Refrigerant stop valve simplification

Abstract

The present disclosure provides "refrigerant stop valve simplification". A vehicle system includes a refrigerant circuit having a specific arrangement of valves and evaporators or heat exchangers to reduce the number of valves required. The vehicle system includes a refrigerant circuit including a first thermal expansion valve located downstream of a condenser and upstream of a first evaporator. A second thermal expansion valve is located downstream of the condenser and upstream of a second evaporator. A third thermal expansion valve is located upstream of a battery cooler. This arrangement allows for simplification of the valves such that none of the thermal expansion valves include a binary stop valve. A multiple flow position valve can be positioned at a location that combines the outlets of the first and second evaporators.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to methods and systems for providing climate control for a vehicle. The methods and systems can be particularly useful for vehicles that are solely electrically propelled or vehicles that include a hybrid powertrain. BACKGROUND

[0002] It is known that various systems in a vehicle can be cooled via a fluid (e.g., coolant) system or circuit. For example, a heating, ventilation, and air conditioning (HVAC) system in a vehicle includes a fluid system or circuit that exchanges heat to allow a passenger cabin to be heated or cooled. The HVAC fluid system can include multiple heat exchangers that are isolated within the HVAC fluid system itself. It is known that the HVAC fluid system and a hybrid powertrain coolant system can be in thermal communication with one another to exchange heat between the two systems.

[0003] Such HVAC fluid systems can have three binary (on / off) refrigerant stop valves, one for each heat exchanger, and each valve is located upstream of the associated heat exchanger. All three heat exchangers can be supplied with refrigerant from a corresponding fluid line that branches from a single source, such as an AC condenser. SUMMARY

[0004] In one embodiment, a vehicle system includes a refrigerant circuit that includes a first expansion device (such as a thermal expansion valve (TXV)) located downstream of a condenser and upstream of a first evaporator. A second expansion device is located downstream of the condenser and upstream of a second evaporator. A third expansion device is located upstream of a battery cooler. None of the expansion devices include a binary stop valve.

[0005] In another embodiment, a vehicle system includes a refrigerant circuit that includes a first expansion device located upstream of a first evaporator to control a flow of refrigerant through the first evaporator, a second expansion device located upstream of a second evaporator to control a flow of refrigerant through the second evaporator, and a third expansion device located upstream of a battery cooler to control a flow of refrigerant through the battery cooler. Only one of the expansion devices includes a stop valve.

[0006] In yet another embodiment, a refrigerant circuit is configured to transfer thermal energy to or from a passenger cabin of a vehicle. The refrigerant circuit includes a plurality of evaporators and a plurality of thermal expansion valves. Each valve is located upstream of a corresponding evaporator of the evaporators, and each valve does not include a stop valve. A multiple flow position valve is located downstream of the evaporators. BRIEF DESCRIPTION OF DRAWINGS

[0007] Figure 1This is a perspective view of a vehicle having a climate control system disclosed herein, according to various embodiments.

[0008] Figure 2 This is an example of a schematic diagram of a refrigerant circuit in a climate control system, where the fluid delivered to multiple heat exchangers is controlled by individual shut-off valves.

[0009] Figure 3 This is an example of a schematic diagram of a refrigerant circuit in a climate control system according to one embodiment, wherein the number of shut-off valves is reduced and repositioned relative to the heat exchanger.

[0010] Figure 4 This is another example of a schematic diagram of a refrigerant circuit for a climate control system according to another embodiment, wherein the number of shut-off valves is reduced and repositioned relative to the heat exchanger. Detailed Implementation

[0011] Embodiments of this disclosure are described herein. However, it should be understood that the disclosed embodiments are merely examples and other embodiments may take various and alternative forms. The drawings are not necessarily drawn to scale; some features may be enlarged or minimized to show details of particular components. Therefore, the specific structural and functional details disclosed herein should not be construed as limiting, but rather as a representative basis for teaching those skilled in the art to employ the embodiments in various ways. As will be understood by those skilled in the art, various features shown and described with reference to any of the drawings may be combined with features shown in one or more other drawings to produce embodiments not explicitly shown or described. The combinations of features shown provide representative embodiments for typical applications. However, various combinations and modifications of features consistent with the teachings of this disclosure may be desired for particular applications or implementations.

[0012] This disclosure relates to a climate control system for a vehicle. The vehicle climate control system may include, for example... Figure 1 In the electric or hybrid vehicles shown. Reference Figure 1The diagram illustrates a vehicle 10 including an engine 12, a motor 14, and an energy storage device 11. In one example, the vehicle may be propelled solely by the engine 12, solely by the motor 14, or by both the engine 12 and the motor 14. The motor may be powered via the energy storage device 11. The energy storage device 11 may be recharged via the engine 12, which powers the motor 14, and the motor, which outputs electrical energy to the energy storage device 11. Optionally, the energy storage device may be recharged during vehicle deceleration or downhill driving by converting the vehicle's kinetic energy into electrical energy via the motor 14. The energy storage device 11 may also be recharged from the grid via a home charging system or a remote charging system (e.g., a charging station). In one example, the energy storage device 11 is a battery. Optionally, the energy storage device 11 may be a capacitor or other storage device.

[0013] Vehicle 10 may have a power source 12, which may be configured as an internal combustion engine suitable for burning any suitable type of fuel, such as gasoline, diesel, or hydrogen. Alternatively, vehicle 10 may be configured as a hybrid vehicle, which may have multiple power sources, such as non-power sources like engines and power sources. An energy storage device (e.g., a battery) is one example.

[0014] The coolant system disclosed herein can be implemented in various types of vehicles. For example, U.S. Patent Publication No. 2015 / 0052913 discloses a vehicle having a refrigerant circuit and a coolant circuit according to various embodiments. This is merely one example of a vehicle system that can implement the teachings of this disclosure.

[0015] Figures 2 to 4 Simplified illustrations of a specific embodiment of a refrigerant loop for a climate control system are provided. The terminology used below is simplified, but its full meaning as described in the foregoing disclosure should be given. For example, the condenser and evaporator described below can be more broadly referred to as heat exchangers, and are an example of a heat exchanger. Furthermore, Figures 2 to 4 The illustrative examples shown include a front HVAC evaporator core, a rear HVAC evaporator core, and a battery cooler. These may be more broadly referred to as evaporators or evaporator cores. The figures are merely exemplary; the teachings of this disclosure can be applied to any refrigeration system having more than one evaporative heat exchanger or expansion device and one or more associated shut-off valves.

[0016] refer to Figure 2The illustrated embodiment shows a simplified refrigerant circuit or refrigerant cycle system 110 for a vehicle. The vehicle may be a hybrid electric vehicle, a pure electric vehicle, a fuel cell vehicle, or other similar vehicle that provides a secondary propulsion source other than an internal combustion engine. The system includes three evaporators or heat exchangers: a front HVAC evaporator 112, a rear HVAC evaporator 114, and a battery cooler 116. The battery cooler may be a compact plate-to-plate heat exchanger configured to transfer heat from the battery coolant circuit to the vehicle's refrigerant circuit to maintain optimal battery temperature. An internal heat exchanger (IHX) 118 may also be located upstream of the front evaporator 112 and the rear evaporator 114. In another embodiment, the IHX 118 is not present.

[0017] System 110 also includes a pump or compressor 120 that pumps refrigerant or fluid to an external heat exchanger or condenser 122. A pressure sensor 124 may be located at the outlet of compressor 120 or between compressor and condenser 122 and provides feedback data to the controller to change the compressor output (if necessary). Some refrigerant is then pumped to an internal heat exchanger 118, where it is not selectively sent to evaporators 112, 114, but selectively sent to either or both of them, while some refrigerant is pumped to a battery cooler 116.

[0018] Three binary (on / off) refrigerant shut-off valves are provided, one for each evaporator 112, 114, and 116. Specifically, a front expansion device, such as a thermal expansion valve 126, is located upstream of the front HVAC evaporator 112, a rear expansion device 128 is located upstream of the rear HVAC evaporator 114, and a battery cooler expansion device 130 is located upstream of the battery cooler 116. While the reference to "expansion device" can include thermal expansion valves as shown, other embodiments to which this disclosure applies include electronic expansion valves (EXVs), orifice tubes, etc.

[0019] All three evaporators 112, 114, and 116 can be selectively supplied with refrigerant from a single source (condenser 122) and branched from a single refrigerant line to supply refrigerant to each individual evaporator. Corresponding shut-off valves are constructed in separate refrigerant line branches to supply refrigerant to each evaporator.

[0020] When both HVAC shut-off valves 126 and 128 are closed and the battery cooler shut-off valve 130 is open, the system may experience significant peak refrigerant pressure. While this is the desired operating condition for the vehicle, the refrigerant pressure encountered is undesirable.

[0021] Therefore, according to various embodiments of this disclosure, an additional system is shown in which the number of refrigerant shut-off valves is reduced and repositioned within the refrigeration system. As will be described in further detail below, some shut-off valves are combined and repositioned downstream of the evaporator, on the refrigerant return line from the evaporator to the compressor. Figures 3 to 4 Two such embodiments are shown, which are merely examples of possible configurations.

[0022] refer to Figure 3 An embodiment of an HVAC refrigerant system 140 is provided, wherein a single multi-flow position valve 142 is located where all return refrigerant lines are recombined at valve 142, and the multi-flow position valve outputs to a single refrigerant line 144 connected to a compressor or pump. Specifically, each of the front HVAC evaporator 112, the rear HVAC evaporator 114, and the battery cooler 116 has an inlet (or upstream) side and an outlet (or downstream) side. Similarly, each inlet is provided with an expansion device. However, in this embodiment, the expansion devices 126', 128', and 130' are not provided with a binary (on / off) feature. In other words, the expansion devices do not include binary shut-off valves. Instead, the multi-flow position valve 142 is positioned downstream of the outlets of these evaporators 112, 114, and 116. The multi-flow position valve 142, in conjunction with valves 126', 128', and 130', controls which outlets are fed into the compressor 120. Binary flow control valves allow or block fluid flow. In contrast, multi-position flow control valves, via some mechanism, allow various combinations of inlet flows to be combined into a single outlet flow. Multi-position flow control valves allow for more control than binary flow control valves, ranging from blocking all inlet flows to a single inlet flow to a single outlet flow, up to and including combining all inlet flows into a single outlet flow. The configuration shown allows for specific control of those heat exchangers supplied with refrigerant and which do not have binary (on / off) valves upstream of the evaporator and battery cooler, while avoiding the high system pressure conditions described above. This configuration also prevents any unintended cooling of customers or vehicle occupants.

[0023] refer to Figure 4Another embodiment of the HVAC refrigerant system 140' is shown. In this embodiment, the multi-flow position valve 142' now receives fluid only from the outlets of the front HVAC evaporator 112 and the rear HVAC evaporator 114. These two lines combine at valve 142' into a single refrigerant line 146. In this embodiment, valve 130" now includes a binary (on / off) shut-off feature. The battery cooler 116 outlet bypass valve 142' combines the battery cooler 116 outlet line 148 with the line 146 downstream of the evaporators 112, 114 and upstream of the optional internal heat exchanger 118. This configuration also allows for specific control of those heat exchangers supplying refrigerant and binary (on / off) refrigerant flow control of the battery cooler 116, while avoiding the aforementioned high system pressure conditions. This configuration also prevents any unintended cooling of customers or vehicle occupants.

[0024] exist Figure 4 In one embodiment, the multi-flow position valve 142' does not include a binary state (on / off) shut-off feature. In another embodiment, not shown, valve 142' is a binary state (on / off) shut-off valve. This provides two binary (on / off) shut-off valves for the refrigerant circuit, one downstream of the front evaporator 112 and the rear evaporator 114, and one upstream of the battery cooler 116.

[0025] While exemplary embodiments have been described above, it is not intended that these embodiments describe all possible forms covered by the claims. The vocabulary used in the specification is descriptive and not restrictive, and it should be understood that various changes may be made without departing from the spirit and scope of this disclosure. As previously stated, features of various embodiments may be combined to form further embodiments of the invention that may not be explicitly described or shown. While various embodiments may have been described as providing advantages or superiority over other embodiments or prior art implementations with respect to one or more desired characteristics, those skilled in the art will recognize that one or more features or characteristics may be sacrificed to achieve desired overall system properties, depending on the specific application and implementation. These properties may include, but are not limited to, cost, strength, durability, lifecycle cost, marketability, appearance, packaging, size, serviceability, weight, manufacturability, ease of assembly, etc. Therefore, with respect to one or more characteristics, these embodiments are not outside the scope of this disclosure and may be desirable for a particular application to the extent that any implementation is described as less desirable than other embodiments or prior art implementations.

[0026] According to the present invention, a vehicle system is provided having a refrigerant circuit comprising: a first expansion device located downstream of a condenser and upstream of a first evaporator; a second expansion device located downstream of the condenser and upstream of the second evaporator; and a third expansion device located upstream of a battery cooler, wherein none of the expansion devices includes a binary shut-off valve.

[0027] According to an embodiment, the invention is further characterized by a multi-flow position valve located downstream of the first evaporator, the second evaporator, and the battery cooler.

[0028] According to an embodiment, the multi-flow position valve combines the refrigerant from the first evaporator, the second evaporator, and the battery cooler into a single refrigerant line.

[0029] According to an embodiment, the single refrigerant line allows refrigerant to pass through an internal heat exchanger (IHX), and the IHX is configured to transfer heat between the refrigerant upstream of the battery cooler and the refrigerant downstream of the first, second, and third expansion devices.

[0030] According to an embodiment, the multi-flow position valve is not a binary shut-off valve, which is configured to prevent refrigerant from flowing through the multi-flow position valve.

[0031] According to an embodiment, the refrigerant circuit does not include a binary shut-off valve configured to prevent refrigerant from flowing through the associated thermal expansion valve.

[0032] According to an embodiment, the first evaporator is a front HVAC evaporator core configured to transfer heat to a system that controls the climate at the front of the vehicle, and the second evaporator is a rear HVAC evaporator core configured to transfer heat to a system that controls the climate at the rear of the vehicle.

[0033] According to the present invention, a vehicle system is provided having a refrigerant circuit comprising: a first expansion device located upstream of a first evaporator for controlling the refrigerant flow through the first evaporator; a second expansion device located upstream of a second evaporator for controlling the refrigerant flow through the second evaporator; and a third expansion device located upstream of a battery cooler for controlling the refrigerant flow through the battery cooler, wherein only one of the expansion devices includes a shut-off valve.

[0034] According to an embodiment, the third expansion device includes the shut-off valve.

[0035] According to an embodiment, the shut-off valve is configured to prevent refrigerant from flowing through the third expansion device.

[0036] According to an embodiment, the invention is further characterized by a multi-flow position valve located downstream of the first evaporator and the second evaporator.

[0037] According to an embodiment, the invention is further characterized in that the multi-flow position valve does not include a shut-off valve configured to prevent refrigerant from flowing through the multi-flow position valve.

[0038] According to an embodiment, the multi-flow position valve combines the refrigerant from the first evaporator and the second evaporator into a single line.

[0039] According to an embodiment, the invention is further characterized by an outlet line located downstream of the battery cooler, which bypasses the multi-flow position valve and is recombined with a single line downstream of the multi-flow position valve.

[0040] According to an embodiment, the invention is further characterized by a binary refrigerant flow cut-off valve located downstream of the first evaporator and the second evaporator.

[0041] According to an embodiment, the binary refrigerant flow cut-off valve combines the refrigerant from the first evaporator and the second evaporator into a single pipeline.

[0042] According to an embodiment, the invention is further characterized by an outlet pipeline located downstream of the battery cooler that bypasses the binary refrigerant flow shut-off valve and is recombined with a single pipeline downstream of the binary refrigerant flow shut-off valve.

[0043] According to the present invention, a refrigerant circuit configured to transfer heat energy to or from the passenger compartment of a vehicle is provided, the refrigerant circuit having: a plurality of evaporators; a plurality of thermal expansion valves, each thermal expansion valve being located upstream of a corresponding evaporator in the evaporator, and each thermal expansion valve not including a shut-off valve; and a plurality of flow position valves located downstream of the evaporators.

[0044] According to an embodiment, the invention is further characterized by another thermal expansion valve located upstream of the battery cooler, wherein the other thermal expansion valve does not include a shut-off valve.

[0045] According to an embodiment, each evaporator includes a corresponding outlet, and the outlets are combined into a single refrigerant line, and the multi-flow position valve fluidly connects the outlet to the single refrigerant line.

Claims

1. A vehicle system comprising: The refrigerant circuit includes: The first thermal expansion valve is located downstream of the condenser and upstream of the first evaporator. The second thermal expansion valve is located downstream of the condenser and upstream of the second evaporator. The third thermal expansion valve, located upstream of the battery cooler, and A multi-flow position valve is located downstream of the first evaporator, the second evaporator, and the battery cooler. None of the first, second, and third thermal expansion valves include binary shut-off valves. The multi-flow position valve is not a binary shut-off valve configured to prevent refrigerant from flowing through it.

2. The vehicle system of claim 1, wherein the multi-flow position valve combines refrigerant from the first evaporator, the second evaporator, and the battery cooler into a single refrigerant line.

3. The vehicle system of claim 2, wherein the single refrigerant line allows refrigerant to pass through an internal heat exchanger, and the internal heat exchanger is configured to transfer heat between refrigerant upstream of the first thermal expansion valve and the second thermal expansion valve and refrigerant downstream of the first thermal expansion valve, the second thermal expansion valve and the third thermal expansion valve.

4. The vehicle system of claim 1, wherein the refrigerant circuit does not include a binary shut-off valve configured to prevent refrigerant from flowing through the associated thermal expansion valve.

5. The vehicle system of claim 1, wherein the first evaporator is a front HVAC evaporator core configured to transfer heat to a system controlling the climate of the front of the vehicle, and the second evaporator is a rear HVAC evaporator core configured to transfer heat to a system controlling the climate of the rear of the vehicle.

6. A vehicle system comprising: A refrigerant circuit, comprising: a first thermal expansion valve located upstream of a first evaporator for controlling the refrigerant flow rate through the first evaporator; a second thermal expansion valve located upstream of a second evaporator for controlling the refrigerant flow rate through the second evaporator; a third thermal expansion valve located upstream of a battery cooler for controlling the refrigerant flow rate through the battery cooler; and a multi-flow position valve located downstream of the first and second evaporators but not downstream of the battery cooler. Of the first thermal expansion valve, the second thermal expansion valve, and the third thermal expansion valve, only the third thermal expansion valve includes a shut-off valve. The multi-flow position valve does not include a shut-off valve configured to prevent refrigerant from flowing through the multi-flow position valve.

7. The vehicle system of claim 6, wherein the shut-off valve of the third thermal expansion valve is configured to prevent refrigerant from flowing through the third thermal expansion valve.

8. The vehicle system of claim 6, wherein the multi-flow position valve combines refrigerant from the first evaporator and the second evaporator into a single line.

9. The vehicle system of claim 8, further comprising an outlet line located downstream of the battery cooler, the outlet line bypassing the multi-flow position valve and recombining with the single line downstream of the multi-flow position valve.

Images