Receiver drier bottle

Abstract

A receiver drier bottle for a climate control system is provided that includes a housing, a filter and a desiccant disposed within the housing, and an electronic expansion valve disposed within the housing. The electronic expansion valve is configured to receive refrigerant from at least one of the filter or the desiccant.

Description

TECHNICAL FIELD

[0001] The disclosure relates in general to a receiver drier bottle for use within a climate control system.BACKGROUND

[0002] A receiver drier or receiver drier bottle (RDB) is a known component within heating, ventilation, and air conditioning (HVAC) systems that removes debris and moisture as well as stores a certain amount of refrigerant that is cycling through the system. The RDB is typically integrated within an HVAC system via refrigerant lines or pipes that connect the RDB to both an expansion valve and a condenser. Solutions are needed to reduce a packaging size of HVAC systems.SUMMARY

[0003] An example embodiment of a receiver drier bottle for a climate control system is provided that includes a housing, a filter and desiccant disposed within the housing, and an electronic expansion valve disposed within the housing. The electronic expansion valve is configured to receive refrigerant from at least one of the filter or the desiccant.

[0004] In an example embodiment, the electronic expansion valve is disposed within an aperture of the housing. In a further aspect, the electronic expansion valve is mounted on the aperture of the housing and an electronic connector of the electronic expansion valve extends outside of the aperture.

[0005] In an example embodiment, the housing includes an integrated fluid gallery that extends from a first end of the housing to the aperture.

[0006] In an example embodiment, the housing is a die-cast housing.

[0007] In an example embodiment, the housing includes at least one landing configured to be mounted to an evaporator.

[0008] An example embodiment of a method of flowing a refrigerant through a climate control system includes: i) providing a receiver drier bottle connected to a condenser and an evaporator; ii) receiving a refrigerant from a condenser into the receiver drier bottle; iii) removing at least one of debris or moisture from the refrigerant within the receiver drier bottle; iv) flowing the refrigerant through an integrated internal passage of the receiver drier bottle; and v) decreasing a pressure of the refrigerant via an electronic expansion valve arranged within the integrated internal passage.

[0009] In an example embodiment, the electronic expansion valve extends outside of the integrated internal passage.

[0010] In an example embodiment, the electronic expansion valve is removably fixed to the integrated internal passage.

[0011] In an example embodiment, the integrated internal passage is a through-passage with a first open end and a second open end, and the electronic expansion valve closes the first open end.

[0012] An example embodiment of a receiver drier bottle for a climate control system includes a housing configured to be fluidly connected to a condenser and an evaporator, a filter and a moisture remover disposed within the housing, and an expansion valve mounted on the housing. The expansion valve is configured to receive a refrigerant from at least one of the filter or the moisture remover.

[0013] In an example embodiment, the filter and the moisture remover are retained within the housing via a retaining ring.

[0014] In an example embodiment, the housing includes two separate integral inlets for the expansion valve.

[0015] In an example embodiment, the housing includes a reservoir downstream of the filter and moisture remover.

[0016] In an example embodiment, the housing includes an integral gallery extending from the reservoir to the expansion valve.

[0017] In an example embodiment, an insertion axis of at least one of the filter or moisture remover is orthogonal to an insertion axis of the expansion valve.

[0018] In an example embodiment, the housing includes a hollow body that receives the filter and moisture remover, and a passage integral with the hollow body. An expansion valve is disposed within the passage.BRIEF DESCRIPTION OF THE DRAWINGS

[0019] FIG. 1 is an exploded perspective view of an example embodiment of a receiver drier bottle with an integrated expansion valve (RDBEV), and an evaporator.

[0020] FIG. 2 is a schematic diagram of an example embodiment of a refrigeration system.

[0021] FIG. 3 is a front view of the RDBEV of FIG. 1.

[0022] FIG. 4A is a side view of the RDBEV of FIG. 1.

[0023] FIG. 4B is a partial cross-sectional view taken from FIG. 1.

[0024] FIG. 5 is an exploded perspective view of the RDBEV and evaporator of FIG. 1.

[0025] FIG. 6 is a cross-sectional view taken from FIG. 5.

[0026] FIG. 7 is a cross-sectional view taken from FIG. 5.

[0027] FIG. 8 is a cross-sectional view taken from FIG. 1.

[0028] FIG. 9 is a schematic diagram of an example embodiment of a prior art refrigeration system.DETAILED DESCRIPTION

[0029] Embodiments of the present disclosure are described herein. It should be appreciated that like drawing numbers appearing in different drawing views identify identical, or functionally similar, structural elements. Also, it is to be understood that the disclosed embodiments are merely examples and other embodiments can take various and alternative forms. The figures are not necessarily to scale; some features could be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the embodiments. As those of ordinary skill in the art will understand, various features illustrated and described with reference to any one of the figures can be combined with features illustrated in one or more other figures to produce embodiments that are not explicitly illustrated or described. The combinations of features illustrated provide representative embodiments for typical applications. Various combinations and modifications of the features consistent with the teachings of this disclosure, however, could be desired for particular applications or implementations.

[0030] The terminology used herein is for the purpose of describing particular aspects only, and is not intended to limit the scope of the present disclosure. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this disclosure belongs. Although any methods, devices or materials similar or equivalent to those described herein can be used in the practice or testing of the disclosure, the following example methods, devices, and materials are now described.

[0031] The term “refrigerant” utilized herein is meant to signify any suitable substance that can be utilized within HVAC systems to carry out a refrigeration cycle or a thermodynamic heat pump cycle.

[0032] The terms “unitary” or “integrated” utilized herein are meant to signify a one-piece construction. For example, if element A is integrated within element B, element A and element B are combined or incorporated within a single component.

[0033] The term “fluidly connected” utilized herein is meant to apply to a liquid, gas, vapor or any other substance that can be classified as a fluid.

[0034] FIG. 1 is an exploded perspective view of an example embodiment of a receiver drier bottle 10 with an integrated expansion valve 40 (the assembly of which is hereafter referred to as “RDBEV 20”), and an evaporator 90 that is fixed to the RDBEV 20 via a coupling 80 and a mounting plate 64. FIG. 2 is a schematic diagram of an example embodiment of a refrigeration system 100 that utilizes the RDBEV 20. FIG. 3 is a front view of the RDBEV 20 of FIG. 1. FIG. 4A is a side view of the RDBEV 20 of FIG. 1. FIG. 4B is a partial cross-sectional view of the RDBEV 20 taken from FIG. 1. FIG. 5 is an exploded perspective view of the RDBEV 20 and evaporator 90 of FIG. 1. FIGS. 6 and 7 are cross-sectional views of the RDBEV 20 taken from FIG. 5. FIG. 8 is a cross-sectional view of the RDBEV 20 taken from FIG. 1. FIG. 9 is a schematic diagram of a prior art refrigeration system 100A that utilizes an isolated or separated expansion valve 40A. The following discussion should be read in light of FIGS. 1 through 9.

[0035] The principles of a refrigeration or air conditioning systems are known. Expansion valves or thermal expansion valves are known devices within such refrigeration systems that reduce a pressure of a refrigerant so as to decrease its boiling point. At this “reduced boiling point” stage, the refrigerant passes through an evaporator and cools down and absorbs heat from a space that is being cooled, causing the refrigerant to boil. Incoming refrigerant to an expansion valve can be in liquid form and exiting fluid from an expansion valve can be a combination of liquid and vapor.

[0036] The RDBEV 20 includes the receiver drier bottle 10 and the integrated expansion valve 40. The receiver drier bottle includes a housing 12 that houses a filter element 14 and a desiccant 16. The filter element 14 and desiccant 16 can be housed within a first housing 11A and a second housing 11B that form a sub-assembly 17 for ease of installation within the housing 12. The filter element 14 removes debris from the refrigerant, while the desiccant 16 removes moisture from the refrigerant, both of which can be harmful to components of the refrigeration system 100. The desiccant could also be referred to as a moisture absorber, a moisture remover, or a moisture extractor. As shown in FIG. 7, the filter element 14 includes a first filter element 14A and a second filter element 14B that surround or sandwich a desiccant element 16. Any suitable filter type or filter material can be utilized as known in the field of receiver drier bottles including, but not limited to, a mesh or fibrous media. Any suitable desiccant type or desiccant material can be utilized as known in the field of receiver drier bottles including, but not limited to, a silica gel or activated alumina. Further, any suitable arrangement of the filter element and the desiccant is possible and is not limited to the arrangement shown in the Figures.

[0037] In an example embodiment, the housing 12 includes a hollow body 23, a tube-shaped extension 30, a receiver drier bottle inlet boss 35, a hollow protuberance 37, a through-aperture 50, and a mounting web 38. The tube-shaped extension 30 extends from a first end 26A of the hollow body 23. It could also be stated that the tube-shaped extension 30 extends from a top side 33 of the hollow body 23. The receiver drier bottle inlet boss 35 extends from both a curved outer surface of the tube-shaped extension 30 and a first flat lateral side 31A of the hollow body 23. It could be stated that the receiver drier bottle inlet boss 35 extends orthogonally to the tube-shaped extension 30. The receiver drier bottle inlet boss 35 includes an inlet aperture 21, defining an inlet 34 of the RDB 10 or the housing 12 thereof, that receives liquid refrigerant from a condenser 96 and delivers the liquid refrigerant to an opening 28 defined by the tube-shaped extension 30.

[0038] The hollow protuberance 37 extends along a curved bottom contour of the hollow body 23 and defines a fluid gallery 24 or passageway that fluidly connects a well 18 or reservoir (formed at the bottom or second end 26B of the hollow body 23) to the through-aperture 50. The fluid gallery 24 extends adjacently to a third flat lateral side 31C of the hollow body 23. The through-aperture 50 can be a bore that is formed within a tube 39 that extends orthogonally relative to the tube-shaped extension 30.

[0039] The mounting web 38 can be utilized to mount the RDBEV 20 to the evaporator 90 or any other suitable structure, including, but not limited to a vehicle chassis or a refrigeration system frame. The mounting web 38 includes: i) a first web 58A that extends from a second flat lateral side 31B of the hollow body 23 and a first landing 22A that is formed at an end of the first web 58A, ii) a second web 58B that extends from the tube 39 of the through-aperture 50 and a second landing 22B that is formed at an end of the second web 58B, iii) a third web 58C that extends from the hollow protuberance 37 and a third landing 22C that is formed at an end of the third web 58C, iv) a fourth web 58D that connects the second landing 22B to the third landing 22C, and v) a fourth landing 22D that extends from the tube-shaped extension 30. Each of the three landings 22A, 22B, 22C includes a through-aperture through which a fastener can extend to axially clamp each of the respective landings to the evaporator 90. Other suitable means of attaching the housing 12 to the evaporator 90 are also possible.

[0040] An opening 28 formed by the tube-shaped extension 30 can serve as: i) a pass-through opening for a lower portion of the sub-assembly 17, ii) a sealing interface for the sub-assembly 17, and iii) a retention interface for the sub-assembly 17. The first and second housings 11A, 11B of the sub-assembly 17 include O-ring seals 32 that sealably engage a radial surface of the opening 28. The sub-assembly 17 is retained in an axial direction (relative to an axis AX1) via an axial stop 19 defined by the sub-assembly 17 and a retaining ring 13 disposed within a groove 29 of the opening 28 (see FIG. 7). The axis AX1 also serves as an insertion axis for the sub-assembly 17 such that the sub-assembly 17 travels along this axis during its insertion within the housing 12.

[0041] The expansion valve 40 is mounted to the through-aperture 50 of the tube 39. The term “through-aperture” is meant to describe an aperture that is open on each of its two ends; that is, none of the ends are closed via material of the housing 12 that it extends through. The through-aperture 50 could also be described as a through-bore, a passage, or a gallery. An axis AX2 of the through-aperture is orthogonal to the axis AX1 of the opening 28 of the tube-shaped extension 30. It could also be stated that the axis AX2 serves as an insertion axis for the expansion valve 40 such that the expansion valve 40 travels along this axis during its insertion within the through-aperture 50. In an example embodiment, the expansion valve 40 is an electronic valve that includes an electronic portion 42 and a valve portion 44 that are separable from each other. The electronic portion 42 includes an electronic connector 43 that facilitates electronic control of the expansion valve 40 via a controller 98. The valve portion 44 includes O-rings 45 that sealably engage a stepped radial surface of through-aperture 50. External threads 46 of the valve portion 44 engage internal threads 52 of the through-aperture 50 to provide fixation of the valve portion 44 to the housing 12. Given this internal / external thread arrangement, it could be stated that the valve portion 44 is removably fixed to the through-aperture 50. After threadably fixing the valve portion 44 to the through-aperture 50, the electronic portion 42 can be fixed to the valve portion 44 via flexible fingers 47 of the electronic portion 42 that resiliently snap into a groove 48 of the valve portion 44. The expansion valve 40 could be described as being disposed (or at least partially disposed) within the through-aperture 50 or being installed or mounted on the through-aperture 50; in particular, the valve portion 44 is disposed within the through-aperture 50. Further, it could be stated that the electronic portion 42 of the expansion valve 40 extends or resides partially inside of the through-aperture 50 and partially outside of the through-aperture 50.

[0042] The housing 12 includes separate first and second expansion valve inlets 41A, 41B and an expansion valve outlet 36. The first expansion valve inlet 41A is facilitated by the fluid gallery 24 formed or integrated within the housing 12 via the hollow protuberance 37. The fluid gallery 24 extends from a second end 26B (or reservoir end) of the housing 12 towards the first end 26A of the housing 12. A first end 27A of the fluid gallery 24 is fluidly connected to a bottom of the reservoir 18 that stores filtered and moisture-removed liquid refrigerant. A second end 27B of the fluid gallery 24 intersects (or is fluidly connected) with the through-aperture 50; it could be stated that the second end 27B of the fluid gallery 24 serves as the first expansion valve inlet 41A. As known in HVAC systems, the expansion valve 40 can regulate an amount of refrigerant entering the evaporator 90. The expansion valve reduces a pressure of liquid refrigerant so that it can boil (evaporate) more easily in the evaporator 90. In an example embodiment, a pressure drop across the thermal expansion valve ranges from 50 to 300 psi; that is, a difference in pressure between an incoming refrigerant and an exiting refrigerant can range between 50 psi to 300 psi. This pressure drop can cause the refrigerant to turn into a combination of cold liquid and vapor as it exits the expansion valve 40 into the expansion valve outlet 36. The expansion valve outlet 36 is a downstream portion of the through-aperture 50. Thus, refrigerant having a pressure P1: i) enters the through-aperture 50 at a medial position defined by the first expansion valve inlet 41A, ii) enters and travels through the valve portion 44, and iii) exits the valve portion 44 into the expansion valve outlet 36 having a pressure P2 that is less than P1. In an example embodiment, a ratio of P1 to P2 ranges from 1:4 to 1:10. From the expansion valve outlet 36, the refrigerant flows through an opening of the coupling 80 and then enters the evaporator 90.

[0043] The second expansion valve inlet 41B of the housing 12 intersects the through-aperture 50 at a medial position (FIGS. 1 and 4B). The second expansion valve inlet 41B is defined by a valve inlet boss 60 that extends from the tube 39; an inlet aperture 62 extends through the valve inlet boss 60.

[0044] After receiving refrigerant from the condenser 96 via the inlet 34 of the housing 12, the refrigerant flows through the RDBEV 20 as follows: i) through the sub-assembly 17 of the filter element 14 and the desiccant element 16 until reaching the well 18 or reservoir, ii) from the well 18 to the integrated fluid gallery 24, and iii) from the integrated fluid gallery 24 to the through-aperture 50, iv) from the through-aperture 50 to the expansion valve 40, and from the expansion valve 40 to a second open end 56 of the through-aperture 50 for delivery to the evaporator 90.

[0045] As shown in the figures, the expansion valve 40 is installed on a first open end 54 of the through-aperture 50. It could be stated that the expansion valve 40 closes the first open end 54. Further, the refrigerant pressures present within the through-aperture 50 can be defined as being the same as the inlet and outlet refrigerant pressures of the expansion valve 40. Stated otherwise, the pressure differential that is present within the through-aperture 50 can be the same as the pressure differential across the expansion valve 40.

[0046] In an example embodiment, the housing 12 is a unitary or one-piece die-cast housing that includes the hollow body 23, the tube-shaped extension 30, the receiver drier bottle inlet boss 35, the hollow protuberance 37, the tube 39, the mounting web 38, and the valve inlet boss 60. The manufacturing method (casting) utilized for the housing eliminates a need for a separate bracket often found in non-cast housings.

[0047] The previously described RDBEV 20 offers several advantages over the prior art, some of which will now be discussed. The prior art refrigeration system 100A of FIG. 9 includes a compressor 94, a condenser 96, an RDB (receiver drier bottle) 10A, an expansion valve 40A, and an evaporator 90. The prior art refrigeration system 100A utilizes a refrigeration line 80A or pipe between the RDB 10A and the expansion valve 40A, and a refrigeration line 82A or pipe between the expansion valve 40A and the evaporator 90. In addition to the obvious increase in packaging space, the presence of such refrigeration lines or piping increases a systematic pressure decay or pressure drop; such a pressure loss is detrimental to the heat rejection capacity of the prior art refrigeration system 100A. Thus, integration of the expansion valve within the RDB as provided by the RDBEV 20 eliminates such a pressure loss and reduces packaging space. Refrigerant flows to the expansion valve 40 within the housing 12 without passing through another component outside of the housing 12. Further, the previously described coupling 80 and mounting plate 64 eliminate the need for the refrigeration line 82A between the expansion valve 40A and the evaporator 90, further reducing pressure loss. In a further example embodiment, one of either the coupling 80 or the mounting plate 64 are eliminated which reduces the number of components and complexity of the assembly of the refrigeration system components.

[0048] The housing 12 of the RDBEV 20 provides a simple means of servicing the expansion valve 40 and the sub-assembly 17 of the filter element(s) 14 and desiccant element 16 without removal or manipulation of the refrigerant connections or lines associated with delivering refrigerant to the RDBEV 20 (or the RDB 10 thereof). Access to the filter element(s) 14 or desiccant element 16 for replacement purposes requires removal of the retaining ring 13 and upward displacement of the sub-assembly 17.

[0049] While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms encompassed by the claims. The words used in the specification are words of description rather than limitation, and it is understood that various changes can be made without departing from the spirit and scope of the disclosure. As previously described, the features of various embodiments can be combined to form further embodiments of the disclosure that may not be explicitly described or illustrated. While various embodiments could have been described as providing advantages or being preferred over other embodiments or prior art implementations with respect to one or more desired characteristics, those of ordinary skill in the art recognize that one or more features or characteristics can be compromised to achieve desired overall system attributes, which depend on the specific application and implementation. As such, to the extent any embodiments are described as less desirable than other embodiments or prior art implementations with respect to one or more characteristics, these embodiments are not outside the scope of the disclosure and can be desirable for particular applications.

Claims

1. A receiver drier bottle for a climate control system, comprising:a housing configured to: i) receive refrigerant from a condenser, and ii) deliver refrigerant to an evaporator;a filter disposed within the housing;a desiccant disposed within the housing; andan electronic expansion valve disposed within the housing, the electronic expansion valve configured to receive refrigerant from at least one of the filter or the desiccant.

2. The receiver drier bottle of claim 1, wherein the electronic expansion valve is disposed within an aperture of the housing.

3. The receiver drier bottle of claim 2, wherein the housing further comprises an integrated fluid gallery that extends from a first end of the housing to the aperture.

4. The receiver drier bottle of claim 2, wherein the electronic expansion valve is mounted on the aperture.

5. The receiver drier bottle of claim 4, wherein the electronic expansion valve extends outside of the aperture.

6. The receiver drier bottle of claim 5, wherein the electronic expansion valve further comprises an electronic connector disposed outside of the aperture.

7. The receiver drier bottle of claim 1, wherein the housing is a die-cast housing.

8. The receiver drier bottle of claim 1, wherein the housing further comprises at least one landing configured to be mounted to an evaporator.

9. A method of flowing refrigerant through a climate control system, comprising:providing a receiver drier bottle fluidly connected to a condenser and an evaporator;receiving a refrigerant from the condenser into the receiver drier bottle;removing at least one of debris or moisture from the refrigerant within the receiver drier bottle;flowing the refrigerant through an integrated internal passage of the receiver drier bottle; anddecreasing a pressure of the refrigerant via an electronic expansion valve arranged within the integrated internal passage.

10. The method of claim 9, wherein the electronic expansion valve extends outside of the integrated internal passage.

11. The method of claim 10, wherein the electronic expansion valve is removably fixed to the integrated internal passage.

12. The method of claim 9, wherein the integrated internal passage is a through-passage with a first open end and a second open end, and the electronic expansion valve closes the first open end.

13. A receiver drier bottle for a climate control system, comprising:a housing configured to be connected to a condenser and an evaporator;a filter disposed within the housing;a moisture remover disposed within the housing; andan expansion valve mounted on the housing, the expansion valve configured to receive a refrigerant from at least one of the filter or the moisture remover.

14. The receiver drier bottle of claim 13, wherein the filter and the moisture remover are retained within the housing via a retaining ring.

15. The receiver drier bottle of claim 13, wherein the housing further comprises two separate integral inlets for the expansion valve.

16. The receiver drier bottle of claim 13, wherein the housing further comprises integral mounts configured to fix the housing to the evaporator.

17. The receiver drier bottle of claim 13, wherein the housing further comprises a reservoir downstream of the filter and the moisture remover.

18. The receiver drier bottle of claim 17, wherein the housing further comprises an integral gallery extending from the reservoir to the expansion valve.

19. The receiver drier bottle of claim 13, wherein an insertion axis of at least one of the filter or moisture remover is orthogonal to an insertion axis of the expansion valve.

20. The receiver drier bottle of claim 13, wherein the housing further comprises:a hollow body that receives the filter and moisture remover; anda passage integral with the hollow body; andthe expansion valve is disposed within the passage.

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