Thermomanagementsystem

Abstract

Thermal management system (1), in particular for a motor vehicle, comprising a refrigerant circuit (3) designed to carry a refrigerant with at least one compressor unit (2) designed to compress the refrigerant in the refrigerant circuit (3), wherein the thermal management system (1) has at least one separator unit (7) designed to separate at least one substance, in particular oil, from the refrigerant carried in the refrigerant circuit (3), wherein the separator unit (7) has at least a first substructure (8) and a second substructure (9), wherein the first substructure (8) is formed by a first component (10) of the thermal management system (1) and the second substructure (9) by a second component (11) of the thermal management system (1).

Description

[0001] The invention relates to a thermal management system, in particular for a motor vehicle, comprising a refrigerant circuit designed to carry a refrigerant with at least one compressor device designed to compress the refrigerant in the refrigerant circuit, wherein the thermal management system has at least one separator device designed to separate at least one substance, in particular oil, from the refrigerant carried in the refrigerant circuit.

[0002] Thermal management systems of the type mentioned above, which include a refrigerant circuit, for example a heat pump, in which refrigerant is circulated, namely compressed by means of a compressor unit, and fed in the refrigerant circuit to a condenser heat exchanger, an expansion valve, and an evaporator heat exchanger in order to achieve appropriate temperature control of the vehicle or various units that can be coupled to the refrigerant circuit by means of heat exchange, are generally known from the prior art. It is further known that for the operation of the compression unit, for example a compressor, a separator unit is provided for separating operating fluids, in particular an oil separator for separating oil, from the refrigerant circuit.

[0003] If, for example, oil enters the refrigerant circuit during the operation of the compressor, it forms a two-phase mixture that can reduce the operation of the refrigerant circuit, particularly its efficiency. Therefore, it is desirable to separate the operating fluid, or oil, from the refrigerant circuit using a separator, so that the refrigerant used can be as pure as possible. This is typically achieved by a separate oil separator integrated into the refrigerant circuit, through which the refrigerant is circulated in such a way that the oil and refrigerant separate, allowing the oil to be selectively removed.

[0004] However, this requires the manufacture or provision of a separate oil separator, which must be produced as an individual component or assembly and installed in the thermal management system. This increases the effort required for manufacturing and assembly, as well as the installation space and number of parts, and consequently the cost of the thermal management system. However, for the reasons mentioned above, omitting the separator is not possible, as the two-phase mixture would otherwise impair the operation of the thermal management system, particularly reducing its efficiency.

[0005] The invention is based on the objective of providing an improved thermal management system in which, in particular, the separation device is improved.

[0006] The problem is solved by a thermal management system with the features of claim 1. Advantageous embodiments are the subject of the dependent claims.

[0007] As described, the invention relates to a thermal management system, specifically for a motor vehicle or vehicles. The thermal management system comprises at least one compressor unit by which refrigerant in the refrigerant circuit of the thermal management system can be compressed or circulated and thus carried through the refrigerant circuit. The thermal management system further comprises a separator unit by which at least one substance, for example, oil, can be separated from the refrigerant carried in the refrigerant circuit. The substance can therefore, in particular, be an operating fluid of the compressor unit, for example, oil, which is provided or supplied for the operation of the compressor unit.

[0008] During operation of the thermal management system, particularly during compressor operation, the substance, specifically the operating fluid, can enter the refrigerant circuit and mix with the refrigerant circulating within it. This creates a two-phase mixture, which can be separated again using the separator. The separator separates the substance from the refrigerant, allowing for its selective or largely complete removal. The substance can remain within a certain portion of the refrigerant circuit.

[0009] The invention is based on the finding that the separator comprises at least a first substructure and a second substructure, wherein the first substructure is formed by a first component of the thermal management system and the second substructure by a second component of the thermal management system. The invention thus proposes that, instead of a separate oil separator typically known in the prior art, which is provided as a separate or independent assembly and integrated into the refrigerant circuit, the separator be formed by a first substructure and a second substructure. In principle, the number of substructures forming the separator is arbitrary, although specifically, exactly two substructures can be provided to form the separator.

[0010] This means that the separator is not provided as a separate and independent unit integrated into the refrigeration circuit, but rather that it is formed by parts or sections of components that are, or will be, integrated into the refrigerant circuit. The first component provides the first substructure of the separator, and the second component provides the second substructure. In the assembled and operational state of the thermal management system, these two components together form the separator by providing the substructures. Consequently, the installation space is reduced, as a separate separator is no longer required. Furthermore, the number of parts, the weight, and the required assembly effort are correspondingly reduced.This is particularly advantageous because the arrangement of the thermal management system is intended to be in a limited installation space, for example an engine compartment, of a motor vehicle.

[0011] The thermal management system can further be provided that the first substructure forms a first sub-chamber of a separation chamber designed for the separation of the at least one substance, and the second substructure forms a second sub-chamber of the separation chamber designed for the separation of the at least one substance. The refrigerant or the two-phase mixture, i.e., the refrigerant containing the substance, can be supplied to the separation chamber in order to carry out the separation there, i.e., to separate the substance, in particular oil, from the refrigerant.

[0012] Instead of a separation device known from the prior art, which has a single-piece separation chamber, for example a cylinder, the separation chamber according to the embodiment described herein is formed by two, in particular exactly two, sub-chambers provided by the first sub-structure and the second sub-structure. In other words, the first component and the second component can be spatially arranged such that the first sub-structure and the second sub-structure abut each other in such a way that the provided first sub-chamber and the second sub-chamber together form the separation chamber. For example, the first component and the second component can be arranged next to each other or connected to each other so that the first sub-chamber and the second sub-chamber come into contact and thus form the separation chamber through the contacting sub-structures.Consequently, the separation chamber can be divided into the two sub-chambers and distributed between the two components. Thus, each component provides a substructure that forms a sub-chamber.

[0013] Furthermore, the thermal management system may include a wall of the first sub-chamber formed in a first component section of the first component, and a wall of the second sub-chamber formed in a second component section of the second component. These walls can, for example, define the outer boundaries of the separation chamber, such as the inner walls of the separation device. The separation chamber can be cylindrical, elliptical, polygonal, cyclone-shaped, or any other shape, particularly as seen in a cross-sectional view.

[0014] When the two sub-chambers are joined, their walls merge to form a single wall, thus defining the separation chamber, for example, as the common inner wall of the separation device. Furthermore, the components, for instance, do not have smooth or straight sections on their end faces. Instead, a contour or three-dimensional profile is intentionally incorporated into the first and second component sections, each contour forming a sub-chamber. When joined, these profiles or contours together form the separation device or separation chamber. In other words, the separation device is created by joining the first and second components, either between the two components or through the contact between their respective component sections.The separation device can therefore be divided into two substructures and distributed between the two adjacent components.

[0015] The thermal management system can be further developed such that the first and second components are arranged adjacent to each other in the refrigerant circuit in the direction of refrigerant flow. The two components thus form spatially adjacent components, such that, for example, the first component follows the second component in the direction of flow, or vice versa. This means that the two components can be arranged arbitrarily one behind the other in the direction of flow. The two components are, in particular, directly adjacent, so that they are in contact with the previously described component sections. Viewed in the direction of flow, the arrangement of the first and second components can be located at the compression stage, i.e., that the first and second components are arranged downstream of the compression stage or at least partially integrated into it.

[0016] Furthermore, the thermal management system may include a surface in the first and / or second component that modifies the flow of a two-phase mixture consisting of the at least one substance and the refrigerant. The two-phase mixture leaving the compression unit, or generated by the substance flowing into the refrigerant within the compression unit, is consequently modified by the surface of the first and / or second component with respect to its flow; in particular, it is diverted, guided, and the like. This allows, in particular, the generation of a two-phase mixture flow that is conducive to the separation of the substance from the refrigerant.

[0017] The thermal management system may further provide that the first component and / or the second component is designed as part of the compressor unit, in particular as an internal subsection of the compressor unit or as an end section of the compressor unit. The first component and the second component may be in direct or indirect contact with each other at their end faces.

[0018] According to a further embodiment of the thermal management system, the first component can be configured as a compressor unit, in particular the first component section as the end section of the compressor unit, and / or the second component can be configured as the housing cover of the compressor unit. As previously described, the separator formed by the two component sections can be arranged downstream of the compressor unit. In the described embodiment, the first component can be configured as a compressor unit, i.e., for example, as that downstream section of the compressor unit, i.e., that section of the compressor unit from which the refrigerant exits compressed.

[0019] The first component section can, for example, be designed as the end section of a compressor unit's base. The second component can additionally or alternatively be designed as a housing cover for the compressor unit, for example, a compressor lid. By mounting the housing cover to the compressor unit, the first component is joined to the second component, as described above. Thus, the two component sections form the two compartments of the separation device and thereby create the separation space between the two components.

[0020] According to another embodiment, the separation chamber can be designed as a cyclone, or cylindrical, elliptical, or polygonal. More generally, the separation chamber can be designed such that the separation of the two-phase mixture of substance and refrigerant, particularly oil and refrigerant, can be advantageously carried out. In this context, it can be particularly useful to exploit the fact that gaseous refrigerant can rise, while the substance, e.g., oil, sinks or exhibits different physical properties than the substance. Known separation mechanisms, for example, based on centrifugal force, gravity, and the like, can therefore be used to perform the separation in the separation chamber.

[0021] In principle, the first and second components can be manufactured in any way. In a specific embodiment, the first and / or second component can be designed as a casting or as an additively manufactured component. As described, the components have sections such that, when arranged together in the refrigerant circuit, they form the sub-chambers or sub-structures of the separation device.

[0022] The thermal management system is specifically designed as a thermal management system for a motor vehicle. The thermal management system includes, in particular, a heat pump, a distribution unit, and a compressor unit. In the present invention, temperature control is understood to mean cooling or heating. A thermal management system is defined as a system that controls the temperature of at least two consumers. A consumer is therefore a device to be cooled or heated. One consumer can be cooled and the other heated. These consumers can even be located in a cooling circuit, as will be shown below.

[0023] Preferably, a consumer can be an electric machine. Furthermore, a consumer can be an inverter. Additionally or alternatively, a consumer can be a passenger compartment. Advantageously, a consumer can be a battery.

[0024] The thermal management system comprises at least one refrigerant circuit. Preferably, the thermal management system comprises at least one refrigerant circuit and one coolant circuit. At least one cooling device may be arranged in the refrigerant circuit. This device cools the refrigerant. The cooling circuit is cooled via the refrigerant and is in direct connection with at least one consumer.

[0025] Furthermore, the thermal management system can have at least two, and in particular exactly two, coolant circuits and one refrigerant circuit. At least one cooling device is arranged in the refrigerant circuit. This device cools the refrigerant. The cooling circuits are cooled via the refrigerant and are in direct contact with the consumers.

[0026] Preferably, one of the refrigerant circuits can be arranged as a high-temperature circuit and the other as a low-temperature circuit. The high-temperature circuit is thermally connected to the refrigeration circuit at a first point, and the low-temperature circuit at a second point. The first point has a higher temperature than the second point. In particular, the high-temperature circuit can be connected downstream of a compressor. Preferably, the low-temperature circuit can be connected downstream of an evaporator.

[0027] The temperature to which the high-temperature circuit is cooled can be, for example, 40°C. This temperature can be used simultaneously to heat one component, such as the passenger compartment, and to cool another component, such as an electric motor.

[0028] The low-temperature circuit is cooled to a lower temperature than the high-temperature circuit. This allows the cooling capacity to be concentrated on the low-temperature circuit, to which the largest cooling load, such as power electronics, is connected. This optimizes the provision of cooling capacity and allows, for example, the compressor to be smaller.

[0029] A radiator can preferably be arranged in the low-temperature circuit.

[0030] Advantageously, a passenger compartment and / or an electric motor and / or a battery can be arranged as consumers in the high-temperature circuit. Furthermore, a power electronics assembly, in particular an inverter, can be arranged in the low-temperature circuit.

[0031] The cooling device can be designed as a heat pump. The heat pump comprises at least two heat exchangers and a compressor. One of the heat exchangers can be designed as a condenser and the other as an evaporator.

[0032] Preferably, the refrigerant in the refrigerant circuit is a natural refrigerant, in particular propane. Alternatively, the coolant in the cooling circuit(s) can be a water-glycol mixture.

[0033] Preferably, the thermal management system includes a distribution unit. The distribution unit controls which circuit is connected to which other circuit and which consumer. The distribution unit is also referred to as a Fluid Control Unit (FCU). Advantageously, the distribution unit includes a valve unit with at least one valve. The valve can be a spool valve, in particular an axial spool valve or a rotary spool valve. In particular, the valve unit can include at least four, preferably exactly four, valves.

[0034] The distribution unit can have at least two housing parts. Channel structures and / or valve mounting areas can be formed on the adjacent sides of the housing parts. Alternatively, one housing part can be designed as a cover without any structures, and only one housing part can have channel structures and / or valve mounting areas. It is also conceivable to provide only valve mounting areas in one housing part and only channel structures in the other housing part.

[0035] Furthermore, the thermal management system comprises a pump arrangement with at least one pump. Preferably, the pump arrangement can comprise at least two, and in particular exactly two, pumps. At least one pump can be designed as a gerotor pump. At least one pump can be designed as a vane pump.

[0036] Alternatively, the thermal management system can also be installed in a stationary position, e.g. in a building.

[0037] In a further embodiment, the thermal management system can have at least one inlet through which refrigerant can be supplied to the separation chamber and at least one outlet, in particular two outlets, through which the refrigerant can flow out of the separation chamber. One outlet can be for the refrigerant and one for the separated substance. The inlet and / or the at least one outlet, in particular the two outlets, can be arranged off-center with respect to a central axis and / or central plane of the separation chamber.

[0038] In addition, the invention relates to a motor vehicle with a described thermal management system. Furthermore, the invention relates to a method for manufacturing a thermal management system, particularly for a motor vehicle, comprising a refrigerant circuit designed to carry a refrigerant and at least one compressor unit designed to compress the refrigerant in the refrigerant circuit, wherein the thermal management system has at least one separator designed to separate at least one substance, in particular oil, from the refrigerant carried in the refrigerant circuit, wherein the separator has at least a first substructure and a second substructure, wherein the first substructure is formed by a first component of the thermal management system and the second substructure by a second component of the thermal management system.In addition, the invention relates to a building with a thermal management system designed as described.

[0039] The invention is explained below with reference to exemplary embodiments and the figures. The figures are schematic representations and show: Fig. 1 a thermal management system according to an exemplary embodiment; Fig. 2 a sectional view through a separation device of the thermal management system of Fig. 1 in the upward direction; Fig. 3 A cross-sectional view through a separation device of the thermal management system of Fig. 1, Fig. 2 in the longitudinal direction; and Fig. 4 A cross-sectional view through a separation device of the thermal management system of Fig. 1-3 in the transverse direction.

[0040] Fig. Figure 1 schematically shows a thermal management system 1, specifically for a motor vehicle. The thermal management system 1 includes a compressor unit 2, which is designed to compress refrigerant circulating in a refrigerant circuit 3 of the thermal management system 1. Furthermore, the refrigerant 3 is circulated in the refrigerant circuit 3 by the compressor unit 2, for example, a compressor. The refrigerant 3 is fed, for example, to a condenser 4 and introduced into an evaporator 6 via an expansion valve 5. The condenser 4 and evaporator 6 can be coupled with heat exchangers, enabling them to regulate the temperature of integrated thermal consumers through thermal contact with temperature control circuits. The condenser 4 and evaporator 6 can themselves be heat exchangers and can also be combined with other heat exchangers, e.g., an interior heater.

[0041] The compressor unit 2 is supplied with a substance during operation, in particular a lubricating fluid, for example oil. This substance can enter the refrigerant circuit 3 and mix with the refrigerant there, creating a two-phase mixture. To prevent the substance from entering the refrigerant circuit 3 or to keep its concentration as low as possible, a separator 7 is provided in the thermal management system 1.

[0042] The separator 7 comprises at least a first substructure 8 and a second substructure 9. The first substructure 8 is provided by a first component 10, and the second substructure 9 is provided by a second component 11 of the thermal management system 1. The components 10 and 11 that provide the separator 7 and its substructures 8 and 9, respectively, can be selected arbitrarily. In the illustrated embodiment, the components 10 and 11 are arranged adjacent to each other in the refrigerant circuit 3 in the direction of refrigerant flow. Specifically, they follow each other directly in the refrigerant circuit 3 and are in contact with each other. For example, the first component 10 is configured as the compressor unit 2 or an end section of the compressor unit 2, such as an outlet section, and the second component 11 is configured as the housing or housing cover of the compressor unit 2.

[0043] Fig. Figure 2 shows a schematic sectional view of the separation device 7 in the vertical direction. The separation device 7 clearly has a separation chamber 12, which is formed partly by the first substructure 8 and partly by the second substructure 9. To manufacture or assemble the separation device 7, the first component 10 is attached to the second component 11, or vice versa. A first wall 13 of a first sub-chamber 14 is formed on the first component 10, and a second wall 15 of a second sub-chamber 16 is formed on the second component 11. This means that when the second component 11 is attached to the first component 10, the component sections containing the first wall 13 and the second wall 15 are joined together, thus forming the separation chamber 12 by joining the sub-chambers 14 and 16.

[0044] Walls 13 and 15 influence the two-phase mixture as it flows into the separation chamber 12. This is purely an example, as also shown in... Fig. 3, Fig. As shown in Figure 4, the separation chamber 12 is designed as a cyclone. This allows, in particular, gaseous refrigerant to exit the separation chamber 12 via a first outlet 17. The substance, which is, for example, oil, is deposited on the walls 13, 15 due to its greater mass compared to the refrigerant and sinks to a lower area of ​​the separation chamber 12 due to gravity, thus exiting via outlet 18. The refrigerant or the two-phase mixture is fed into the separation chamber 12 via a feeder 19.

[0045] By way of example, the first sub-chamber 14 and the second sub-chamber 16 can thus be half-shells or half-chambers of the separation chamber 12, which are integrated into or provided by the two components 10 and 11. The separation chamber 12 is assembled by joining the components 10 and 11. Advantageously, it is therefore not necessary to provide a separate separation chamber or a separate separation chamber 12 in addition to the components 10 and 11 and to arrange it in the thermal management system 1. Instead, the component sections of components 10 and 11 fulfill an additional function, namely the construction of the separation chamber 12. In this context, the compressor unit 2 can, for example, be provided pre-assembled, so that it provides the separation chamber 12 and thus the separation unit 7 in an integrated manner.

[0046] The advantages, details and features shown in the individual embodiments can be combined, interchanged and transferred to one another as desired.

[0047] The method described herein can be used to manufacture the thermal management system 1, in particular the separator device 7. The thermal management system 1 can, as described, be installed in or intended for installation in a motor vehicle. The preceding description is therefore also fully applicable to the method and the motor vehicle. Reference sign 1 Thermal management system 2 compressor unit 3 Refrigerant circuit 4 Capacitor 5 Expansion valve 6 evaporators 7 Separation device 8, 9 Substructure 10, 11 Component 12 Separation chamber 13 first wall 14 first sub-area 15 second wall 16 second sub-area 17, 18 Exit 19 Feed

Claims

[1] Thermal management system (1), in particular for a motor vehicle, comprising a refrigerant circuit (3) designed to carry a refrigerant with at least one compressor unit (2) designed to compress the refrigerant in the refrigerant circuit (3), wherein the thermal management system (1) has at least one separator unit (7) designed to separate at least one substance, in particular oil, from the refrigerant carried in the refrigerant circuit (3), characterized by , that the separation device (7) has at least a first substructure (8) and a second substructure (9), wherein the first substructure (8) is formed by a first component (10) of the thermal management system (1) and the second substructure (9) is formed by a second component (11) of the thermal management system (1). [2] Thermal management system (1) according to claim 1, characterized by, that the first substructure (8) forms a first sub-space (14) of a separation space (12) provided for the separation of the at least one substance and the second substructure (9) forms a second sub-space (16) of the separation space (12) provided for the separation of the at least one substance. [3] Thermal management system (1) according to claim 2, characterized by , that a wall (13) of the first sub-space (14) is formed in a first component section of the first component (10) and a wall (15) of the second sub-space (16) is formed in a second component section of the second component (11). [4] Thermal management system (1) according to any one of the preceding claims, characterized by , that the first and second components (10, 11) are arranged adjacent to each other in the refrigerant circuit (3) in the direction of flow of the refrigerant. [5] Thermal management system (1) according to any one of the preceding claims, characterized by, that the first and / or the second component (10, 11) comprises a surface that modifies the flow of a two-phase mixture consisting of the at least one substance and the refrigerant. [6] Thermal management system (1) according to any one of the preceding claims, characterized by , that the first component (10) and / or the second component (11) is designed as part of the compressor unit (2), in particular as an internal subsection of the compressor unit or as an end section of the compressor unit (2). [7] Thermal management system (1) according to any one of the preceding claims, characterized by , that the separation chamber (12) is designed as a cyclone or cylindrical or elliptical or polygonal. [8] Thermal management system (1) according to any one of the preceding claims, characterized by , that the first component (10) and / or the second component (11) is designed as a casting or as an additively manufactured component. [9] Thermal management system (1) according to any one of the preceding claims, characterized by , that the thermal management system (1) has at least one inlet (19) designed for supplying refrigerant to the separator chamber (12), and / or at least one outlet (17, 18) designed for dispensing refrigerant and / or substance. [10] Motor vehicle comprising a thermal management system (1) according to any one of the preceding claims. [11] Method for manufacturing a thermal management system (1), in particular for a motor vehicle, comprising a refrigerant circuit (3) designed to carry a refrigerant with at least one compressor unit (2) designed to compress the refrigerant in the refrigerant circuit (3), wherein the thermal management system (1) has at least one separator unit (7) designed to separate at least one substance, in particular oil, from the refrigerant carried in the refrigerant circuit (3), characterized by , that the separation device (7) has at least a first substructure (8) and a second substructure (9), wherein the first substructure (8) is formed by a first component (10) of the thermal management system (1) and the second substructure (9) is formed by a second component (11) of the thermal management system (1).

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