951,431, filed
Jul. 23, 2007, the entirety of which is hereby incorporated by
reference herein.
BACKGROUND
[0002] 1. Technical Field
[0003] This disclosure relates generally to temperature control
devices, and more particularly, to thermoelectric heat exchangers
useful for producing a heated and/or cooled fluid.
[0004] 2. Description of the Related Art
[0005] U.S. Pat. No. 5,626,021 describes a temperature control
system that comprises a thermoelectric unit and a blower, which can
be used to provide heated and/or cooled air to a surface of an
automobile seat. Such a system can also be used to provide heated
and/or cooled air to an enclosed space, bed, chair, other seating
assembly and/or directly to a user.
[0006] With respect to automobile seats, in such arrangements, the
heated and/or cooled air can be distributed to the occupant by
passing the air through one or more air ducts formed into the seat
and then through the seat surface to the occupant. The amount of
space available within, below, and around the seat for such
temperature control systems is often severely limited. For example,
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. Furthermore,
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, is often designed to be as small as
possible to reduce the amount of cabin space consumed by the seat,
thereby increasing passenger space and/or decreasing weight.
[0007] Present temperature control systems can be too large to be
mounted within, below or around vehicle seats. Conventional systems
can have a blower five or six inches in diameter generating an air
flow that passes through a duct to reach a heat exchanger that
selectively adjusts the temperature of the air. The heat exchanger
can be several inches wide and long, and can be an inch or so
thick. From the heat exchanger the air is transported through ducts
to the bottom of the seat cushion and/or to the back of the seat
cushion. Such systems are often bulky and difficult to fit
underneath or inside car seats.
[0008] The ducting used with these systems can also be 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. The larger fan can
require additional space, may need to be operated at greater speeds
and/or may generate 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. 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. In addition, a more compact and
energy-efficient heating and cooling system also has uses in other
localized conditioned air settings.
SUMMARY
[0009] According to some embodiments, a heat exchange device
includes a housing, having at least one inlet, at least one first
outlet and at least one second outlet. The device further includes
an impeller positioned within the housing and configured to receive
fluid from the at least one inlet and transfer it to at least one
of the first outlet and the second outlet. In addition, the device
comprises one or more heat exchange modules configured to receive a
volume of fluid and selectively thermally condition it before said
fluid exits through the first outlet or the second outlet. In one
embodiment, the heat exchange module is partially or completely
positioned within the housing.
[0010] In some embodiments, the heat exchange module comprises a
thermoelectric device. In other arrangements, the thermoelectric
device comprises a Peltier circuit. In another embodiment, the heat
exchange module further comprises heat exchangers that are in
thermal communication with the thermoelectric device, such that at
least a portion of the volume of fluid is directed through or near
such heat exchangers. In one arrangement, the heat exchangers are
in thermal communication with a substrate that includes a thermally
conductive and electrically non-conductive material.
[0011] In other arrangements, the heat exchange module is
positioned along an outer perimeter portion of the interior of the
housing. In another embodiment, the heat exchange module extends
along substantially the entire perimeter portion of the housing. In
still another arrangement, the device comprises at least two
separate heat exchange modules. In one embodiment, the heat
exchange modules are substantially equally spaced apart within the
interior of the housing. In other embodiments, the heat exchange
modules are electrically connected to each other. In one
embodiment, the heat exchange modules are electrically connected to
each other using end couplings, said end coupling comprising
extensions of a substrate of a thermoelectric device.
[0012] According to some arrangements, the heat exchange module
comprises a set of upper heat exchangers in fluid communication
with an upper side of the thermoelectric device and a set of lower
heat exchangers in fluid communication with a lower side of the
thermoelectric device. In one arrangement, the at least one first
outlet is in fluid communication with the set of upper heat
exchangers and the at least one second outlet is in fluid
communication with the set of lower heat exchangers. In another
arrangement, the at least first outlet is located along a sidewall
portion of the housing and wherein the at least second outlet is
located along a bottom portion of the housing.
[0013] In some embodiments, the impeller is configured to
substantially deliver an equal volume of fluid to the at least
first outlet and the at least second outlet. In other arrangements,
the heat exchangers are oriented along a direction that generally
coincides with a fluid flow direction approaching said heat
exchangers. In yet another embodiment, the device is configured to
supply thermally conditioned fluid to a seat assembly, such as, for
example, a vehicle seat, a bed, a sofa, a chair, a wheelchair, a
stadium seat and/or the like. According to some embodiments, the
heat exchange module is configured to accommodate thermal stresses
when in use. In one embodiment, a substrate of the heat exchange
module comprises at least one expansion joint.
[0014] According to other arrangements, a climate controlled seat
assembly comprises a seat bottom portion, a seat back portion and a
heat exchange device. The heat exchange device includes a housing,
having at least one inlet, at least one first outlet and at least
one second outlet, an impeller positioned within the housing, the
impeller configured to receive fluid from the at least one inlet
and transfer it to at least one of the first outlet and the second
outlet and at least one heat exchange module configured to receive
a volume of fluid and selectively thermally condition said fluid
before said fluid exits through the first outlet or the second
outlet. In some arrangements the heat exchange module is positioned
within the housing. In other embodiments, thermally conditioned
fluid exiting the first outlet or the second outlet of the heat
exchange device is configured to be delivered within an opening of
at least of the seat bottom portion and the seat back portion.
Further, in some embodiments, thermally conditioned fluid is
configured to be transferred toward a occupant of the seat
assembly. In some arrangements, the heat exchange device is mounted
to a surface of the seat back portion or the seat bottom portion.
In another embodiment, at least one of the first outlet and the
second outlet is configured to generally align with and be in fluid
communication with the opening of the seat bottom portion or the
seat back portion.
[0015] According to other embodiments, a method of thermally
conditioning a fluid includes positioning at least one heat
exchange module within a housing of a blower. The at least one heat
exchange module is configured to receive a volume of fluid and
selectively thermally condition said fluid before said fluid exits
through an outlet of the housing. The method further comprises
selectively heating or cooling said fluid by electrically
energizing said heat exchange module and activating an impeller of
the blower. In some arrangements, the heat exchange module
comprises a thermoelectric device.
[0016] U.S. Pat. No. 6,606,866 discloses various configurations of
a thermoelectric device (TED) with a radial heat exchanger and
thermoelectric unit that are configured to address many of the
shortcomings discussed above. While representing an improvement
over the art, several aspects of the '866 design have limited its
commercial application. For example, the radial thermoelectric
modules disclosed in the '866 module can be difficult to
manufacture and may result in fatigue damage caused by thermal
expansion forces. In addition, the air flow through the radial heat
exchangers may not be optimized for commercial applications.
[0017] Some embodiments provide an annular heat exchanger system
comprising a heat exchanger module system. The heat exchanger
module system comprising: an inner perimeter defining an opening in
the heat exchanger module system; a thermoelectric device
comprising: a first substrate comprising a plurality of sectors
defining at least a portion of an outer perimeter of the
thermoelectric device; a second substrate; and a plurality of
thermoelectric pellets disposed between the first substrate and the
second substrate.
[0018] Some embodiments provide a heat exchanger module system
comprising: a plurality of heat exchanger modules defining at least
a portion of an outer perimeter and an opening. Each heat exchanger
module comprises: a thermoelectric device comprising a first
substrate, a second substrate, and a plurality to thermoelectric
pellets disposed therebetween; a first heat exchanger thermally
coupled to the first substrate; and a second heat exchanger
thermally coupled to the second substrate.
[0019] Some embodiments provide a heat exchanger module system
comprising: a plurality of heat exchanger modules, wherein each
heat exchanger module comprises: a thermoelectric device comprising
a first substrate, a second substrate, and a plurality to
thermoelectric pellets disposed therebetween; a first heat
exchanger thermally coupled to the first substrate; and a second
heat exchanger thermally coupled to the second substrate; and a
plurality of coupling members coupling at least some adjacent heat
exchanger modules.
[0020] Some embodiments provide a method of manufacturing a heat
exchanger module system comprising: deforming coupling members of a
heat exchanger module system comprising: a plurality of heat
exchanger modules disposed in a substantially linear array; and
coupling members coupling adjacent heat exchanger modules to form a
substantially polygonal heat exchanger module system.
[0021] Some embodiments provide a method for conditioning a fluid,
the method comprising: applying a potential to a thermoelectric
device of a heat exchanger module, wherein the heat exchanger
module comprises a thermoelectric device comprising a first
substrate, a second substrate, a plurality of thermoelectric
pellets disposed therebetween, a first heat exchanger thermally
coupled to the first substrate, and a second heat exchanger
thermally coupled to the second substrate, and the potential
effectively generates a temperature differential between the first
substrate and the second substrate; and flowing fluid through first
and second heat exchangers of a heat exchanger module system. The
heat exchanger module system comprises a plurality of heat
exchanger modules defining at least a portion of a perimeter of the
heat exchanger module system and a perimeter of an opening, each
module comprising an upper portion and a lower portion, and a first
portion of the fluid flows radially from the perimeter of the
opening through the upper portion of the heat exchanger module
system and then radially out of the system and a second portion of
the fluid flow flows radially from the perimeter of the opening
through the lower portion of the heat exchanger module system and
then turns approximately 90 degrees and exits in an axial
direction.
[0022] Some embodiments provide a thermal module for delivering
conditioned air, the module comprising: a housing comprising an
upper portion, lower portion and a side wall extending between the
upper and lower portions, the housing defining an interior cavity
and the upper portion defining, at least in part, an inlet into the
interior cavity, the side wall defining, at least in part, a first
outlet and the lower portion defining, at least in part, a second
outlet; an impeller positioned within the housing, the impeller
comprising a plurality of blades configured to rotate about a
rotational axis and draw air into the housing through the inlet and
then direct the flow in a radial direction towards the side wall; a
thermoelectric heat exchanger system positioned within the housing.
The thermoelectric heat exchanger system comprises: a first heat
exchanger formed about the rotational axis of the impeller axis and
configured such that fluid flows along the first heat exchanger at
least partially in a first direction; a second heat exchanger
formed about the rotational axis of the impeller and positioned
below the first heat exchanger and configured such that fluid flows
along the second heat exchanger at least partially in the first
direction; and a thermoelectric device having opposing surfaces
that generate a temperature gradient between one surface and an
opposing surface in response to electrical current flowing through
the thermoelectric device, the one surface in thermal communication
with the first heat exchanger and the opposing surface in thermal
communication with the second heat exchanger, wherein a portion of
the housing extends between an outlet of the first heat exchanger
and an outlet of the second heat exchanger such that fluid from the
first heat exchanger is directed toward the first outlet and fluid
from the second heat exchanger is directed to the second
outlet.
[0023] Some embodiments provide a radial outlet blower comprising a
housing that includes an upper portion, a lower portion and a side
wall extending between the upper and lower portions. The housing
generally defines an interior cavity, and the upper portion
generally defines, at least in part, an inlet into the interior
cavity. Further, the lower portion defines, at least in part, a
substantially circumferentially and/or radially symmetrical outlet.
The radial outlet blower further includes an impeller positioned
within the housing, the impeller comprising a plurality of blades
configured to rotate about a rotational axis and draw air into the
housing through the inlet and then direct the flow in radial and/or
axial direction towards one or more outlets.
[0024] These and other features are disclosed in further detail
herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] These and other features, aspects and advantages of the
present devices, systems and methods are described in detail below
with reference to drawings of certain preferred embodiments, which
are intended to illustrate, but not to limit, the present
inventions. The drawings contain seventy-six (76) figures. It is to
be understood that the attached drawings are for the purpose of
illustrating concepts of the present inventions and may not be to
scale.
[0026] FIG. 1A is a perspective view from above of an embodiment of
a thermoelectric heat exchanger system.
[0027] FIG. 1B is a perspective view from below the thermoelectric
heat exchanger system illustrated in FIG. 1A.
[0028] FIG. 1C is an exploded view of the thermoelectric heat
exchanger system illustrated in FIG. 1A.
[0029] FIG. 1D is a side cross section of the heat exchanger system
FIG. 1A.
[0030] FIG. 1E is a perspective view of an embodiment of a heat
exchanger module.
[0031] FIG. 1F is a perspective view of the heat exchanger module
of FIG. 1E mounted on an embodiment of a flow director.
[0032] FIG. 1G is a top view of a blower assembly comprising three
heat exchanger modules according to one embodiment.
[0033] FIG. 1H is a top view of a blower assembly comprising two
heat exchanger modules according to one embodiment.
[0034] FIG. 1I is a top view of a blower assembly comprising two
heat exchanger modules according to another embodiment.
[0035] FIG. 2A is a top view of an embodiment of a polygonal heat
exchanger module system comprising a plurality of rectangular heat
exchangers.
[0036] FIG. 2B is a top view of another embodiment of a polygonal
heat exchanger module system comprising a plurality of rectangular
heat exchangers.
[0037] FIG. 2C is a top view of another embodiment of a polygonal
heat exchanger module system comprising a plurality of rectangular
heat exchangers.
[0038] FIG. 2D illustrates a top view of a system comprising
coupling members useful for coupling adjacent heat exchanger
modules.
[0039] FIG. 2E illustrates a top view of adjacent heat exchanger
modules connected to each other using coupling members according to
one embodiment.
[0040] FIG. 2F illustrates a side view of coupling members of
adjacent heat exchanger modules being attached to one another using
a spot weld according to one embodiment.
[0041] FIG. 2G illustrates a side view of coupling members of
adjacent heat exchanger modules being positioned next to one
another according to one embodiment.
[0042] FIG. 2H illustrates the coupling members of FIG. 2G being
spot welded to each other using according to one embodiment.
[0043] FIG. 2I illustrates a top view of an assembly comprising
flow blocking members positioned between adjacent heat exchanger
modules according to one embodiment.
[0044] FIG. 3A illustrates a top view of an embodiment of a linear
heat exchanger module system comprising deformable coupling
members.
[0045] FIG. 3B illustrates the linear heat exchanger module system
of FIG. 3A converted into a polygonal form.
[0046] FIGS. 3C and 3D are perspective views of an embodiment of a
deformation of a coupling member in converting the linear
embodiment of the heat exchanger module system illustrated in FIG.
3A into the polygonal embodiment illustrated in FIG. 3B.
[0047] FIG. 4A illustrates a top view of another embodiment of a
detail linear heat exchanger module system comprising deformable
coupling members.
[0048] FIGS. 4B and 4C are perspective views of an embodiment of a
deformation of the coupling member of 4A.
[0049] FIG. 5A illustrates a top view of another embodiment of a
detail linear heat exchanger module system comprising deformable
coupling members.
[0050] FIGS. 5B and 5C are perspective views of an embodiment of a
deformation of the coupling member of 5A.
[0051] FIG. 6A illustrates a top view of another embodiment of a
detail linear heat exchanger module system comprising deformable
coupling members.
[0052] FIGS. 6B and 6C are perspective views of an embodiment of a
deformation of the coupling member of 6A.
[0053] FIG. 6D is a top view of a layout used in the manufacture of
the heat exchanger module system of FIG. 6A.
[0054] FIG. 6E is a top view of a printed circuit board configured
for use in a blower assembly comprising one or more heat exchanger
modules according to one embodiment.
[0055] FIG. 7A illustrates in perspective an embodiment of an
annular heat exchanger module suitable for use in a heat exchanger
system.
[0056] FIGS. 7B-7D are a perspective and detail views of an
embodiment of a heat exchanger useful in the heat exchanger module
of FIG. 7A.
[0057] FIG. 7E is a cross-section view of an embodiment of the heat
exchanger module illustrated in FIG. 7A.
[0058] FIG. 7F is a cross-section view of the heat exchanger module
of FIG. 7E illustrating the effect of a temperature differential
between first and second substrates thereof.
[0059] FIG. 7G is a top view of an embodiment of a thermoelectric
device used in the heat exchanger illustrated in FIG. 7A showing
the effect of a temperature differential between first and second
substrates thereof.
[0060] FIG. 7H illustrates a top view of an embodiment of a portion
of a segmented substrate.
[0061] FIG. 8A is a top view of an embodiment of an annular
thermoelectric device comprising a sectored first substrate and a
non-sectored second substrate.
[0062] FIG. 8B is a bottom view of an embodiment of an annular
thermoelectric device comprising a sectored first substrate and a
non-sectored second substrate.
[0063] FIG. 9A is a top view of a sheet from which substrates of
the thermoelectric devices are obtained according to one
embodiment.
[0064] FIG. 9B is a top view of an embodiment of a thermoelectric
device that comprises a plurality of arc-shaped substrate portions
cut or otherwise provided from the sheet of FIG. 9A.
[0065] FIG. 9C is a top view of a sheet from which substrates of
the thermoelectric devices are obtained according to another
embodiment.
[0066] FIG. 9D is a top view of a sheet from which substrates of
the thermoelectric devices are obtained according to still another
embodiment.
[0067] FIG. 10 is a side cross-sectional view of an embodiment of a
heat exchanger system in which first and second heat exchangers are
positioned lower compared with the embodiment illustrated in FIG.
1D, thereby equalizing the airflow through the first and second
heat exchangers.
[0068] FIG. 11A is a top view of an embodiment of a heat exchanger
system comprising fins or vanes for modifying the lateral
distribution of airflow through the first and second heat
exchangers.
[0069] FIG. 11B is a top view of another embodiment of a heat
exchanger system comprising fins or vanes for modifying the lateral
distribution airflow through the first and second heat
exchangers.
[0070] FIG. 11C illustrates a top view of one embodiment of air
being transferred from an impeller toward a heat exchanger module
positioned within an interior of a blower assembly.
[0071] FIG. 11D illustrates a detailed top view of the blower
assembly of FIG. 11C.
[0072] FIGS. 11E-11G illustrates top views of various embodiments
of heat exchangers of a heat exchanger module positioned within a
blower assembly.
[0073] FIG. 11H illustrates a perspective view of a folded heat
exchanger according to one embodiment.
[0074] FIGS. 11I and 11J illustrates top and side views,
respectively, of a folded heat exchanger having a wave-like shape
according to one embodiment.
[0075] FIG. 12A is a cross section of an embodiment of a
motor-impeller assembly in which the impeller comprises a vertical
splitter plate configured to modify the relative airflow through
first and second heat exchangers.
[0076] FIG. 12B is a top view of an embodiment of a motor-impeller
assembly comprising the vertical splitter plate of FIG. 12A.
[0077] FIGS. 13A and 13B are cross sections of another embodiment
of a motor-impeller assembly in which the impeller comprises an
angled splitter plate configured to modify the relative airflow
through first and second heat exchangers.
[0078] FIGS. 14A and 14B illustrate in perspective and in a side
cross-section an embodiment of the motor-impeller assembly
comprising a top ring.
[0079] FIG. 14C is a cross-sectional view of a calculated airflow
for a motor motor-impeller assembly as illustrated in FIGS. 14A and
14B.
[0080] FIG. 15 is a side cross sectional view of an embodiment of
the motor-impeller assembly that does not comprise a top ring.
[0081] FIG. 16 illustrates embodiment of a motor-impeller assembly
comprising a different number of upper blade portions and lower
blade portions.
[0082] FIG. 17 a schematic illustration of a ventilation system
that includes thermoelectric device in accordance with one
embodiment.
[0083] FIG. 18A is a cross sectional view and FIG. 18B is a
perspective of an embodiment of a radial outlet blower.
[0084] FIGS. 18C and 18D are a top view and a side view of an
embodiment of a radial outlet blower mounted in a seat cushion.
[0085] FIG. 19A illustrates a blower in which the airflow outlet is
turned 90.degree. using a snout.
[0086] FIGS. 19B and 19C are a top view and a side view of the
blower illustrated in FIG. 19A mounted in a seat cushion.
[0087] FIG. 20 illustrates a side cross sectional view of an
embodiment of a seating system comprising an embodiment of a radial
outlet blower.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0088] Embodiments described below illustrate various
configurations that may be employed to achieve one or more
improvements. The particular embodiments and examples are
illustrative only and are not intended to limit the concepts
presented herein, and/or the various aspects and/or features
thereof. As used herein, the terms "cooling side," "heating side,"
"cold side," "hot side," "cooler side," "hotter side," and the like
are relative terms and do not refer to any particular temperature.
For example, the "hot," "heating," or "hotter" side of a
thermoelectric element or array may be at ambient temperature, with
the "cold," "cooling," or "cooler" side at a temperature cooler
than ambient temperature. Conversely, the "cold," "cooling," or
"cooler" side may be at ambient temperature with the "hot,"
"heating" or "hotter" side at a temperature higher than ambient
temperature. Thus, the terms are relative to each other to indicate
that one side of the thermoelectric is at a higher or lower
temperature than the counter-designed side.
[0089] In addition, fluid flow is referenced in the discussion
below as having direction. When such references are made, they
generally refer to the direction as depicted in the drawings. For
example, fluid flow over or through a heat exchanger may be
described as away from or along an axis about which these heat
exchangers are disposed. One skilled in the art will understand
that the fluid flow pattern in a device may take the form of a
spiral, circular motion, another turbulent or laminar flow pattern
and/or the like. The terminology indicating "away" from an axis or
"along" an axis, or any other direction described in the
application is meant to be an illustrative generalization of the
direction with respect to the drawings. Directional terms such as
"top," "bottom," "upper," "lower," "left," "right," "front,"
"back," "clockwise," and "counterclockwise" are also relative to
the configuration illustrated in the drawings.
[0090] FIG. 1A is a top perspective view of an embodiment of a
generally disk-shaped thermoelectric heat exchanger system 100. The
illustrated thermoelectric heat exchanger system 100 comprises a
flattened cylindrical outer housing 110, which defines an interior
cavity or chamber 111 (see FIG. 1D). The housing 110 generally
comprises a top wall 112, a bottom wall 114 and a side wall 116.
The top wall 112 and bottom wall 114 are generally flat and
circular in the illustrated embodiment, and the side wall 116 is
generally cylindrical. Those skilled in the art will understand
that in other arrangements or embodiments the shape of the housing
110, top wall 112, bottom wall 114 side wall 116 and/or any other
portion of the system 100 can be modified as desired or
required.
[0091] A generally circular intake or inlet 122 can be provided at
or near the center of the top wall 112. In other embodiments, an
intake can be formed in the bottom wall 114, either in addition to
or instead of the illustrated intake 122. A first outlet 124
comprises one or more openings formed in a top or upper portion of
the side wall 116. Further, a second outlet 126 (shown in FIG. 1B)
comprises one or more openings 126 formed around the periphery of
the bottom wall 114. The intake 122, first outlet 124 and/or second
outlet 126 may each extend into and may be in fluid communication
with an interior cavity of the housing 110.
[0092] With continued reference to FIG. 1A, a motor-impeller or fan
assembly 130 is disposed within the housing 110 and is visible
through the intake 122. As shown, a portion of a flow director or
separator 140 can bisect and extend through the side wall 116. In
the illustrated embodiment, the flow director 140 divides the
housing 110 into an upper portion 110a that comprises the top wall
112 and an upper portion of the sidewall 116, and a lower portion
110b that comprises a lower portion of the sidewall 116 and the
bottom wall 114. The separator 140 is described in greater detail
herein.
[0093] FIG. 1B is a bottom perspective view of the thermoelectric
heat exchanger system 100, showing the second outlet 126 formed in
the bottom wall 114. In many applications, the first outlet 124
and/or second outlet 126 are in fluid communication with a ducting
system that directs conditioned fluid provided by the
thermoelectric heat exchanger system 100 to and/or from one or more
desired locations. Those skilled in the art will understand that
other arrangements for the intake 122, first outlet 124 and second
outlet 126 are used in other embodiments, depending on the
particular application or use. For example, the shape and location
of the illustrated embodiments of the intake 122, first outlet 124
and/or second outlet 126 can be modified in other embodiments as
desired or required.
[0094] FIG. 1C is an exploded view of the thermoelectric heat
exchanger system 100 illustrated in FIGS. 1A and 1B. From top to
bottom, FIG. 1C illustrates the upper portion 110a of the housing,
a heat exchanger module system 150 comprising a plurality of heat
exchanger modules 152, the flow director 140, and the lower portion
110b of the housing into which is mounted the motor-impeller
assembly 130. In the illustrated embodiment, the heat exchanger
module system 150 comprises a plurality of heat exchanger modules
152 that are oriented in a polygonal arrangement, for example, as a
regular hexagon. Such an arrangement is also referred to herein as
a "polygonal heat exchanger module system," which is discussed in
greater detail herein. As is explained in greater detail herein, it
is anticipated that in modified embodiments, the polygonal heat
exchanger module system 150 can include more or fewer than six heat
exchanger modules 152. In addition, while in the illustrated
embodiment the heat exchanger modules 152 are generally rectangular
with flat sides, it is anticipated that modified embodiments can
include heat exchanger modules 152 with sides that are not flat.
For example, in one particular arrangement, the heat exchanger
system 150 comprises a plurality of arc-shaped segments that are
arranged in a generally circular pattern.
[0095] FIG. 1D is a cross-sectional view along the circumferential
edge of a thermoelectric heat exchanger system 100, which, because
of the generally rotational symmetry of the device 100 around a
central axis 102, shows approximately only one half of the device
100. As discussed, the housing 110 can comprise a top portion 110a
and a bottom portion 110b. In the illustrated arrangement, a flow
director 140 is disposed between the top 110a and bottom 110b
portions of the housing. The motor-impeller assembly 130 is
centrally mounted to the bottom wall 114 within the cavity 111
defined by the housing 110. The intake 122 is centrally formed on
the top wall 112. The heat exchanger module 152 contacts the flow
director 140, and extends between the top wall 112 and bottom wall
114 such that substantially all of the fluid flowing through the
device 100 flows through one or more of the heat exchanger modules
152 situated therein.
[0096] With continued reference to the embodiment illustrated in
FIG. 1D, the heat exchanger module 152 comprises a first heat
exchanger 154, a second heat exchanger 156 and a thermoelectric
device 160 generally positioned therebetween. In some arrangements,
the heat exchange modules 152, 154 comprise fins (e.g., folded
fins) or the like. The thermoelectric device 160 is advantageously
adapted to convert electrical energy into a temperature
differential or gradient. One example of a suitable thermoelectric
device 160 is a Peltier device, which comprises at least one pair
of dissimilar materials connected electrically in series and
thermally in parallel, for example, a series of n-type and p-type
semiconductor pellets or elements. In some arrangements, a
plurality of the semiconductor pellets are disposed between a first
substrate 164 and a second substrate 166. Depending on the
direction of current passing through the thermoelectric device 160,
one of the first 164 or second 166 substrates will be heated and
the other will be cooled. The substrates 164 and 166 typically
comprise materials known in the art with high thermal conductivity
and low electrical conductivity, such as, for example, certain
ceramic materials and/or polymer resins. In one embodiment, the
substrates 164, 166 comprise polyimide (e.g., filled polyimide),
epoxy and/or the like.
[0097] In the illustrated embodiments, the first heat exchanger 154
is thermally coupled to the first substrate 164 and the second heat
exchanger 156 is thermally coupled to the second substrate 166. The
heat exchangers are thermally coupled to the substrates by any
suitable means. In one arrangement, the substrate comprises copper
or other metallic members secured to one on or both sides of a
polyimide layer. Thus, the heat exchangers (e.g., fins) can be
welded or otherwise fastened to an outer layer of copper or other
metal included in the substrate. In other arrangements, the heat
exchangers can be thermally coupled to an adjacent substrate by
disposing one or more thermal compounds therebetween, such as, for
example, thermal adhesive, thermal epoxy, thermal grease, thermal
paste, and/or other thermal compounds known in the art. In
embodiments using a thermal adhesive and/or thermal epoxy, the
thermal compound can also serve to mechanically secure the heat
exchanger to the substrate. In some embodiments, the heat
exchangers are secured to the substrates using mechanical fasteners
known in the art. The heat exchangers 154 and 156 typically
comprise thermally conductive materials formed in a high
surface-area geometry, for example, as fins, blades, pins, channels
and/or the like, that permits radial fluid flow.
[0098] As discussed in greater detail herein, in some embodiments,
the first 154 and second 156 heat exchangers are radially segmented
(e.g., in the direction of fluid flow, in a direction generally
perpendicular to the direction of flow and/or in any other
direction). Segmenting a heat exchanger can help increase the
efficiency of the heat transfer from the heat exchanger to a fluid
by thermally isolating adjacent segments from each other. In
addition, segmentation of the heat exchangers and/or the substrate
can help reduce the thermal stresses to the system when air or
other fluid is being heated or cooled by the thermoelectric device.
In other embodiments, the first 154 and second 156 heat exchangers
can be formed without radial segmentation or with partial radial
segmentation.
[0099] In the illustrated embodiment, the flow director 140 or
divider contacts and extends radially from the thermoelectric
device 160, which together with the top wall 112 and upper portion
of the side wall 116, define a first chamber 118 around the
periphery of the top of the cavity 111. Similarly, the flow
director 140, thermoelectric device 160, bottom wall 114 and lower
portion of the side wall 116 define a second chamber 119 around the
periphery of the bottom of the cavity. Because heated fluid will
flow through one of the first 118 and second 119 chambers and
cooled fluid will flow through the other, in some embodiments, the
flow director 140 comprises a thermally insulating material known
in the art. Examples of suitable thermally insulating materials
comprise one or more polymer resins, for example, polyurethane,
polyvinyl chloride, polypropylene, polyethylene, polyolefin,
acrylonitrile-butadiene-styrene, acrylic, polyamide, polyester,
polyimide, polysulfone, polyurea, polycarbonate, and copolymers,
blends, and mixtures thereof. In some embodiments, the thermally
insulating material is expanded, for example, using a blowing
agent, which improves the insulation value of the material. Some
embodiments of the flow director 140 comprise a composite material,
which provides, for example, both the desired insulating properties
as well as the desired mechanical properties. For example, in some
embodiments, a composite is formed comprising one or more polymer
materials, and one or more fiber reinforcing materials known in the
art (e.g., fiber glass, carbon fiber, boron fiber, etc.). In
preferred embodiments, substantially no fluid flows between the
first chamber 118 and the second chamber 119. The first outlet 124
can place the first chamber 118 in fluid communication with a first
exterior portion of the device 100, while the second outlet 126 can
place the second chamber 119 in fluid communication with a second
exterior portion of the device 100.
[0100] As shown in the embodiment of a heat exchanger module 152
illustrated in FIG. 1E, the first heat exchanger 154 and second
heat exchanger 156 can be longer (radially) than the thermoelectric
device, thereby forming a slot 158. With reference now to FIG. 1F,
in the illustrated arrangement, at least a portion of the flow
director 140 is dimensioned and configured to be received in the
slot 158 generally formed between the heat exchangers 154, 156.
Accordingly, in some embodiments, the flow director 140 and
vertical dimension of the slot 158 of the thermoelectric device 160
have substantially the same thickness. In the illustrated
embodiment, the flow director 140 comprises a plurality of
engagement members 142 dimensioned to engage and secure each heat
exchanger module 152 laterally (i.e., at their respective ends),
thereby reducing lateral movement thereof.
[0101] With continued reference to FIG. 1D, the motor-impeller
assembly 130 can include a plurality of fan blades 132 secured to a
motor rotor 134. Details of electrical circuitry current paths and
terminals that power the thermoelectric device 160 and the
motor-impeller assembly 130 are omitted for clarity.
[0102] In use, a fluid, for example, air, is drawn into the
thermoelectric heat exchanger system 100 through the intake 122 by
the motor-impeller assembly 130, which compresses or otherwise
exerts energy on the fluid. Consequently, the air or other fluid
can be expelled radially into the chamber 111 within the housing
110. A first portion of fluid is forced through the first heat
exchanger 154, which, for example, cools the first portion of
fluid. The cooled first portion of fluid then enters the first
chamber 118 and exits the device through the first outlet 124
(e.g., waste outlet). Likewise, a second portion of fluid is forced
through the second heat exchanger 156, which in this example, heats
the second portion of fluid. The second portion of fluid enters the
second chamber 119 and exits the device 100 through the second
outlet 126 (e.g., main outlet). In the illustrated embodiment, the
first and second heat exchangers 154, 156 and the first and second
chambers 118, 119 are all positioned within the housing 110 and
thus part of the cavity 111 defined by the housing 110.
[0103] Arrows in FIG. 1D indicate the general fluid flow through
the heat exchanger system 100. With reference to these arrows, in
the illustrated arrangement, the fluid enters the system 100 in a
first direction A that is generally parallel or substantially
parallel to the rotational axis of the motor-impeller assembly 130
and perpendicular to the disc-shaped housing 110. The fluid is then
turned approximately 90 degrees such that it is directed in a
substantially radial direction B with respect to the rotational
axis of the motor-impeller assembly 130. The flow continues in this
radial direction through the first and the second heat exchangers
154, 156. In the illustrated arrangement, the flow through the
first heat exchanger 154 continues radially through the first
outlet 124 and out of the housing 110. In the illustrated
embodiment, the flow through the second heat exchanger 156
continues and is turned about 90 degrees by the side wall 116 and
exits through the second outlet 126 and out of the housing 110 in a
direction that is generally perpendicular to the radial direction B
and parallel to the rotational axis of the motor-impeller assembly
130. Those skilled in the art will understand that in modified
embodiments the first outlet 124 and/or the second outlet 126 can
be independently configured to discharge fluid radially,
tangentially, axially or in any intermediate direction.
[0104] In one embodiment, the first heat exchanger 154 comprises
the "waste side" of the heat exchanger system 100. That is, the
flow of the air through the second heat exchanger 156 can be
directed to a surface of a seating assembly (e.g., vehicle seat,
bed, etc.) that is to be cooled and/or heated by the heat exchanger
system 100. Depending whether the air through the second heat
exchanger is to be heated or cooled, heat is either removed from or
transferred to the air flowing through the first heat exchanger
152. In modified embodiments, the system 100 can be reversed, with
the second heat exchanger 156 operating as the "waste side" of the
heat exchanger system 100. For example, such a reversal in heating
and cooling modes can be accomplished by changing the direction of
the current being delivered to the Peltier circuit or other
thermoelectric device.
[0105] According to some embodiments, as illustrated in FIGS. 1G-1I
and discussed in greater detail herein, a heat exchanger module
system can include one or more heat exchange systems (e.g.,
thermoelectric devices, heat exchangers, etc.) that are not
positioned around the entire periphery of system. For example, in
the arrangement illustrated in FIG. 1G, the system comprises a
total of three heat exchange systems 150' that are oriented (e.g.,
at equally or substantially equally spaced intervals, such as 120
degree increments) around a center impeller 130'. In other
embodiments, the quantity, size, shape, spacing, location and/or
other details of the heat exchange systems 150' can vary, as
desired or required. In some embodiments, the heat exchange systems
150' are electrically connected to each other (e.g., the pellets
are electrically connected in series to one another). However, in
other arrangements, the heat exchange systems 150' are powered and
controlled separately of each other.
[0106] Intermittently spaced heat exchange systems 150', as
illustrated in FIGS. 1G-1I, function in a similar manner as those
that include a heat exchange system around the entire or most of
the system (e.g., FIGS. 1C, 2A, etc.). Air is directed to one or
more of the heat exchange systems 150' for thermal conditioning. As
discussed, a portion of the air exits the system through a main
outlet while the remainder of the air exits the system through a
waste outlet. The housing of the system can include openings that
are intermittently located. For example, in one embodiment, the
openings (e.g., outlets, exits, etc.) generally coincide with the
location, size, space and/or other characteristics of the heat
exchange systems 150'.
[0107] The system depicted in FIG. 1H is similar to the embodiment
illustrated in FIG. 1G and discussed herein. However, as shown, the
illustrated system includes only two heat exchange systems 150''
that are positioned generally on opposite ends of the impeller
130''. In FIGS. 1G and 1H, the heat exchange systems include a
curved shape to generally match the contoured shape of the housing,
the impeller and/or one or more other components or features of the
system. However, as illustrated in FIG. 1I, the heat exchange
systems 150''' can include a generally rectangular shape or any
other shape.
[0108] The embodiments illustrated in FIGS. 1G-1I can help reduce
manufacturing costs of such assemblies as the size and complexity
of the heat exchange modules (e.g., the quantity of components,
amount of materials needed, etc.) is reduced. Such a configuration
can also help provide additional packaging flexibility to an
assembly.
[0109] FIG. 2A illustrates a top view of a modified embodiment of a
polygonal heat exchanger module system 2200 that can be used in a
heat exchanger system 100 as described herein. In contrast to the
embodiment illustrated described above, the embodiment of FIG. 2A
comprises a set of eight heat exchanger modules 2210, each of which
form at least a portion of a side of the polygon. Collectively, the
heat exchanger modules 2210 form at least a portion of a perimeter
of the polygonal heat exchanger module system 2200. An opening 2240
in the heat exchanger module system 2200 is shaped, dimensioned and
otherwise configured to receive, for example, a motor-impeller
assembly, as discussed above. In the illustrated embodiment, the
heat exchanger modules 2210 also define at least a portion of the
perimeter of the opening 2240. The illustrated embodiment is
generally symmetrical about a central axis 2250, forming a regular
polygon (e.g., an octagon). Those skilled in the art will
understand that other embodiments may not be rotationally
symmetrical.
[0110] In the illustrated embodiment, adjacent heat exchanger
modules 2210 generally abut each other, thereby forming a closed
figure with small gaps or without any gaps at all. Such a
configuration can help direct fluid through the heat exchanger
module system 2200. As discussed, the illustrated heat exchanger
module system 2200 is suitable for use, for example, in the heat
exchanger system illustrated in FIGS. 1A-1F. Each heat exchanger
module 2210 can comprise first and second (not illustrated) heat
exchangers that are thermally coupled to opposite faces of a
thermoelectric device 2216. In some embodiments, the area of the
thermoelectric device 2216 is not coextensive with the areas of the
first 2212 and second (not illustrated) heat exchangers. For
example, in the illustrated embodiment, the thermoelectric device
2216 is narrower than the first 2212 and second heat exchangers, as
indicated by the shading. Thus, the heat exchanger module system
2200 is configured to permit fluid flow from the opening 2240
inside the polygon to outside the polygon through the heat
exchangers thermally coupled to the thermoelectric devices. As
discussed, this can allow such air or other fluid to be selectively
heated or cooled, as desired.
[0111] In the illustrated embodiment, each heat exchanger module
2210 is generally rectangular or linear as viewed from the top, in
contrast to the curved heat exchanger modules discussed below.
Embodiments of systems incorporating rectangular heat exchanger
modules can provide one or more of the following advantages: ease
of manufacture of the thermoelectric device 2216 and/or heat
exchanger module 2210; reduced cost; interchangeability;
replaceability; design flexibility; and the like. For example,
although the illustrated embodiment comprises heat exchanger
modules 2210 substantially of generally equal dimensions, other
embodiments comprise heat exchanger modules with at least two
different dimensions.
[0112] In other embodiments, a heat exchanger module system
comprises a plurality of thermoelectric devices defining a least a
portion of a perimeter of a polygon, and first and second heat
exchangers thermally coupled thereto. At least one of the first and
second heat exchangers spans adjacent thermoelectric devices. For
example, some embodiments comprise unitary annular heat exchangers
of the type illustrated in FIGS. 7A and 7B that are sized, shaped
and otherwise configured to extend along some or all of the heat
exchanger modules (e.g., thermoelectric devices, substrates, etc.)
included within a particular housing, such as those illustrated in
FIGS. 2A-2C. Accordingly, the advantages of a polygonal array of
thermoelectric devices with the heat transfer advantages of
unitary, annular heat exchangers, can be combined, as discussed in
greater detail herein.
[0113] FIG. 2B illustrates a top view of another embodiment of a
heat exchanger module system 2200 which is similar to the
embodiment illustrated in FIG. 2A. However, as shown, the
embodiment depicted in FIG. 2B includes a total of six heat
exchanger modules 2210. The embodiment of a heat exchanger module
system 2200 illustrated in a top view in FIG. 2C is similar to the
embodiment illustrated in FIG. 2B except that it comprises gaps
2202 between adjacent heat exchanger modules 2210. In some
embodiments, the gaps 2202 improve the manufacturability of the
heat exchanger module system 2200. For example, such gaps can
permit wider dimensional tolerances for one or more of the
individual components. The gaps 2202 can also permit relative
motion of the heat exchanger modules 2210 and/or components
thereof, for example, thermal expansion and contraction, mechanical
motion and/or the like. Gaps between heat exchanger modules can be
filled, for example, using a suitably configured flow director
and/or using separate filler strips, thereby preventing fluid from
bypassing the heat exchanger module system. Other embodiments do
not comprise gaps between every adjacent pair of heat exchanger
modules. It will be appreciated that in embodiments that comprise
gaps between adjacent heat exchanger modules, the size of such gaps
can vary as desired or required by a particular application.
[0114] FIG. 2D illustrates a portion of an embodiment of a system
2200 for coupling adjacent heat exchanger modules 2210,
mechanically and/or electrically. In the illustrated embodiment,
each heat exchanger module 2210 comprises a coupling member 2230 in
the form of an interconnect tab at each end that is dimensioned and
configured to couple one or more components (e.g., substrates, heat
exchangers, etc.) and/or portions of adjacent heat exchanger
modules 2210, mechanically and/or electrically. For example, the
substrates of adjacent heat exchanger modules 2210 can be
electrically coupled to each other to advantageously transmit an
electrical current throughout the pellets of two or more adjacent
thermoelectric devices. The coupling members 2230 are coupled by
any method known in the art, for example, using plugs, sockets,
quick connects, clips, solder joints, welds, screws, swages,
rivets, adhesives, combinations thereof and/or the like. As
discussed, one or more portions or components of adjacent heat
exchange modules (e.g., thermoelectric devices, substrates, fins or
other heat exchangers, etc.) can be joined to each other using one
or more attachment methods or devices. In some embodiments, the
modules are electrically and/or thermally connected to each other
to simplify the design of the system.
[0115] As illustrated in FIG. 2E, adjacent heat exchange modules
can be attached to each other along coupling members 2230' or
another portion that extends along the edges of the modules. In
some embodiments, the coupling members 2230' are generally
rectangular tab members that are shaped, sized and otherwise
configured to overlap with coupling members 2230' of adjacent heat
exchange modules. In some arrangements, the coupling members 2230'
comprise a metal layer or strip or another conductive member that
is configured to place the thermoelectric devices of the adjacent
modules in electrical communication with one another. As a result,
a current supplied to one module can be advantageously transmitted
to one or more other modules within a particular system.
[0116] FIG. 2F illustrates a side view of adjacent coupling members
2230' being spot welded to each other. As shown, spot welding
electrodes E+, E- can be positioned along opposite ends of the
coupling members 2230'. Once a sufficient force has been applied to
urge the coupling members 2230' into contact with one another, a
current can be passed from one electrode E+ to the other electrode
E-. This process can result in a spot weld 2268 being formed at or
near a location where the coupling members 2230' are in contact
with one another.
[0117] In some embodiments, the coupling members 2230' are simply
an extension of the upper and/or lower substrate of the
thermoelectric device. As discussed, such a substrate preferably
includes a thermally conductive and electrically insulating layer,
such as, for example, polyimide, ceramic and/or the like. As a
result, the extension of such an electrically non-conductive layer
into the coupling members 2230' can make it additionally difficult
to spot weld the coupling members 2230' to each other, as there
must a conductive path for the electrical current to pass from one
electrode E+ to the other electrode E-, through the coupling
members 2230'. Consequently, the electrically non-conductive layer
or portion (e.g., polyimide, ceramic, etc.) of the substrate may
need to be removed, penetrated or otherwise compromised before the
spot welding process can be completed.
[0118] FIG. 2G illustrates a side view of two coupling members
2230' that are essentially a continuation of the substrates 2264
(e.g., upper or lower) of the thermoelectric devices in the
adjacent heat exchange modules. As shown, each coupling member
2230' includes a metal (e.g., copper) layer 2266 that is configured
to contact or be adjacent to a metal layer 2266 of the adjacent
coupling member 2230'. In addition, the opposite sides of the
substrate 2264 include a layer of polyimide 2265, ceramic or some
other electrically non-conductive material. Thus, as discussed,
this layer of electrically non-conductive material 2265 may need to
be removed, sliced, punctured or otherwise compromised before a
spot weld 2268 can be formed between the coupling members
2230'.
[0119] According to one embodiment, a spot weld 2268 can be formed
between adjacent coupling members 2230' without compromising the
electrically non-conductive layer 2265 is illustrated in FIG. 2H.
As shown, electrodes E+, E- may be positioned along the metal
layers 2266 of each coupling member 2230' in locations that are not
horizontally aligned with each other. Consequently, for stability,
there may be a need to apply counteracting or balancing forces B
opposite of each electrode E+, E-. In addition, pinching or
squeezing forces F may be applied along the portion of the coupling
members 2230' where the spot weld 2268 is desired to ensure proper
contact between the metal layers or member 2266. As shown,
electrical current can be routed through the metal layer or member
2266 along a less direct route than normally conducted when spot
welding (e.g., FIG. 2F). Nevertheless, this spot welding method may
allow an adequate spot weld 2268 to be formed between the coupling
members 2230' without the need to remove polyimide or another
electrically non-conductive layer therefrom. It will be appreciated
that such a spot welding technique can be applied to other fields
of use besides connecting adjacent heat exchange modules of a heat
exchanger system.
[0120] FIG. 2I illustrates a top view of a plurality of heat
exchanger modules 150 positioned within a heat exchange assembly.
As discussed, the modules 150 can be oriented in such a way that
creates gaps 188 between adjacent heat exchangers (e.g., fins) that
are in thermal communication with thermoelectric devices. In order
to ensure that air or other fluid being moved by the blower does
not bypass or short-circuit the heat exchangers of the modules 150,
flow-blocking tabs 190 or other members can be strategically
positioned at one or more such gaps 188. In some embodiments, the
tabs 190 are attached to the housing (e.g., the upper plate, the
lower plate, the sidewalls, etc.). However, in other embodiments,
the tabs 190 or other flow-blocking members are attached to the
modules 150 and/or another portion of the assembly.
[0121] FIG. 3A illustrates a top view of an embodiment of a heat
exchanger module system 2300 comprising a plurality of heat
exchanger modules 2310 and a plurality of coupling members 2360
coupling adjacent heat exchanger modules 2310. A terminal coupling
member 2370 extends from each terminal heat exchanger module 2310a.
Embodiments of the system 2300 are useful, for example, for
fabricating a heat exchanger module system similar to that
illustrated in FIG. 2A. Each heat exchanger module 2310 is
substantially as described above, comprising a thermoelectric
device and first and second heat exchangers.
[0122] With continued reference to FIG. 3A, an edge of each of the
heat exchanger modules 2310, an edge of each of the coupling
members 2360 and an edge of each of the terminal coupling members
2370 can be substantially collinear. The illustrated embodiment is,
for example, the configuration of the device 2300 as manufactured.
However, those skilled in the art will understand that different
arrangements can be used in other embodiments. In the illustrated
embodiment, the coupling members 2360 mechanically and electrically
couple adjacent heat exchanger modules 2310, and the terminal
coupling members 2370 are mechanically and electrically coupled to
the terminal heat exchanger modules 2310a. In some arrangements, at
least a portion of each coupling member 2360 is flexible, bendable
and/or deformable, as will be described in greater detail
below.
[0123] FIG. 3B illustrates a top view of a conversion of the heat
exchanger module system 2300 from the linear configuration
illustrated in FIG. 3A (in phantom), into a polygonal (e.g.,
hexagonal in the illustrated embodiment) configuration. In the
illustrated embodiment, the conversion is effected by bending or
deforming the coupling members 2360 to provide the desired
configuration. In the illustrated embodiment, the terminal coupling
members 2370 are proximal in the final configuration.
[0124] FIGS. 3C and 3D are perspective views of a possible folding
of the coupling members 2360 to reconfigure the device 2300 from
the linear form illustrated in FIG. 2300A to the closed form such
as the one illustrated in FIG. 3B.
[0125] FIG. 4A illustrates a top view of a detail of another
embodiment of a coupling member 2460 and adjacent heat exchanger
modules 2410 suitable for fabricating a heat exchanger module
system of the type generally illustrated in FIG. 2A. FIGS. 4B and
4C illustrate suitable foldings or deformations of the coupling
member 2460. As best seen in FIG. 4B, portions 2462 of the coupling
member 2460 can be positioned downstream of the heat exchanger
module 2410, and consequently, be configured to partially or
completely block airflow therefrom.
[0126] FIG. 5A illustrates a top view of a detail of another
embodiment of a coupling member 2560 and adjacent heat exchanger
modules 2510 suitable for fabricating a heat exchanger module
system of the type illustrated in FIG. 2A. FIGS. 5B and 5C
illustrate suitable foldings or deformations of the coupling member
2560.
[0127] FIG. 6A illustrates a top view of a detail of another
embodiment of a coupling member 2660 and adjacent heat exchanger
modules 2610 suitable for fabricating a heat exchanger module
system of the type illustrated in FIG. 2A. FIGS. 6B and 6C
illustrate suitable foldings or deformations of the coupling member
2660. In the folded configurations illustrated in FIGS. 5A and 6A,
because no portion of the coupling member 2560, 2660 is positioned
downstream of a heat exchanger module 2510, 2610, airflow blockage
is not a problem.
[0128] Furthermore, as best seen in FIG. 6A, the coupling member
2660 can be formed entirely within the envelope of the heat
exchanger modules 2610 (e.g., that is, within the bounds of the
width of the heat exchanger modules). Consequently, in embodiments
in which at least a portion of the coupling member 2660 is formed
integrally with at least a portion of the heat exchanger module
2610, for example, with the substrate or other portion or component
of the thermoelectric device, the illustrated embodiment can be
manufactured with reduced waste compared with embodiments in which
the coupling member extends beyond the envelope of the heat
exchanger module, for example, the embodiments illustrated in FIGS.
4A-4C and 5A-5C. An exemplary layout of two heat exchanger modules
2610 is illustrated in FIG. 6D, showing such an efficient layout.
Accordingly, embodiments of the heat exchanger module system
illustrated in FIGS. 6A-6C can be more efficient, easier and/or
less expensive to manufacture.
[0129] FIG. 6E illustrates one embodiment of a printed circuit
board (PCB) 180 or other electrical bus that can be used to
facilitate attaching one or more heat exchanger modules 150
thereto. As shown, the PCB 180 or other base member can include a
plurality of slits 182 or other connection points onto which ends
151 of a module 150 can be mounted. The slits 182 can be configured
to permit the ends 151 of a module 150 to be placed in electrical
communication with one another (e.g., in a series configuration)
using a main electrical strip 181 or conductive member that
advantageously is exposed at each slit 182. As a result, one or
more modules 150 (e.g., thermoelectric devices, fins or other heat
exchangers, etc.) can be easily secured to the PCB 180 or similar
base. For example, the modules 150 can include end terminals 151
that can be soldered to the PCB 180 at the slits 182 or other
connection points. This permits a user to conveniently customize a
particular assembly by choosing the quantity, type and other
details regarding the heat exchanger modules 150. Further, the
simple connection to the PCB eliminates the need for more
complicated, labor intensive and expensive electrical connections
between adjacent modules 150. It will be appreciated that a PCB or
other electrical bus member can be incorporated into any of the
embodiments illustrated and/or described herein, or equivalents
thereof.
[0130] The embodiments illustrated in FIGS. 4-6 are also useful in
heat exchanger systems comprising a plurality of thermoelectric
devices defining a perimeter of a polygon thermally coupled to
first and second heat exchangers, at least a portion of which spans
a plurality of thermoelectric devices, for example, a heat
exchanger similar to the embodiment illustrated in FIG. 7B, which
is discussed below.
[0131] FIG. 7A illustrates a perspective view of an embodiment of a
heat exchanger module 1900 suitable for use in a heat exchanger
system, for example, the systems described and/or illustrated
herein (e.g., FIG. 1, 9, etc.). The illustrated heat exchanger
module 1900 comprises a thermoelectric device 1910, a first heat
exchanger 1920 disposed on an upper surface of the thermoelectric
device 1910 and a second heat exchanger 1930 disposed on a lower
surface of the thermoelectric device 1910. In the illustrated
embodiment, the thermoelectric device 1910 is in the form of a
thin, ring-shaped or annular disk defined by minor (R1) radius
forming a perimeter of an opening 1940 and major (R2) radius
forming a perimeter of the heat exchanger module 1900. In some
embodiments, the opening 1940 is dimensioned and configured to
receive a motor-impeller assembly, for example, as described above
and illustrated in FIG. 1D. In the illustrated embodiment, each of
the heat exchangers 1920 and 1930 is substantially ring-shaped,
with similar or substantially similar heights (H), and with similar
or substantially similar minor (R1) and major (R2) radii as the
thermoelectric device 1910. However, in other arrangements, the
relative heights (H), the minor and/or major radii and/or any other
property of the module may be varied as desired or required.
[0132] In the embodiment illustrated in FIG. 7A, the heat
exchangers 1920 and 1930 are manufactured by pleating or
fan-folding one or more thermally conductive materials to form a
plurality of fins 1922, as illustrated in FIGS. 7B-7D. Those
skilled in the art will understand that other embodiments may use
different fan-fold geometries. As depicted in FIGS. 7C and 7D,
which are detailed views of the heat exchanger 1920 shown in FIG.
7B, the fins 1922 are closer together at the minor radius R1 and
spread farther apart in the radial direction to a maximum spacing
at the major radius R2. Accordingly, the fin density is highest at
the center of the heat exchangers 1920 and 1930, which in the
illustrated arrangement is upstream in the fluid flow, and lowest
at the outer edge, which is downstream in the fluid flow.
[0133] In some arrangements, heat transfer for a fluid flow through
a pipe may depend on two variables of interest: the heat transfer
coefficient, h, and the heat transfer surface area, A. It is
generally known that the heat transfer coefficient h is highest at
the pipe inlet, here the upstream end of the heat exchanger at R1.
The surface area A is also highest at R1 because the fin density is
highest there. Both of these effects combine to provide improved
heat exchange in heat exchangers with higher fin densities at the
inlet and lower fin densities at the outlet, which is achieved in
the illustrated embodiment by bending or deforming a putative
rectangular heat exchanger around an axis normal to the top and
bottom of the heat exchanger to modify the fin spacing. In the
illustrated embodiment, the deformation is circular, resulting in a
ring-shaped heat exchanger. Those skilled in the art will
understand that the same result is achieved using other
deformations in other embodiments, for example deformation into an
arc shape.
[0134] FIG. 7E illustrates a cross section of the heat exchanger
module 1900 along section E-E of FIG. 7A. The thermoelectric device
1910 comprises a first substrate 1912, a second substrate 1914 and
a plurality of semiconductor pellets 1916 disposed therebetween.
The semiconductor pellets 1916 are of any type known in the art for
converting electrical energy into a temperature gradient. The
substrates 1912 and 1914 typically comprise materials with high
thermal conductivity and low electrical conductivity known in the
art, as discussed above.
[0135] The first heat exchanger 1920 is secured to the first
substrate 1912 (e.g., a copper or other metal layer disposed on the
substrate) and the second heat exchanger 1930 is similarly secured
to the second substrate 1914. As discussed, the heat exchangers
1920 and 1930 are typically secured to the substrates 1912 and
1914, respectively, in a manner that provides a suitable thermal
conductivity therebetween, while ensuring that the two portions
will remain adequately connected to one another during use.
[0136] In use, one of the first substrate 1912 and second substrate
1914 warms (hot), while the other cools (cold) when a voltage is
applied across the pellets. For materials with normal (positive)
coefficients of thermal expansion, the hot substrate expands, and
the cold substrate contracts, as illustrated in FIG. 7F, in which
the first substrate 1912 is the hot substrate and the second
substrate 1914 is the cold substrate. This differential expansion
of the substrates 1912 and 1914 produces shear and bending moments
and stresses at the pellets 1906, which can lead to mechanical
failure of the thermoelectric device 1910. The physical deformation
of the thermoelectric device 1910 can also affect fluid dynamics in
the heat exchanger system, thereby reducing efficiency of the
system. The magnitudes of the shear and bending forces and stresses
may depend on the coefficient(s) of thermal expansion of the
substrates 1912 and 1914, the temperature differential
(.DELTA.T=Th-Tc), the size (e.g., length, width, thickness, etc.)
of the substrates 1912 and 1914 (L) and/or one or more other
factors.
[0137] FIG. 7G illustrates a top view of the thermoelectric device
1910 depicted in FIG. 7A during use, showing the expansion of the
first substrate 1912 and the contraction of the second substrate
1914. The effective length L for this device 1910 is the outer
diameter (2R2) of the entire thermoelectric device 1910, rather
than the difference between the major and minor radii (R2-R1),
which is smaller. Such a larger effective dimension may result in
relatively large shear and bending forces in the illustrated
embodiment.
[0138] FIGS. 8A and 8B illustrate top and bottom views,
respectively, of an annular thermoelectric device 2010 that reduces
at least some of the detrimental effects of the differential
expansion, while retaining the advantage of increased heat transfer
from curved or ring-shaped heat exchangers. The thermoelectric
device 2010 is similar to the thermoelectric device 1910
illustrated in FIGS. 7A-7F, with a generally circular shape, and is
suitable for similar applications, for example, as a component of a
thermoelectric heat exchanger module as illustrated in FIG. 7A
and/or in the thermoelectric heat exchanger system illustrated in
FIG. 1. The depicted thermoelectric device 2010 comprises first and
second substrates 2012 and 2014, respectively, and a plurality of
pellets (not illustrated) disposed therebetween. A generally
circular opening 2040 is provided, for example, to receive a
motor-impeller assembly as discussed above. In the illustrated
embodiment, the second substrate 2014 and the pellets are generally
as described above for the thermoelectric device 1910. The first
substrate 2012, however, comprises a plurality of sectors or pieces
2012a. In the illustrated embodiment, the sectors 2012a are
substantially rotationally symmetrical around a central axis 2050.
Accordingly, each of the seven sectors 2012a has a generally
similar size. Those skilled in the art will understand that other
embodiments comprise unequally sized sectors, and/or other more or
fewer sectors. Because the sectors 2012a of the first substrate are
free to move individually rather than as a single unit, the
relevant length L in evaluating the shear and bending forces
induced by a temperature differential between the first 2012 and
second 2014 substrates is the radial width of each sector 2012a
(R2-R1) and/or the circumferential width W of each sector 2012a,
whichever is larger, rather than the diameter of the substrate 2010
(2R2). Because R2-R1 is less than 2R2, and in some embodiments,
significantly less, the shear and bending forces and stresses can
be advantageously reduced. In essence, dividing the first substrate
2012 into sectors 2012a provides "expansion joints" 2013 therefor.
It will be appreciated that a substrate can comprise such expansion
joints 2013 or gaps in the radial and/or circumferential direction,
as desired or required.
[0139] In the illustrated embodiment, the sectors 2012a are
generally arc-shaped, or truncated wedges, corresponding to the
single-piece first substrate 1912 (FIG. 7G) with a plurality of
generally radial cuts, thereby resulting in a plurality of
laterally or circumferentially separated sectors that define at
least a portion of the perimeter of the first substrate 1912. In
the illustrated embodiment, the sectors 2012a, define both the
perimeter of the first substrate 2012 (R1) as well as the perimeter
of the opening 2040 (R2). In some embodiments, an annular first
heat exchanger similar to the embodiment illustrated in FIG. 7B is
thermally coupled to the first substrate 2010. Other embodiments
use a multicomponent heat exchanger, for example, each component
corresponding to a sector 2012a. In other arrangements, a single
heat exchanger can extend, partially or completely, over two or
more different sectors 2012a of a substrate having expansion
joints. The sectored substrate 2012 is distinct from the segmented
heat exchangers described above in connection with the embodiment
illustrated in FIG. 1D, which are generally radially rather than
laterally separated. Some embodiments of a heat exchanger module or
system comprising the sectored substrate 2012 also comprise one or
more radially segmented heat exchangers, which provide thermal
isolation between the segments in the direction of flow and
improved thermal performance.
[0140] FIG. 7H is a top view of an embodiment of a portion of a
first substrate 2010, which is divided into sectors 2010a both
laterally and radially, thereby even further reducing mechanical
stress that arises from a temperature differential between the
first and second substrates of the thermoelectric device.
Accordingly, by segmenting the substrates in a circumferential
direction stress can be reduced in the circumferential direction
during heating and/or cooling. In addition, segmentation in the
radial direction can also reduce stress if there is a large radial
dimension in the device. In addition, radial segmentation can also
provide for thermal isolation that can result in more efficient
heat transfer. For additional details regarding the reduction of
thermal stresses imposed during the use of a thermoelectric device,
please refer to U.S. Patent Application No. 60/951,432, filed Jul.
23, 2007 and the non-provisional application (application serial
number unknown), filed on Jul. 23, 2008 and titled SEGMENTED
THERMOELECTRIC DEVICE, which claims the priority benefit under 35
U.S.C. .sctn. 119(e) of U.S. Patent Application No. 60/951,432, the
entireties of which are hereby incorporated by reference
herein.
[0141] FIG. 9A illustrates a top view of a sheet 2109A of a
thermally conductive, electrically non-conductive material which
may be cut or otherwise shaped to supply the upper and/or lower
substrates of an annular thermoelectric device 2110 similar to the
embodiment illustrated in FIGS. 8A and 8B. The sheet 2109A or other
member from which the substrate for the thermoelectric device 2110
is obtained can comprise a relatively large rectangular shape. As
illustrated in FIG. 9A, in embodiments where the thermoelectric
device 2110 includes a generally curved shape, the substrate can
comprise a plurality of arc-shaped member. This may be the case
when one of the substrates (e.g., upper or lower) of the
thermoelectric device includes radial expansion joints to help
relieve thermal stresses during use, as discussed in greater detail
herein. Thus, the first substrate 2112 may be divided into sectors
2112a similar to the first substrate 2012 of the embodiment
illustrated in FIG. 8A.
[0142] With continued reference to FIG. 9A, the use of such
arc-shaped substrates can help increase the "packing efficiency" of
the substrate sheet from which the individual substrate portions
are extracted. In other words, the amount of material of the sheet
2109A that is wasted (e.g., not capable of being used to cut out or
otherwise be used to provide a portion of a substrate) can be
advantageously reduced. This can lower the manufacturing and/or
assembly cost for such devices, especially where the relative cost
of the substrate material is relatively high. In contrast, one of
skill in the art will appreciate that the amount of "wasted" sheet
material would be significantly higher if a single annular
substrate (FIG. 8B) was used in lieu of a plurality of segmented
arc-shaped portions.
[0143] Heat exchanger modules fabricated from the thermoelectric
device 2110 further comprise a first heat exchanger thermally
coupled to the first substrate 2112 and a second heat exchanger
thermally coupled to the second substrate 2114, as described above.
In some embodiments, the first and second heat exchangers
substantially correspond in shape to the arc-shaped thermoelectric
device subunits 2110a, thereby forming arc-shaped heat exchanger
submodules. Alternatively, each of the arc-shaped heat exchanger
units can be viewed as an individual heat exchanger module, and the
assembly of the individual heat exchanger modules viewed as forming
a heat exchanger module assembly or system.
[0144] In other embodiments, the boundaries of at least one of the
first and second heat exchangers does not substantially correspond
to one of the boundaries to at least one of the arc-shaped
thermoelectric device subunits 2110a. For example, in some
embodiments, each of the first and second heat exchangers comprise
a unitary heat exchanger, for example, as illustrated in FIG. 7B.
In some embodiments, at least one of the first and second substrate
of the thermoelectric device comprises sectors that are divided
radially, essentially forming concentric thermoelectric devices in
some embodiments. A detailed description of such an arrangement can
be found in U.S. Pat. No. 6,539,725, the entirety of which is
hereby incorporated by reference herein.
[0145] FIG. 9B illustrates a top view of an embodiment of a
thermoelectric device 2110 in which a plurality of substrate
portions 2110a, in the illustrated embodiment, three thermoelectric
device subunits, are nested in a radial direction. As discussed,
when compared to a single circular or donut shaped substrate, the
use of a plurality of arc-shaped substrates 2110a may help reduce
manufacturing costs by reducing waste. Specifically, the arc-shaped
substrate portions may be cut next to each other in a stacked or
nested arrangement to reduce waste between cutouts as shown in FIG.
9B. In contrast, the use of circular or donut-shaped thermoelectric
devices may result in a larger amount of wasted substrate material
(e.g., polyimide with copper or other metal portions on one or both
of its surfaces) as the hole of the substrate is wasted when the
annular or donut-shaped substrate portions are cut or stamped out
of a sheet or other member 2109C (see FIG. 9C).
[0146] With reference to FIG. 9D, it will be appreciated that the
use of rectangular substrate portions can further reduce the amount
of waste material produced when the sheet 2109D of thermally
conductive material is being cut or otherwise processed. As shown,
in some embodiments, the use of rectangular substrates can help
minimize the amount of wasted substrate material, as the sheet
2109D can simply be cut along a plurality of horizontal and
vertical lines. One embodiment of a device that comprises a
plurality of rectangular thermoelectric devices 2112D that would be
configured to use such rectangular substrate portions in
illustrated in FIG. 9D.
[0147] As was described herein with reference to FIG. 1D, the air
from the first heat exchanger 154 (e.g., waste air) can be directed
in a radial direction while the air from the second heat exchanger
156 (e.g., main air) can be directed in a direction that is
parallel to the rotational axis of the motor-impeller assembly 130.
In addition to the different exit directions, the flow from the
motor-impeller may be biased to the lower side of the cavity 111.
This can result in uneven flow between heat exchangers 154, 156. In
general, it is desirable to have equal or approximately equal
amount of air delivered to both heat exchangers 154, 156.
[0148] FIG. 10 illustrates a modified heat exchanger system 300. In
the depicted embodiment, the upper and lower housing portions 302,
304 and the separator 306 are configured such that the first and
second heat exchangers 154, 156 are positioned lower than the
embodiments of FIGS. 1A-1D described above. Accordingly, the air
exiting the motor-impeller assembly 130 moves in a radial and
downward direction before entering the first and second heat
exchangers 154, 156. This arrangement pushes more air through the
first heat exchanger 154 compensating for the bias of air to the
lower portions of the cavity 111.
[0149] FIG. 1A illustrates additional embodiments in which
flow-conditioning or flow-directing fins or vanes 320 can be
positioned upstream and/or downstream of the first and second
exchangers 154, 156. These vanes can be used to provide for lateral
distribution of air flow through the outlet of the device. In some
embodiments, the fins or vanes 320 are configured to provide equal
or substantially equal flow to the thermoelectric devices. In other
embodiments, such fins or vanes 320 are used to achieve a desired
flow pattern.
[0150] FIG. 11B illustrates an embodiment in which the outlet 126
of the second heat exchanger 156 is provided with fins or vanes 322
that can be selectively used to restrict flow and thus bias flow
though the first heat exchanger 154. It will be appreciated that
one or more other devices or methods can be used to distribute
and/or condition air as it is directed radially away from the
impeller toward one or more thermoelectric devices and/or
outlets.
[0151] As discussed, the air or other fluid displaced by an
impeller may not be directed in a direction that allows easy fluid
entry into the fins or other heat exchangers. Thus, as illustrated
in FIGS. 11C and 11D, the heat exchanger system 150C can be
configured to better receive the air directed toward it by the
impeller 130C. With reference to the detailed top view of FIG. 11D,
adjacent fins 156C or other heat exchangers can be oriented in such
a way as to facilitate entry of fluid therethrough. For example,
the fins 156C can be skewed relative to radial direction by a
particular angle .theta..sub.2 that is generally adapted to match
or substantially match the anticipated airflow direction A. As a
result, fluid head-losses through the system can be advantageously
reduced. Further, such features can help reduce noise, improve the
efficiency of the system and provide one or more other
advantages.
[0152] FIGS. 11E-11G illustrates various other embodiments of heat
exchanger systems 150E, 150F, 150G that are configured to better
accommodate air or other fluid as it approaches the leading end of
these systems. For example, as with the arrangement illustrated in
FIG. 1 ID, the three embodiments depicted in FIGS. 11E-11G comprise
fins 156E, 156F, 156G with leading ends that are curved according
to the anticipated direction of the airflow A leaving the
impeller.
[0153] As shown in FIG. 11E, the tail ends of the fins 156E or
other heat exchangers can also be curved (e.g., either in the same
direction as the leading ends or in the opposite direction).
Further, the tail ends of the fins 156F can be non-curved (e.g.,
generally aligned with the radial direction) as illustrated in FIG.
11F. In addition, as shown in FIG. 11G, the fins 156G or other heat
exchangers can have any other shape or configuration to permit the
air entering and passing therethrough to be directed in a desired
manner.
[0154] FIG. 11H illustrates a perspective view of folded fins 156H
configured to be used with any of the embodiments disclosed herein.
As discussed, such fins or other heat exchangers can be placed in
thermal communication with one or more thermoelectric devices or
substrates. A particular assembly can include one, two or more sets
of such fins 156H, as desired or required. As discussed, a unitary
structure of such heat exchangers can be placed on the top or the
bottom of one, two or more heat exchanger modules.
[0155] FIGS. 11I and 11J illustrate top and side view,
respectively, of another embodiment of folded heat exchangers 156I
(e.g., fins). As shown, the fins 156I can include a curved or
fluted shape. For example, as discussed, such a configuration can
facilitate the entry of air or other fluid therethrough. It will be
appreciated that heat exchangers can include one or more other
shapes, designs or configurations, as desired or required.
[0156] FIG. 12A illustrates another arrangement for biasing flow
between the first and second heat exchanger 154, 156. In this
embodiment, the motor-impeller assembly 130 comprises a horizontal
splitter plate 138 that divides the blades of the impeller 130 into
an upper portion 132a with a height L1 and a lower portion 132b
with a height L2, where L2>L1. By increasing the relative depth
or other dimension of either the upper portion 132a or lower
portion 132b, air can be biased to either the first or second heat
exchanger 154, 156, as desired or required by a particular
application or use. As compared to the embodiment of FIG. 10, this
embodiment advantageously can maintain the generally flat profile
of the top surface of the system (i.e., the top wall 302 of FIG. 10
can include a step).
[0157] FIG. 12B illustrates a top view of an embodiment of a
motor-impeller assembly 130 comprising the horizontal splitter
plate 138 illustrated in FIG. 12A. A plurality of spokes 136
extending from the motor rotor 134 to the splitter plate 138/blade
132a, 132b assembly may permit fluid drawn in through the intake or
inlet 122 (FIG. 1D) to flow to the lower portion 132b of the
blades. Those skilled in the art will understand that other means
for providing fluid to the lower portion 132b of the blades can be
used in other embodiments, either in lieu of or in addition to the
devices and methods specifically disclosed herein. For example, one
or more fluid intakes in the bottom wall 114 (FIG. 1D) can be
provided.
[0158] FIG. 13A illustrates a modified embodiment of the
arrangement of FIG. 12. In this embodiment, the splitter plate 138
can be angled upwardly or downwardly at an angle .theta. from the
radial direction in order to provide a smooth transition as the air
is turned towards either the first or second heat exchangers. This
can reduce and/or eliminate turbulence caused as the air contacts
the splitter plate 138. FIG. 13B is a detailed view of the region
around the splitter plate 138 in which the relative fluid flow is
generally indicated by arrows. In some embodiments, the splitter
plate 138 can also include a curved or otherwise shaped profile to
further reduce turbulence as desired or required by a particular
application or use.
[0159] FIGS. 14A and 14B illustrate an embodiment of the
motor-impeller assembly 130 comprising a top ring 139 in a
perspective view and in a side cross-sectional view, respectively.
In some embodiments, the top ring 139 reduces airflow through the
upper heat exchanger that is in fluid communication with the upper
chamber 118, as shown in FIG. 14C, which is a cross-sectional view
of a computational fluid dynamics (CFD) model of a motor
motor-impeller assembly 130 comprising a top ring 139. It is
believed that turbulence from the top ring 139 may be responsible
for the reduced airflow through the upper heat exchanger, which
results in an unbalanced airflow between the first and second heat
exchangers.
[0160] Accordingly, some embodiments of the motor-impeller assembly
130 do not comprise a top ring, an embodiment of which is
illustrated in FIG. 15 in a side cross sectional view. Some
embodiments of the motor-impeller assembly 130 provide improved
airflow through the upper heat exchanger compared with similar
motor-impeller assemblies comprising a top ring, thereby resulting
in a more balanced airflow between the first and second heat
exchangers.
[0161] FIG. 16 illustrates a side view of another embodiment of a
motor-impeller assembly 130 that permits control over the relative
airflow through the first and second heat exchangers. As shown, the
motor-impeller assembly 130 can comprise a vertical splitter plate
138 that generally divides the blades into an upper portion 132a
and a lower portion 132b, similar to the embodiments illustrated in
FIGS. 12A, 13A, and 13B. In the illustrated embodiment, the
relative airflow is modified by varying the number of upper
portions 132a and/or lower portions 132b of the blades. For
example, the illustrated embodiment comprises 50 upper blade
portions 132a, 80 lower blade portions 132b. Those skilled in the
art will understand that other embodiments comprise a different
number of upper blade portions 132a and lower blade portions 132b,
as desired or required. Further, the number of upper blade portions
132a can be greater than the number of lower blade portions 132b.
Factors affecting the number of upper blade portions 132a and lower
blade portions 132b in a particular application may include, but
are not limited to, the specific geometry (e.g., shape, size, etc.)
of the motor-impeller assembly 130 and overall device, the
characteristics of the heat exchangers and/or the like. In some
embodiments, such factors are determined by modeling, for example,
by CFD, by using one or more empirical methods and/or the like.
[0162] As discussed herein, some embodiments are useful in
providing conditioned air to vehicle seats, beds, furnishings,
wheelchairs, other stationary or mobile seating assemblies or other
devices and/or the like, but are not limited to such uses. The
method and apparatus is useful anywhere a localized flow of
conditioned air is desired. In some arrangements, such fluid
transfer systems and devices adapted to selectively thermally
condition air or other fluids can be directed toward one or more
users either directly (e.g., spot heating or cooling) or through a
fluid distribution system of a seat assembly or other device. FIG.
17 illustrates one embodiment in which heat exchange systems 100,
as described herein, are used in combination with a ventilated
vehicle seat 10. Such systems 100 can be controlled separately
through dedicated controllers 12 or through a main control unit
(not shown).
[0163] Embodiments of the systems, devices, and methods described
herein are not limited to conditioning air and/or other gases or
fluids. Some gases, for example helium, have greater thermal
conductivity than air and are desirable in certain applications,
while other gases such as oxygen, nitrogen and/or argon are
desirable in other applications. A variety of gases and gas
mixtures can be used depending on the particular application.
[0164] Some embodiments are useful in heating or cooling other
fluids, for example, liquids and/or supercritical fluids through
the use of appropriate seals, insulators, and/or other components
known in the art, thereby preventing such fluids from adversely
affecting the performance of electrical contacts, the
thermoelectric device and/or any other electrical and/or mechanical
components. Thus, liquids such as water and antifreeze are
compatible with embodiments of the method and apparatus described
herein, as are liquid metals (e.g., liquid sodium), slurries of
fluids and solids, other Newtonian or non-Newtonian fluids and/or
the like.
[0165] Because the temperature change available from a
thermoelectric system can be significant, the heat exchanger
systems described herein and variations thereof can be applicable
to a wide variety of uses. The method and apparatus described
herein are generally applicable to any situation where there is a
desire to transfer (e.g., pump) a thermally conditioned fluid. Such
applications include constant temperature devices, for example,
devices using a reference temperature as in a thermocouple
assembly. Another exemplary application is as a component in a
constant temperature bath, for example, for laboratory and/or
industrial applications. The method and apparatus described herein
are useful in applications with low flow rates and/or small
temperature changes, as well as applications with large flow rates
and/or substantial temperature differences.
[0166] By placing a temperature sensor at a predetermined location,
whether on the heat exchanger, upstream or downstream of the heat
exchanger and/or elsewhere, and electronically controlling the
impeller 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, some embodiments are particularly useful where
localized thermal control is desired, for example, in vehicle
seats, beds, waterbeds, aquariums, water coolers, cooling of
beverages and the like.
[0167] In certain embodiments, the thermoelectric device can
comprise one or more sensors. In some embodiments, such sensors,
which can be disposed within the thermoelectric device or outside
the thermoelectric device, can be configured to communicate with
one or more of the control devices (not shown) such that the
temperature can be used as part of a control routine and/or as part
of a fail-safe mechanism. In other embodiments, the temperature
sensor can be positioned at other positions within the
blower/thermoelectric device assembly and/or upstream and/or
downstream of the assembly.
[0168] Furthermore, some embodiments find particular application in
situations where a fluid with different temperatures at different
times is desired. In some embodiments, the device is operated as a
fan, and the thermoelectric aspect is activated as desired. Thus,
some embodiments provide warmer, cooler, and/or ambient temperature
fluid.
[0169] In another embodiment illustrated in cross section in FIG.
18A and in perspective in FIG. 18B, the device 1800 does not
comprise a TED, heat exchanger, heater, or other temperature or
thermal modifying unit. Instead, the device or system can be
configured as a radial outlet blower 1800 comprising a housing
1810, an intake 1822, an outlet 1824 and a motor-impeller assembly
1830, similar to the corresponding components in the device 100. In
the illustrated embodiment, the direction of the airflow out of the
outlet 1824 is generally coaxial with an axis of symmetry of the
device 1800. Such a configuration has advantages in applications in
which ventilation is distributed over a large surface, for example,
for a seat, a cushion, or a bed, because air distribution channels
1892 can be fluidly connected around the perimeter of the outlet
1824, as illustrated in FIGS. 18C and 18D in a top view and a side
view of an embodiment of a radial outlet blower 1800 mounted in a
seat cushion 1890. Because the airflow is spread out at the blower
outlet, less pressure is required compared with other blower
assemblies discussed herein.
[0170] In a blower 1900 in which the airflow out of an outlet 1924
is turned (e.g., by 90 degrees or so) using a snout, for example as
illustrated in FIG. 19A, one or more distribution channels of a
seating assembly, bed or other device are coupled through the
snout, resulting in a more complicated fluid connection system.
Such a system may also exhibit greater back pressure, for example,
as illustrated in FIGS. 19B and 19C in a top view and a side view
of a blower 1900 mounted in a seat cushion 1990 and associated
distribution channels 1902.
[0171] Some embodiments of the radial outlet blower 1800 also
exhibit reduced noise compared with other types of blowers. For
example, a blower 1900 illustrated in FIG. 19A comprises a "cutoff
zone" 1980 at the cutoff of the scroll. In some arrangements, at
such a cutoff zone, a portion of the air exits the outlet 1924 and
another portion continues to circulate within the housing of the
blower 1900, which can create noise depending on the configuration
of the scroll, the impeller and the cutoff. Because the radial
outlet blower 1800 illustrated in FIG. 18A does not comprise a
cutoff, the device 1800 does not generate any cutoff noise,
resulting in a quieter device. Moreover, noise in a blower is also
associated with non-uniformities in flow, pressure, velocity and/or
one or more other flow characteristics or properties, which result
in pressure gradients around the circumference of the housing. The
symmetry of the radial outlet blower 1800 can be configured to
reduce such non-uniformities, thereby reducing noise at a similar
flow rate and backpressure.
[0172] Some embodiments of radial outlet blowers 1800 do not
generate as high a back pressure at a similar airflow as a blower
comprising a scroll, however, and consequently, are not suitable
for certain applications in which a relatively higher back pressure
is desired.
[0173] FIG. 20 illustrates a side cross sectional view of an
embodiment of a seating system 2000 comprising radial outlet
blowers 1800 configured to ventilate a seating surface 2010 and a
back 2020. The illustrated embodiment comprises optional heating
mats 2030 or other heating elements disposed below seat trim 2040
on both the seat surface 2010 and back 2020.
[0174] In any of the embodiments disclosed herein, the integrated
blower-TED device can be configured to direct thermally-conditioned
air or other fluid directly to one or more users. For example, such
air can be delivered to a user's neck, shoulders, legs and/or other
anatomical area using a duct or other conduit (e.g., internal
channels of a seating assembly, bed, etc.). In some arrangements,
such ducts or conduits are positioned outside of a seating assembly
(e.g., routed along a side of a seat, bed, etc.).
[0175] In other embodiments, as illustrated in FIG. 20, one or more
main outlets of a combined blower-TED device can be configured to
be in fluid communication with corresponding channels, inlets or
other conduits formed within a cushion, mattress (e.g., core
portion, topper portion, etc.) or any other member or component of
a seating assembly (e.g., vehicle seat, bed, etc.). As discussed,
this can eliminate the need for separate conduits or
interconnecting duct members, which may be particularly
advantageous in embodiments where space is generally relatively
limited.
[0176] Although several preferred embodiments and certain features
are described herein, it will be understood that various omissions,
substitutions, combinations, and changes one or more of the details
of the system, apparatus, and/or method, may be made by those
skilled in the art without departing from the present disclosure.
Also, one or more various components of one figure and/or
embodiment may be used in different combinations with components of
other figures and/or embodiments to produce specific combinations
not illustrated and/or described in any particular figure or
embodiment. Consequently, the scope of the disclosure is not
limited by the foregoing discussion, which is intended to
illustrate.
* * * * *