Refrigerant distributor

Abstract

Proposed is a refrigerant distributor (1, 1') for refrigeration circuits of a vehicle, comprising a first distributor plate (3) and a second distributor plate (4), which are stacked on top of one another at a parting plane (5) and delimit refrigerant channels (10, 11, 21, 22) running on both sides thereof, as well as refrigerant connections (2) opening into the refrigerant channels, at which the refrigerant distributor can be integrated into the refrigeration circuits. The refrigerant distributor comprises valve receptacles (6) joined to the distributor plates, each of which, by means of a refrigerant valve received or receivable therein, establishes a separable connection between a refrigerant channel (10, 22) running on one side of the parting plane and a refrigerant channel (11, 21) running on the other side of the parting plane.

Description

[0001] The invention relates to a refrigerant distributor for refrigeration circuits of a vehicle, comprising a first distributor plate and a second distributor plate, which are stacked on top of one another at a parting plane and delimit refrigerant channels running on both sides of the parting plane, as well as refrigerant connections opening into the refrigerant channels, at which the refrigerant distributor can be integrated into the refrigeration circuits.

[0002] Such a refrigerant distributor is known from US 11 453 267 B2.

[0003] WO 2022 / 255769 A1 discloses a plate-shaped coolant distributor.

[0004] EP 4 265 448 A1 discloses a refrigerant module.

[0005] DE 10 2022 104 198 A1 discloses a thermal management system.

[0006] Refrigerant distributors are used, particularly in battery-electric vehicles with complex refrigeration circuits and various operating modes (cooling and heating of the passenger compartment, conditioning of the traction battery, etc.), to provide the required wiring of valves and the connections to other components such as refrigerant compressors and various heat exchangers in a compact and integrated design.

[0007] Previously known designs are multi-part, with open half refrigerant channels with valve seats and other functional surfaces formed in a molded plate, and either a second half-shell or a simple stamped sheet metal joined to seal the refrigerant channels. This requires very delicate contours to be tightly connected to one another along a large channel path. This is particularly challenging in refrigeration circuits with CO 2As a refrigerant, the very high operating pressures present a significant challenge and incur additional costs. Various casting or forging processes are generally used to manufacture half-shells with open refrigerant channels, enabling the complex geometries to be produced in large quantities. However, due to the high pressure-tightness requirements, not every casting process and alloy are suitable. Furthermore, the process used and the corresponding alloy must be compatible with the respective joining process and meet the required strength requirements.

[0008] Various welding and brazing processes are used as joining methods. In the case of stamped sheet metal as the second half-shell, additional limitations and challenges arise due to the compatibility of the cast or forged alloy with the sheet alloy and the filler material for brazing and welding.

[0009] Furthermore, the design of expansion and shut-off valves in the refrigeration circuit means that the valves' inlet and outlet channels are not aligned. Due to the channel offset, not all channels can be drilled in alignment with one another or formed in alignment with one another using inserts or slides. This results in internal channel geometries that would require either a multi-part design or lost cores.

[0010] The present invention is based on the object of structurally improving a refrigerant distributor of the type mentioned above.

[0011] The solution to this problem arises from the features of claim 1. Accordingly, the refrigerant distributor is to comprise valve receptacles joined to the distributor plates, each of which, by means of a refrigerant valve received or receivable therein, establishes a separable connection between a refrigerant channel running on one side of the parting plane and a refrigerant channel running on the other side of the parting plane. The refrigerant channels each run predominantly and preferably entirely on only one side of the parting plane and are connected to one another within the refrigerant distributor solely via the valve receptacles, with the refrigerant valves received therein establishing, throttling, or interrupting this connection depending on their valve position.

[0012] Advantageous embodiments of the invention are the subject of the dependent claims.

[0013] The distribution plates can be formed sheet metal parts joined together at the parting plane. The refrigerant channels, offset on both sides relative to the parting plane, are each formed as a recess in one of the sheet metal parts and, depending on the number of plates, are completed either by the other sheet metal part or by a separating plate inserted between the distribution plates. In the two-layer design of the refrigerant distributor, which is structurally simplest, lightest in weight, and most cost-effective, a separating plate separating the distribution plates is omitted. The refrigerant channels are each delimited by the two distribution plates.

[0014] In contrast, a crossing course of separated refrigerant channels (in plan view of the parting plane) is made possible by the separating plate, which then completes the refrigerant channels formed in the distributor plates with both sides.

[0015] The refrigerant connections, which serve as interfaces to external refrigeration circuit components such as heat exchangers, accumulators, receivers, and refrigerant compressors, can be molded directly into the distribution plates if the sheet metal wall thickness is sufficient. Alternatively, the connections can be attached to the distribution plates as separate parts.

[0016] The valve receptacles are preferably sleeves that are open on both sides. Each of these penetrates a bore in one of the distributor plates and rests on the face of the other distributor plate at the parting plane. The refrigerant inflow or outflow into the refrigerant valve accommodated by the valve receptacle then occurs through the open face of the sleeve, and the refrigerant inflow or outflow occurs via a transverse bore in the sleeve.

[0017] Further features of the invention will become apparent from the following description and the drawings, which show a two-layer and a three-layer refrigerant distributor as exemplary embodiments of the invention. Unless otherwise stated, identical or functionally equivalent features or components are provided with the same reference numerals. They show: Fig. 1 the two-layer refrigerant distributor with valves in perspective view; Fig. 2 the refrigerant distributor according to Fig. 1 without valves in perspective view; Fig. 3 the refrigerant distributor according to Fig. 1 without valves in perspective exploded view; Fig. 4 the section AA according to Fig. 2; Fig. 5 the upper distribution plate of the refrigerant distributor according to Fig. 1 without valve seats in perspective top view; Fig. 6 the upper distributor plate according to Fig. 5 as an intermediate; Fig. 7 the lower distribution plate of the refrigerant distributor according to Fig. 1 in perspective top view; Fig. 8 one of the valve seats of the refrigerant distributor according to Fig. 1 as a perspective single part; Fig. 9 the valve holder according to Fig. 8 in longitudinal section; Fig. 10 the three-layer refrigerant distributor without valves in perspective view; Fig. 11 the refrigerant distributor according to Fig. 10 in perspective explosion; Fig. 12 the separating plate of the refrigerant distributor according to Fig. 10 as a perspective single part; Fig. 13 a section through two separate refrigerant channels of the refrigerant distributor according to Fig. 10; Fig. 14 the section AA according to Fig. 10.

[0018] The Fig. 1 to 3 show the first embodiment of a refrigerant distributor 1 according to the invention in various views. In the installed operating state, the refrigerant distributor 1 is connected to refrigerant connections 2 (see Fig. 7) in CO 2-refrigeration circuits of a battery-electric vehicle, wherein the refrigerant connections 2 open into various refrigerant channels that pass through the refrigerant distributor 1. The present two-layer refrigerant distributor 1 comprises an (upper) first distributor plate 3 and a (lower) second distributor plate 4, which are stacked on top of each other at a parting plane 5 and delimit the refrigerant channels running on both sides of the parting plane 5, as well as valve receptacles 6 joined to the distributor plates 3, 4, each of which, by means of a refrigerant valve that can be accommodated therein and is accommodated in this case, establishes a separable connection between a refrigerant channel running on one side of the parting plane 5 and a refrigerant channel running on the other side of the parting plane 5. In summary of the Fig. 1 and Fig. 4, examples include the refrigerant channels 7 and 8, which are separably connected to one another via an expansion valve 9, and the refrigerant channels 10 and 11, which are separably connected to one another via a shut-off valve 12. The refrigerant distributor 1 comprises three further expansion valves 9 and two further shut-off valves 12 as refrigerant valves, each fastened in the valve receptacles 6.

[0019] The distributor plates 3, 4 are components formed from flat sheet metal blanks, into which the refrigerant channels and the refrigerant connections 2 are formed as troughs. The parting plane 5 is formed by the contacting, undeformed surfaces of the sheet metal blanks. The cross-sections of the refrigerant channels are delimited in terms of their longitudinal extent, predominantly or completely by the trough formed in one of the distributor plates 3, 4 on the one hand and the other distributor plate 4, 3 which is undeformed in the area of ​​the trough and is flat there on the other hand. The distributor plates 3, 4 are joined to one another in a material-to-material manner in the parting plane 5 and are pressure-tight to the valve receptacles 6. The joining can be carried out by applying solder in a soldering furnace, by welding or a combination of soldering and welding. For the soldered connections, solder material can either be applied to both distributor plates 3, 4 in their contact area next to the refrigerant channels and, if necessary,be applied in the form of pastes or stamped grids next to the valve seats 6. Alternatively, the solder can be rolled onto the entire surface of one of the distributor plates 3, 4.

[0020] The following examples of installation options are available: Option 1 - Complete soldering: a. Apply solder coating to required areas b. Bring all parts, ie distributor plates 3, 4 and valve seats 6 together and c. solder together in the soldering furnace Option 2 - Pre-assemble valve holders 6 on the first distributor plate 3 a. Insert the valve seats 6 into the distributor plate 3 and weld them b. Apply solder coating to required areas c. Merge distributor plates 3 and 4 and d. solder together in the soldering furnace Option 3 - Pre-assemble valve mounts 6 on the second distributor plate 4 a. Weld the valve seats 6 to the front of the distributor plate 4 b. Apply solder coating to required areas c. Join distributor plates 3 and 4 together (optionally weld the valve seats 6 to the distributor plate 3 instead of soldering them) and d. solder together in the soldering furnace Option 4 - Complete welding a. Weld valve seats 6 to one of the distributor plates 3 or 4 b. Attach the other distribution plate 4 or 3 and c. weld together next to the refrigerant channels in the area of ​​the parting line 5 and with the valve seats 6

[0021] An essential manufacturing step of the first distributor plate 3 results from the Fig. 5 and Fig. 6. Fig. Figure 6 shows the sheet metal blank with the refrigerant channels formed therein and the pre-machined refrigerant connections, only one of which is marked with its reference number 2. From this intermediate product, passages 13 for the valve receptacles 6 are then drilled. This creates a flat joint contact next to each refrigerant channel without radii that could create an internal leakage path for the refrigerant. The outer contour and any required holes 14 for screwing points and / or mutual positioning of the distributor plates 3, 4 can either be punched into the sheet metal blank or created subsequently. The sealing contour of the refrigerant connections 2 is subsequently machined.

[0022] The second distributor plate 4 is available as a single part in Fig. 7. The production is carried out analogously to the first distributor plate 3 by punching and forming a (flat) sheet metal plate, whereby trough-shaped refrigerant channels and the two refrigerant connections 2 as well as the bores 14 are also formed.

[0023] The Fig. 8 and Fig. 9 The valve receptacles 6 shown as individual parts are sleeves that are open on both sides and each form the interface to the refrigerant valves on the inside. These include threads, sealing surfaces and stops. On the outside are the joining surfaces for soldering or welding as well as a stop and, if necessary, other geometries to enable alignment of the sleeves during assembly. The sleeves pass through the drilled openings 13 in the first distributor plate 3 and rest on the end face of the second distributor plate 4 in the parting plane 6. The refrigerant outflow from the refrigerant valve accommodated in the valve receptacle 6 then occurs through the open end face 15 of the sleeve, and the refrigerant inflow into the refrigerant valve occurs via a transverse bore 16 in the sleeve.

[0024] The Fig. 10 to 14 show the second embodiment of a refrigerant distributor 1' according to the invention in various views. The refrigerant distributor 1' has exactly three layers compared to the refrigerant distributor and comprises, as a third layer, a separating plate 17 forming the separating plane 6, which is inserted in a sandwich construction between the first distributor plate 3 and the second distributor plate 4. The first distributor plate 3, together with one (upper) side 18 of the separating plate 17, delimits a portion of the refrigerant channels, and the second distributor plate 4, together with the other (lower) side 19 of the separating plate 17, delimits the other portion of the refrigerant channels separated from one portion. The valve receptacles 6 pass through the passages 13 in the first valve plate 3 and corresponding bores 20 in the separating plate 17 and rest on the end face of the second valve plate 4 (see Fig. 14). The separating plate 17 allows the separated refrigerant channels - viewed in plan view of the separating plane 6 - to cross each other. This allows the topologies of the refrigeration circuits to be more complex and / or implemented in a smaller space. Examples in this regard include a refrigerant channel 21 delimited by the first distributor plate 3 and one side 18 of the separating plate 17 and a further refrigerant channel 22 delimited by the second distributor plate 4 and the other side 19 of the separating plate 17, which delimits the refrigerant channel 21 according to the Fig. 10, Fig. 11 and Fig. 13 crosses.

[0025] The separating plate 17 is according to Fig.12 a flat sheet metal plate with the holes 20 and, if necessary, the holes 14 for screwing points and / or mutual positioning of the distributor plates 3, 4 and the separating plate 17. Further holes 23 connect part of the refrigerant channels with part of the refrigerant connections 2. The three-layer sheet package here can be joined as a whole, as already described.

Claims

[1] Refrigerant distributor (1, 1') for refrigeration circuits of a vehicle, comprising a first distributor plate (3) and a second distributor plate (4), which are stacked on top of one another at a parting plane (5) and delimit refrigerant channels (7, 8; 10, 11; 21, 22) running on both sides of the parting plane (5), as well as refrigerant connections (2) opening into the refrigerant channels (7, 8; 10, 11; 21, 22), at which the refrigerant distributor (1, 1') can be integrated into the refrigeration circuits, characterized by that the refrigerant distributor (1, 1') comprises valve receptacles (6) joined to the distributor plates (3, 4), each of which, by means of a refrigerant valve received or receivable therein, establishes a separable connection between a refrigerant channel (7, 10, 22) running on one side of the parting plane (5) and a refrigerant channel (8, 11, 21) running on the other side of the parting plane (5). [2] Refrigerant distributor (1, 1') according to claim 1, characterized bythat the distributor plates (3, 4) are sheet metal parts which are joined together in the parting plane (5). [3] Refrigerant distributor (1, 1') according to claim 1 or 2, characterized by that the valve receptacles (6) are sleeves open on both sides, each of which passes through a passage (13) in one of the distributor plates (3) and rests on the end face of the other distributor plate (4) in the parting plane (5). [4] Refrigerant distributor (1') according to one of the preceding claims, characterized by that the separating plane (5) is formed by a separating plate (17) inserted between the distributor plates (3, 4), wherein the first distributor plate (3) delimits one of the refrigerant channels (21) with one side (18) of the separating plate (17) and the second distributor plate (4) delimits another of the refrigerant channels (22) with the other side (19) of the separating plate (17), and wherein the one refrigerant channel (21) and the further refrigerant channel (22) are separated from one another. [5] Refrigerant distributor (1') according to claim 4, characterized by that one refrigerant channel (21) and the other refrigerant channel (22) intersect when viewed in plan view onto the parting plane (5). [6] Refrigerant distributor (1) according to one of claims 1 to 3, characterized by exactly two layers formed by the distribution plates (3, 4). [7] Refrigerant distributor (1') according to claim 4 or 5, characterized by exactly three layers formed by the distribution plates (3, 4) and the separating plate (17).

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