Component arrangement of a refrigerant circuit of a vehicle air conditioning system and an air conditioning system having a vehicle refrigerant circuit

Abstract

To provide a vehicle air conditioning system in which components of a refrigerant circuit can be arranged compactly. The present invention relates to a component arrangement for components of a refrigerant circuit of a vehicle air conditioning system, the component arrangement including a heat exchanger for evaporating a refrigerant, an electrically operated compressor disposed within a compressor housing configured to compress the vaporized refrigerant, a valve block including valves for controlling the flow path of the refrigerant, and refrigerant lines, the refrigerant lines fluidly connecting the components to each other. The present invention is characterized in that the components of the component arrangement are each directly coupled to the compressor housing without a separate disconnect, the compressor housing has a mounting portion that allows the component arrangement to be mounted to a vehicle, and the refrigerant lines have connectors for fluidly integrating them into the refrigerant circuit of the air conditioning system.

Description

[Technical Field]

[0001] The present invention relates to an arrangement of components in a refrigerant circuit of an air conditioning system for a vehicle, in particular for a battery electric vehicle (BEV).Furthermore, the present invention relates to an air conditioning system with a refrigerant circuit for a vehicle, in particular for a battery electric vehicle (BEV). [Background technology]

[0002] Heat pump-based air conditioning systems are increasingly commonly employed in vehicles, particularly battery electric vehicles, for vehicle temperature control or air conditioning. According to the prior art, components or subcomponents of the air conditioning system's refrigerant circuit, such as a heat exchanger, a refrigerant compressor, a valve block with valves, and associated connecting lines, are often secured to predetermined locations within the vehicle with separate support devices or secured to predetermined locations on the vehicle body with separate decoupling devices. An alternative configuration uses a central, larger-sized support device to which multiple components of the refrigerant circuit are attached separately from one another, and the support device is attached within the vehicle, for example, to the vehicle body. While a central support device increases weight due to the robust design required to receive the components, multiple separate support devices for attaching the components separately result in increased assembly work and increased costs due to the large number of individual parts and the packaging materials required.

[0003] The use of a central support requires a relatively large structural installation space, which has been found to limit the design possibilities of the air conditioning system for installation within a vehicle. In particular, due to the large space required and the need for specific component location specifications, the central, and therefore bulky, support reduces structural flexibility when designing the air conditioning system. Thus, the structural installation space occupied by the central support, on which the components of the refrigerant circuit of the air conditioning system are individually separated, creates space problems within the vehicle design concept for the peripheral components. In particular, there is also the disadvantage of increasing the overall weight of the air conditioning system. Furthermore, if the clearance between the individually separated components of the refrigerant circuit of the air conditioning system is too large, thermal bridges may be formed, which adversely affects the system efficiency of the air conditioning system. Summary of the Invention [Problem to be solved by the invention]

[0004] SUMMARY OF THE INVENTION It is an object of the present invention to provide an air conditioning system for a vehicle which allows a compact arrangement of the components of the refrigerant circuit and does not require additional bulky supports for connecting the components separately. [Means for solving the problem]

[0005] According to the concept of the present invention, an arrangement of components of a refrigerant circuit of an air conditioning system of a vehicle, in particular a battery electric vehicle (BEV), is provided in a component arrangement for these components provided for this purpose. The component arrangement includes, as components of the refrigerant circuit of the air conditioning system of a vehicle, in particular a battery electric vehicle (BEV), at least one heat exchanger, an electrically operated compressor, a valve block with valves, and refrigerant lines, which are fluidly connected to each other by means of the heat exchanger. The heat exchanger serves to evaporate the refrigerant, and an electric compressor arranged in a compressor housing is configured to compress the refrigerant in vapor form.

[0006] A valve block having valves is provided to control the flow path of the refrigerant, the valves being configured as 3 / 2-way or 2 / 2-way valves. According to the present invention, the components of the component arrangement are connected to each other with separate decouplings directly and immediately connected to the compressor housing, which has a first mounting portion through which the component arrangement can be mounted to a vehicle. Thus, the refrigerant lines have connectors for fluidly integrating the component arrangement into the refrigerant circuit of the air conditioning system.

[0007] For the purposes of the present invention, a mounting point is understood as a location on the compressor housing or on the component arrangement at which the compressor housing or the component arrangement as a whole can be mounted to a vehicle, in particular the body of the vehicle. Alternatively, the mounting point can be configured as an integral structure at which the compressor housing or the component arrangement can be mounted to a vehicle, in particular the body of the vehicle. Furthermore, the component arrangement can also be provided so that it can be mounted to the body of the vehicle at a first mounting point directly, i.e. without any additional support structure.

[0008] The component arrangement forms a self-supporting structure for selected components of the refrigerant circuit of the air conditioning system, with the compressor housing forming a central support for the selected components. The mechanical coupling and the compact arrangement of the components on the compressor housing provide the component arrangement with particularly good rigidity, especially good torsional rigidity, thereby eliminating the need for additional, robust supports. Therefore, the support, which can be attached to at least one mounting portion for attaching the component arrangement to a vehicle, can be configured to have low structural complexity and be intentionally designed with simple dimensions. The mechanical coupling, i.e., the mechanical connection between the components, further promotes the rigidity of the component arrangement and thus contributes to further improving the rigidity of the component arrangement. For this purpose, the components of the component arrangement are fixedly connected to each other by mechanical couplings.

[0009] Preferably, the compressor housing, which forms a central support for the components of the component arrangement, is configured to be particularly torsionally rigid and robust. The torsionally rigid structure is achieved by additional structural components, such as cross braces. The compressor housing can have such additional structural components and / or can be constructed from a material that provides the compressor housing with increased rigidity, particularly torsional rigidity. As an example, the compressor housing can be configured with additional cross braces or cross ribs as stiffening structural components.

[0010] As an essential part of the component arrangement, the compressor housing is dimensioned to receive and carry the components connected to it, i.e. at least the heat exchanger and the valve block. The compressor housing and the components (also called sub-components) connected to it replace the large supports that would be required at the module level to receive components, components or sub-components according to the prior art. At the module level, all components are fixedly connected to the compressor housing, where the compressor is arranged as a component of the refrigerant circuit.

[0011] Additionally, the component arrangement may have a second mounting portion for mounting the component arrangement to a vehicle. According to an advantageous embodiment of the component arrangement according to the invention, in addition to the mounting portion arranged on the compressor housing, a second mounting portion for attachment to the vehicle can be arranged on the compressor housing or on a component connected to the compressor housing. In this way, it is particularly advantageous if the mounting portion arranged on the compressor housing and the further second mounting portion are arranged radially relative to the component arrangement, which contributes to an advantageous load distribution.

[0012] Preferably, the component arrangement has exactly two mounting portions for attachment to a support structure for attachment to a vehicle, in particular to the body of the vehicle, the two mounting portions being arranged radially relative to the component arrangement. This means that the mounting portions to which the support structure can be attached can be arranged so as to be radially arranged at different positions on the component arrangement. Alternatively, it can be provided that the two mounting portions each have an integrated structure for attachment to a vehicle, the structures being arranged radially, i.e. at opposite positions on the component arrangement.

[0013] According to a further embodiment of the component arrangement, a support structure for mounting to a vehicle, particularly a vehicle body, can also be provided as part of the component arrangement. Thus, an upper support structure can be attached to mounting points configured on the compressor housing, and a lower support structure can be attached to additional mounting points. Decoupling components can be arranged between the support structure and the component arrangement, i.e., between the upper support structure and the component arrangement and between the lower support structure and the component arrangement. The support structure can be attached to the component arrangement with one or two mounting means, such as screws. Preferably, the support structure is structurally simple and compact, and has low weight. Furthermore, it serves as an interface or connecting element for mounting and integrating the component arrangement into various vehicle space concepts.

[0014] The compressor housing design allows for a particularly compact and robust coupling of components to avoid movement between the components, especially at their contact interfaces. Thus, the compressor housing can have an integrated structure that holds the components in a fixed and aligned position, which is also advantageous in minimizing leakage and vibration.

[0015] Intermediate parts in the form of surface seals made of a resilient material such as plastic or rubber can be placed between the opposing interconnected components and / or between the compressor housing and the opposing connected components, advantageously contributing to sealing and vibration reduction.

[0016] The compact design of such a component arrangement allows the refrigerant lines within the component arrangement to be as short as possible, i.e., have a short length. For this reason, the refrigerant lines fluidly connecting the components can be fully integrated. That is, the refrigerant lines can be configured as part of the component housing, with the openings of the integrated refrigerant lines being configured at the housing boundary. The integrated refrigerant lines can correspond to openings on the housings of adjacent components, allowing the refrigerant to pass from one component to the second component without the need for separate refrigerant lines between the components. This particularly applies to the refrigerant lines between the components of the component arrangement, eliminating the need for additional hose lines for the flow paths within the component arrangement. To avoid leakage, seals in the form of O-rings or surface seals can be configured between adjacent components, especially in the area of ​​the refrigerant lines. Furthermore, it may be provided that the refrigerant lines fluidly connecting the components to each other are configured within the compressor housing.

[0017] In this manner, the compressor housing can have internal refrigerant lines that allow refrigerant flow between components. In this manner, when the components of the component arrangement are coupled together, a unified flow path for the refrigerant is provided. Advantageously, this results in a reduction in the number of separate refrigerant lines and a reduction in the overall line length of the refrigerant lines.

[0018] The heat exchanger and valve block are coupled to the compressor housing as components that are mechanically coupled to each other and offset by an angle of 90° relative to the compressor's rotational axis, thereby achieving a particularly compact arrangement of components. The compressor housing can have multiple mounting parts or surfaces to allow for simple and quick assembly of the components. Similarly, the components can have mounting parts or surfaces to allow for space-saving arrangement and attachment to the compressor housing and each other.

[0019] According to a particularly preferred embodiment of the component arrangement according to the invention, it can be provided that each component of the component arrangement is coupled and connected to the compressor housing and to at least one further component of the component arrangement. Corresponding embodiments facilitate a compact, space-saving arrangement of the components of the component arrangement.

[0020] Preferably, the components are fixedly screwed together. In addition to screw connections, for example U-clamp connections can also be provided as mounting parts. The housings of the components may further have interlocking parts with latching and / or plug-in connections, which allow connections between the components to be made without additional separate connecting parts.

[0021] In order to simplify the assembly of the component arrangement as much as possible, it can be provided that all connectors of the refrigerant lines for fluid integration into the refrigerant circuit of the air conditioning system are arranged to be concentrated on one side of the component arrangement, which means that all connectors of the refrigerant lines are arranged on one side of the component arrangement, so that specific connection links for fluid integration into the refrigerant circuit of the air conditioning system are predetermined, and no additional connection lines are required to extend the refrigerant flow paths.

[0022] The component arrangement according to the invention can be used in particular in the refrigerant circuit of an air conditioning system of a vehicle, in particular a battery electric vehicle (BEV). The component arrangement according to the invention is particularly suited to BEVs due to its compact design. The use of the component arrangement for operation with the refrigerants R1234yf, R134a, R744, R404a, R600a, R290, R152a, R32 or a mixture of two or more of these refrigerants is provided. A further aspect of the invention is an air conditioning system with a refrigerant circuit for a vehicle, in particular a battery electric vehicle (BEV), comprising at least the following components: - a heat exchanger that evaporates the refrigerant, an electrically operated compressor disposed in a compressor housing configured to compress a refrigerant in vapor form; a valve block with valves for controlling the flow path of the refrigerant; The refrigerant lines fluidly connect the components to one another.

[0023] The air conditioning system is characterized in that the components in the component arrangement are each connected without a separate decoupling, directly coupled to a compressor housing, the compressor housing having a mounting portion by which the component arrangement is attached to a vehicle, in particular to a body of the vehicle, and the refrigerant lines are fluidly connected to the refrigerant circuit of the air conditioning system by connectors. By connecting the component arrangement to the refrigerant lines of the air conditioning system, a closed refrigerant circuit is formed.

[0024] In particular, for operation of the arrangement according to the invention with refrigerant R290, no further refrigeration circuit components need to be provided in addition to the components associated with the arrangement. The component layout of the air conditioning system may be configured according to one or more of the embodiments described above. [Effects of the Invention]

[0025] The advantages achievable by the present invention are summarized as follows: -Cost savings due to elimination of central support for individual component connections; -More compact design, -Improved acoustic performance due to increased mass compared to a separate compressor -Lightweight, - Overall improvement of the ecological footprint of production, transportation and on-board operations. [Brief explanation of the drawings]

[0026] [Figure 1] 1 is a schematic perspective view of an exemplary embodiment of a component arrangement according to the present invention; [Figure 2] 2 is a further schematic perspective view of the exemplary embodiment of the component arrangement according to the present invention shown in FIG. 1; [Figure 3] 2 is a first side view of the exemplary embodiment of the component arrangement according to the present invention shown in FIG. 1; [Figure 4] 2 is a second side view of the exemplary embodiment of the component arrangement according to the present invention shown in FIG. 1; [Figure 5] 2 is a third side view of the exemplary embodiment of the component arrangement according to the present invention shown in FIG. 1; [Figure 6] 2 is a fourth side view of the exemplary embodiment of the component arrangement according to the present invention shown in FIG. 1; [Figure 7] 2 is a top view of an exemplary embodiment of a component arrangement according to the present invention shown in FIG. 1; [Figure 8] 2 is a bottom view of the exemplary embodiment of the component arrangement according to the present invention shown in FIG. 1. DETAILED DESCRIPTION OF THE INVENTION

[0027] FIG. 1 is a schematic perspective view of an exemplary embodiment of a component arrangement 1 according to the present invention. The component arrangement 1 is provided for integration into the refrigerant circuit of a vehicle air conditioning system, in particular an air conditioning system for a battery electric vehicle (BEV), and includes, as components of the refrigerant circuit of the vehicle air conditioning system, at least one heat exchanger 2, an electrically operated compressor arranged in a compressor housing 3, a valve block 4 having four valves 4.1, and refrigerant lines 5 by which the components are fluidly connected to one another. In this embodiment, the valve block 4 includes four valves 4.1. However, it is also possible to provide embodiments with a valve block as a component having fewer or more than four valves for controlling the flow path of the refrigerant. The refrigerant lines 5 include connectors 5.1 by which the component arrangement 1 can be fluidly integrated into the refrigerant circuit of the vehicle air conditioning system.

[0028] The heat exchanger 2 serves to evaporate the refrigerant supplied via the refrigerant line 5, and an electrically operated compressor arranged in the compressor housing 3 is configured to compress the vaporized refrigerant. To control the refrigerant flow path, the valve 4.1 of the valve block 4 can be configured as a 3 / 2-way valve or a 2 / 2-way valve. According to the invention, the components of the heat exchanger 2 and the valve block 4 are directly coupled to the compressor housing 3 and connected to each other without a separate disconnect. In this way, the heat exchanger 2 and the valve block 4 are connected to each other and to the compressor housing 3 while being offset by an angle of 90° relative to the compressor's rotation axis. This arrangement allows the heat exchanger 2 and the valve block 4 to be arranged particularly compactly within the component arrangement 1.

[0029] To mount the components 2 and 4 on the compressor housing 3, the compressor housing 3 is provided with threaded holes, and the components 2 and 4 have corresponding threaded bushings into which screws 8 inserted into the compressor housing 3 can be threaded, and via these screws 8 the components 2 and 4, i.e. the heat exchanger 2 and the valve block 4, are screwed onto the compressor housing 3. The compressor housing 3 is provided with receiving structures in the form of profiles, stop edges and cavities to hold the heat exchanger 2 and the valve block 4 in place.

[0030] The refrigerant lines 5 are configured to be fully integrated between the components of the component arrangement 1 and are therefore hidden. Only portions of the refrigerant lines 5 are configured as separate connection lines for the fluid connections of the components and protrude from the components for maintenance purposes. Inspection valves can be arranged along the externally accessible refrigerant lines 5 so that portions of the refrigerant lines 5 can be shut off.

[0031] The compressor housing 3 is made up of three consecutive housing segments 3.1, 3.2, and 3.3, with the first housing segment 3.1 housing the compressor, the electric motor for driving the compressor being located in the second housing segment 3.2, and the inverter being housed in the third housing segment 3.3.

[0032] The valve block 4 is screwed to the first housing segment 3.1 by means of screws 8. The valve block 4 is thus arranged radially relative to the rotation axis of the compressor or electric motor. The compressor housing 3 has a first mounting portion 6 in the form of a threaded hole on its upper side. At the first mounting portion 6, the component arrangement 1 can be attached to a support structure for mounting to the vehicle or directly to the vehicle body. The attachment to the first mounting portion 6 can have a decoupling in the form of a rubber bumper.

[0033] Figure 2 is a further schematic perspective view of the exemplary embodiment of the component arrangement 1 according to the invention shown in Figure 1. In this view, the heat exchanger 2 and the four connectors 5.1 of the refrigerant lines 5 of the component arrangement 1 are visible. The four connectors 5.1 of the refrigerant lines 5 are arranged on one side of the component arrangement 1.

[0034] 3 is a first side view of an exemplary embodiment of the component arrangement 1 according to the invention shown in FIG. 1. In this view, the end face of the first housing segment 3.1, in which the compressor is housed, is visible. Above the compressor housing 3, a valve block 4 with valves 4.1 is arranged and is screwed to the compressor housing 3. The heat exchanger 2 is arranged to the right of the valve block 4 and is screwed to the valve block 4 and the compressor housing 3. Reference numeral 9 indicates the location of a second mounting portion for mounting the component arrangement 1 to a support structure for mounting the component arrangement 1 to a vehicle. The second mounting portion 9 is arranged on the underside of the component arrangement 1.

[0035] 4 is a second side view of the exemplary embodiment of the component arrangement 1 according to the invention shown in FIG. 1. This figure shows a side top view of the component arrangement 1, on which the four connectors 5.1 of the refrigerant lines 5 are arranged. In the plate part 7, the heat exchanger 2 is screwed with screws 8 to the third housing segment 3.3 of the compressor housing 3.

[0036] 5 is a third side view of the exemplary embodiment of the component arrangement 1 according to the invention shown in FIG. 1. In this view, the end face of the third housing segment 3.3, in which the inverter is housed, is visible. The first mounting part 6 is located on the upper side of the third housing segment 3.3.

[0037] Figure 6 is a fourth side view of the exemplary embodiment of the component arrangement 1 according to the invention shown in Figure 1. In this view, the longitudinal side of the compressor housing 3 is visible. The positions of the first mounting portion 6 and the second mounting portion 9 on the component arrangement 1 are substantially diametrically opposed.

[0038] 7 is a top view of an exemplary embodiment of the component arrangement 1 according to the invention shown in FIG. 1. In this view, the upper side of the component arrangement 1 is visible. In the plate part 7, the heat exchanger 2 is screwed with screws 8 to the third housing segment 3.3 of the compressor housing 3.

[0039] Figure 8 is a bottom view of the exemplary embodiment of the component arrangement 1 according to the invention shown in Figure 1. In this view, the second mounting part 9 configured on the underside of the component arrangement 1 can be seen, this second mounting part 9 being configured as a plate with an opening. The attachment to the second mounting part 9 can have a decoupling in the form of a rubber bumper. [Explanation of symbols]

[0040] 1. Component placement 2 Heat exchanger 3 Compressor housing 3.1 First Housing Segment 3.2 Second Housing Segment 3.3 The third housing segment 4 Valve Block 4.1 Valves 5 Refrigerant lines 5.1 Connectors 6 First mounting point 7 Plate parts 8 screws 9 Second mounting point

Claims

1. A component arrangement (1) for components (2, 4, 5) of a refrigerant circuit of an air conditioning system for a vehicle, in particular for a battery electric vehicle (BEV), comprising: a heat exchanger (2) for evaporating a refrigerant; an electrically operated compressor disposed within a compressor housing (3) configured to compress a vapor-state refrigerant; a valve block (4) with valves (4.1) for controlling the flow path of the refrigerant; The refrigerant line (5) is a component arrangement (1) in which the components (2, 4) are fluidly connected to one another, the component arrangement (1) of the components (2, 4, 5) is respectively directly coupled to the compressor housing (3) without a separate disconnect, the compressor housing (3) has a first mounting part (6) by which the component arrangement (1) can be mounted to a vehicle, and the refrigerant line (5) has a connector (5.1) for fluid integration into the refrigerant circuit of an air conditioning system.

2. Component arrangement (1) according to claim 1, characterized in that the compressor housing (3) is constructed to be torsionally rigid.

3. Component arrangement (1) according to claim 1, further comprising a second mounting part (9) for mounting said component arrangement (1) to a vehicle.

4. 2. The component arrangement (1) according to claim 1, characterized in that the first mounting portion (6) and the second mounting portion (9) configured on the compressor housing (3) are arranged diametrically opposite each other.

5. Component arrangement (1) according to claim 1, characterized in that the compressor housing (3) has a unitary structure which holds the components (2, 4, 5) in a fixed and aligned position.

6. Component arrangement (1) according to claim 1, characterized in that intermediate parts in the form of surface seals made of elastic material are arranged between the oppositely interconnected components (2, 4) and / or between the compressor housing (3) and the oppositely connected components (2, 4), respectively.

7. Component arrangement (1) according to claim 1, characterized in that the refrigerant lines (5) fluidly connecting the components (2, 4) are configured to be completely integrated.

8. Component arrangement (1) according to claim 1, characterized in that the compressor housing (3) has internal refrigerant lines that allow the flow of refrigerant between the components (2, 4).

9. 2. The component arrangement (1) according to claim 1, characterized in that the heat exchanger (2) and the valve block (4) are connected to the compressor housing (3) in a manner that they are offset from each other by an angle of 90° relative to the rotation axis of the compressor.

10. Component arrangement (1) according to claim 1, characterized in that the compressor housing (3) has a number of mounting parts or surfaces that allow for easy and quick assembly of the components (2, 4).

11. Component arrangement (1) according to claim 1, characterized in that the components (2, 4) have mounting parts or surfaces that allow for space-saving arrangement and attachment to the compressor housing (3) and to each other.

12. Component arrangement (1) according to claim 1, characterized in that each component (2, 4) of the component arrangement (1) is coupled and connected to the compressor housing (3) and to at least one further component (2, 4) of the component arrangement (1).

13. Component arrangement (1) according to claim 1, characterized in that the connector (5.1) of the refrigerant line (5) is configured to be fluidly integrated into the refrigerant circuit of the air conditioning system on one side of the component arrangement (1).

14. Use of a component arrangement (1) according to claims 1 to 13 in the refrigerant circuit of an air conditioning system of a vehicle, in particular a battery electric vehicle (BEV).

15. 14. Use of the component arrangement (1) according to claims 1 to 13 for operation with refrigerants R1234yf, R134a, R744, R404a, R600a, R290, R152a or R32, or a mixture of two or more of these refrigerants.

16. 1. An air conditioning system having a refrigerant circuit for a vehicle, in particular a battery electric vehicle (BEV), characterized in that the air conditioning system comprises at least the following components: a heat exchanger (2) for evaporating the refrigerant, an electrically operated compressor arranged in a compressor housing (3) adapted to compress a refrigerant in vapor form; a valve block (4) with valves (4.1) for controlling the flow path of the coolant, - the compressor housing (3) has mounting parts (6, 9) by which the component arrangement (1) is attached to the vehicle, in particular to the body of the vehicle, and the refrigerant line (5) is connected to a connector (5.1), characterized in that the components (2, 4) are fluidly connected to one another and the components (2, 4) in the component arrangement (1) are respectively connected and directly coupled to the compressor housing (3) without being separately disconnected by the refrigerant line (5).

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