Gas injection refrigeration system, control, and apparatus

Abstract

An air conditioning (AC) system has a compressor flowing a fluid through the system, a condenser after the compressor, a liquid-gas separator after the condenser, and an evaporator after the liquid-gas separator. Between the condenser and the liquid-gas separator and between the liquid-gas separator and the evaporator is expansion valves to transform the fluid from a gaseous state to a mixed, liquid and gaseous state. Controlling the expansion valve between the condenser and the liquid-gas separator is based on a sensor along a superheat line after the evaporator and before the compressor, and controlling the other expansion valve is based on the first expansion valve, or vice versa. An expansion valve with two expansion chambers and a single pin can provide control of both expansion valves by one assembly.

Description

FIELD

[0001] The present disclosure relates to a heating and cooling system, such as a heating and cooling system with gas injection for a vehicle.BACKGROUND

[0002] This section provides background information related to the present disclosure, which is not necessarily prior art.

[0003] Typical air conditioning (AC) systems for a vehicle are a closed fluid system including a compressor, a condenser, an expansion valve, and an evaporator for cooling the vehicle's passenger cabin. The fluid in the system is a refrigerant that undergoes various transformations to its physical state, such as being in a liquid state or a gaseous / vapor state, depending on the pressure and temperature of the fluid at stages in the system. Other AC systems utilize a liquid-gas separator and a gas-injection line connecting the liquid-gas separator to the compressor.

[0004] An issue faced by typical AC systems for a vehicle is that the fluid travels through the system and the system components and returns to the compressor in a mixed, liquid and gaseous state, which damages the compressor due to the increased load necessary to pressurize the liquid fluid. Thus, AC systems require a system and apparatus that will depressurize the fluid in the system further than a typical AC system with only a singular expansion valve would, allowing lower pressure, increased transformation of the fluid to a gaseous state, and increased heat removal of the system through rerouting of the fluid in a gaseous state. AC systems that utilize a liquid-gas separator and a gas-injection line require a method and apparatus to control the reduction of pressure at two stages in the AC system cycle.

[0005] While current AC systems are suitable for their intended use, they are subject to improvement. For example, an AC system that reduces load on the compressor by inhibiting the fluid from reaching the compressor in a liquid state by reducing the pressure through an additional expansion valve in the system as well as injecting the fluid in a gaseous state to the compressor before it reaches the evaporator would be desirable. An expansion valve that can control the fluid flow and reduction in pressure at two stages in the AC system cycle simultaneously is also desirable.SUMMARY

[0006] This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.

[0007] The present disclosure includes an air conditioning (AC) system comprised of a compressor, a condenser, a first expansion valve, a liquid-gas separator, a second expansion valve, an evaporator, and sensor. The compressor flows a fluid through the AC system. The condenser receives the fluid from the compressor. The first expansion chamber receives the fluid from the condenser and has a first expansion area. The liquid-gas separator receives the fluid from the first expansion valve and partitions the fluid between a main line and a gas-injection line. The second expansion valve receives the fluid from the liquid-gas separator and has a second expansion area. The evaporator receives the fluid from the second expansion valve and discharges the fluid to the compressor along the main line. The sensor measures a pressure and a temperature of the fluid discharged from the evaporator. One of the first expansion area and the second expansion area is controlled by the associated expansion valve based on the pressure and the temperature of the fluid measured by the sensor and the other of the first expansion area and the second expansion area is controlled by the associated expansion valve based on the one of the first expansion area and the second expansion area.

[0008] According to a further aspect, the compressor receives the fluid in only a gaseous state.

[0009] According to a further aspect, the first expansion area is controlled by the first expansion valve based on the pressure and the temperature and the corresponding super heat temperature of the fluid measured by the sensor and the second expansion area of the second expansion valve is controlled based on the first expansion area.

[0010] According to a further aspect, wherein the second expansion area is controlled by the second expansion valve based on the pressure and the temperature and the corresponding super heat temperature of the fluid measured by the sensor and the first expansion area of the first expansion valve is controlled based on the second expansion area.

[0011] According to a further aspect, the liquid-gas separator is configured to allow the flow of the fluid in a liquid state to the main line and the flow of the fluid in a gaseous state to the gas-injection line.

[0012] According to a further aspect, the gas-injection line is configured to allow the flow of the fluid in the gaseous state to a compressor gas injection port.

[0013] According to a further aspect, a controller configured to relay the sensor feedback to one of the first expansion valve and the second expansion valve.

[0014] According to a further aspect, the evaporator includes a water-chiller, a secondary evaporator, and an oil-cooler.

[0015] According to an aspect of the present disclosure, an expansion valve assembly comprises a valve body, a first expansion chamber, a second expansion chamber, a pin, a middle valve disk, and an end valve disk. The first expansion chamber has a first inlet, a first outlet and a first orifice. The second expansion chamber has a second inlet, a second outlet, and a second orifice. The pin has an upper portion, a lower portion, and an intermediate portion disposed between the upper portion and the lower portion. The pin extends through the valve body, the first orifice, and the second orifice. The pin has the middle valve disk attached to the intermediate portion and the end valve disk attached to the lower portion. The pin is configured to move by an actuator disposed to the upper portion of the pin. The middle valve disk and the end valve disk alter the fluid flow through the first orifice and the second orifice respectively by a position of the pin.

[0016] According to a further aspect, a separation plate is between the first expansion chamber and the second expansion chamber, the separation plate includes a pin shaft opening.

[0017] According to a further aspect, the pin extends through the pin shaft opening and allows the position of the pin to determine the alteration of the fluid flow through the first orifice by the middle valve disk and the alteration of the another fluid flow through the second orifice by the end valve disk simultaneously.

[0018] According to a further aspect, the actuator of the expansion valve assembly is one of a motor driven linear actuator and a camshaft actuator.

[0019] According to a further aspect, a refrigerant chamber included in the valve body, the refrigerant chamber allows the fluid to flow through the valve body and detect a pressure and a temperature of the fluid.

[0020] According to a further aspect, the pressure and the temperature of the fluid through the refrigerant chamber determines the position of the pin by a thermostatic expansion valve.

[0021] According to an aspect of the present disclosure, an air conditioning (AC) system comprises a compressor, a condenser, an expansion valve assembly, a liquid-gas separator, and an evaporator. The compressor flows a fluid through the system. The condenser is in fluid communication with the compressor. The expansion valve assembly includes a valve body with a first expansion chamber and a second expansion chamber. The first expansion chamber is in fluid communication with the condenser. The liquid-gas separator is in fluid communication with the first expansion chamber and partitions the fluid to a main line and a gas injection line. The main line creates fluid communication between the liquid-gas separator and the second expansion chamber of the expansion valve assembly, and the gas-injection line creates fluid communication between the liquid-gas separator and the compressor. The evaporator is in fluid communication with the second expansion chamber of the expansion valve assembly and is in fluid communication with the compressor by a superheat line. The expansion valve assembly determines a position of a pin inside the valve body, the first expansion chamber, and the second expansion chamber. The position of the pin transforms the flow of the fluid through the AC system.

[0022] According to a further aspect, a sensor is along the superheat line between the evaporator and the compressor, the sensor measures a pressure and a temperature of the fluid flowing in the superheat line.

[0023] According to a further aspect, the expansion valve assembly includes an actuator in communication with the sensor, the actuator is configured to determine the position of the pin based on the pressure and the temperature of the fluid flowing in the superheat line measured by the sensor.

[0024] According to a further aspect, the actuator of the expansion valve assembly the actuator is one of a motor driven linear and a camshaft actuator.

[0025] According to a further aspect, the valve body of the expansion valve assembly includes a refrigerant chamber along the superheat line, the refrigerant chamber allows the fluid flowing through the superheat line to flow through the valve body and detect a pressure and a temperature of the fluid.

[0026] According to a further aspect, the pressure and the temperature of the fluid flowing through the refrigerant chamber of the expansion valve assembly determines the position of the pin by a thermostatic expansion valve.

[0027] Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.DRAWINGS

[0028] The drawings described herein are for illustrative purposes only of select embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

[0029] FIG. 1 illustrates an exemplary air conditioning (AC) system in accordance with the present disclosure;

[0030] FIG. 2. illustrates an exemplary configuration of the AC system of the present disclosure;

[0031] FIG. 3 illustrates a cross-sectional view an expansion valve assembly in accordance with the present disclosure;

[0032] FIG. 4 illustrates a cross-sectional view of an expansion valve assembly in accordance with the present disclosure;

[0033] FIG. 5 illustrates an exemplary AC system in accordance with the presentation disclosure including an expansion valve in accordance with the present disclosure; and

[0034] FIG. 6 illustrates an exemplary AC system in accordance with the presentation disclosure including an expansion valve in accordance with the present disclosure.

[0035] Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.DETAILED DESCRIPTION

[0036] Example embodiments will now be described more fully with reference to the accompanying drawings.

[0037] FIGS. 1 and 2 illustrate an air conditioning (AC) system 10. The AC system is useful for providing cooled air in an enclosed space, like a passenger cabin for a vehicle or a building, through a closed, cyclical process. The AC system 10 can include a compressor 12, a condenser 14, a first expansion valve 22, a liquid-gas separator 16, a second expansion valve 24, and an evaporator 18. A fluid in the AC system 10, typically a refrigerant such as a chlorofluorocarbon refrigerant, a hydrochlorofluorocarbon refrigerant, a hydrofluorocarbon refrigerant (e.g. R-134a), a hydrofluoroolefin refrigerant (e.g. R-1234yf), or a natural refrigerant, is pumped or flowed through refrigerant lines 26 throughout the AC system 10. The refrigerant lines 26 connect the AC system 10 components and maintain pressure and temperature of the fluid in the AC system 10. The type of fluid refrigerant in the AC system 10 depends on the system parameters, capabilities, and requirements the AC system 10 is designed to fulfill. The AC system 10 components facilitate various transformations to the fluid physical state. The fluid, depending on its pressure and temperature at stages inside the AC system 10, is transformed between a gaseous / vapor state, a liquid state, and a mixed state of both gas and liquid. The fluid can also be in a superheated vapor state in which the fluid temperature is higher than the saturation temperature of the fluid, where the saturation temperature is the boiling point of the fluid, resulting in the fluid being in a complete gaseous state.

[0038] As shown in FIGS. 1 and 2, the fluid in the AC system 10 can only flow along one flow direction 34 from the compressor 12 and ultimately returns to the compressor 12 after the AC system 10 cycle. The compressor 12 pumps the fluid through the AC system 10 and applies pressure and heat to the fluid, putting the fluid in a superheated vapor state of high pressure and high temperature as it begins its flow through the AC system 10. From the compressor 12, the fluid flows to the condenser 14 by the refrigerant lines 26 in a high-pressure level. The condenser 14 can receive the fluid and can have passages that allow the fluid to pass through the condenser 14. The fluid flowing through the condenser 14 passages can allow heat to be extracted by air passing over the fluid passages, resulting in the fluid condensing to the liquid state inside the condenser 14. The condenser 14 can maintain the pressure of the fluid as it flows through the passages. The fluid can exit the condenser 14 in a high pressure, low temperature liquid state. It is contemplated a system sensor 40 can be along the refrigerant lines 26 between the compressor 12 and the condenser 14 to monitor and determine the fluid flow through the AC system 10, depending on the AC system 10 requirements. From the condenser 14, and along the flow direction 34, the AC system 10 can include a receiver 20. The receiver 20 can store additional fluid for the AC system 10. Alternatively, the receiver 20 can be removed from the AC system 10 layout depending on the AC system 10 requirements.

[0039] The fluid in the AC system 10 can continue its flow direction 34 through the refrigerant lines 26 after the condenser 14 and receiver 20 to a first expansion valve 22. The first expansion valve 22 can include a first expansion valve actuator 44, a first expansion valve pin 46, and a first expansion area 52. The first expansion valve 22 can receive the fluid of the AC system 10 from the condenser 14 and can regulate and modify the fluid flow through the first expansion valve 22 by a position of the first expansion valve pin 46. The position of the first expansion valve pin 46 can determine the size of the first expansion area 52 that the fluid can flow through. The position of the first expansion valve pin 46 can be determined by the first expansion valve actuator 44.

[0040] The fluid pressure can be rapidly reduced by passing through the first expansion area 52 of the first expansion valve 22, and the reduction of pressure can be determined by the position of the first expansion valve pin 46. The pressure can be reduced to an intermediate-pressure level from the high-pressure level it was in through the condenser 14. The position of the first expansion valve pin 46 can control the fluid flow rate and an amount of the fluid passing through the first expansion valve 22 being boiled and transformed from the liquid state to the gaseous state. The fluid can exit the first expansion valve 22 in a mixed state of liquid and gas fluid. The first expansion valve actuator 44 can be, for example, a motor driven linear actuator, a camshaft actuator, or another type of actuator.

[0041] From the first expansion valve 22, the fluid in the mixed state flows to the liquid-gas separator 16 by the refrigerant lines 26. The liquid-gas separator 16 is useful to reduce dangerous liquid injection to the compressor 12, maintain the pressure and temperature of the fluid in the mixed state, and partition the fluid in the liquid state and the fluid in the gaseous state to be separate. The liquid-gas separator 16 can partition the fluid in the liquid state to a main line 30 and the fluid in the gaseous state to a gas-injection line 32. The gas-injection line 32 connects the liquid-gas separator 16 to the compressor 12 gas-injection port 56 by the refrigerant lines 26. The main line 30 connects the liquid gas-separator 16 to the second expansion valve 24 by the refrigerant lines 26. It is contemplated the liquid-gas separator 16 can provide fluid flow to additional lines, such as an auxiliary line, an oil-cooling line, or any additional line that would require the fluid refrigerant in either the liquid state or the gaseous state for AC system 10 cooling.

[0042] The second expansion valve 24 can be along the main line 30 and receive the fluid along the fluid flow direction 34. The second expansion valve 24 is similar to the first expansion valve 24 and can function similarly by receiving the fluid in the intermediate-pressure level liquid state, control the fluid flow rate, and rapidly reduce the fluid pressure from the intermediate-pressure level to a low-pressure level which allows an amount of the fluid to boil and transition to the gaseous state. The second expansion valve can include a second expansion valve actuator 48, a second expansion valve pin 50, and a second expansion area 54. The position of the second expansion valve pin 46 can determine the size of the second expansion area 52 that the fluid can flow through. The second expansion valve actuator 48 can determine a position of the second expansion valve pin 50. The second expansion valve actuator 48 can be either a motor driven linear actuator, a camshaft actuator, or another type of actuator. The fluid in the AC system 10 exits the second expansion valve 24 in the mixed state.

[0043] Continuing along the main line 30, and after the second expansion valve 24, the fluid in the mixed state at the low-pressure level can flow in the refrigerant lines 26 along the flow direction 34 to the evaporator 18. The evaporator 18 is a heat exchanger, similar to the condenser 14, with passages for the fluid flow while maintaining the fluid pressure, but instead of condensing the fluid to the liquid state, the fluid absorbs heat from air passing over the fluid passages of the evaporator 18 and transforms the fluid to the gaseous state. The fluid can completely boil inside the evaporator 18 for the fluid to completely be in the gaseous state while continuing to absorb heat, resulting in the fluid being in the superheated vapor state. From the evaporator 18, the fluid continues its flow direction 34 along the main line 30 to a superheat line 36. The superheat line 36 connects the evaporator 18 to the compressor 12 by refrigerant lines 26. Along the superheat line 36 is a sensor 38 that measures the pressure and the temperature and the corresponding super heat temperature of the fluid before it completes the AC system 10 cycle and reenters the compressor 18 to begin the cycle again. It is contemplated the evaporator can be a water-chiller (not shown), a secondary evaporator (not shown), or an oil-cooler (not shown) depending on the AC system 10 requirements.

[0044] FIG. 1 illustrates the sensor 38 along the superheat line 36 as being in communication with, or connected to, the first expansion valve 22. The first expansion valve 22 is interlinked, in communication with, or connected to, the second expansion valve 24. In the configuration as shown in FIG. 1, the first expansion valve 22 can be controlled by feedback received from the sensor 38. The feedback received from the sensor 38 can control the first expansion valve actuator 44 which determines the position of the first expansion valve pin 46, and ultimately the size of the first expansion valve area 52. The feedback of the sensor 38 being relayed to the first expansion valve 22 can determine the flow of the fluid and pressure reduction the fluid experiences in the AC system 10 before the liquid gas separator 16. The feedback provided to the first expansion valve 22 by the sensor 38 is based on the pressure and the temperature and the corresponding super heat temperature of the fluid the sensor 38 measures along the superheat line 36, and it can be relayed to the first expansion valve 22 through wired or wireless communication by a controller 42. It is contemplated the sensor 38 can be a sensing bulb (not shown) and the first expansion valve actuator 44 can be a thermostatic or thermal expansion valve (not shown) that would mechanically determine the position of the first expansion valve pin 46 by the temperature of the fluid in the superheat line 36.

[0045] As shown in FIG. 1, the first expansion valve 22 can be interlinked with and control the second expansion valve 24. The interlinking between the first expansion valve 22 and the second expansion valve 24 can be through wired or wireless communication provided by the controller 42 or another controller (not shown). The first expansion valve 22 control of the fluid flow directly determines the second expansion valve 24 control of the fluid flow along the main line 30. The fluid flow through the second expansion valve 24 depends on the position of the second expansion valve pin 50 which determines the size of the second expansion area 54, and the determination of the position of the second expansion valve pin 50 is based on the position of the first expansion valve pin 46 and first expansion area 52.

[0046] Based on the first expansion valve area 52, the second expansion area can be determined by a fixed ratio or an equation where the second expansion area is a function of the first expansion area 52. The first expansion valve 22 and the second expansion valve 24 being interlinked can provide robust fluid control through the AC system 10 such that fluid in the liquid state does not return to the compressor 12, reducing damage the compressor 12, and provides more efficient cooling and heating of the fluid in the AC system 10.

[0047] As shown in FIG. 2, the sensor 38 along the superheat line 36 can be in communication with, or connected to, the second expansion valve 24 and the second expansion valve 24 can be interlinked with the first expansion valve 22. The interlink between the second expansion valve 24 and the first expansion valve 22 can be like as described in FIG. 1 and can be through wired or wireless communication. The second expansion valve actuator 48 can receive feedback from the sensor 38 by the controller 42 and can determine the position of the second expansion valve pin 50, ultimately determining the size of the second expansion area 54.

[0048] The second expansion area 54 of the second expansion valve 24 can directly determine the position of the first expansion valve pin 46 and first expansion area 52 by either a fixed ratio or an equation of the second expansion area 54. It is contemplated the sensor 38 can be a thermal bulb (not shown) and the second expansion valve actuator 48 can be a thermostatic expansion valve (not shown) that would mechanically determine the position of the second expansion valve pin 50 and the second expansion area 54 by the temperature of the fluid in the superheat line 36.

[0049] FIGS. 1 and 2 illustrate that the first expansion valve 22 and the second expansion valve 24, either being in communication with the sensor 38, can interchangeably determine the control of the fluid flow in the AC system 10. As shown in FIG. 1, the fluid flow through the first expansion valve 22 can be based on feedback by the sensor 38, and the fluid flow through the second expansion valve 24 can be controlled based on the interlink with the first expansion valve. As shown in FIG. 2, the fluid flow through the second expansion valve 24 can be based on feedback by the sensor 38, and the fluid flow through the first expansion valve 22 can be controlled based on the interlink with the second expansion valve 24.

[0050] Both configurations enable the fluid in the system to be continuously controlled and determined to prevent the compressor 12 from receiving the fluid in the liquid state by either the gas-injection line 32 and the gas injection port 56 from the liquid-gas separator 16 or by the superheat line 36. The communication between the sensor 38 and either the first expansion valve 22 and the second expansion valve 24 can be facilitated wired or wirelessly by the controller 42, and the interlink between the first expansion valve 22 and the second expansion valve 24 can be facilitated wired or wireless by the controller 42, a mechanical interlink (not shown), or another controller (not shown) based on a fixed ratio or an equation of based on the position of the first or second expansion valve pin 46, 50.

[0051] FIG. 3 illustrates an expansion valve assembly 100. The expansion valve assembly 100 can include a valve body 102, a first expansion chamber 104, a second expansion chamber 106, a pin 108, and an actuator 124. Like described above and illustrated in FIGS. 1 and 2, the AC system 10 can include a fluid, typically a refrigerant, that transforms physical states at various stages in the AC system 10 cycle. An AC system that requires more than one rapid pressure decrease can more easily be controlled by the expansion valve assembly 100 including the first expansion chamber 104 and the second expansion chamber 106. The expansion valve assembly 100 is useful for controlling the expansion of the fluid in the AC system 10 at two stages in the AC system 10 cycle by the pin 108 of the expansion valve assembly 100. The expansion valve 100 having a position of the pin 108 with a single degree of movement being determined by the actuator 124 enables the expansion of the fluid in the AC system in the first expansion chamber 104 to always be a fixed ratio to the expansion of the fluid in the second expansion chamber 106, and vice versa.

[0052] The valve body 102 of the expansion valve assembly 100 can include a first inlet 110, a first outlet 112, a second inlet 114, a second outlet 116, and a separation plate 118. The valve body 102 can provide the structure for the actuator 124 to determine the position of the pin 108 inside the first expansion chamber 104 and the second expansion chamber 106 while also providing the fluid with a sealed environment. The first inlet 110 and the first outlet 112 can provide a flow path 120a into and out of the first expansion chamber 104. The second inlet 114 and the second outlet 116 can function similarly to the first inlet 110 and the first outlet 112 by providing the flow path 120b into and out of the second expansion chamber 106.

[0053] The separation plate 118 can be included in the valve body 102 and can include a pin shaft opening 122. The pin shaft opening can allow the pin 108 of the expansion valve assembly 100 to simultaneously be positioned in the first expansion chamber 104 and the second expansion chamber 106. The pin shaft opening 122 can include a seal 152 that surrounds the pin 108 and inhibits leakage or pressure loss between the first expansion chamber 104 and the second expansion chamber 106. The valve body 102 can be comprised of aluminum, steel, or another material that will maintain structure and maintain the pressure of the fluid inside the AC system 10 while in use. It is contemplated the valve body 102 can include additional inlets and outlets separated by additional separation plates 118 with pin shaft openings 122 to create additional expansion chambers for auxiliary fluid flow paths that require AC system fluid.

[0054] The pin 108 and the actuator 124 of the expansion valve assembly 100 can determine the pressure reduction the fluid of the AC system 10 experiences. The pin 108 can include an upper portion 126, a lower portion 128, and an intermediate portion 130 disposed between the upper portion 126 and the lower portion 128. The actuator 124 can be attached to the upper portion 120 of the pin 108 and an upper seal 150 can surround the pin 108 in an opening 154 through the valve body 102 to abate leakage. There can be a middle valve disk 132 attached to the intermediate portion 130 of the pin 108 and an end valve disk 134 attached to the lower portion 128 of the pin 108.

[0055] The actuator 124 can determine a position of the pin 108 so that the middle valve disk 132 and the end valve disk 134 simultaneously control fluid flow through the flow paths 120a, 120b and pressure reduction across a first orifice 136 in the first expansion chamber 104 and a second orifice 138 in the second expansion chamber 106. The actuator 104 can be a motor driven actuator, a cam shaft actuator, or another actuator capable of positioning the pin 108. It is contemplated the pin 108 can control the fluid flow and pressure reduction through the first orifice 136 of the first expansion chamber 104 and through the second orifice 138 of the second chamber 106 through other means such as pin diameters and other pin structures other than the middle valve disk 132 and the end valve disk 134. It is also contemplated that the pin 108 could include additional valve disks to control the fluid flow and pressure reduction across additional areas of additional expansion chambers.

[0056] FIG. 4 illustrates the expansion valve assembly 100 of FIG. 3 with a refrigerant chamber 140. The refrigerant chamber 140 can provide an additional flow path 120c through the valve body 102 of the expansion valve assembly 100. The refrigerant chamber 140 can provide a sensing bulb 142 of a thermostatic or thermal expansion valve 144 to measure a temperature of the fluid flowing through the flow path 120c and mechanically determine the position of the pin 108 by the thermostatic or thermal expansion valve 140. The thermostatic expansion valve 144 can be attached to the upper portion 126 of the pin 108. The refrigerant chamber 140 can remain separated from the first expansion chamber 104 and the second expansion chamber 106 by an upper separation plate 146 of the valve body 102, similar to the separation plate 118. The upper separation plate 146 can include an upper pin shaft opening 148 with an upper seal 150 that allows the pin 108 to continue to control the fluid flow and pressure reduction in the first expansion chamber 104 and the second expansion chamber 106.

[0057] FIG. 5 illustrates the AC system 10 of FIGS. 1 and 2 with the expansion valve 100 of FIG. 3. In this configuration, the first expansion valve 22 and the second expansion valve 24 are replaced with the expansion valve assembly 100 with the first expansion chamber 104 and the second expansion chamber 106. The expansion valve assembly 100 can determine the flow of the fluid as it travels along the flow direction 34. The expansion valve assembly 100 can also determine the reduction of pressure in the AC system 10 after the condenser 14 and receiver 20 before the liquid-gas separator 16 by refrigerant lines 26 connecting to the first expansion chamber 104 and also along the main line 30 after the liquid-gas separator 16 and before the evaporator 18 by refrigerant lines connecting to the second expansion chamber 106.

[0058] The actuator 124 of the expansion valve assembly 100 can be in communication with the sensor 38 along the superheat line 36 and can determine the position of the pin 108 of the expansion valve assembly 100 based on feedback received from the sensor 38. The actuator 124 can be in wired or wireless communication with the sensor 38 by the controller 42. The position of the pin 108 in the expansion valve assembly 100 determines the control of the flow of the fluid and the pressure reduction in both the first expansion chamber 104 and the second expansion chamber 106, allowing robust control of the fluid in the AC system 10 and inhibiting the fluid in the liquid state from reaching the compressor 12 through the gas-injection line 32 and the gas injection port 56 or the main line 30.

[0059] FIG. 6 illustrates the AC system of FIGS. 1, 2, and 5 with the expansion valve assembly 100 with the refrigerant chamber 140 in place of the sensor 38 along the superheat line 36. The refrigerant chamber 140 of the expansion valve 100 can include a sensing bulb 142 that measures the super heat temperature of the fluid in the superheat line 36. In the FIG. 6 configuration, the sensor 38 can be removed from the AC system 10 because the sensing bulb 142 in the refrigerant chamber 140 measures the temperature of the fluid. The temperature of the fluid in the superheat line 36 can determine actuation of the thermostatic expansion valve 144 which, in turn, determines the position of the pin 108 inside the expansion valve 100. Like illustrated in FIG. 5, the position of the pin 108 inside the expansion valve 100 can determine the fluid flow of the fluid inside the AC system 10 and the pressure reduction of the fluid between the condenser 14 and receiver 20 before the liquid gas-separator 16 by the first expansion chamber 104 and the fluid flow and pressure reduction of the fluid between the liquid-gas separator 16 and the evaporator 18 by the second expansion chamber 106.

[0060] In both configurations illustrated in FIGS. 5 and 6 the expansion valve assembly 100 replaces the first expansion valve 22 and the second expansion valve 24 in the AC system 10. Both configurations allow for robust control of the fluid in the AC system 10 and provide direct control of the fluid passing through the first expansion chamber 104 and the second expansion chamber 106 by the position of the pin 108 determined by the actuator 124 (shown in FIG. 5) or the thermostatic expansion valve 144 (shown in FIG. 6). Control of the fluid in the AC system 10 can provide that the compressor 12 of the AC system 10 does not receive liquid fluid, reducing dangerous compressor wear, and can provide increased efficiency of the AC system 10 in its cooling capacity.

[0061] The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

[0062] Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.

[0063] The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,”“an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,”“comprising,”“including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

[0064] When an element or layer is referred to as being “on,”“engaged to,”“connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,”“directly engaged to,”“directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,”“adjacent” versus “directly adjacent,” etc.). As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0065] Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and / or sections, these elements, components, regions, layers and / or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,”“second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

[0066] Spatially relative terms, such as “inner,”“outer,”“beneath,”“below,”“lower,”“above,”“upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

Claims

1. An air conditioning (AC) system comprising:a compressor configured to flow a fluid through the system;a condenser configured to receive fluid discharged from the compressor;a first expansion valve configured to receive fluid from the condenser and having a first expansion area;a liquid-gas separator configured to receive fluid from the first expansion valve and to partition the fluid between a main line and a gas-injection line;a second expansion valve configured to receive fluid from the liquid-gas separator and having a second expansion area;an evaporator configured to receive fluid from the second expansion valve and to discharge fluid to the compressor along the main line; anda sensor configured to measure a pressure and a temperature of fluid discharged by the evaporator;wherein one of the first expansion area and the second expansion area is controlled by the associated expansion valve based on the pressure and the temperature of the fluid measured by the sensor and the other of the first expansion area and the second expansion area is controlled by the associated expansion valve based on the one of the first expansion area and the second expansion area.

2. The AC system of claim 1, wherein the compressor receives the fluid in only a gaseous state.

3. The AC system of claim 1, wherein the first expansion area is controlled by the first expansion valve based on the pressure and the temperature and the corresponding superheat temperature of the fluid measured by the sensor and the second expansion area of the second expansion valve is controlled based on the first expansion area.

4. The AC system of claim 1, wherein the second expansion area is controlled by the second expansion valve based on the pressure and the temperature and the corresponding superheat temperature of the fluid measured by the sensor and the first expansion area of the first expansion valve is controlled based on the second expansion area.

5. The AC system of claim 1, wherein the liquid-gas separator is configured to allow the flow of the fluid in a liquid state to the main line and the flow of the fluid in a gaseous state to the gas-injection line.

6. The AC system of claim 5, wherein the gas-injection line is configured to allow the flow of the fluid in the gaseous state to a compressor gas-injection port.

7. The AC system of claim 1, further comprising a controller configured to relay the sensor feedback to one of the first expansion valve and the second expansion valve.

8. The AC system of claim 1, wherein the evaporator includes a water-chiller, a secondary evaporator, and an oil-cooler.

9. An expansion valve assembly, comprising:a valve body;a first expansion chamber including a first inlet, a first outlet, and a first orifice;a second expansion chamber including a second inlet, a second outlet, and a second orifice;a pin including an upper portion, a lower portion, and an intermediate portion disposed between the upper portion and the lower portion, the pin extending through the valve body, the first orifice of the first expansion chamber, and the second orifice of the second expansion chamber;a middle valve disk attached to the intermediate portion of the pin, the middle valve disk altering a fluid flow through the first orifice of the first expansion chamber; andan end valve disk attached to the lower portion of the pin, the end valve disk altering another fluid flow through the second orifice of the second expansion chamber;wherein the pin is configured to move by an actuator disposed to the upper portion of the pin, the alteration of the fluid flow through the first orifice by the middle valve disk and the alteration of the another fluid flow through the second orifice by the end valve disk is determined by a position of the pin.

10. The expansion valve assembly of claim 9, further comprising a separation plate between the first expansion chamber and the second expansion chamber, the separation plate includes a pin shaft opening.

11. The expansion valve assembly of claim 10, wherein the pin extends through the pin shaft opening and allows the position of the pin to determine the alteration of the fluid flow through the first orifice by the middle valve disk and the alteration of the another fluid flow through the second orifice by the end valve disk simultaneously.

12. The expansion valve assembly of claim 9, wherein the actuator of the expansion valve assembly is one of a motor driven linear actuator and a camshaft actuator.

13. The expansion valve assembly of claim 9, further including a refrigerant chamber included in the valve body, the refrigerant chamber configured to allow the fluid to flow through the valve body and detect a pressure and a temperature of the fluid.

14. The expansion valve assembly of claim 13, wherein the pressure and the temperature of the fluid through the refrigerant chamber determines the position of the pin by a thermostatic expansion valve.

15. An air conditioning (AC) system, comprising:a compressor configured to flow a fluid through the system;a condenser in fluid communication with the compressor;an expansion valve assembly including a valve body with a first expansion chamber and a second expansion chamber, the first expansion chamber in fluid communication with the condenser;a liquid-gas separator in fluid communication with the first expansion chamber, the liquid-gas separator configured to partition the fluid to a main line and a gas-injection line, the main line creating fluid communication between the liquid-gas separator and the second expansion chamber of the expansion valve assembly, the gas-injection line creating fluid communication between the liquid-gas separator and the compressor; andan evaporator in fluid communication with the second expansion chamber of the expansion valve assembly, the evaporator in fluid communication with the compressor by a superheat line,wherein the expansion valve assembly is configured to determine a position of a pin inside the valve body, the first expansion chamber, and the second expansion chamber, the position of the pin configured to transform the flow of the fluid through the AC system.

16. The AC system of claim 15, further including a sensor along the superheat line between the evaporator and the compressor, the sensor configured to measure a pressure and a temperature and the corresponding superheat temperature of the fluid flowing in the superheat line.

17. The AC system of claim 16, wherein the expansion valve assembly includes an actuator in communication with the sensor, the actuator is configured to determine the position of the pin based on the pressure and the temperature and the corresponding superheat temperature of the fluid flowing in the superheat line measured by the sensor.

18. The AC system of claim 17, wherein the actuator of the expansion valve assembly is one of a motor driven linear actuator and a camshaft actuator.

19. The AC system of claim 15, wherein the valve body of the expansion valve assembly includes a refrigerant chamber along the superheat line, the refrigerant chamber configured to allow the fluid flowing through the superheat line to flow through the valve body and detect a pressure and a temperature of the fluid.

20. The AC system of claim 19, wherein the pressure and the temperature of the fluid flowing through the refrigerant chamber of the expansion valve assembly determines the position of the pin by a thermostatic expansion valve.

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