Thermal management module for vehicle

Abstract

A thermal management module for a vehicle is provided. The thermal management module includes a housing surrounding a compressor, the housing fixedly holding a condenser, an expansion device, and a chiller. A plurality of flow paths are integrally formed in the shell, and the plurality of flow paths are configured to allow a refrigerant to flow through; the plurality of flow paths includes a first flow path from a discharge port of the compressor to an inlet of the condenser, a second flow path from the expansion device to an inlet of the cooler, and a third flow path from the cooler to a suction port of the compressor, each of the first flow path, the second flow path, and the third flow path is integrally formed within the housing.

Description

Cross Reference to Related Applications

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 661231 filed June 18, 2024 and U.S. Provisional Patent Application No. 63 / 665059 filed June 27, 2024, the entire contents of each of which are incorporated herein by reference. BACKGROUND

[0002] A thermal management module is a module that includes all or most of the components within a refrigeration system that are fixed together. The thermal management module is connected as a single unit, such that the thermal management module can be installed as a single installation step within a vehicle or machine that will include HVAC functionality. SUMMARY

[0003] A representative embodiment of the present disclosure is provided. The embodiment includes a thermal management module. The thermal management module can be within a vehicle such as a passenger car (sedan, SUV, truck), or within a machine like a tractor or crane, or within other types of equipment where a passenger or operator space or equipment requires controllable heating or cooling. The thermal management module includes a housing that encloses a compressor, the housing fixedly holding a condenser, an expansion device, and a chiller. The housing has integrally formed within the housing a plurality of flow paths configured for refrigerant flow therethrough, the plurality of flow paths including a first flow path from a discharge port of the compressor to an inlet of the condenser, a second flow path from the expansion device to an inlet of the chiller, and a third flow path from the chiller to a suction port of the compressor, wherein each of the first flow path, the second flow path, and the third flow path are integrally formed within the housing.

[0004] Other representative embodiments are provided in the form of one or more representative paragraphs provided at the end of this specification.

[0005] The advantages of the present disclosure will become more readily apparent to those normally skilled in the art from the following description of the preferred embodiments of the present disclosure which have been shown and described by way of illustration. As will be realized, the disclosed subject matter is capable of other and different embodiments and its details are capable of modifications in various respects. Accordingly, the drawings and descriptions are to be regarded as illustrative in nature and not as restrictive. BRIEF DESCRIPTION OF DRAWINGS

[0006] Figure 1 is a side cross-sectional view of a thermal management module depicting a compressor, a condenser, a subcooler, a receiver / dryer, an expansion valve, and a chiller each enclosed within a housing, and various fluid connections within the housing for circulating refrigerant flow therethrough, the fluid connections integrally formed by the housing.

[0007] Figure 2 is Figure 1 a top sectional view of the section Z-Z.

[0008] Figure 3 is a perspective view of a prior art thermal management module. DETAILED DESCRIPTION

[0009] Turning now Figures 1 to 2 , a thermal management module 10 is provided. Thermal management modules are often used within an automobile or truck or other vehicle or machine having a passenger compartment and / or requiring a portion of the machine to be maintained in a climate controlled manner, such as a tractor or crane. While the thermal management module can be successfully used with various types of vehicles or machines, for the sake of brevity, the present description will discuss the thermal management module 10 of the present application configured to be disposed within a passenger vehicle, such as an automobile. Those of at least ordinary skill in the art having read and understood the present description will readily understand how to implement the disclosed thermal management module 10 in other vehicles or machines without undue experimentation.

[0010] The thermal management module 10 is an assembly that includes all of the components of a typical refrigeration cycle, such as those used within the HVAC system of a vehicle, that control the temperature of the air within the passenger compartment of the vehicle, or provide heat controlled air, such as for the defrost or defog system of the vehicle. The thermal management module typically includes some or all of the components of a refrigeration system, such as a compressor, a condenser, and an evaporator, that selectively and based on how the thermal management module is installed within the vehicle, can provide heat or cooling to the air within the HVAC system. The thermal management module is typically a single unit that can be installed into the vehicle as a single unit, where the installation involves securing the thermal management module in place within the vehicle, connecting various coolant connections (or other fluid connections with the vehicle or systems within the vehicle), and connecting power and control signals between the vehicle and the thermal management module.

[0011] Figure 3 A prior art thermal management module is depicted having a housing 310 that supports a compressor 330, a condenser 380, and a chiller Figure 3(Not shown in the view, it performs the function of an evaporator in a typical refrigeration system). The housing supports these components, and the thermal management module includes refrigerant flow paths within the thermal management module, such as a first pipe 470 extending from the discharge port of compressor 330 to the inlet of condenser 380, and a second pipe 410 extending from a cooler (not shown) to the inlet of compressor 330. The thermal management module also has an inlet connection 382 and an outlet connection 383 for connection to a vehicle coolant system having condenser 380, allowing heat to be added to the coolant flowing into the condenser (via inlet connection 382) and the outlet, which allows heated coolant to flow to loads within the vehicle using the coolant system. Similar coolant connections are located on the cooler to allow heat from the coolant system to be transferred to the refrigerant system. The refrigerant flow paths (e.g., 410, 470) are typically hoses or pipes connected to components within the thermal management module during module assembly.

[0012] Figures 1 to 2 An improved version of the prior art thermal management module 10 is depicted. The module includes a housing 20 that supports and surrounds the components of the thermal management module and provides connections to auxiliary systems provided to the thermal management module 10, such as a vehicle coolant system, an electrical distribution system, and a control system (1000, schematic, which may be a control system for operating an HVAC system, a dedicated control system for the thermal management module, or a whole vehicle control system) operating the thermal management module 10. The housing is configured as a support structure for the components and establishes various refrigerant flow paths within the thermal management module, as discussed in more detail below. The thermal management module 10 is configured to allow the module to be installed virtually anywhere within the vehicle, and the housing protects the components within it from interference with or against other components within the vehicle, such as rotating components, significantly hot components, components subjected to significant wind, etc.

[0013] Figure 1 A cross-sectional view of the thermal management module 10 is provided. This module includes all components for the complete refrigeration cycle (or heat pump) and holds them in place to minimize the distance between the various components (thus limiting the volume of refrigerant required within the thermal management module and restricting heat transfer into or out of the refrigerant as it flows between the various components of the system, which would otherwise reduce the overall module efficiency). The module also includes fluid flow channels integrally formed within the housing, eliminating many fluid connections found in conventional thermal management modules (e.g., the two connections to the hose 470 between the compressor 330 discharge port and the condenser 380, such as...). Figure 3As depicted, it can be the source of fluid leaks, improper assembly, or damage due to external factors, perhaps caused by expansion operations. The presence of internal passageways within the housing 20 (discussed in more detail below) eliminates many of the possibilities of failure at the fluid connections. Due to various beneficial properties (e.g., good thermal capacity, as well as no harm to the environment associated with other conventional refrigerants), HVAC systems for vehicles have recently been designed to use flammable refrigerants such as propane (R-290), and leaks from external tubing and hoses, or at connections between external tubing or hoses and components of the system, can create hazards such as fires or explosions. The enclosure of all internal passageways for systems with flammable refrigerants within the housing 20 makes these designs an improvement over conventional thermal management module designs with external refrigerant tubing or hoses that must be connected to various components of the system.

[0014] The presence of internal passageways within the housing 20 also prevents or minimizes any external factors from affecting the volume of flow through the passageways, or reducing due to external components crimping or compressing the external flow tubes / tubing, which minimizes the size of the refrigerant flow path within the tubes / tubing.

[0015] Figure 1 Components within the thermal management module 10 are depicted. The housing 20 is provided, and supports and encloses the components as well as various refrigerant fluid flow passageways. The module 10 includes a compressor 30, which typically includes a motor 32 that rotates a shaft 34 (arrow R), which rotates one or more stages for raising the pressure of refrigerant entering the compressor, such that the refrigerant exits the compressor 30 (particularly a compression section 36) as a high pressure gas. A first flow passageway 210 is connected between a discharge 36a of the compressor (the discharge of the final stage of a multi-stage compressor 36) and an inlet 44 of a condenser 40.

[0016] In some embodiments, the item that performs the condensing function 40 (i.e., reduces the heat of the refrigerant by giving off heat to a coolant flowing therethrough) typically causes the refrigerant received by the item to change from a superheated vapor to a saturated vapor or sometimes to a liquid / vapor mixture. In some embodiments where the refrigerant is always a gas throughout the cycle (such as carbon dioxide systems), the component that performs the condenser function is typically referred to as a gas cooler, as the refrigerant remains a gas through the gas cooler (i.e., the gas does not condense to a liquid within the gas cooler). The operation and construction of the housing 20 and related components when the item that removes energy is a gas cooler (due to the type of refrigerant that the thermal management module 10 is designed to receive) is the same as the construction of the housing and related components when the item is a condenser, unless specific differences are noted herein. For brevity, the component that condenses the refrigerant, as well as the gas cooler (which removes heat but the refrigerant remains a gas) are referred to herein as the condenser 40.

[0017] In some embodiments, the condenser 40 can receive a flow of coolant from a coolant system within the vehicle, where the coolant flows into the condenser 40 through the inlet 42 (flow W) and exits the condenser 40 through the outlet 43 (flow X). The coolant entering the condenser receives heat from the refrigerant, which is given off in the form of condensation latent heat, as the high pressure and high temperature gas (typically superheated) initially becomes saturated vapor and then condenses into a mixture of gas and liquid. The heat given off from the refrigerant is transferred to the coolant, such that the coolant exiting the condenser (X) is at a higher temperature than the coolant entering the condenser (W).

[0018] In some embodiments, the system 10 includes a subcooler (or intercooler) 60, where the refrigerant exiting the condenser 40 flows across a component from the refrigerant flowing from the receiver / dryer 50, where heat is exchanged across the subcooler 60. A second flow path 220 / 230 extends from the outlet 45 of the condenser to the receiver / dryer 50.

[0019] The receiver / dryer is formed within the housing and receives refrigerant from the condenser 40. If a subcooler is present in the system, the receiver / dryer 50 in the system receives the refrigerant flow from the condenser 40. If no subcooler is present in the system, the refrigerant flows directly to the receiver / dryer 50. The receiver / dryer 50 can include an expansion volume for the refrigerant, which can hold refrigerant that is not currently needed to flow through the circuit within the system. The receiver / dryer 50 can include a desiccant to remove water entrained with the refrigerant, and can include a filter to remove debris from the refrigerant.

[0020] The refrigerant exits the receiver / dryer 50 via a fourth flow path 240 extending from the receiver / dryer 50 to the subcooler 60, as described above. The refrigerant then flows through a fifth flow path 250 to the expansion valve 70. In some embodiments, the housing 20 does not include a subcooler 60, and the refrigerant flows directly from the condenser 40 to the receiver / dryer 50, and then to the expansion valve 70 via a flow path extending between the refrigerant outlet of the receiver / dryer 50 to the expansion valve 70. As is known, the expansion valve 70 reduces the pressure of the refrigerant and allows the refrigerant to phase change into a gas / liquid mixture (in systems having refrigerant that phase changes during a cycle between liquid and gas). The refrigerant exits the expansion valve 70 and flows to the chiller 80 via a sixth flow path 260.

[0021] The cooler 80 receives a flow of coolant from the vehicle's coolant system, with the coolant flowing into the cooler inlet 82 (flow Y) and the coolant flowing out of the cooler outlet 83 (flow Z). As is known, a low pressure mixture of liquid and gaseous refrigerant enters the cooler 80. The refrigerant receives heat from the coolant, which causes the low pressure refrigerant to become a vapor therein. The transfer of heat reduces the temperature of the coolant, such that the coolant leaving the cooler 80 (flow Z) is at a lower temperature than the coolant entering the cooler (flow Y).

[0022] The refrigerant, which is a low pressure vapor at the outlet of the cooler 80, flows via the seventh flow path 270 to the compressor inlet, and the cycle continues. The controller controls the operation (speed and duty cycle) of the compressor to control the circulation of refrigerant through the housing 20, as discussed herein.

[0023] The housing 20 includes an outer shell that receives the compressor 30, and in particular, the motor 32 and the various stages of the compression section 36 within the compressor 30 that are operated by the motor 32. The housing 20 includes an outer shell in which the receiver / dryer 50 is disposed (when provided). The housing includes an outer shell in which the expansion valve 70 is disposed.

[0024] In some embodiments, the housing 20 includes the condenser 40, while in other embodiments, the condenser 40 is rigidly mounted to the housing. In embodiments in which the condenser is rigidly mounted to the housing 20, the first flow passage 210 is aligned with the inlet 44 of the condenser 40 when the condenser is properly positioned on the housing 20. Similarly, the second flow path 220 (condenser to receiver / dryer 50) within the housing 20 is aligned with the condenser outlet 45. In embodiments in which the subcooler 60 is not provided, the flow path 220 / 230 from the condenser to the receiver / dryer 50 within the housing 20 is aligned with the condenser outlet 45 when the condenser 40 is properly positioned on the housing 20. In further embodiments in which the refrigerant flows directly from the condenser 40 to the expansion valve 70, the flow path within the housing is aligned with the condenser outlet 45 when the condenser 40 is properly positioned on the housing.

[0025] In some embodiments, a gasket is provided between the housing 20 and the condenser 40 to prevent leakage along the seam between the two components. Other known structures to prevent leakage can be provided.

[0026] In some embodiments, the shell 20 includes a cooler, while in other embodiments, the cooler is rigidly mounted to the shell 20. In embodiments where the cooler is rigidly mounted to the shell 20, the sixth flow passage 260 is aligned with the inlet 84 into the cooler when the cooler 80 is properly positioned on the shell 20. Similarly, the seventh flow path 270 (cooler to compressor inlet) within the shell 20 is aligned with the cooler outlet. As with the condenser, a gasket can be provided between the shell 20 and the cooler 80 to prevent leakage along the joint between the two components. Other known structures to prevent leakage can be provided.

[0027] One or both of the condenser 40 and the cooler 80 can be constructed with a plurality of parallel plates, with refrigerant and coolant flowing between the separate spaces between adjacent parallel plates. In other embodiments, one or both of the condenser 40 or the cooler 80 can be constructed with a tube and shell configuration. Other types of heat exchangers for the condenser 40 / cooler 80 can be provided, including condenser and cooler types held within a shell (e.g., the shells 49 and 89 discussed herein). The term “parallel plates” is defined with respect to the formation of the condenser 40 and / or the cooler 80, such that the plates are aligned along their length with a uniform spacing between adjacent plates, such that a line extending through a first plate is parallel or substantially parallel to a line extending through an adjacent plate. In this context, the term parallel does not require that the line through any plate be a straight line - the line can be a straight line, a curved line, or a line having multiple portions, such as several straight line portions at an angle to each other, or a straight line portion extending to a curved portion, etc. The term substantially parallel includes lines that are exactly parallel as well as lines that diverge from being exactly parallel to each other by a small amount, such as no more than 20 degrees.

[0028] Figure 1 A side cross-sectional view of the shell 20 and the first through seventh flow paths 210-270 collectively forming a refrigerant circuit is depicted. As shown, each of the flow paths extends in a straight line along a respective longitudinal axis of the respective flow path. In some embodiments, the entire length of one, some, or all of the flow paths extends along a straight longitudinal axis through the respective flow path. In other embodiments, one, some, or all of the flow paths extends along a respective straight longitudinal axis for a substantial portion of the length of the respective flow path. The term substantial portion is defined herein to include the entire length of the flow path as well as at least 75% of the total length of the flow path. In embodiments where a portion of the flow path does not extend along a straight longitudinal axis, the curved portion is curved with a gradual bend (and / or a larger diameter along the curved portion) to minimize any excess head loss through the curved portion. The flow path can be formed with a constant diameter along the portion that extends along a straight longitudinal axis.

[0029] The flow paths 210, 220, 230, 240, 250, 260, and 270 are formed within the housing. In some embodiments, one, some, or all of the flow paths are formed by and integral with portions of the housing 20. For example, in these embodiments, the flow paths formed by portions of the housing can be formed by machining the flow paths within the housing, such as by drilling the flow paths within the housing 20. In embodiments where the flow paths are integral with the housing 20, the flow paths are less likely to leak as frequently as flow paths that include external hoses or tubes that are secured to connections to components connected within the housing 20.

[0030] In some embodiments, a circulating refrigerant flow (as driven by operation of the compressor 30) within the housing 20 from the compressor 30, in some embodiments to the condenser 40, to the receiver / dryer 50, to the expansion valve 70, to the chiller 80, and back to the compressor 30. In some embodiments, the arrangement is to the receiver / dryer 50 and back to the subcooler 60, to the expansion valve 70, to the chiller 80, and back to the compressor 30 without any tubing or hoses that are not integral within the walls of the housing 20. In this embodiment, the housing 20 is considered to include the condenser housing 49, the subcooler housing 69, and the chiller housing 89 when any of these components are formed as separate housings that are secured to the housing 20. If the compressor 30 unit itself has any tubing or hoses that are part of the compressor, this is consistent with the housing not having any tubing or hoses for refrigerant flow into or out of the compressor. In other embodiments, the refrigerant is circulated from the condenser 40 to the receiver / dryer 50, then to the expansion valve 70, and in this embodiment, the circulating flow paths are arranged without any tubing or hoses that are not integral with the walls of the housing, via direct flow paths (not shown, similar to the flow path 250 in Figure 1

[0031] In embodiments where the condenser 40 and / or the chiller 80 are formed as separate components to the housing 20 but are secured to the housing, the fluid connection between the sixth flow passage (260 - from the expansion valve 70 to the chiller inlet 84) can be a fluid connection of the sixth flow passage 260 and the inlet of the chiller 80 that is integral with the chiller housing 89 that mates with the sixth flow passage 260 when the chiller housing 89 is properly connected to the housing 20. Similarly, with respect to the seventh flow path 270 (from the chiller outlet 85 to the compressor 30 inlet), the fluid connection between the seventh flow path 270 and the chiller outlet 85 is mated when the chiller housing 89 is properly connected to the housing 20.

[0032] ​Similarly, in embodiments where the condenser is located within a condenser housing 49 that mates with the housing 20, the first flow path 210 (from the compressor outlet to the condenser inlet 44) mates together when the condenser housing 49 is properly connected to the housing 20. Further, the second flow path 220 (condenser to receiver / dryer 50) mates with the condenser outlet 45 when the condenser housing 49 is properly connected to the housing. In some embodiments, the subcooler 60 can be integrally formed within the housing 20. The subcooler 60 can include a plurality of parallel plates that establish a plurality of flow channels for flow from the refrigerant to flow through the subcooler 60 (first coolant flow (from the coolant inlet stream W and a second refrigerant flow directly from the receiver / dryer 50)). In other embodiments, the subcooler 60 can be a separate housing 69 that is fixedly mated directly to the housing 20, and the condenser can be fixedly mated directly to the subcooler 60. In this embodiment, the second flow path 220 is integrally formed within the subcooler housing 69. In this embodiment, the subcooler housing 69 includes a flow path 210a that forms a portion of the first flow path 210 (from the compressor outlet to the condenser inlet 44) to flow therethrough. In this embodiment, the flow path 210a mates directly with the first flow path 210 (through the housing 20) and the condenser inlet 44 when the subcooler housing 69 is properly fixedly positioned on the housing 20 and when the condenser housing 49 is properly fixedly positioned on the subcooler housing 69.

[0033] In embodiments where the subcooler 60 has a housing 69 that is separate from the housing 20, when the subcooler housing 69 is properly fixedly positioned on the housing 20, both the fourth flow path (240 - receiver / dryer 50 to subcooler 60) and the fifth flow path (250 - subcooler 60 to expansion valve 70) mate with the respective inlets into the subcooler housing 60 to allow refrigerant flow from the receiver / dryer 50 into the subcooler 60 and therethrough, and then back to the housing via the fifth flow path 250, where these connections can fixedly mate when the subcooler housing 69 is properly connected to the housing 20.

[0034] Figure 2 is a cross-sectional view of the housing and depicts several of the flow paths. In this view, the third flow path 230 is provided from the subcooler 60 to the receiver / dryer. This view also shows the fourth flow path 240, the fifth flow path 250, and the first flow path 210. This view shows the motor 32 of the compressor.

[0035] In some embodiments, the housing 20 includes an electronics module 120 that is secured to the housing or can be integrally formed with the housing 20. The electronics module 120 is configured to receive electrical power for powering the compressor motor 32, such as DC power from a battery (not shown) of the vehicle, or in some embodiments AC power from an alternator of the vehicle. In embodiments where DC current is received by the electronics module 120, the electronics module includes an inverter that converts the DC current to AC current, which is required for an AC motor operated compressor. The electronics module 120 also receives control signals from an HVAC or vehicle controller (not shown) that provides the control signals to control operation of the compressor as needed by the HVAC system or the coolant system. The housing 20 includes a plurality of electrodes that mate with corresponding electrodes on the electronics module 120 to establish one or more current flow paths between the electronics module 120 and the housing 20 when the electronics module 120 is properly and fixedly mated to the housing 20, which establishes one or more current flow paths between the housing 20 and the electronics module for current flow to power the compressor motor 32 and for control signal transfer to control operation of the compressor 30. In some embodiments, control signals are received only within the electronics module 120 and current is supplied to control the compressor motor 32, but there is no separate control signal transferred from the electronics module 120 to the compressor 30 separately.

[0036] The term "about" is specifically defined herein to include a range of plus or minus 5% of a reference value and the reference value. The term "substantially the same" is when an item being compared is within 5% of a reference value of the item.

[0037] The computing elements or functions disclosed herein, such as the vehicle or HVAC controller and electronic module 120, can include a processor and a memory storing computer-readable instructions executable by the processor. In some embodiments, the processor is a hardware processor configured to perform a predefined set of basic operations in response to receiving a corresponding basic instruction selected from a predefined local code instruction set. Each of the modules defined herein can include a corresponding set of machine code selected from the local instruction set, and it can be stored in the memory. Embodiments can be implemented as a software product stored in a machine-readable medium (also referred to as a computer-readable medium, a processor-readable medium, or a computer-usable medium containing computer readable program code). The machine-readable medium can be any suitable tangible medium, including magnetic, optical, or electrical storage media, including a magnetic disk, an optical disk, a memory device (volatile or non-volatile), or similar storage mechanism. The machine-readable medium can contain various sets of instructions, code sequences, configuration information, or other data, which, when executed, cause a processor to perform steps in a method according to embodiments of the application. Those of ordinary skill in the art will appreciate that other instructions and operations necessary for implementing the described embodiments can also be stored on the machine-readable medium. Software running from the machine-readable medium can interface with circuitry to perform the described tasks. Moreover, embodiments can be implemented on application specific integrated circuits (ASICs) or very large scale integrated (VLSI) circuits. Indeed, the person of ordinary skill in the art can utilize any number of suitable structures capable of performing the logical operations according to embodiments.

[0038] Naturally, in light of the teachings and disclosure provided herein, those of ordinary skill in the art can appreciate that alternative designs and / or embodiments of the application can be possible (e.g., substituting one or more components for others, substituting alternative configurations of components, etc.). Although some components, relationships, configurations and / or steps according to the application are not specifically referenced and / or depicted in association with one another, they can be used and / or adapted for use in association with one another and / or adapted for use. All the foregoing and any other structures, configurations, relationships, utilities, etc. that can be depicted and / or based on the various other structures, configurations, relationships, utilities, etc. herein can but need not be incorporated in and / or accomplished by the present application. Any one or more of the foregoing and / or depicted structures, configurations, relationships, utilities, etc. can be implemented in and / or by the present application, alone and / or without reference to, consideration of, or likewise implementing any other foregoing structures, configurations, relationships, utilities, etc., in various permutations and combinations, as will be apparent to those of skill in the art, without departing from the essence, spirit, and scope of the disclosed application.

[0039] While the preferred embodiments of the disclosure have been described, it is to be understood that the disclosure is not limited to those precise embodiments, and that modifications can be made therein without departing from the scope of the disclosure. The scope of the disclosure is defined by the claims appended hereto, and all devices which come within the meaning of the claims, either literally or by equivalence, are intended to be encompassed therein.

[0040] The present description can be readily understood by reference to the following representative paragraphs:

[0041] Representative Paragraph 1 : A thermal management module comprising: a housing enclosing a compressor, the housing fixedly holding a condenser, an expansion device, and a chiller, wherein the housing integrally forms within the housing a plurality of flow paths configured to flow refrigerant therethrough, the plurality of flow paths including a first flow path from a discharge of the compressor to an inlet of the condenser, a second flow path from the expansion device to an inlet of the chiller, and a third flow path from the chiller to a suction inlet of the compressor, wherein each of the first flow path, the second flow path, and the third flow path are integrally formed within the housing.

[0042] Representative Paragraph 2: The thermal management module of Representative Paragraph 1, further comprising a receiver / dryer enclosed within the housing, and a fourth flow path from an outlet of the condenser to the receiver / dryer, wherein the fourth flow path is integrally formed within the housing.

[0043] Representative Paragraph 3: The thermal management module of Representative Paragraph 2, further comprising a subcooler having an inlet to receive a flow from the receiver / dryer and an outlet to send a flow to an expansion valve, and further comprising a fifth flow path from the receiver / dryer to an inlet of the subcooler, and a sixth flow path from an outlet of the subcooler to the expansion valve, wherein the fifth flow path and the sixth flow path are integrally formed within the housing.

[0044] Representative Paragraph 4: The thermal management module of Representative Paragraph 3, wherein the subcooler includes a second inlet to receive a flow from the condenser and a second outlet to send a flow to the receiver / dryer, the fourth flow path including a first portion of refrigerant flow from the condenser outlet to the subcooler and a second portion of refrigerant flow from the subcooler to the receiver / dryer.

[0045] Representative Paragraph 5: The thermal management module of any of Representative Paragraphs 1 to 4, wherein the condenser has a coolant inlet and a coolant outlet, wherein a flow of coolant flows through the condenser via the coolant inlet and the coolant outlet of the condenser.

[0046] Representative Paragraph 6: The thermal management module of any of representative paragraphs 1-5, wherein the chiller has a coolant inlet and a coolant outlet, wherein a flow of coolant flows through the chiller via the coolant inlet and the coolant outlet of the chiller.

[0047] Representative Paragraph 7: The thermal management module of any of representative paragraphs 2-6, wherein the condenser is secured to the housing such that a refrigerant inlet of the condenser is in fluid connection with the first flow path, and wherein a refrigerant outlet of the condenser is in fluid connection with the fourth flow path.

[0048] Representative Paragraph 8: The thermal management module of any of representative paragraphs 1-7, wherein the chiller is secured to the housing such that a refrigerant inlet of the chiller is in fluid connection with the second flow path, and wherein a refrigerant outlet of the chiller is in fluid connection with the third flow path.

[0049] Representative Paragraph 9: The thermal management module of any of representative paragraphs 1-8, wherein a circulating flow of refrigerant within the housing from the compressor to the condenser, ultimately to the expansion device, to the chiller, and back to the compressor is provided without any tubing or hoses that are not integral to walls of the housing.

[0050] Representative Paragraph 10: The thermal management module of any of representative paragraphs 1-9, wherein one or more of the first flow path, the second flow path, and the third flow path are aligned along a respective straight longitudinal axis for at least a substantial portion of a length of the respective flow path.

[0051] Representative Paragraph 11: The thermal management module of representative paragraph 10, wherein all of the first flow path, the second flow path, and the third flow path are aligned along a respective straight longitudinal axis for at least a substantial portion of a length of the respective flow path.

[0052] Representative Paragraph 12: The thermal management module of representative paragraph 10, wherein one or more of the first flow path, the second flow path, and the third flow path are aligned along a straight longitudinal axis for an entire length of the respective flow path.

[0053] Representative Paragraph 13: The thermal management module of representative paragraph 2, wherein the fourth flow path is aligned along a straight longitudinal axis for at least a substantial portion of a length of the fourth flow path.

[0054] Representative Paragraph 14: The thermal management module of any of representative paragraphs 1-13, wherein the condenser is configured in a plurality of parallel plates and the cooler is configured in a plurality of parallel plates.

[0055] Representative Paragraph 15: The thermal management module of any of representative paragraphs 1-14, further comprising an electronic module secured to the housing, the electronic module configured to receive electrical current to operate the compressor.

[0056] Representative Paragraph 16: The thermal management module of representative paragraph 15, wherein the electronic module comprises an inverter to convert received DC current to AC current for powering the compressor.

[0057] Representative Paragraph 17: The thermal management module of any of representative paragraphs 1-16, wherein the housing comprises one or more electrodes that mate with corresponding electrodes on the electronic module to establish one or more current flow paths between the housing and the electronic module when the electronic module is secured to the housing.

Claims

1. A thermal management module comprising: a housing enclosing a compressor, the housing fixedly holding a condenser, an expansion device, and a chiller, wherein the housing integrally forms within the housing a plurality of flow paths configured for refrigerant flow, the plurality of flow paths including a first flow path from a discharge of the compressor to an inlet of the condenser, a second flow path from the expansion device to an inlet of the chiller, and a third flow path from the chiller to a suction inlet of the compressor, wherein each of the first, second, and third flow paths is integrally formed within the housing.

2. The thermal management module of claim 1, further comprising a receiver / dryer enclosed within the housing, and a fourth flow path from an outlet of the condenser to the receiver / dryer, wherein the fourth flow path is integrally formed within the housing.

3. The thermal management module of claim 2, further comprising a subcooler having an inlet to receive a flow from the receiver / dryer and an outlet to send a flow to the expansion valve, and further comprising a fifth flow path from the receiver / dryer to an inlet of the subcooler, and a sixth flow path from an outlet of the subcooler to the expansion valve, wherein the fifth and sixth flow paths are integrally formed within the housing.

4. The thermal management module of claim 3, wherein, the subcooler including a second inlet to receive a flow from the condenser and a second outlet to send a flow to the receiver / dryer, the fourth flow path including a first portion in which refrigerant flows from the condenser outlet to the subcooler and a second portion in which refrigerant flows from the subcooler to the receiver / dryer.

5. The thermal management module of claim 1, wherein, the condenser having a coolant inlet and a coolant outlet, wherein a coolant flow flows through the condenser via the coolant inlet and the coolant outlet of the condenser.

6. The thermal management module of claim 1, wherein, the chiller having a coolant inlet and a coolant outlet, wherein a coolant flow flows through the chiller via the coolant inlet and the coolant outlet of the chiller.

7. The thermal management module of claim 2, wherein, the condenser is fixed to the housing such that a refrigerant inlet of the condenser is in fluid connection with the first flow path, and wherein a refrigerant outlet of the condenser is in fluid connection with the fourth flow path.

8. The thermal management module of claim 1, wherein, the chiller is fixed to the housing such that a refrigerant inlet of the chiller is in fluid connection with the second flow path, and wherein a refrigerant outlet of the chiller is in fluid connection with the third flow path.

9. The thermal management module of claim 1, wherein, The circulating refrigerant flow within the housing from the compressor to the condenser, ultimately to the expansion device, to the chiller, and back to the compressor is provided without any tubing or hoses not integrally formed by walls of the housing.

10. The thermal management module of claim 1, wherein, One or more of the first, second, and third flow paths are aligned along a respective straight longitudinal axis for at least a substantial portion of a length of the respective flow path.

11. The thermal management module of claim 10, wherein, All of the first flow path, the second flow path, and the third flow path are aligned along a respective straight longitudinal axis for at least a substantial portion of a length of the respective flow path.

12. The thermal management module of claim 10, wherein, The one or more of the first flow path, the second flow path, and the third flow path are aligned along the straight longitudinal axis for an entire length of the respective flow path.

13. The thermal management module of claim 2, wherein, The fourth flow path is aligned along a straight longitudinal axis for at least a substantial portion of a length of the fourth flow path.

14. The thermal management module of claim 1, wherein, The condenser is constructed with a plurality of parallel plates, and the cooler is constructed with a plurality of parallel plates.

15. The thermal management module of claim 1, further comprising an electronic module secured to the housing, the electronic module configured to receive electrical current to operate the compressor.

16. The thermal management module of claim 15, wherein, The electronic module includes an inverter for converting received DC current to AC current for powering the compressor.

17. The thermal management module of claim 1, wherein, The housing includes one or more electrodes that mate with corresponding electrodes on the electronic module to establish one or more electrical current flow paths between the housing and the electronic module when the electronic module is secured to the housing.

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