Heat pump system with bypass refrigerant line

Abstract

The invention relates to a heat pump system with a bypass refrigerant line. Aspects of the present disclosure relate to a heat pump system having a selectable bypass flow path that allows refrigerant to bypass one or more heat exchangers of the heat pump system. The bypass flow path may be used to provide enhanced thermal energy (e.g., heat) generation for a passenger compartment of a vehicle, for example by a compressor, particularly at relatively low ambient temperatures and / or during fast charging of a vehicle battery.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 639,490, filed April 26, 2024, entitled "HEAT PUMP SYSTEMS WITH A BYPASSREFRIGERANT LINE," the entire contents of which are incorporated herein by reference. Background Technology

[0003] Heat pump systems are typically installed in vehicles to provide heating or cooling for the passenger compartment.

[0004] Various aspects of the technologies in this subject matter can help improve the efficiency and / or performance of heat pump systems used in electric vehicles, which can help mitigate climate change by reducing greenhouse gas emissions. Summary of the Invention

[0005] Various aspects of this disclosure relate to a heat pump system having a selectable bypass flow path that allows refrigerant to bypass one or more heat exchangers of the heat pump system, thereby providing enhanced heating to the passenger compartment of a vehicle, particularly in low ambient temperature environments.

[0006] In one or more aspects of this disclosure, an apparatus is described. The apparatus may include a heat pump system. The heat pump may include a first refrigerant line connected to a compressor and a first heat exchanger. The heat pump system may also include a second refrigerant line connected to the first refrigerant line. The second refrigerant line may be in fluid communication with an accumulator. The heat pump system may also include a valve integrated with the second refrigerant line. A first position of the valve is configured to allow flow of refrigerant from the compressor to the first heat exchanger, and a second position of the valve is configured to allow flow of refrigerant to bypass (e.g., partially bypass) the first heat exchanger and flow to the accumulator.

[0007] The heat pump system can be implemented in a vehicle, and the valve can be configured to partially direct the flow of refrigerant from a first heat exchanger to a second refrigerant line based on at least one of environmental conditions or the vehicle's operating mode. Environmental conditions may include temperature, and in response to a temperature below a threshold temperature, the valve is configured to operate in a second position. The first position may include a closed position of the valve, and the second position may include an open position of the valve. The vehicle's operating mode may include an occupancy status, and the heat pump system can be configured to heat the passenger compartment of the vehicle based on the occupancy status.

[0008] The heat pump system may also include a second heat exchanger. The heat pump system may also include a third refrigerant line connected to the outlet of the second heat exchanger. The second refrigerant line may be connected to a first inlet of the accumulator, and the third refrigerant line may be connected to a second inlet of the accumulator. The heat pump system may also include a fourth refrigerant line configured to connect to the third heat exchanger. The fourth refrigerant line may be connected to a third inlet of the accumulator. A valve in a second position may be further configured to allow refrigerant flow to bypass (e.g., partially bypass) the second heat exchanger.

[0009] In one or more aspects of this disclosure, a method is described. The method may include supplying refrigerant from a compressor of a heat pump system to a first heat exchanger via a first refrigerant line, based on a first position of a valve. The method may also include monitoring conditions by a sensor. The method may further include, in response to determination that the conditions are below a threshold condition, providing a command by a controller to change the valve from the first position to a second position. The second position may be configured to allow refrigerant to bypass (e.g., partially bypass) the first heat exchanger and flow to an accumulator of the heat pump system. Conditions may include ambient conditions, and threshold conditions may include a threshold temperature. The method may also include providing a command to change the valve from the first position to the second position, which may include changing the valve from a closed position to an open position.

[0010] The method may further include supplying refrigerant via a second refrigerant line in response to the valve being in a second position. The second refrigerant line may be connected to an accumulator. The valve in the second position may be further configured to allow refrigerant to bypass at least a second heat exchanger. The first and second heat exchangers may be in fluid communication in response to the valve being in a first position. The first position may include an open position of the valve, and the second position may include a closed position of the valve.

[0011] The method may also include monitoring the operating mode of the vehicle. The operating mode may include the vehicle's occupancy status.

[0012] In one or more aspects of this disclosure, an electric vehicle is described. The electric vehicle may include a heat pump system. The heat pump may include a first refrigerant line connected to a compressor and a first heat exchanger. The heat pump system may also include a second refrigerant line connected to the first refrigerant line. The second refrigerant line may be in fluid communication with an accumulator. The heat pump system may also include a valve integrated with the second refrigerant line. A first position of the valve is configured to allow flow of refrigerant from the compressor to the first heat exchanger, and a second position of the valve is configured to allow flow of refrigerant to bypass (e.g., partially bypass) the first heat exchanger and flow to the accumulator.

[0013] The valve may be configured to switch the flow of refrigerant from a first heat exchanger to a second refrigerant line based on at least one of environmental conditions or the operating mode of the vehicle. Environmental conditions may include temperature, and the valve is configured to operate in a second position in response to the temperature falling below a threshold temperature. The first position may include an open position of the valve, and the second position may include a closed position of the valve. Attached Figure Description

[0014] Certain features of the subject matter are set forth in the appended claims. However, for illustrative purposes, several embodiments of the subject matter are illustrated in the following figures.

[0015] Figure 1A and Figure 1B A schematic perspective side view illustrating an example embodiment of a vehicle having a heat pump system according to one or more embodiments of this disclosure is shown.

[0016] Figure 2 , Figure 3 , Figure 4 and Figure 5 A schematic diagram of a heat pump system according to one or more specific embodiments of the present disclosure is illustrated.

[0017] Figure 6 A schematic diagram and associated pressure-enthalpy diagram are shown illustrating the basic principle of a refrigerant vapor compression cycle utilized in an exemplary heat pump system according to one or more specific embodiments of this disclosure.

[0018] Figure 7 A perspective view illustrating an embodiment of a valve according to one or more specific embodiments of this disclosure is shown.

[0019] Figure 8 A schematic diagram illustrating an embodiment of a system having valves for guiding fluid throughout the system, according to one or more specific embodiments of the present disclosure.

[0020] Figure 9A , Figure 9B , Figure 9C , Figure 9D , Figure 9E , Figure 9F Examples illustrating one or more specific embodiments of this disclosure are shown. Figure 8 The diagram shows different modes of valves used for flow regulation.

[0021] Figure 10 A schematic diagram illustrating an alternative embodiment of a heat pump system according to one or more specific embodiments of the present disclosure is shown, the heat pump system having a bypass flow path and including operable portions for providing heating and / or cooling to two or more parts and / or components of a vehicle or other device.

[0022] Figure 11A , Figure 11B , Figure 11C and Figure 11D Examples illustrating one or more specific embodiments of this disclosure are shown. Figure 10 The diagram shows different modes of valves used for flow regulation.

[0023] Figure 12 A flowchart illustrating exemplary operations of a heat pump system with a bypass flow path, according to one or more specific embodiments of this disclosure, is provided. Detailed Implementation

[0024] The specific embodiments described below are intended to illustrate various constructions of the subject matter and are not intended to represent only the constructions in which the subject matter can be practiced. The accompanying drawings are incorporated herein and form part of the specific embodiments. The specific embodiments include detailed descriptions intended to provide a thorough understanding of the subject matter. However, the subject matter is not limited to the specific details set forth herein and can be practiced using one or more other specific embodiments. In one or more specific embodiments, well-known structures and components are shown in block diagram form to avoid confusion with the concepts of the subject matter.

[0025] The aspects of the subject matter described herein relate to a heat pump system comprising a compressor, an accumulator, and one or more heat exchangers, as well as a selectable bypass flow path around the heat exchangers. When the refrigerant is redirected around the heat exchangers via the bypass flow path in some operating modes, the refrigerant is directed from the compressor outlet to the accumulator inlet, where the refrigerant is at a relatively high pressure and temperature. Advantageously, heating enhancement can be provided for one or more parts of a device (such as a vehicle) heated by the heat pump system.

[0026] A heat pump system may include a refrigerant line and an expansion valve (EXV), each of which may be integrated with the heat pump system at the compressor outlet, which bypasses one or more heat exchangers (and in some cases, all heat exchangers) and merges into the accumulator bottle inlet. In this respect, the refrigerant line may take the form of a bypass refrigerant line that feeds hot (e.g., superheated) refrigerant back to the accumulator to increase suction temperature and pressure and enhance compressor heating performance. Alternatively, in another embodiment, the refrigerant line and EXV are added to the compressor outlet, which bypasses one or more heat exchangers (and in some cases, all heat exchangers) and merges into a pre-evaporator outlet refrigerant line leading to the accumulator bottle to enhance compressor heating performance. When these features of a heat pump system are integrated with a vehicle, the compressor can provide heating under certain environmental conditions, such as in cold weather (e.g., -10 degrees Celsius or lower) or at the interior temperature of the vehicle (e.g., passenger compartment or cabin), and / or in certain operating modes of the vehicle.

[0027] Figure 1A These are schematic diagrams illustrating exemplary embodiments of the apparatus described herein. Figure 1A In the example, the device is a mobile device implemented as vehicle 100. As shown, vehicle 100 may include one or more batteries 110. Battery 110 may include one or more battery modules or may not have any battery modules (e.g., in a cell-to-pack construction), and the one or more battery modules may include one or more battery cells.

[0028] Battery 110 can be coupled to the electrical system of vehicle 100 to receive power for charging the battery and / or to supply power to the vehicle's electrical system and / or to a thermal control system (such as heat pump system 104). As shown, heat pump system 104 may include an accumulator 106. For example, accumulator 106 may be configured to buffer a fluid (e.g., liquid refrigerant) that may contain more liquid when heat pump system 104 is used in cooling mode and less liquid when heat pump system 104 is used in heating mode. Accumulator 106 may also be configured to separate fluid refrigerant from vapor refrigerant and help ensure that the fluid leaves and reaches the compressor in a saturated state (e.g., for compressor protection), and may be configured to store and pick up oil for compressor oil lubrication.

[0029] Various features of the heat pump system 104 are described in further detail below. In one or more embodiments, the heat pump system 104 may be operated to heat and / or cool various parts and / or components of the vehicle 100, such as the passenger compartment 108, its various parts, the battery 110, and / or the power electronics of the vehicle 100.

[0030] In one or more embodiments, vehicle 100 may be an electric vehicle having one or more electric motors that use electricity from battery 110 to drive the wheels 102 of the vehicle. In one or more embodiments, vehicle 100 may also or alternatively include one or more chemically powered engines, such as gasoline engines or fuel cell-powered motors. For example, the electric vehicle may be fully electric or partially electric (e.g., hybrid or plug-in hybrid).

[0031] exist Figure 1A In the example, vehicle 100 is implemented as a truck (e.g., a pickup truck) with a heat pump system 104, which has an energy storage device 106. However, Figure 1A The example of vehicle 100 being implemented as a pickup truck with a cargo box is merely illustrative. For example, Figure 1B Another specific embodiment is illustrated, in which a vehicle 100 with a battery 110 and a heat pump system 104 having an energy storage device 106 is implemented as a sport utility vehicle (SUV), such as an electric sport utility vehicle. Figure 1B In one example, a vehicle 100 including battery 110 and heat pump system 104 with energy storage 106 may include a cargo storage area at least in the rear of the vehicle, which is enclosed within the vehicle 100 (e.g., behind a row of seats in the vehicle's cabin). In other embodiments, vehicle 100 may be implemented as another type of electric truck, electric delivery vehicle, electric motor vehicle, electric car, electric motorcycle, electric scooter, electric bus, electric passenger or commercial truck, hybrid vehicle, or other vehicle, such as maritime or air transport vehicles, aircraft, helicopters, submarines, ships, or drones, and / or any other mobile device having battery 110 and heat pump system 104 including energy storage 106.

[0032] In one or more specific embodiments, the heat pump system 104 as described herein may also be implemented in another device such as a building (e.g., a residential or commercial building, or any other building).

[0033] Figure 2 , Figure 3 , Figure 4 and Figure 5A schematic diagram of a heat pump system according to one or more specific embodiments of this disclosure is illustrated. For simplicity, some components (e.g., valves) are shown in... Figure 2 , Figure 3 , Figure 4 and Figure 5 As shown, but not labeled. Each heat pump in the heat pump can be connected to a vehicle (e.g., Figure 1A or Figure 1B The vehicles shown (100) are integrated into one unit.

[0034] Figure 2 A schematic diagram illustrating an embodiment of a heat pump system 104 according to one or more specific embodiments of the present disclosure is shown. The heat pump system 104 may take the form of a thermal management heat pump system. As shown, the heat pump system 104 includes a thermal management loop 112a and a thermal management loop 112b. The thermal management loops 112a and 112b may respectively take the form of a refrigerant-side cabin thermal management loop and a coolant-side energy storage system (ESS) thermal management loop.

[0035] Thermal management circuit 112a may include compressor 114, which may take the form of an electric compressor for hybrid electric vehicles or pure electric vehicles (EVs) or a belt-driven compressor for internal combustion engine (ICE) vehicles. Compressor 114 may be coupled to heat exchanger 116a. In Figure 1, heat exchanger 116a is a refrigerant-air condenser located within HVAC enclosure 118 to directly exchange heat with cabin airflow. An alternative embodiment uses a refrigerant-coolant heat exchanger combined with a circuit involving a heater core to indirectly exchange heat with cabin airflow. HVAC enclosure 118 may include a temperature mixing door 120 located near the cabin condenser, which allows for full airflow, partial airflow, or no airflow by correspondingly moving the door position. Optionally, HVAC enclosure 118 may also include a heater, such as a positive temperature coefficient (PTC) electric heater, to provide supplemental heat when needed. Other components typical of HVAC enclosures, such as blowers, recirculation doors, and mode selection doors, are not depicted herein and are known to those skilled in the art.

[0036] Heat exchanger 116a is coupled to valve 122a. The term "coupled" can refer to one structure (e.g., heat exchanger 116a) being connected (including fluidly connected) to another structure (e.g., valve 122a). In one or more embodiments, valve 122a takes the form of an expansion valve (EXV) that operates in one of three modes: an expansion mode that throttles high-pressure refrigerant to low-pressure refrigerant, an open mode that allows free flow, and a closed mode that prevents any flow. Heat exchanger 116a is also coupled to valve 124a. In one or more embodiments, valve 124a takes the form of a shut-off valve (SOV). As shown, valve 124a is connected in parallel and is operable to allow or prevent refrigerant flow. Valve 122a is coupled to heat exchanger 116b, which may be located at the front end of a vehicle and is capable of operating as a condenser to discharge heat to an external fluid (e.g., air) or as an evaporator to absorb heat from an external fluid (e.g., air), depending on the operating mode.

[0037] Heat exchanger 116b is coupled to valve 124b. In one or more embodiments, valve 124a is in the form of an SOV (Self-Standing Vapor). Alternatively, heat exchanger 116b may be in the form of an evaporator. 124b may be positioned to allow or prevent refrigerant flow and coupled in parallel to accumulator 126 and valve 128a. In one or more embodiments, valve 128a is in the form of a check valve (CV). Accumulator 126 is a container that stores refrigerant and oil, ensuring sufficient oil return and essentially allowing vaporized refrigerant to return to compressor 114. Compressor 114 can be used with high-temperature, high-pressure refrigerants, while accumulator 126 can be used with low-temperature, low-pressure refrigerants. Compressor 114 can draw in low-temperature, low-pressure refrigerant and compress the refrigerant, causing high-temperature, high-pressure refrigerant to exit compressor 114. Therefore, the refrigerant in compressor 114 can be at a relatively higher temperature and pressure compared to the refrigerant in accumulator 126. Valve 128a is coupled to heat exchanger 116b via valve 122b (e.g., expansion valve) and to heat exchanger 116d via valve 122c (e.g., expansion valve). Figure 2In this embodiment, heat exchanger 116d is a refrigerant-air evaporator located within HVAC enclosure 118 for cooling cabin airflow. Those skilled in the art will understand that alternative embodiments using a refrigerant-coolant heat exchanger in conjunction with a circuit involving the cooler core to indirectly exchange heat with cabin airflow are also possible. Additionally, heat pump system 104 may include valve 122d (e.g., EXV) which operates at least in expansion mode to throttle high-pressure refrigerant to low-pressure refrigerant and in a closed mode to prevent any flow, while valve 122c operates in one of three modes: an expansion mode throttling high-pressure refrigerant to low-pressure refrigerant, an open mode allowing free flow, and a closed mode preventing any flow, similar to valve 122a. Valve 122d may be optional. In this respect, in one or more embodiments, heat pump system 104 does not include valve 122d. Considerations for the use of valve 122d may include, for example, heating performance and cost. Heat exchanger 116a and heat exchanger 116d are coupled to accumulator 126 to allow refrigerant to flow into accumulator 126 and ultimately back to compressor 114. Additionally, heat pump system 104 may include valves 128b and 128c, each of which may be in the form of a check valve (CV). Each of valves 128a and 128b prevents backflow / charge migration.

[0038] Thermal management circuit 112a is coupled to thermal management circuit 116b via heat exchanger 112c. Thermal management circuit 112b typically includes ESS 130, such as a battery or battery pack. Optionally, heater 132 may be included for auxiliary heating. In general, ESS 130, heat exchanger 116c, coolant pump assembly 133, and heater 132 are operable to control the environment associated with ESS 130.

[0039] Furthermore, the heat pump system 104 may include a refrigerant line 134a connected to the compressor 114 and the heat exchanger 116a. As shown, the refrigerant line 134a is connected to the outlet of the compressor 114 and the inlet of the heat exchanger 116a. The heat pump system 104 may include a refrigerant line 134b connected to the refrigerant line 134a, which may be in fluid communication with the accumulator 126 via a refrigerant line 134c. As shown, the refrigerant line 134c is connected to the inlet of the accumulator 126. In this respect, the refrigerant line 134b partially forms a recirculation line between the compressor 114 and the accumulator 126.

[0040] Furthermore, valve 122e (e.g., EXV) is integrated with refrigerant line 134b, and therefore, valve 122e is in fluid communication with compressor 114 and accumulator 126. Specifically, valve 122e is in fluid communication with the outlet of compressor 114 at the connection point between compressor 114 and heat exchanger 116a. In this respect, when valve 122e is in the closed position, refrigerant ( Figure 2 (Not shown) Refrigerant can flow from compressor 114 to heat exchanger 116a. Conversely, when valve 122e is in the open position, refrigerant line 134b forms a bypass refrigerant line that allows refrigerant to bypass or at least partially bypass heat exchanger 116a and merge (e.g., directly merge) accumulator 126. Therefore, with valve 122e in the open position, refrigerant can flow to accumulator 126. Thus, refrigerant line 134b can feed hot refrigerant back to accumulator 126 to increase suction temperature and pressure and enhance the heating performance of compressor 114. Additionally, when valve 122e is in the open position, refrigerant can bypass each of heat exchangers 116b, 116c, and 116d, which represent all the heat exchangers in heat pump system 104. The refrigerant flow at the outlet of compressor 114 is split, with one refrigerant path leading to one or more heat exchangers in the heat exchangers to heat the vehicle cabin, ESS130, or both, and the other refrigerant path leading to a bypass line to enhance low-side temperature and pressure. Some valves (e.g., valve 122a) may work in conjunction with other valves (e.g., valves 122e, 124a, and 124b) to appropriately split the refrigerant flow for heating purposes.

[0041] Additionally, controller 136 (e.g., microcontroller, MEMS controller, integrated circuit) can provide instructions or commands to operate heat pump system 104. Furthermore, sensor 138 can be electrically coupled to controller 136. In one or more embodiments, sensor 138 takes the form of a temperature sensor (e.g., thermocouple, thermistor, coolant temperature sensor, battery temperature sensor, etc.). Furthermore, sensor 138 can be located on a vehicle (e.g., Figure 1A or Figure 1BIn the illustrated vehicle 100, environmental conditions, such as ambient temperature, are detected. In this regard, sensor 138 can provide an input (e.g., an electrical signal) to controller 136, where the input indicates the ambient temperature. Controller 136 can compare the environmental conditions to threshold conditions and provide instructions to valve 122e based on the comparison. For example, controller 136 can compare the ambient temperature to a threshold temperature and provide instructions to open valve 122e based on controller 136's determination that the ambient temperature is at or below the threshold temperature. When the ambient temperature is above the threshold temperature, controller 136 can instruct valve 122e to remain closed. Alternatively or in combination, sensor 138 can detect internal conditions, such as the passenger compartment of the vehicle (e.g., Figure 1A and Figure 1B The temperature in the passenger compartment 108 (shown) is considered. The controller 136 can use inputs to operate the valve 122e (e.g., comparing the passenger compartment temperature with a threshold temperature to determine whether to open or close the valve 122e). For example, when the controller 136 determines, based on input from the sensor 138, that the temperature is at or below the threshold temperature, the controller 136 can open the valve 122e. In one or more embodiments, the threshold temperature is -10 degrees Celsius. The threshold temperature can be selected from values ​​in the range of approximately -20 degrees Celsius to 0 degrees Celsius. Therefore, the heat pump system 104 can provide enhanced heating performance via the compressor 114 under low-temperature conditions.

[0042] Additionally or alternatively, controller 136 may control valve 122e based on the vehicle's operating mode. In this regard, as a non-limiting example, sensor 138 may take the form of an occupancy sensor, which may be implemented as a weight sensor or pressure sensor (e.g., measuring weight changes at a seat in the vehicle to determine if a passenger is seated in the vehicle), an image sensor (e.g., a camera) for capturing one or more images of the passenger compartment of the vehicle to determine if an occupant is in the vehicle, or a combination thereof. As an example, the vehicle's operating mode may include the vehicle's charging mode and / or the vehicle's occupant status. For example, the charging mode may be where the battery 110 of vehicle 100 (e.g., ...) is charged. Figure 1A and Figure 1B (As shown) an idle mode where the vehicle 100's battery 110 is not being charged, a standard charging mode in which the vehicle 100's battery 110 is charged at a first rate, or a fast charging mode in which the vehicle 100's battery 110 is charged at a second rate higher than the first rate (e.g., a direct current (DC) fast charging mode). The occupant status of the vehicle may include one or more occupants in the passenger compartment 108 of the vehicle 100 (e.g., ...). Figure 1A and Figure 1BThe vehicle's heating state can be either an occupied state (as shown) or an unoccupied state in which no occupants are present in the passenger compartment 108 of the vehicle. The vehicle's heating state can include an active heating state in which the heat pump system 104 is operated to heat one or more portions of the passenger compartment 108 of the vehicle (e.g., the vehicle's climate control system is activated). Sensor 138 can include a current sensor or voltmeter designed to monitor current or voltage, which can be used to determine the charging state.

[0043] Figure 3 A schematic diagram illustrating an alternative embodiment of a heat pump system 204 according to one or more specific embodiments of the present disclosure is shown. As shown, the heat pump system 204 includes a thermal management loop 212a and a thermal management loop 212b. Thermal management loops 212a and 212b may respectively take the form of a refrigerant-side cabin thermal management loop and a coolant-side ESS thermal management loop. The heat pump system 204 includes heat exchangers 216a and 216d, each of which is part of an HVAC enclosure 218. Furthermore, the heat pump system 204 may include a refrigerant line 234a connected to a compressor 214 and a heat exchanger 216a. As shown, the refrigerant line 234a connects to the outlet of the compressor 214 and the inlet of the heat exchanger 216a. The heat pump system 204 may include a refrigerant line 234b connected to a refrigerant line 234a, which may be in fluid communication with the accumulator 226. In this respect, the refrigerant line 234b partially forms a recirculation line between the compressor 214 and the accumulator 226. The compressor 214 may be used with high-temperature, high-pressure refrigerants, while the accumulator 226 may be used with low-temperature, low-pressure refrigerants. The compressor 214 may draw in low-temperature, low-pressure refrigerant and compress the refrigerant, causing high-temperature, high-pressure refrigerant to exit the compressor 214. Therefore, the refrigerant in the compressor 214 may be at a relatively higher temperature and pressure compared to the refrigerant in the accumulator 226.

[0044] Furthermore, valve 222e (e.g., EXV) is integrated with refrigerant line 234b, and therefore, valve 222e is in fluid communication with compressor 214 and accumulator 226. Specifically, valve 222e is in fluid communication with the outlet of compressor 214 at the connection point between compressor 214 and heat exchanger 216a. In this respect, when valve 222e is in the closed position, refrigerant ( Figure 2(Not shown) Refrigerant can flow from compressor 214 to heat exchanger 216a. Conversely, when valve 222e is in the open position, refrigerant line 234b forms a bypass refrigerant line that allows refrigerant to bypass or at least partially bypass heat exchanger 216a and merge (e.g., directly merge) accumulator 226. Therefore, in the open position of valve 222e, refrigerant can flow to accumulator 226. Thus, refrigerant line 234b can feed hot refrigerant back to accumulator 226 to increase suction temperature and pressure and enhance the heating performance of compressor 214. Additionally, when valve 222e is in the open position, refrigerant can bypass or at least partially bypass each of the heat exchangers in heat pump system 204.

[0045] The heat pump system 204 may also include a refrigerant line 234c connected to the inlet of the accumulator 226 and indirectly (or, in some cases, directly) connected to the heat exchanger 216c of the thermal management loop 212b. The heat pump system 204 may also include a refrigerant line 234d connected to the outlet of the heat exchanger 216d and the inlet of the accumulator 226. In this respect, the accumulator 226 includes three inlets (e.g., a first inlet, a second inlet, and a third inlet), each inlet being separate from the remaining inlets and connected to one of the refrigerant lines 234b, 234c, and 234d. Furthermore, the heat pump system 204 may include a controller 236 and a sensor 238, wherein the controller 236 is designed to control valve 222e using sensor 238 in the manner previously described.

[0046] Figure 4A schematic diagram illustrating an alternative embodiment of a heat pump system 304 according to one or more specific embodiments of the present disclosure is shown. As shown, the heat pump system 304 includes a thermal management loop 312a and a thermal management loop 312b. Thermal management loops 312a and 312b may respectively take the form of a refrigerant-side cabin thermal management loop and a coolant-side ESS thermal management loop. The heat pump system 304 includes heat exchangers 316a and 316d, each of which is part of an HVAC enclosure 318. Furthermore, the heat pump system 304 may include a refrigerant line 334a connected to a compressor 314 and a heat exchanger 316a. As shown, the refrigerant line 334a is connected to the outlet of the compressor 314 and the inlet of the heat exchanger 316a. The heat pump system 304 may include a refrigerant line 334b ​​connected to a refrigerant line 334a, which may be in fluid communication with the accumulator 326. In this respect, the refrigerant line 334b ​​partially forms a recirculation line between the compressor 314 and the accumulator 326. The compressor 314 can be used with high-temperature, high-pressure refrigerants, while the accumulator 326 can be used with low-temperature, low-pressure refrigerants. Therefore, the refrigerant in the compressor 314 can be at a relatively higher temperature and pressure compared to the refrigerant in the accumulator 326.

[0047] Furthermore, valve 322 (e.g., EXV) is integrated with refrigerant line 334b, and therefore, valve 322 is in fluid communication with compressor 314 and accumulator 326. Specifically, valve 322 is in fluid communication with the outlet of compressor 314 at the connection point between compressor 314 and the inlet, which is at least indirectly connected to accumulator 326. Additionally, valve 322 is in fluid communication with the outlet of heat exchanger 316d. In this respect, when valve 322 is in the closed position, refrigerant ( Figure 4(Not shown) Refrigerant can flow from compressor 314 to heat exchanger 316a. Conversely, when valve 322 is in the open position, refrigerant line 334b ​​forms a bypass refrigerant line that allows refrigerant to bypass or at least partially bypass heat exchanger 316a and merge (e.g., directly merge) to the outlet of heat exchanger 316d, which is connected to refrigerant line 334c, which is connected to accumulator 326. Therefore, with valve 322 open, refrigerant can flow to accumulator 326. Thus, refrigerant lines 334b ​​and 334c can feed hot refrigerant back to accumulator 326 to increase suction temperature and pressure and enhance the heating performance of compressor 314. Additionally, when valve 322 is open, refrigerant can bypass each of the heat exchangers in heat pump system 304. Furthermore, the heat pump system 304 may include a controller 336 and a sensor 338, wherein the controller 336 is designed to control the valve 322 using the sensor 338 in the manner previously described. Additionally, based on the merging of the valve 322 with the outlet of the heat exchanger 316d, the HVAC enclosure 318 may include the valve 322. Advantageously, the HVAC enclosure 318 can be installed as a sub-assembly because the valve 322 is not an externally located valve.

[0048] Figure 5 A schematic diagram illustrating an alternative embodiment of a heat pump system 404 according to one or more specific embodiments of the present disclosure is shown. As shown, the heat pump system 404 includes a thermal management loop 412a and a thermal management loop 412b. Thermal management loops 412a and 412b may respectively take the form of a refrigerant-side cabin thermal management loop and a coolant-side ESS thermal management loop. The heat pump system 404 includes heat exchangers 416a and 416d, each of which is part of an HVAC enclosure 418. Furthermore, the heat pump system 404 may include a refrigerant line 434a connected to a compressor 414 and a heat exchanger 416a. As shown, the refrigerant line 434a is connected to the outlet of the compressor 414 and the inlet of the heat exchanger 416a. The heat pump system 404 may include a refrigerant line 434b connected to a refrigerant line 434a, which may be in fluid communication with the accumulator 426. In this respect, the refrigerant line 434b partially forms a recirculation line between the compressor 414 and the accumulator 426. The compressor 414 can be used with high-temperature, high-pressure refrigerants, while the accumulator 426 can be used with low-temperature, low-pressure refrigerants. Therefore, the refrigerant in the compressor 414 can be at a relatively higher temperature and pressure compared to the refrigerant in the accumulator 426.

[0049] Furthermore, valve 422 (e.g., EXV) is integrated with refrigerant line 434b, and therefore, valve 422 is in fluid communication with compressor 414 and accumulator 426 via refrigerant line 434c. Specifically, valve 422 is in fluid communication with the outlet of compressor 414 at the connection point between compressor 414 and the inlet, which is at least indirectly connected to accumulator 426. Additionally, heat pump system 404 may include controller 436 and sensor 438, wherein controller 436 is designed to control valve 422 using sensor 438 in the manner previously described. Furthermore, heat pump system 404 may include refrigerant line 434d connected or at least indirectly connected to the outlet of heat exchanger 416d. Heat pump system 404 may also include valve 428 (e.g., check valve) designed to prevent the flow (e.g., backflow) of refrigerant in refrigerant line 434d from entering the outlet of heat exchanger 416d.

[0050] Figure 6 An exemplary heat pump system of this disclosure is illustrated (e.g., in...). Figure 2 , Figure 3 , Figure 4 and Figure 5 The diagram illustrates the basic principle of the refrigerant vapor compression cycle utilized by the heat pump systems 104, 204, 304, and 204 shown, along with associated pressure-enthalpy diagrams (for subcritical refrigerants such as R134a or R1234yf). The refrigerant is compressed into high-pressure, high-temperature vapor and discharged from the compressor (point 1). The high-pressure, high-temperature vapor dissipates heat to an external fluid (e.g., air) via a hot heat exchanger (e.g., a cabin condenser or an external heat exchanger) and condenses into a high-pressure, medium-temperature liquid at the outlet of the hot heat exchanger (point 2). An expansion valve throttles the high-pressure, medium-temperature liquid into a low-pressure, low-temperature liquid-vapor mixture (point 3), which enters a cold heat exchanger (e.g., an evaporator or cooler) to absorb heat from an external fluid (e.g., air or coolant) and boils into a low-pressure, low-temperature, essentially vaporous mixture (i.e., pure vapor or primarily vapor with a small liquid component) at the outlet of the cold heat exchanger (point 4). Low-pressure, low-temperature refrigerant, essentially a vapor, enters the accumulator, experiences a pressure loss to point 4', and then flows back to the compressor in a low-pressure, low-temperature, essentially vapor state to complete the cycle. Depending on the operating mode, different parts of the heat pump system can function as heat exchangers, expansion valves, and cold heat exchangers.

[0051] There are generally three types of expansion valves: i) capillary (fixed orifice size; the simplest), ii) thermal expansion valve (a mechanical device used to adjust the orifice size so that the outlet flow rate meets a preset condition), and iii) electronic expansion valve (an electronic device used to adjust the orifice size so that the outlet flow rate meets a desired condition; the most advanced). For example... Figure 2The expansion valve shown and / or described may be in the form of an electronic expansion valve, but other valve assemblies may also achieve similar functionality. The expansion valve described herein can operate in one of three modes: expansion, opening, and closing.

[0052] Figure 7 A perspective view illustrating an embodiment of valve 540 according to one or more specific embodiments of the present disclosure is shown. As shown, valve 540 includes a plurality of ports. For example, valve 540 includes ports 542a, 542b, 542c, 542d, and 542e. In this respect, valve 540 can be characterized as a multi-port valve, including a five-way multi-port valve. Fluid (e.g., coolant) can flow through each of ports 542a, 542b, 542c, 542d, and 542e. Furthermore, port 542e can be partially formed by a movable body 544 of valve 540. The movable body 544 can be formed by a motor ( Figure 7 The valve 540 can be driven (e.g., rotaryally driven) by a servo motor or other DC motor, as shown in the diagram. Therefore, when port 542e is driven in one or more specific ways, valve 540 can position two or more valves in fluid communication with each other. This will be shown in further detail below. Furthermore, although valve 540 is shown as a 5-port valve, it can include a different number of ports. For example, valve 540 can take the form of a 6-port valve.

[0053] Figure 8 A schematic diagram illustrating an embodiment of a system 560 according to one or more specific embodiments of the present disclosure, having a valve 540 for guiding fluid throughout the system 560. As shown, system 560 includes a heat pump system 504 and a coolant system 562. Coolant system 562 is designed to cool various vehicle components, such as an ESS 530a, a front drive unit 564 (e.g., a front motor), and a rear drive unit 566 (e.g., a rear motor). Front drive unit 564 and rear drive unit 566 may be combined to partially form the powertrain of the vehicle. System 560 may include multiple loops, such as loop 568a (ESS loop) and loop 568b (powertrain loop). Loops 568a and 568b may be connected in parallel or in series, or may be bypassed or partially bypassed.

[0054] Figure 9A , Figure 9B , Figure 9C , Figure 9D , Figure 9E , Figure 9F Examples illustrating one or more specific embodiments of this disclosure are shown. Figure 8 The diagram shows different modes of flow regulation for valve 540. Figures 9A to 9F Points A, B, C, D, and E in the diagram correspond to... Figure 8Points A, B, C, D, and E in the diagram. Figures 9A to 9F Each of them represents a port 542e relative to the other ports (e.g., ...). Figure 7 The position of the valve 540 (shown) in system 560 is determined by the position of the valve 540. Figure 8 The corresponding mode is enabled (as shown).

[0055] Figure 9A This illustrates that valve 540 allows flow from point E to point A and from point B to point C, thereby connecting loops 568a and 568b (as shown). Figure 8 (As shown) are placed in parallel. Figure 9B The diagram shows that valve 540 allows flow from point E to point D and from point B to point C, thus placing loops 568a and 568b in parallel, but bypassing ESS 530. Figure 9C The diagram shows that valve 540 allows flow from point E to points A and D, and from point B to point C, but partially bypasses ESS 530. Figure 9D The diagram shows that valve 540 allows flow from point E to point C and from point B to point A, thereby connecting loops 568a and 568b in series. Figure 9E The diagram shows that valve 540 allows flow from point E to point C and from point B to point D, thus placing loops 568a and 568b in series, but bypassing ESS 530. Figure 9F The diagram shows that valve 540 allows flow from point E to point C and from point B to points A and D, but partially bypasses ESS 530.

[0056] Figure 10 A schematic diagram illustrating an embodiment of a system 660 having a valve 540 for guiding fluid throughout the system 660, according to one or more specific embodiments of the present disclosure, is shown. As shown, with Figure 8 In contrast, valve 540 is oriented differently. As shown, system 660 includes a heat pump system 604 and a coolant system 662. Coolant system 662 is designed to cool various vehicle components, such as the ESS 630, front drive unit 664 (e.g., front motor), and rear drive unit 666 (e.g., rear motor). Front drive unit 664 and rear drive unit 666 can be combined to partially form the vehicle's powertrain. Furthermore, radiator 670 can be connected to coolant system 662. System 660 may include multiple loops, such as loop 668a (ESS loop) and loop 668b (powertrain loop). Loops 668a and 668b can be connected in parallel or in series, or can be bypassed or partially bypassed. Enhanced heating and cooling can be achieved based on the orientation of valve 540.

[0057] Figure 11A , Figure 11B , Figure 11C and Figure 11DExamples illustrating one or more specific embodiments of this disclosure are shown. Figure 10 The diagram shows different modes of flow regulation for valve 540. Figures 9A to 9F Points A, B, C, D, and E in the diagram correspond to... Figure 8 Points A, B, C, D, and E in the diagram. Figures 9A to 9F Each of them represents a port 542e relative to the other ports (e.g., ...). Figure 7 The position of the valve 540 (shown) in system 660 is determined by the position of the valve 540. Figure 10 The corresponding mode is enabled (as shown).

[0058] Figure 11A This illustrates that valve 540 allows flow from point A to point E and from point C to point B, thereby connecting loops 668a and 668b (as shown in the diagram). Figure 10 (As shown) are placed in parallel. Figure 11B The diagram shows that valve 540 allows flow from point C to point B and from point D to point E, thus placing loops 668a and 668b in parallel, but bypassing radiator 670 (e.g., Figure 10 (As shown). Figure 11C The diagram shows that valve 540 allows flow from point C to point E and from point A to point B, thereby connecting loops 668a and 668b in series. Figure 11D The diagram shows that valve 540 allows flow from point C to point E and from point D to point B, thereby placing loops 668a and 668b in series, but bypassing radiator 670.

[0059] Figure 12 A flowchart illustrating an example process for operating a heat pump system according to a specific implementation of the subject matter is shown. For illustrative purposes, reference is made primarily herein. Figures 2 to 5 The process 700 is described using a heat pump system 104. However, the process 700 is not limited to... Figures 2 to 5 The heat pump system 104, and one or more blocks (or operations) of process 700 may be performed by one or more other components of other suitable movable devices, equipment, or systems. Further for illustrative purposes, some blocks of process 700 are described herein as occurring sequentially or linearly. However, multiple blocks of process 700 may occur in parallel. Furthermore, the blocks of process 700 need not be performed in the order shown, and / or one or more blocks of process 700 need not be performed and / or may be replaced by other operations.

[0060] At box 702, based on the valve (e.g., Figure 2 The valve 122e shown is in its first position (e.g., closed position) via the first refrigerant line (e.g., Figure 2 The refrigerant line 134a shown draws refrigerant from the heat pump system (e.g., Figure 2The compressor of the heat pump system 104 shown (e.g., Figure 2 The compressor 114 shown provides power to the first heat exchanger (e.g., Figure 2 The heat exchanger shown is 116a.

[0061] At box 704, the sensor (e.g., Figure 2 The sensor 138 shown monitors conditions. Conditions may include environmental conditions, such as ambient cold weather (e.g., -10 degrees Celsius or lower) or interior temperature of the vehicle (e.g., passenger compartment or cabin), and / or certain operating modes of the vehicle.

[0062] At block 706, in response to the determination that a condition is below a threshold condition, the controller (e.g., the controller) provides an instruction to change the valve from a first position to a second position (e.g., an open position). The second position is configured to allow refrigerant to bypass the first heat exchanger and flow to the accumulator of the heat pump system.

[0063] The disclosed heating enhancements can help achieve heating for vehicles with large cabin sizes (e.g., three rows of passenger seats), such as by enhancing cabin heating performance and maintaining cabin comfort in cold environments and / or high solar load conditions while driving, idling, and / or DC fast charging. This can provide improved heating efficiency and also help improve occupant comfort, safety, experience, and satisfaction.

[0064] Unless otherwise specified, elements mentioned in the singular are not intended to mean one and only one, but rather one or more. For example, a “one” module can refer to one or more modules. Without further constraints, elements beginning with “a,” “an,” “the,” or “the” do not exclude the presence of additional identical elements.

[0065] Titles and subtitles (if any) are used for convenience only and do not limit the invention. The use of the word "exemplary" is intended to mean as an example or illustration. With regard to the scope of use of terms such as "comprising" or "having," such terms are intended to be inclusive in a manner similar to the term "including," as understood when "comprising" is used as a transitional word in the claims. Relational terms such as "first" and "second" can be used to distinguish one entity or action from another without necessarily requiring or implying any actual such relationship or order between these entities or actions.

[0066] Phrases such as "aspect," "that aspect," "on the other hand," "some aspects," "one or more aspects," "one embodiment," "that embodiment," "another embodiment," "some embodiments," "one or more embodiments," "an implementation scheme," "that implementation scheme," "another implementation scheme," "some implementation schemes," "one or more implementation schemes," "a construction," "that construction," "another construction," "some constructions," "one or more constructions," "the subject matter," "the disclosure," "this disclosure," and other variations thereof are used for convenience and do not imply that the disclosure associated with such phrases is necessary for the subject matter or that such disclosure applies to all constructions of the subject matter. The disclosure associated with such phrases may apply to all constructions or one or more constructions. One or more examples of the disclosure associated with such phrases may be provided. Phrases such as "aspect" or "some aspects" may refer to one or more aspects, and vice versa, and this similarly applies to other foregoing phrases.

[0067] The phrase “at least one of” following a list of items modifies the list as a whole, not as each component of the list, along with the terms “and” or “or” used to separate any of these items. The phrase “at least one of” does not require the selection of at least one item; rather, it allows for the inclusion of the meaning of: at least one of any of these items, and / or at least one of any combination of these items, and / or at least one of each of these items. For example, each of the phrases “at least one of A, B, and C” or “at least one of A, B, or C” refers to only A, only B, or only C; any combination of A, B, and C; and / or at least one of each of A, B, and C.

[0068] It should be understood that the specific order or hierarchy of the disclosed steps, operations, or processes is an example of an exemplary method. Unless otherwise expressly stated, it should be understood that the specific order or hierarchy of steps, operations, or processes may be performed in a different order. Some steps, operations, or processes may be performed simultaneously. The appended method claims (if any) present elements of various steps, operations, or processes in a sample order and are not intended to limit them to the specific order or hierarchy presented. These may be performed sequentially, linearly, in parallel, or in a different order. It should be understood that the described instructions, operations, and systems may generally be integrated together in a single software / hardware product or packaged into multiple software / hardware products.

[0069] In one respect, the term "coupling" can refer to direct coupling. In another respect, the term "coupling" can refer to indirect coupling.

[0070] Terms such as top, bottom, front, back, side, horizontal, and vertical refer to arbitrary frames of reference, not ordinary gravitational frames of reference. Therefore, such terms can extend upward, downward, diagonally, or horizontally within a gravitational frame of reference.

[0071] This disclosure is provided to enable any person skilled in the art to practice the various aspects described herein. In some instances, well-known structures and components are illustrated in block diagram form to avoid confusion with the various concepts of the subject matter. This disclosure provides various examples of the subject matter, and the subject matter is not limited to these examples. Various modifications to these aspects will be readily apparent to those skilled in the art, and the principles described herein can be applied to other aspects.

[0072] All structural and functional equivalences of the various elements of the various aspects described herein are known or will later become apparent to those skilled in the art, and are expressly incorporated herein by reference and intended to be covered in the claims. Furthermore, nothing disclosed herein is intended to serve the public, whether or not such disclosure is expressly stated in the claims. No claim element should be interpreted in accordance with 35 U.S.SC §112(f) unless the element is expressly stated using the phrase “component for…” or, in the case of a method claim, using the phrase “step for…”.

[0073] Those skilled in the art will understand that the various exemplary blocks, modules, elements, components, methods, and algorithms described herein can be implemented as hardware, electronic hardware, computer software, or combinations thereof. To illustrate this hardware-software interchangeability, various exemplary blocks, modules, elements, components, methods, and algorithms have been described above in terms of their functionality. Whether this functionality is implemented as hardware or software depends on the specific application and the design constraints imposed on the system as a whole. Those skilled in the art can implement the described functionality in different ways for each specific application. Various components and blocks can be arranged differently (e.g., in different orders or divided in different ways), all without departing from the scope of the subject matter.

[0074] The title of the invention, background art, description of the drawings, abstract of the specification, and drawings are hereby incorporated in this disclosure and are provided as illustrative examples rather than as limiting descriptions. It is understood at the time of filing this document that they are not intended to limit the scope or meaning of the claims. Furthermore, in the detailed description, it will be apparent that the description provides illustrative examples for the purpose of simplifying the disclosure, and various features are grouped together in various specific embodiments. The approach of this disclosure should not be construed as reflecting an intention to require more features than expressly stated in each claim. Rather, as reflected in the claims, the inventive subject matter lies in all features of fewer than those in a single disclosure configuration or operation. The claims are hereby incorporated in the detailed description, wherein each claim is independently claimed as a separate subject matter.

[0075] The claims are not intended to be limited to the aspects described herein, but should be given the full scope consistent with the language of the claims and to cover all legal equivalents. Nevertheless, none of the claims is intended to include subject matter that fails to meet the requirements of applicable patent law, nor should it be interpreted in this way.

Claims

1. An apparatus, the apparatus comprising: A heat pump system, the heat pump system comprising: A first refrigerant line is connected to a compressor and a first heat exchanger; A second refrigerant line, the second refrigerant line being connected to the first refrigerant line, wherein the second refrigerant line is in fluid communication with the accumulator; and A valve, which is integrated with the second refrigerant line, wherein a first position of the valve is configured to allow the flow of refrigerant from the compressor to the first heat exchanger, and a second position of the valve is configured to allow the flow of refrigerant to bypass the first heat exchanger and flow to the accumulator.

2. The apparatus according to claim 1, wherein: The heat pump system is implemented in a vehicle, and The valve is configured to switch the flow of refrigerant from the first heat exchanger to the second refrigerant line based on at least one of environmental conditions or the operating mode of the vehicle.

3. The apparatus according to claim 2, wherein: The environmental conditions include temperature, and In response to the temperature being below a threshold temperature, the valve is configured to operate in the second position.

4. The apparatus according to claim 3, wherein: The first position includes the closed position of the valve, and The second position includes the open position of the valve.

5. The apparatus according to claim 2, wherein: The operating mode of the vehicle includes the occupancy status of the vehicle, and The heat pump system is configured to heat the passenger compartment of the vehicle based on the occupancy status.

6. The apparatus of claim 1, wherein the heat pump system further comprises: Second heat exchanger; and A third refrigerant line is connected to the outlet of the second heat exchanger, wherein: The second refrigerant line is connected to the first inlet of the accumulator, and The third refrigerant line is connected to the second inlet of the accumulator.

7. The apparatus of claim 6, wherein the heat pump system further comprises a fourth refrigerant line configured to be connected to a third heat exchanger, wherein the fourth refrigerant line is connected to a third inlet of the accumulator.

8. The apparatus of claim 6, wherein the valve in the second position is further configured to allow the flow of the refrigerant to bypass the second heat exchanger.

9. A method, the method comprising: Based on the first position of the valve, refrigerant is supplied from the compressor of the heat pump system to the first heat exchanger via the first refrigerant line; Conditions are monitored by sensors; as well as In response to the determination that the condition is below a threshold condition, the controller provides an instruction to change the valve from the first position to a second position, wherein the second position is configured to allow the refrigerant to bypass the first heat exchanger and flow to the accumulator of the heat pump system.

10. The method according to claim 9, wherein: The conditions include environmental conditions, and The threshold condition includes a threshold temperature.

11. The method of claim 9, wherein providing the instruction to change the valve from the first position to the second position includes changing the valve from the closed position to the open position.

12. The method of claim 9, further comprising supplying refrigerant via a second refrigerant line in response to the valve being in the second position, wherein the second refrigerant line is connected to the accumulator.

13. The method of claim 9, wherein the valve in the second position is further configured to allow the refrigerant to bypass at least a second heat exchanger.

14. The method of claim 13, wherein the first heat exchanger and the second heat exchanger are in fluid communication in response to the valve being in the first position.

15. The method according to claim 9, wherein: The first position includes the open position of the valve, and The second position includes the closed position of the valve.

16. The method of claim 9, further comprising monitoring the operating mode of a vehicle, wherein the operating mode includes the occupancy status of the vehicle.

17. An electric vehicle, the electric vehicle comprising: A heat pump system, the heat pump system comprising: A first refrigerant line is connected to the compressor and the heat exchanger; A second refrigerant line, the second refrigerant line being connected to the first refrigerant line, wherein the second refrigerant line is in fluid communication with the accumulator; and A valve, integral with the second refrigerant line, wherein a first position of the valve is configured to allow refrigerant flow from the compressor to the heat exchanger, and a second position of the valve is configured to allow the refrigerant flow to bypass the heat exchanger and flow to the accumulator.

18. The electric vehicle of claim 17, wherein the valve is configured to switch the flow of the refrigerant from the heat exchanger to the second refrigerant line based on at least one of environmental conditions or operating modes.

19. The electric vehicle according to claim 18, wherein: The environmental conditions include temperature, and In response to the temperature being below a threshold temperature, the valve is configured to operate in the second position.

20. The electric vehicle according to claim 19, wherein: The first position includes the open position of the valve, and The second position includes the closed position of the valve.

Images