Refrigerant module for thermal management system and method of manufacturing the same

Abstract

The invention relates to a refrigerant module for a thermal management system, comprising a refrigerant unit consisting of two plates (2, 3) designed to constitute channels for distributing a refrigerant fluid in the thermal management system, at least one of the channels being referred to as an acoustic channel (4a) comprising at least one silencer (10) formed at least partially by at least one plate (2, 3) of the refrigerant unit.

Description

Technical Field

[0001] The present disclosure relates to a refrigerant module for a thermal management system. Background Art

[0002] The development of electric vehicles has brought new problems to the automotive sector, especially in view of the limited battery range of electric vehicles and the limited space available under the vehicle floor for thermal management systems. For these reasons, compact and lightweight thermal management systems are increasingly sought. Summary of the invention

[0003] The present disclosure improves this situation.

[0004] A refrigerant module for a thermal management system is proposed, comprising a refrigerant unit consisting of two plates, the two plates being designed to constitute channels for distributing the refrigerant fluid in the thermal management system, at least one of the channels being referred to as an acoustic channel, comprising at least one muffler formed at least partially by at least one plate of the refrigerant unit.

[0005] Thanks to the integration of the silencer in the plate of the refrigerant module, the thermal management system is able to guarantee a more compact and lighter weight than the prior art, while ensuring a reduction in the noise and gas pulsations generated by the compressor of the thermal management system.

[0006] In another aspect, the muffler is formed by a plate of the refrigerant unit.

[0007] In another aspect, the muffler is formed by two plates of the refrigerant unit.

[0008] In another aspect, the muffler has an overall shape that is trapezoidal, or cylindrical, or parallelepipedal, or ellipsoidal.

[0009] In another aspect, the acoustic passage is an exhaust passage of the refrigerant module.

[0010] In another aspect, the acoustic channel is a suction channel.

[0011] In another aspect, a muffler includes a housing secured to an acoustic passage.

[0012] In another aspect, the muffler is completely formed by at least one plate of the refrigerant unit.

[0013] In another aspect, the muffler comprises a chamber provided with a refrigerant inlet and a refrigerant outlet in the acoustic channel, the square cross section of the refrigerant inlet (referred to as the inlet cross section) being of the same order of magnitude as the square cross section of the refrigerant outlet (referred to as the outlet cross section).

[0014] In another aspect, the square cross-section of the chamber is larger than the inlet cross-section or the outlet cross-section.

[0015] In another aspect, the muffler is cast or formed or pressed or machined or stamped into at least one plate of the refrigerant unit.

[0016] In another aspect, the cavity of the acoustic channel is arranged between two other channels of the refrigerant unit, and the shape of the cavity between the refrigerant inlet and the refrigerant outlet is at least partially defined by the two other channels. (The other two channels are not directly connected to the cavity).

[0017] In other words, the chamber of the acoustic channel is located between the two other channels, and the two other channels are at least partially adjacent to the chamber along the chamber from the refrigerant inlet to the refrigerant outlet. In other words, the other two channels extend along the wall of the chamber, preferably from the refrigerant inlet to the refrigerant outlet. In other words, the other two ducts are adjacent to the chamber.

[0018] In other words, the cavity of the acoustic channel is arranged between two other channels of the refrigerant unit, and the variation of the square cross-section of the cavity of the acoustic channel in the direction of the refrigerant flow is related to the relative inclination between the two other channels. By nesting the cavity between the two channels, the space in the refrigerant unit can be optimized.

[0019] The present invention also relates to a method for manufacturing a refrigerant module for a thermal management system, the refrigerant module comprising two connected plates designed to constitute channels for distributing a refrigerant fluid in the thermal management unit, the method comprising the step of forming at least one muffler at least partially by at least one plate of the refrigerant unit.

[0020] In another aspect, the step of forming at least one muffler includes casting or forming or pressing or machining or stamping at least one of the two plates of the refrigerant unit.

[0021] The present invention also relates to a thermal management system, which includes a refrigerant module and a fluid source in fluid communication with and attached to the refrigerant module, the fluid source including at least one of a condenser, a cooler, a receiver-drier, a compressor, or a coolant container. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Additional features, details and advantages will be seen in the following detailed description and accompanying drawings, in which:

[0023] Figure 1

[0024] [ Figure 1 ] is a perspective view of a refrigerant module according to an embodiment of the present disclosure.

[0025] Figure 2

[0026] [ Figure 2 ] is a perspective view of a refrigerant plate of a refrigerant module according to one embodiment.

[0027] Figure 3

[0028] [ Figure 3 ] is a perspective view of a refrigerant module according to one embodiment.

[0029] Figure 4

[0030] [ Figure 4 ] is a perspective view of a refrigerant module according to one embodiment.

[0031] Figure 5

[0032] [ Figure 5 ]yes Figure 2 Detail of the refrigerant plate.

[0033] Figure 6

[0034] [ Figure 6 ] is a perspective view of a muffler of a refrigerant module according to any of the preceding figures according to an alternative embodiment.

[0035] Figure 7

[0036] [ Figure 7 ] is a perspective view of a muffler of a refrigerant module of any of the foregoing figures according to another alternative embodiment.

[0037] Figure 8

[0038] [ Figure 8 ] is a perspective view of a refrigerant plate of a refrigerant module according to another embodiment. DETAILED DESCRIPTION

[0039] The present invention relates to a refrigerant module for a thermal management system, which is indicated in the figure by 1. The refrigerant module comprises a refrigerant unit RU composed of a first plate 2 and a second plate 3, which are facing each other and fixed together.

[0040] The first plate 2 comprises channel rails 4, hereinafter referred to as the refrigerant plate 2. The second plate 3 is substantially flat, hereinafter referred to as the back plate 3. The refrigerant plate 2 and the back plate 3 are sealed together to define a closed space, thereby forming channels of the refrigerant module 1. The channels ensure the distribution of the refrigerant fluid in the components of the thermal management system, such as the compressor, the evaporator and the condenser (not shown).

[0041] Different components of the thermal management system may be attached to the refrigerant unit RU like at least: condenser and / or water condenser and / or heat exchanger (evaporator and / or cooler) and / or PT (pressure temperature) sensor, and / or valves, and / or AC (air conditioning) lines.

[0042] The refrigerant plate 2 comprises an inner side 6 and an outer side 7, the cavities from the inner side 6 forming the channel rails 4. The back plate 3 comprises an inner side 8 and an outer side 9. In the module 1 , the inner side 6 of the refrigerant plate 2 is arranged opposite the inner side 8 of the back plate 3.

[0043] As can be seen from the figure, the refrigerant module 1 integrates a muffler 10 to reduce noise and gas pulsation from a compressor (not shown) of the thermal management system. The muffler is arranged in a channel of the refrigerant unit called the acoustic channel 4a.

[0044] The integration of the muffler 10 with the refrigerant unit RU ensures a more compact and lighter thermal management.

[0045] The muffler 10 is at least partially formed by at least one of the refrigerant plate 2 and the back plate 3. The muffler 10 comprises a refrigerant inlet 11, a refrigerant outlet 12 and a chamber 13 therebetween.

[0046] exist Figure 1 In the embodiment, the silencer 10 is formed partly by the refrigerant unit RU and comprises an insert 14 fixed to the acoustic channel 4a. Figure 1 In the embodiment, the muffler 10 can be defined as a box attached to the acoustic channel. This embodiment ensures a simple manufacturing process and adaptability to any refrigerant unit.

[0047] exist Figures 2 to 8 In the embodiment, the silencer 10 is completely formed by the refrigerant unit RU. In other words, the silencer 10 is formed integrally by the deformation 15 in the refrigerant plate 2 and / or the back plate 3. This embodiment ensures a simple manufacturing process and avoids any additional parts, any additional sealing elements and any additional manufacturing steps.

[0048] exist Figure 3 In the embodiment, only the refrigerant plate 2 includes the deformation portion 15, while in Figure 4 In the embodiment, both the refrigerant plate 2 and the back plate 3 include a deformation portion 15 .

[0049] The muffler 10 may be cast or formed or pressed or machined or stamped in at least one plate of the refrigerant unit. In other words, the deformation 15 is integral with the natural shape of the plates 2,3.

[0050] As from Figure 5As best seen, the square section A of the refrigerant inlet 11 is of the same order of magnitude as the square section A' of the refrigerant outlet 12, preferably A is equal to A'. On the other hand, the square section B of the chamber 13 is strictly greater than A, A'. The sharp increase in square section (from A to B) and the subsequent sharp decrease in square section (from B to A') reduce the gas pulsation from the compressor, thereby reducing the noise generated by the compressor.

[0051] The muffler 10 can be of different shapes. It can be trapezoidal ( Figures 1 to 6 and Figure 8 ), semi-cylindrical or cylindrical ( Figure 6 and Figure 7 ) or parallelepiped or ellipsoidal, depending on the amplitude and frequency one wants to dampen from the compressor pulsations.

[0052] In order to optimize the space, the chamber 13 of the acoustic channel is located between two other channels, and the two other channels are at least partially adjacent to the chamber 13, preferably along the chamber from the refrigerant inlet to the refrigerant outlet. In other words, the other two pipes are at least partially adjacent to the chamber along the chamber, preferably along the chamber from the refrigerant inlet to the refrigerant outlet.

[0053] The acoustic channel 4a can be in the exhaust channel ( Figures 1 to 5 ) or suction channel ( Figure 8 ). In addition, Figure 8 As shown, the refrigerant module 1 may include a plurality of mufflers 10 .

[0054] The manufacturing method will now be described.

[0055] The method of manufacturing the refrigerant module 1 comprises the step of forming a muffler in the acoustic channel 4a at least partially through at least one of the refrigerant plate 2 and the back plate 3 of the refrigerant unit.

[0056] When the silencer comprises a box, the manufacturing method comprises a step of fixing the insert 14 , for example by brazing or welding.

[0057] When the silencer is fully integrated into the plates 2 , 3 , the manufacturing method comprises a step of forming the deformation 15 by casting or forming or pressing or machining or stamping at least one of the two plates of the refrigerant unit.

Claims

1. A refrigerant module for a thermal management system, comprising a refrigerant unit consisting of two plates (2, 3), the two plates being designed to constitute channels for distributing a refrigerant fluid in the thermal management system, at least one of the channels being referred to as an acoustic channel (4a), comprising at least one muffler (10), the muffler being at least partially formed by at least one plate (2, 3) of the refrigerant unit.

2. The refrigerant module according to claim 1, wherein: The muffler (10) is formed by a plate of the refrigerant unit.

3. The refrigerant module according to claim 1, wherein: The muffler (10) is formed by the two plates of the refrigerant unit.

4. A refrigerant module according to any one of the preceding claims, wherein: The muffler (10) has an overall shape of a trapezoid, a semi-cylindrical shape, a cylindrical shape, a parallelepiped shape or an ellipsoid shape.

5. A refrigerant module according to any one of the preceding claims, wherein: The muffler (10) comprises a box body.

6. The refrigerant module according to any one of claims 1 to 5, wherein: The silencer (10) is completely formed by at least one plate of the refrigerant unit.

7. A refrigerant module according to any one of the preceding claims, wherein: The muffler (10) comprises a chamber (13) provided with a refrigerant inlet (11) and a refrigerant outlet (12) in the acoustic channel (4a), wherein a square cross section of the refrigerant inlet (11), called an inlet cross section (A), is of the same order of magnitude as a square cross section of the refrigerant outlet (12), called an outlet cross section (A′).

8. The refrigerant module according to claim 7, wherein: The square cross-section (B) of the chamber (13) of the muffler (10) is larger than the inlet cross-section (A) or the outlet cross-section (A′).

9. The refrigerant module according to any one of claims 7 to 8, wherein: The chamber (13) of the acoustic channel is located between two other channels, and the two other channels are at least partially adjacent to the chamber (13) along the chamber from the refrigerant inlet to the refrigerant outlet.

10. A refrigerant module according to any one of the preceding claims, wherein: The muffler is cast or formed or pressed or machined or stamped into at least one plate of the refrigerant unit.

11. A method for manufacturing a refrigerant module for a thermal management system, the refrigerant module comprising two connected plates (2, 3) designed to constitute channels for distributing a refrigerant fluid in the thermal management unit, the method comprising the step of forming at least one muffler (10) at least partially from at least one plate of the refrigerant unit.

12. The method according to claim 11, wherein: The step of forming at least one muffler (10) comprises casting or forming or pressing or machining or stamping at least one of the two plates (2, 3) of the refrigerant unit.

13. A thermal management system comprising a refrigerant module according to any one of the preceding claims, and a fluid source in fluid communication with and attached to the refrigerant module, the fluid source comprising at least one of a condenser, a cooler, a receiver-drier, a compressor or a coolant container.

Images