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Fluid heater control apparatus and method with overtemperature protection Number:6,839,509 from the United States Patent and Trademark Office (PTO) owispatent

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Title: Fluid heater control apparatus and method with overtemperature protection

Abstract: A fluid heater apparatus has fluid discharge temperature control to prevent temperature overshoot. A plurality of heater elements are employed and at least certain of the heater elements are independently controllable. At least one of the heater elements is employed as a "finishing" heater element, with the other heating elements deactivated to enable the "finishing" heater element to more slowly elevate the temperature of the fluid in the body from a first temperature reached by activation all or most of the heater elements to the predetermined discharge temperature. One of more of the heater elements may have a different power output than the other heater elements.

Patent Number: 6,839,509 Issued on 01/04/2005 to Kuebler,   et al.

Inventors: Kuebler; Karl-Heinz (Grand Blanc, MI); Harris; Daryl G. (Oxford, MI)
Assignee: Valeo Electrical Systems, Inc. (Auburn Hills, MI)
Appl. No.: 377345
Filed: February 28, 2003

Current U.S. Class: 392/484; 137/334
Intern'l Class: F24H 001/10
Field of Search: 392/465-484

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Primary Examiner: Campbell; Thor
Attorney, Agent or Firm: Lewis; J. Gordon
Claims


What is claimed is:

1. A method of heating fluid in a vehicle surface wash fluid discharge apparatus comprising the steps of:

providing fluid in an enclosure;

providing a plurality of heating elements for imparting thermal energy to the fluid;

controlling at least two of the heating elements independent of each other;

activating certain ones of the heating elements for a first time period to impart thermal energy to the fluid to rapidly increase the fluid temperature;

monitoring the temperature of the fluid; and

at a first temperature less than a preset maximum discharge fluid temperature, activating certain ones of the heating elements to more slowly elevate the temperature of the fluid to the preset maximum discharge temperature to minimize overshoot of the fluid temperature above the maximum discharge temperature.

2. The method of claim 1 wherein the step of activating certain heating elements comprise the steps of:

activating all of the heater elements to bring the temperature of the fluid up to the first temperature; and

maintaining at least one of the heater elements in an activated state to elevate the temperature of the fluid from the first temperature to the preset discharge temperature.

3. The method of claim 1 further comprising the step of:

providing at least one of the plurality of heater elements with a different power output than the other heater elements.

4. The method of claim 3 wherein the step of providing at least one heater element with a different power output further comprises the step of:

providing the at least one heater element with a lower power output than the other heater elements.

5. The method of claim 1 wherein the steps of activating certain heating elements further comprise the steps of:

activating certain ones of the heater elements to elevate the temperature of the fluid up to the first temperature;

deactivating the certain ones of the heater elements and activating another heating element to elevate the temperature of the fluid from the first temperature to the preset discharge temperature.

6. An apparatus for heating fluid in a vehicle surface wash fluid discharge system comprising:

means for providing fluid in an enclosure;

a plurality of heating elements for imparting thermal energy to the fluid;

means for controlling at least two of the heating elements independent of each other;

means for activating certain heating elements for a first time period to impart thermal energy to the fluid to rapidly increase the fluid temperature;

means for monitoring the temperature of the fluid; and

means, responsive to the temperature monitoring means at a first temperature less than a preset maximum discharge fluid temperature, for activating another one other of the heating elements to more slowly elevate the temperature of the fluid to the preset maximum discharge temperature more slowly to minimize overshoot of the fluid temperature above the maximum discharge temperature.

7. The apparatus of claim 6 further comprising:

at least one of the heating elements having a different power output than the other heating elements.

8. An apparatus for heating fluid in a vehicle surface wash fluid discharge system comprising:

an enclosure having a fluid flow path therethrough for receiving fluid;

a plurality of heater elements thermally coupled to the enclosure for imparting thermal energy to the enclosure and the fluid in the enclosure; and

control means for controlling the plurality of heater elements, with at least two of the heater elements being controlled independent of each other; and wherein

the control means includes means for activating at least certain of the heating elements for a first time period to impart thermal energy to the fluid to rapidly increase the temperature of the fluid in the body to a first temperature less than a preset maximum discharge fluid temperature and activating certain heating elements to more slowly elevate the temperature of the fluid in the body from the first temperature to the preset maximum discharge temperature to minimize overshoot of the fluid temperature above the maximum discharge temperature.

9. The apparatus of claim 8 wherein the control means further comprises:

means for deactivating all of the heating elements activated to elevate the temperature of the fluid to the first temperature; and

means for activating at least another one heating element to elevate the temperature of the fluid from the first temperature to the first preset maximum discharge temperature.

10. The apparatus of claim 8 wherein:

at least one of the heater elements has a different power output than the other heating elements.
Description


BACKGROUND

This invention relates, in general, to fluid heater apparatus and, more particularly, to fluid heater apparatus which provide a heated wash fluid to a cleanable surface, and, still more specifically, to a heated wash fluid apparatus for a vehicle windshield wash system.

It is necessary in many diverse applications to quickly elevate the temperature of a fluid to a higher use temperature. For example, it is desirable to be able to provide instant hot water, for use in homes, offices and campers, as well as for industrial processes.

In cleaning applications, it is known that hot fluid removes dirt and other debris from a surface much better and much faster than colder fluids. One heated fluid application is a vehicle wash fluid system, such as a windshield wash system as well as vehicle wash systems applied to camera lenses, exterior lamps and lamp lenses, mirrors, etc. Vehicles are typically provided with at least one and usually multiple windshield washers which are used to clear the field of vision in a windshield or rear backlight.

Typically, a nozzle or spray device is provided adjacent to or as part of the windshield wiper to disperse a pattern of wash fluid onto the windshield prior to and during the wiping operation to improve the efficiency of the wiping operation so as to provide a clear field of vision for the driver or vehicle passengers. The wash fluid is typically stored in a reservoir in the engine compartment and is pumped through the spray device upon manual activation of a control actuator by the vehicle driver.

Since it is known that warm or heated fluid provides better cleaning efficiency than cold fluid, it is known to provide a heated wash fluid to a vehicle window spray device. However, there is an upper limit to the temperature at which the wash fluid can be heated to avoid evaporation and energy waste. Single element heaters limit the possibilities available for control of the heating sequence since the single heating element is either on or off.

Thus, it would be desirable to provide a fluid heater apparatus which provides a heated fluid in an efficient manner with minimum energy and without heating the fluid to a temperature above the preset maximum operating temperature to avoid evaporation of the fluid.

SUMMARY

The present invention is a method and apparatus for controlling the discharge temperature of a fluid from a fluid heater apparatus to prevent fluid overtemperature. In one aspect, the method includes the steps of:

providing fluid in an enclosure;

providing heating means as a plurality of heating elements for imparting thermal energy to the fluid in the enclosure;

control means for controlling at least two of the heating elements independent of each other;

activating at least one of the heating elements for a first time period to quickly impart thermal energy to the fluid;

monitoring the temperature of the fluid; and

at a first temperature less than a preset maximum discharge fluid temperature maintaining a minimal number of heating elements in an activated state to more slowly elevate the temperature of the fluid to the preset maximum discharge temperature.

In another aspect, the method further comprises the steps of activating all of the heater elements simultaneously to elevate the temperature of the fluid up to the first temperature, and maintaining at least one of the heater elements in an activated state to elevate the temperature of the fluid to the preset discharge temperature.

In another aspect, the method further comprises the steps of activating certain of the heater elements to elevate the temperature of the fluid to the first temperature, and deactivating the certain of the heater elements and activating another heating element to elevate the temperature of the fluid to the preset discharge temperature.

In another aspect, the present invention defines an apparatus for heating fluid. In this aspect, the apparatus includes:

an enclosing having a fluid flow path therethrough for receiving fluid;

a plurality of heater elements thermally coupled to the enclosure for imparting thermal energy to the enclosure and fluid in the enclosure; and

control means for controlling the plurality of heater elements, with at least two of the heater elements being controlled independent of each other; and wherein

the control means includes means for activation at least of the heating elements for a first time period to impart thermal energy to the fluid to elevate the temperature of the fluid in the body to a first temperature less than a preset maximum discharge fluid temperature and activating at least one other heating element to elevate the temperature of the fluid in the body from the first temperature to the preset maximum discharge temperature.

In yet another aspect, the present invention is an apparatus for providing a heated fluid to clean a vehicle surface. In this aspect, the apparatus includes:

an enclosure;

a fluid flow path extending through the enclosure for receiving cleaning fluid;

a plurality of heater elements thermally coupled to the enclosure for imparting thermal energy to the enclosure and the fluid in the enclosure;

control means for controlling the plurality of heater elements, with at least two of the heater elements being controlled independent of each other; and wherein

the control means includes means for activation at least of the heating elements for a first time period to impart thermal energy to the fluid to elevate the temperature of the fluid in the body to a first temperature less than a preset maximum discharge fluid temperature and activating at least one other heating element to elevate the temperature of the fluid in the body from the first temperature to the preset maximum discharge temperature.

In any of the different aspects of the present invention, one or more of the plurality of heater elements may have a different power output or rating than the other heater elements. This enables, for example, a lower power output heating element to act as the finishing and maintaining heater element to reduce total power requirements for the heater module.

The method and apparatus of the present invention uniquely prevents overtemperature of the discharge fluid about the preset maximum temperature which could lead to disadvantageous evaporation of the heated fluid as well as waste of electrical power. The use of a plurality of controllable heater elements enables one of the heater elements to be designated as a "finishing" heater element to more slowly elevate the temperature of the fluid up to the preset discharge temperature or to be activated independently after the other heater elements have been deactivated.

BRIEF DESCRIPTION OF THE DRAWING

The various features, advantages and other uses of the present invention will become more apparent by referring to the following detail description and drawing in which:

FIG. 1 is a block system diagram of a fluid heater apparatus according to the present invention used in an exemplary vehicle window wash fluid delivery system;

FIG. 2 is a perspective view of a heater module according to one aspect of the present invention;

FIG. 3 is an exploded perspective view of the heater module shown in FIG. 2;

FIG. 4 is a perspective view, taken from the right side of FIG. 3, of the heater module of the present invention;

FIG. 5 is a top perspective view of the heater module thermal mass;

FIG. 6 is a bottom elevational view of the heater module thermal mass shown in FIG. 5;

FIG. 7 is a plan view of the interior of the heater module shown in FIG. 4;

FIG. 8 is a longitudinal, cross-sectional view of the heater module shown in FIGS. 2-7;

FIG. 9 is an enlarged, side cross-sectional view of a portion of the heater module shown in FIG. 8;

FIG. 10 is a graph depicting the time sequence of activation of the heater elements according to one aspect of the present invention; and

FIG. 11 is a graph depicting the time sequence of activation of the heater elements according to another aspect of the present invention.

DETAILED DESCRIPTION

Referring now to FIG. 1, there is depicted an environment in which a heater apparatus or module 10 constructed in accordance with the teachings of the present invention can be advantageously utilized. Although the following use of the heater module 10 of the present invention is described in conjunction with a vehicle window wash system, it will be understood that the present heater module may be employed in other applications requiring heated fluid, such as any cleaning system used to clean any vehicle window, i.e., the windshield, rear backlight, or side windows, as well as cleaning systems for other vehicle surfaces such as mirrors, camera, lenses, sensor covers, etc.

It will be understood that the following description of a heater module which uses heater elements embedded in a thermally conductive mass through which a fluid flow path extends is only one example of a heater apparatus which is capable of advantageously using the fluid temperature control of the present invention. For example, fluid heaters employing heater elements mounted in direct or semi-direct contact with a fluid flow can also employ the features of the present invention.

As is conventional, a vehicle window 12, such as a windshield, rear backlight or window, etc., has one or more fluid delivery devices, such as spray nozzles 14 located in a position to dispense or spray a pattern 16 of wash fluid onto the exterior surface of the window 12. The dispersion of the wash fluid 16 is usually in conjunction with activation of a windshield wiper 18 over the window 12.

The wash fluid 16 is supplied from a fluid source, such as a reservoir or container 20. The fluid in the reservoir 20 is pumped to the nozzle(s) 14 by means of a pump 22 usually located in close proximity or attached to the reservoir 20.

As is conventional, an on/off switch 24, which may be mounted on a vehicle steering column stalk switch, is suppled with power from the vehicle battery 26 and enables the vehicle driver to control the on or off operation of the wash pump 22.

According to the invention, the wash fluid pumped from the reservoir 20 to the spray nozzles 14 is heated from ambient temperature to a predetermined higher temperature, such as 65.degree. C. to about 70.degree. C., by example only, by the heater module 10. A suitable control circuit or controller 28 is provided for controlling the operation of the heater elements in the heater module 10. The controller 28 is also supplied with electric power from the vehicle battery 26. The controller 28 is activated by a "on" signal from the vehicle ignition 30 so as to heat the fluid contained within the flow paths in the heater module 10, as described hereafter, whenever the vehicle ignition is in an "on" state.

An optional on/off switch 25 may be connected between the battery 26 and the controller 28 to provide on and off operation for the entire heater system by disconnecting power to the controller 28. This enables the heater system to be activated or remain in an inactive state at the selection of the vehicle driver. As described hereafter, the on/off switch 25 may also be replaced by a separate input signal to the controller 28 from an external signal source, such as a vehicle body controller, to provide for selective deactivation of the heater module 10 under certain circumstances, such as a thermal event, low battery power, etc.

Referring now to FIGS. 2-9, there is depicted one aspect of the heater module 10 according to the present invention.

The heater module 10 includes a heat exchange mass or body 40 formed of a suitable high thermally conductive material. Although the mass 40 is described as being formed of die-cast, molded or machined aluminum, other materials, either homogenous or non-homogenous, may also be employed. For example, the mass 40 can be formed of alumina particles, ceramic materials, etc.

The mass 40, as described in greater detail hereafter, includes a fluid flow path between an inlet 42 and an outlet 44. The inlet and outlet 42 and 44, respectively, receive a fitting 46 and an outer sleeve 48 which are joined together for receiving a fluid sealed connection to a fluid flow conduit, element or tube, not shown. The inlet 42 will be connected to receive the pump output from the window wash fluid reservoir 20; while the outlet 44 will be connected to the spray nozzle(s) 14.

As vehicles typically have several spray nozzles 14, usually one for each of the two windshield wipers, and at least one nozzle 14 for the rear backlight or rear window wiper, it will be understood that the following description of a single heater module 10 for heating all of the fluid discharge from the fluid reservoir 20 will encompass multiple parallel paths, each containing a separate heater module, for heating fluid from the reservoir 20 for each different nozzle 14.

The heat exchange mass 40 is disposed within an insulated enclosure formed by a first cover 50 and a mating second cover 52. The first and second covers 50 and 52 have complementary shapes with a major wall surface 54 and 56, respectively, and a surrounding peripheral lip 60 and 62, respectively.

A necked-down end portion 64 and 66 is formed in each of the first and covers 50 and 52, and forms an extension from one end of the respective major walls 54 and 56 as well as from the peripheral edge lips 60 and 62. The necked-down portions 64 and 66, when joined together, form an end cavity for receiving a connector assembly 70 which connects electrical conductors to the heating element(s). mounted in the joined first and second covers 50 and 52.

The first and second covers 50 and 52 and the beat exchange mass 40 are fixedly joined together, after the connector assembly 70 has been disposed in the extensions 64 and 66 of the first and second covers 50 and 52 by suitable means, such as by heat stake rivets or projections 76 projecting outwardly from opposite major surfaces of the heat exchange mass 40. The projections 76 engage apertures in the major surfaces 60 and 62 of the first and second housing parts 50 and 52 and are heat welded together to join the first and second housing parts 50 and 52 together in a fixed connection.

A pair of seal elements 71 and 72, each having a peripheral shape substantially the same as the peripheral shape of the heat exchange mass 40 are


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