Abstract:
Apparatus and Method for accelerating the warm-up of a heater/defroster in a passenger compartment of an automotive vehicle. A working fluid, such as power steering oil is rapidly heated by pumping it through a small orifice. An oil-to-coolant heat exchanger transfers heat from the working fluid to a liquid coolant. A blower generates an air stream and directs it across heat exchange surfaces of a coolant-to-air heat exchanger. Meanwhile the heated coolant is circulating through the interior of the coolant-to-air heat exchanger. This transfers heat from the liquid coolant and warms the air stream.

Description:
BACKGROUND OF THE INVENTION 
     This invention relates to heating systems for automotive passenger vehicles. A principal object is to speed up the delivery of heat to the heater and the windshield defroster on a cold day. Commonly used prior art automobile heating systems rely upon heat generated in the engine. This heat is transferred to a liquid coolant which is routed through a heater core located in the passenger compartment. 
     During normal operation of the vehicle the coolant is directed through a connected series of internal engine passages. These passages are connected to a radiator which cools the engine by transferring excess heat from the coolant to the outside environment. When the engine is started from an initially cold condition, it passes through an engine warm-up phase during which the coolant bypasses the radiator. This conserves energy and speeds up the onset of smooth, normal operation. 
     On a cold day the engine warm-up phase continues for about 15 minutes, the coolant is insufficiently hot for warming the passengers or defrosting the windshield until after that period of time has elapsed. This is especially true for vehicles equipped with diesel engines. In the future, as engines become more efficient, smaller amounts of excess engine heat will be generated. This then will further prolong the engine warm-up time. 
     Several methods are currently employed for decreasing vehicle warm-up time. One such method involves using an electric heater in line with the pre-existing heat exchanger. This arrangement decreases vehicle warm-up time, but it requires a substantial increase in electrical power supplied by the alternator. As a practical matter, the surplus electrical power available for servicing such a heating system is limited to about 1.0 kw. Other known methods for increasing heat to the passenger compartment include gas fired heaters, viscous shearing devices, and electric seats. 
     SUMMARY OF THE INVENTION 
     This invention speeds up the operation of an automotive heating system by providing a novel local heat generator in the form of an orifice of appropriate size. A working fluid, preferably an oil such as power steering fluid, is heated by pumping it through the orifice at an appropriate mass flow rate. A 5-10 KW hydraulic pump is considered to be suitable for this purpose. The invention may be practiced through the use a dedicated pump, but a shared pump also could be used. A suitable shared pump could provide pressurized hydraulic fluid flow for other functions such as power steering, braking or radiator fan operation. Heat energy, delivered to the working fluid during passage through the orifice, is transferred to an airstream flowing through the passenger compartment, thereby warming the occupants and defrosting the windows. 
     In a first embodiment of the invention the working fluid is a hydraulic fluid, which flows through an oil-to-coolant heat exchanger, following passage through the orifice. As the working fluid passes through the oil-to-coolant heat exchanger, it heats a liquid coolant which is passing concomitantly therethrough. The liquid coolant flows through a coolant-to-air heat exchanger situated in the passenger compartment. A blower fan then heats the passenger compartment by blowing ambient air across heat transfer surfaces in the coolant-to-air heat exchanger. Meanwhile the engine is being separately heated by another flow of liquid coolant flowing in a loop which has a direct return to the engine. 
     Further, in the first embodiment there is a thermostatic valve which directs the return flow of liquid coolant through a radiator when the engine has been heated to a suitably high operating temperature. There is also a bypass valve for isolating and circulating a fraction of the liquid coolant, independently of the main engine coolant circuit. This reduces the thermal mass of the liquid coolant used for heating the passenger compartment, thereby increasing the speed of warm-up. 
     A second embodiment of the invention also uses hydraulic oil as a working fluid. However, two heat exchangers are mounted in the passenger compartment; one of which exchanges heat from oil to air; and the other of which exchanges heat from coolant to air. There is no heat exchange from oil to coolant. The two heat exchangers are positioned in tandem, so that air can be blown in sequence over the two sets of heat exchange surfaces. 
     In a third embodiment of the invention an oil-to-air heat exchanger and a coolant-to-air heat exchanger are placed side-by-side. Air flow is provided by single blower and suitable ductwork. 
    
    
     BRIEF DESCRIPTION OF THE DRAWING 
     FIG. 1 is a sketch of an automobile heater/defroster according to a first embodiment of the invention. 
     FIG. 2 is a sketch of an automobile heater/defroster according to a second embodiment of the invention. 
     FIG. 3 is a sketch of an automobile heater/defroster according to a third embodiment of the invention. 
     FIG. 4 is a plot comparing the warm-up time for the present invention with the warm-up time for a typical prior art automobile heater/defroster. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     FIG. 1 illustrates a preferred embodiment of the invention, able to warm up output air from an automobile heater to a temperature of about 140 degrees Fahrenheit in about 3 minutes, based upon actual performance measurements. The illustrated embodiment operates in association with an internal combustion engine  10  cooled by a liquid coolant flowing through a series of internal passages (not illustrated) within the engine. A 50/50 mixture of ethylene glycol antifreeze and low mineral content water will function satisfactorily as a coolant. During operation at normal temperatures, the coolant flows from engine  10 , via a radiator supply line  23 , to a radiator  12  where excess engine combustion heat is absorbed and radiated to the atmosphere. A primary water pump  14  maintains coolant flow through radiator  12  to engine  10 , so long as the coolant temperature remains above some predetermined minimum. This provides engine cooling, as required. 
     A thermostatic valve  16 , connected as illustrated in FIG. 1, prevents coolant flow through radiator  12  so long as the temperature thereof is below the predetermined minimum. A temperature sensor (not illustrated) causes thermostatic valve  16  to be switched to an alternative position (connections for which may be understood by reference to FIG.  1 ), after the cooling liquid has reached the predetermined minimum temperature. Thermostatic valve  16  operates in a manner known in the prior art to reduce engine warmup time by preventing early heat loss through radiator  12 . 
     The embodiment of FIG. 1 has a bypass valve  18  which can be switched selectively between a first position and a second position, both of which may be understood by referring to the figure. In the condition illustrated in FIG. 1 bypass valve  18  is in the first position in which the coolant flowing through engine  10  is isolated from other coolant flowing through a passenger compartment  400  (illustrated by phantom lines) via a coolant-to-air heat exchanger  24 . In the second position coolant flow leaving engine  10  travels through valve  18  and heat exchanger  24  in which case heat from engine is transferred to passenger compartment  400  as is typical in present art. It will be understood that bypass valve  18  divides coolant between an Engine Loop and a Passenger Compartment Loop maintaining a relatively much smaller volume in the Passenger Compartment Loop. This reduces the thermal mass of the liquid coolant used for heating the passenger compartment, thereby increasing the speed of warm-up. 
     Heat exchanger  24  comprises a conventional heater core, provided with heat exchange surfaces (not illustrated) which remove heat from the coolant flowing within distribution line  22  and transfer it to a stream of air generated by a blower  26 . 
     A secondary water pump  34 , powered by a motor  36 , withdraws coolant from a coolant storage vessel  32  and directs it via a second coolant supply line  42  to an oil-to-coolant heat exchanger  28 . Coolant returns from oil-to-coolant heat exchanger  28  to secondary water pump  34  via second coolant distribution line  31 , first coolant distribution line  22 , coolant-to-air heat exchanger  24 , a second coolant return line  27  and a third coolant return line  29 . 
     While secondary water pump  34  is supplying coolant to oil-to-coolant heat exchanger  28 , an oil pump  38  is withdrawing oil from an oil storage vessel  40  and supplying it to oil-to-coolant heat exchanger  28  via an orifice  44  and an oil distribution line  30 . Preferably, oil pump  38  is of sufficient size to provide 5-10 KW of hydraulic energy at vehicle idle conditions. 
     The task of oil-to-coolant heat exchanger  28  is to rapidly heat coolant being supplied to coolant-to-air heat exchanger  24  during the period of time while engine  10  is warming up from a cold start. Heat exchanger  28  performs this task by withdrawing heat from oil flowing through oil distribution line  30  and transferring it into the flowing liquid coolant being pumped into line  42  by secondary water pump  34 . Preferably oil-to-coolant heat exchanger  28  has a heat transfer capability of about 40 BTU/min-degrees Fahrenheit, and coolant-to-air heat exchanger  24  has a heat transfer capability of about 24 BTU/min-degrees Fahrenheit. These heat transfer capabilities may be achieved by appropriate selection of heat transfer coefficients and surface areas for the heat exchangers, as is well known in the art. A blower rating of 150 cfm is satisfactory. 
     The oil provided by oil distribution line  30  may be power steering oil, commercially available as Mopar MS-5391 or its equivalent. This oil is heated by resistance to flow through orifice  44 . Flow parameters may be selected so as to provide a heating performance of particular interest. By way of example, orifice  44  may have a diameter of about 0.1 inch and may throttle oil flowing therethrough at a rate of about 10 gpm. This provides a pressure drop of approximately 2000 psi and generates heat at a rate of about 500 Btu/min. A suitable oil pump  38  may be either a vane-type or a gear-type, having a displacement of 4.2 cubic inches and a volumetric efficiency of 85%. Of course, the pump must have sufficient structural integrity for handling a head of 2000 psi. 
     A heater/defroster configured as above described will heat the oil flowing through oil distribution line  30  to a temperature of 150 degrees Fahrenheit in approximately one minute. The air blowing past the heat exchange surfaces of coolant-to-air heat exchanger  24  will rise to a temperature of 150 degrees Fahrenheit in approximately 2 to 3 minutes. FIG. 4 compares the computed performance of such a heater/defroster with test results for a typical prior art system not equipped with temperature boosting means according to this invention. As shown therein by curve  50 , the temperature of the heated air provided by this invention rises rapidly to about 170 degrees Fahrenheit in about 5 minutes and then levels off. Curve  52  presents a corresponding plot of temperature vs. time for a typical prior art system. This latter curve climbs much more slowly to a maximum temperature of about 150 degrees Fahrenheit in about 15 minutes. Clearly the invention provides a substantial increase in passenger comfort on cold days, along with much faster windshield defrosting. A secondary benefit is a reduction in engine and transmission warm-up times. This system could be disabled during normal operation to minimize energy consumption, or could be disabled during times when quick acceleration is desired. 
     FIG. 2 illustrates a second embodiment of the invention. For ease of understanding, elements of FIG. 2 have like reference numerals as corresponding elements in FIG.  1 . The alternative embodiment of FIG. 2 differs from the embodiment of FIG. 1 in its elimination of bypass valve  18  and secondary water pump  34 . Also, blower  26  warms the passenger compartment by blowing air over an oil-to-air heat exchanger  240  placed in front of a coolant-to-air heat exchanger  250 . Oil pump  38  and orifice  44  provide a supply of quickly heated oil for use in a fast warm-up of the air stream generated by blower  26 . Thereafter the heat required for warming the above-mentioned air stream is supplied by engine  10 . As mentioned above in connection with the embodiment of FIG. 1, primary water pump  14  pumps liquid coolant through engine  10  and into coolant supply line  20 . Following warm-up, thermostatic valve  16  opens to permit coolant flow through radiator  12 . Heat exchanger  250  is substantially similar to a prior art heater core. This embodiment could be implemented using a 2-part heater core, with oil passing through one half, and coolant through the other half. 
     FIG. 3 illustrates a second alternative embodiment which is substantially similar to the first alternative embodiment of FIG.  2 . The primary difference is that the heat exchangers  240 ,  250  are arranged side-by-side rather than in tandem. This requires a damper door  360  and suitable ductwork, as generally illustrated in the figure.