Cyclic process device, thermal management system, and vehicle

Abstract

The invention relates to a cyclic process device (10), in particular a heat pump, for a vehicle, in particular an electric vehicle or a hybrid vehicle, comprising at least the following functional components: at least one first heat exchanger (11a) and a second heat exchanger (11b) for transferring thermal energy, a compressor unit (12) for compressing a fluid, an expansion valve (13) for adjusting the pressure of a fluid, a housing (14) for receiving at least the compressor unit (12), and a plate element (15) which is provide on the housing (14), at least one of the functional components being at least partly integrated into the plate element (15).

Description

[0001] ZF Friedrichshafen AG File 30551 1 Friedrichshafen 2024-09-26

[0002] closed-loop process device, thermal management system and vehicle

[0003] The present invention relates to a cyclic process device, a thermal management system with such a cyclic process device and a vehicle.

[0004] Cyclic process devices, particularly heat pumps, are known. Heat pumps, for example, consist of a compressor, which can be driven mechanically or electrically, that draws in a gaseous fluid to compress it and then feeds it via a pipe or hose to a heat exchanger, such as a condenser. In the condenser, thermal energy is extracted from the fluid. This cools the fluid, preferably until it falls below a boiling point, allowing the fluid to undergo a phase change and at least partially transition into a liquid state. The liquid fluid is then expanded by passing it through an expansion valve. The fluid is then fed to another heat exchanger, an evaporator. The evaporator transfers thermal energy back to the fluid, causing it to return to a gaseous state.

[0005] It is known that such devices or systems are assembled from standardized components or individual components. These systems require a large amount of installation space because the individual and standard components are only inadequately matched to each other in terms of shape and size. As a result, the power density of such devices is low and their weight is high. Furthermore, numerous interfaces are required, which represent potential sources of error or unavoidable leakage, meaning these systems require regular maintenance and fluid can escape into the environment. Leaks can also occur, potentially leading to increased refrigerant consumption.

[0006] It has thus become apparent that there is a need to provide an improved thermodynamic device, particularly with regard to the level of integration. ZF Friedrichshafen AG File 30551 1 Friedrichshafen 2024-09-26

[0007] The object of the present invention is to provide a cycle process device. It is further an object of the present invention to provide a thermal management system, a vehicle, and a method.

[0008] Within the scope of the invention, the problem is solved with regard to the cycle process device by independent claim 1, the thermal management system by independent claim 9 and the vehicle by independent claim 10.

[0009] One aspect of the present invention relates to a cyclic process device, in particular a heat pump, for a vehicle, in particular an electric vehicle or a hybrid vehicle, comprising at least the following functional components: at least a first heat exchanger and a second heat exchanger for transferring thermal energy, a compressor unit for compressing a fluid, an expansion valve for adjusting the pressure of a fluid, a housing for receiving at least the compressor unit, a plate element arranged on the housing and wherein at least one of the functional components is at least partially integrated into the plate element.

[0010] In contrast to the known state of the art, this method enables a high degree of integration. The plate element allows for the integration of functional components. This integrated approach eliminates the need for individual components, thereby reducing procurement, manufacturing, and assembly costs. For example, integrating pipework reduces the number of sealing points, which in turn improves the overall system's tightness. The resulting circular process device can thus have a more compact, and especially space-saving, design, enabling more efficient operation.

[0011] The cycle device is preferably a heat pump for a vehicle, in particular an electric vehicle or a hybrid vehicle. The cycle device comprises at least the first heat exchanger and the second heat exchanger. The heat exchangers can also be referred to as heat transfer units. ZF Friedrichshafen AG File 30551 1 Friedrichshafen 2024-09-26

[0012] The two heat exchangers can be designed as plate heat exchangers. They are designed to transfer thermal energy from a refrigerant circuit to a coolant circuit.

[0013] The functional components are those components of the circular process device that contribute to a function of the circular process device or to the operation of the circular process device.

[0014] The compressor unit is designed to compress a fluid. The compressor unit preferably includes a drive unit to power a compressor. The drive unit can, for example, be an electric motor. The drive unit can be arranged within the housing together with the compressor unit. The compressor unit and the drive unit are preferably formed as a single unit. Alternatively, the drive unit can be arranged outside the housing and mechanically coupled to the compressor unit. The compressor can be a scroll compressor, a rotary piston compressor, or a turbo compressor. Other suitable compressor types are also possible. The compressor unit can preferably be at least partially integrated with the plate element to provide a highly integrated circular process device.

[0015] The thermodynamic device further comprises at least one expansion valve for adjusting or regulating the fluid pressure. It is possible for the thermodynamic device to include two expansion valves. The at least one expansion valve can be designed as a directly controllable, in particular electrically controllable, valve. The term "regulation" can be understood as the control or regulation of a variable to be set, for example, a pressure. "Control" is understood as a process in which a controlled variable is influenced by another variable. Thus, control is understood as a process in which an input variable influences an output variable in a device or system in a specific way. ZF Friedrichshafen AG File 30551 1 Friedrichshafen 2024-09-26

[0016] The housing is preferably made of aluminum. Alternatively, other metals or suitable plastics may be used. The housing may be manufactured by deep drawing, roll forming, die casting, or other manufacturing processes. The housing is preferably hermetically sealed, in particular fluid-tight. This means that nothing can enter or escape from the inside. In particular, the housing may be welded and / or brazed. The housing may have a cylindrical, circular, oval, square, or rectangular geometry or shape.

[0017] The housing is preferably designed such that the cycle device can be handled as a single unit. In other words, the cycle device can, for example, be designed as a heat pump and installed as a single unit in a vehicle.

[0018] The housing contains at least the compressor unit. This means that the compressor unit is at least partially enclosed by the housing. In other words, the compressor unit can be at least partially part of the housing. An outer wall of the compressor unit can also form an outer wall of the housing. The compressor unit can be at least partially integral with the housing. Alternatively or additionally, the compressor unit can be positively connected, frictionally connected, and / or materially connected to the housing. In one embodiment, the compressor unit is at least partially integral with the housing. Additional functional components can also be arranged within the housing.

[0019] It is possible that the housing has a substantially cylindrical geometry. In particular, the housing has a cylindrical geometry at least in sections. This means that the housing has a central longitudinal axis, at least in sections, extending in an axial direction and passing through the center point of a circular cross-sectional area. It is also conceivable that further shapes or elements are arranged on or project from the cylindrical geometry. Alternatively or additionally, the housing can have a polygonal geometry in sections. Preferably, the two heat exchangers (ZF Friedrichshafen AG File 30551 1 Friedrichshafen 2024-09-26) and / or the compressor unit are adapted to the geometry of the housing or have a substantially corresponding geometry, at least in sections.

[0020] Within the scope of the present invention, the term "essentially" can be understood to mean a deviation of between + / -15%, in particular between + / -10%, and in particular between + / -5%.

[0021] The first heat exchanger can be designed as an evaporator for vaporizing a fluid, and the second heat exchanger can be designed as a condenser for liquefying a fluid. For example, the heat exchangers can each be thermally coupled to a cooling circuit of a vehicle's thermal management system. In particular, a high-temperature circuit can be thermally coupled to the condenser, and a low-temperature circuit to the evaporator. The first and / or the second heat exchanger can be arranged in the axial direction of the housing. The axial direction can refer to the longitudinal direction of the housing. Alternatively, the axial direction can be parallel to a longitudinal axis of the compressor unit's drive unit. Furthermore, the heat exchangers can have different sizes and shapes or geometries. For example, the first heat exchanger can be larger than the second heat exchanger.This allows the two heat exchangers to have different cooling capacities. The heat exchangers can be of any shape, for example, round, oval, square, or rectangular. Depending on the designed operating point, at least one heat exchanger per side can be used.

[0022] The at least one plate element is arranged on the housing. The plate element is preferably located inside the housing and connected to the housing. The at least one plate element is preferably designed in a plate-like shape. This means that the plate element is designed as a component extending in a plane. In other words, the plate element spans a plane. Preferably, the extent of the plate element in a transverse direction of the housing is greater than in a longitudinal direction of the housing. The plane spanned by the plate element is preferably arranged perpendicular to a longitudinal axis of the housing. In other words, the plate element is preferably oriented perpendicular to the longitudinal axis of the housing. Preferably, the plate element is arranged perpendicular to the longitudinal axis of the housing within the housing.The plate element is preferably made of a rigid material. The plate element is specifically designed to withstand forces acting on the extended or spanned plane and moments acting on an axis. The plane extended by the plate element may correspond to a cross-sectional area of ​​the housing. In other words, the plate element can be adapted to a cross-sectional area of ​​the housing. The plate element can, for example, have a round, oval, rectangular, or polygonal shape.

[0023] It is possible that the circular process device comprises several plate elements connected to the housing. For example, the plate elements can be designed as housing covers that limit the housing in the axial direction.

[0024] The at least one functional component is at least partially integrated with the plate element. This means that, in particular, the first heat exchanger and / or the second heat exchanger and / or the compressor unit and / or the expansion valve are at least partially arranged on and / or connected to the at least one plate element and / or formed integrally with the plate element. In one embodiment, the at least one functional component is positively connected and / or frictionally connected and / or materially bonded to the plate element. For example, the at least one plate element can be formed integrally with a functional component. The at least one plate element can be bolted and / or welded and / or clamped to the functional component. For example, a screw connection with multiple screws can be used to connect the plate element to the functional component.This allows for a fixed but detachable connection. Alternatively or additionally, the functional element can be screwed directly onto the plate element. Welding of the plate element with ZF Friedrichshafen AG File 305511 Friedrichshafen 2024-09-26.

[0025] The functional component enables a material-bonded and hermetically sealed connection. Alternatively or additionally, the plate element can be clamped to the functional component. This can be achieved, for example, using elements with corresponding geometries that, when assembled, clamp to each other with a force upon impact.

[0026] In one embodiment, the at least one plate element is arranged at an axial end of the housing. The at least one plate element can thus be configured as a housing cover. In other words, the plate element can form an end face of the housing. It is possible for a plate element to be arranged at both axial ends of the housing. In this way, for example, the first and / or the second heat exchanger can be arranged on the at least one plate element. In other words, the first heat exchanger and / or the second heat exchanger can thus be integrally designed with the at least one plate element.

[0027] In one embodiment, the at least one plate element is at least partially part of a housing wall. As described above, the at least one plate element can be configured as a housing cover. Alternatively, the plate element can be connected to the housing at a different position and form part of a housing wall. For example, the plate element can be arranged on a longitudinal side between the axial ends of the housing.

[0028] In one embodiment, the functional component comprises a fluid line for guiding a fluid through the plate element and / or a seal for sealing the housing to the outside and / or a bearing receptacle for supporting a shaft of the compressor unit and / or an oil separator for separating oil from a fluid. For example, the fluid line can run in the plane of the plate element and / or perpendicular to the plane spanned by the plate element. The fluid line can, for example, connect the first heat exchanger and / or the second heat exchanger to the compressor unit. It is possible that the plate element has at least one fluid line. The fluid line can be configured to connect a heat exchanger, the compressor unit, and / or the ZF Friedrichshafen AG File 30551 1 Friedrichshafen 2024-09-26

[0029] The expansion valve is connected fluidically. The inclusion of at least one fluid line reduces the need for external fluid lines or eliminates the need for additional fluid lines, such as pipes or hoses. This fluid line can be for a fluid, such as a refrigerant and / or a coolant. The fluid can be a gas and / or a liquid. To prevent leaks, seals can be integrated into the plate element. The seals can be located in a contact area between the plate element and the housing. Alternatively or additionally, the seals can be used in combination with a fluid line. The seals are generally located at interfaces with an external surface on the plate element. The plate element can include a bearing receptacle or an integrated bearing receptacle for the shaft.The oil separator can, for example, be at least partially integrated into the plate element or connected to it via a fluid line. For instance, the oil separator can be connected to the plate element via a bolted connection. Alternatively, the oil separator can be designed as a single unit with the plate element.

[0030] In one embodiment, the functional component comprises a sensor for obtaining pressure and / or temperature information and / or a line for transmitting an electrical signal or electrical energy. The sensor can, for example, be arranged in a fluid line extending through the plate element. Alternatively, at least some of the sensor's electronics can be arranged within the plate element. Alternatively or additionally, the line for transmitting an electrical signal (signal line) and / or the line for transmitting electrical energy (energy line) can extend at least partially through the plate element. In this way, for example, a signal from the sensor can be forwarded, particularly to a control unit. Furthermore, the sensor or the compressor unit can, for example, be supplied with energy in this way.

[0031] In one embodiment, the circular process device comprises three plate elements, wherein two plate elements are arranged opposite axial ends of the housing and one plate element is located between a compressor and a ZF Friedrichshafen AG File 30551 1 Friedrichshafen 2024-09-26

[0032] The compressor unit's drive unit is arranged within the housing. The two plate elements located at opposite axial ends of the housing can also serve as housing covers. The plate element positioned between the compressor and the drive unit can be used to support the drive unit's shaft and / or to form a partition within the housing.

[0033] In one embodiment, at least one plate element is integrally formed with the housing. For example, the plate element and the housing can be manufactured in a single production step. The plate element and the housing can be joined or manufactured together, for example, by a single primary forming and / or forming process.

[0034] Another aspect of the present invention relates to a thermal management system with a cycle process device according to one of the preceding embodiments.

[0035] Another aspect of the present invention relates to a vehicle with a thermal management system according to the preceding embodiment and / or a cycle process device according to one of the preceding embodiments.

[0036] Individual features and embodiments of the present invention can be combined with other features in other embodiments to form new embodiments. Advantages and further developments mentioned for the features or embodiments also apply analogously to the new embodiments. Further developments and advantages mentioned in connection with the apparatus also apply analogously to the method and vice versa.

[0037] The following is an exemplary description of the revelation with reference to the accompanying figures, in which they show

[0038] Figure 1: a schematic view of an embodiment of a circular process device according to the invention; and ZF Friedrichshafen AG File 30551 1 Friedrichshafen 2024-09-26

[0039] Figure 2: a schematic view of another embodiment of a circular process device according to the invention.

[0040] Figure 1 shows a thermodynamic device 10 designed as a heat pump. The heat pump comprises a housing 14. The housing 14 is essentially cylindrical. A compressor unit 12 is arranged in the housing 14. The compressor unit 12 comprises a compressor 12a and a drive unit 12b. The compressor 12a is connected to the drive unit 12b in a power-transmitting manner. In other words, the drive unit 12b drives the compressor 12a. For this purpose, the drive unit 12b is connected to the compressor 12a via a shaft. The drive unit 12b can, for example, be designed as an electric motor.

[0041] A first heat exchanger 11a and a second heat exchanger 11b are arranged on the end faces of the housing 14 in the axial direction L'. The first heat exchanger 11a is designed as an evaporator. The first heat exchanger is located on an end face of the housing 14 closest to the drive unit 12b. The second heat exchanger 11b is designed as a condenser. The second heat exchanger 11b is located on an end face of the housing 14 opposite the first heat exchanger 11a. In other words, the second heat exchanger 11b is located on an end face of the housing 14 closest to the compressor 12a.

[0042] An expansion valve 13 is arranged in the housing 14. The expansion valve 13 is located in the area of ​​the drive unit 12b. More precisely, in its installed state, the expansion valve 13 is located below the drive unit 12b. The expansion valve 13 establishes a low-pressure level in a low-pressure line. Alternatively, another expansion valve is conceivable that establishes a medium-pressure level in a medium-pressure line.

[0043] A power electronics unit 16 is arranged on an outer surface of the housing 14. The power electronics unit 16 is connected to the compressor unit 12 via the housing 14 for signal and / or energy transmission. Alternatively, the power electronics unit can be located inside the housing 14. (ZF Friedrichshafen AG File 30551 1 Friedrichshafen 2024-09-26)

[0044] Power electronics 16 has a connection element 16' arranged to supply the power electronics with energy.

[0045] In the longitudinal direction L', 14 plate elements 15 are arranged at the axial ends of the housing. The second heat exchanger 11b is arranged on one of the plate elements 15. More precisely, the second heat exchanger 11b is arranged on an outer side of the plate element 15. The second heat exchanger 11b can be bolted to the plate element 15 or formed as a single unit. An oil separator 19 is arranged on the side of the plate element 15 facing away from the second heat exchanger 11b. The oil separator 19 is rigidly connected to the plate element 15. Alternatively, the oil separator 19 can be formed as a single unit with the plate element 15. The plate element 15 also has two fluid lines 18. The fluid lines 18 each extend through the plate element 15. One fluid line 18 forms an inlet to the second heat exchanger 1 1 b and the other fluid line 18 forms an outlet from the second heat exchanger 1 1 b.

[0046] A further plate element 15 is arranged on an end face of the housing 14 opposite longitudinal direction L'. The first heat exchanger 11a is arranged on a side of the plate element 15 facing away from the housing 14. The plate element 15 has two fluid lines 18, each forming an inlet and at least one outlet for the first heat exchanger 11a. A seal 20 is located in a radially outer region of the plate element 15. The seal 20 is annular in shape. The seal 20 is located on an inner side of the plate element 15 and extends circumferentially. More precisely, the seal 20 is located inside the housing 14. A bearing receptacle 21 is located on an inwardly facing side of the plate element 15. A bearing is arranged in the bearing receptacle 21. The bearing receptacle 21 is designed to accommodate a bearing for a shaft 17. The bearing receptacle 21 has a projection 22.The extension 22 is ring-shaped. The extension 22 extends longitudinally L' from the plate element 15 towards the drive unit 12b. The shaft 17 extends longitudinally L' and serves to drive the compressor 12a. Furthermore, the plate element 15 has a receptacle 13' for the ZF Friedrichshafen AG file 30551 1 Friedrichshafen 2024-09-26.

[0047] Expansion valve 13 opens. This allows the expansion valve 13 to be arranged at least partially in the plate element 15 or connected to the plate element 15.

[0048] Figure 2 shows a circular process device 10 which essentially corresponds to the circular process device 10 described in Figure 1. The circular process device shown in Figure 2 has an additional plate element 15 in addition to the plate elements 15 arranged on the end faces of the housing 14. The additional plate element 15 is arranged between the plate elements 15 arranged on the end faces. More precisely, the additional plate element 15 is arranged between the compressor 12a and the drive unit 12b. This allows the housing 14 to be subdivided into two further sections. For example, the amount of refrigerant required can be reduced in this way.

[0049] Other embodiments of the present invention are possible and can be understood and carried out by persons skilled in the art when applying the claimed subject matter by studying the figures, the disclosure, and the appended claims. In particular, the respective parts / functions of each embodiment described above can also be combined with one another. In the claims, the word "comprising" does not exclude other elements or steps, and the indefinite article "a" or "an" does not exclude a plurality. The mere fact that certain measures are mentioned in interdependent claims does not mean that a combination of these measures cannot be advantageous. Any reference numerals in the claims should not be interpreted as limiting the scope of the claims.

[0050] ZF Friedrichshafen AG File 305511 Friedrichshafen 2024-09-26

[0051] Reference mark

[0052] L' Longitudinal direction

[0053] 10 Circular process device

[0054] 11 a first heat exchanger

[0055] 11 b second heat exchanger

[0056] 12 compressor unit

[0057] 12a Compressor

[0058] 12b Electric motor

[0059] 13 Expansion valve

[0060] 13' recording

[0061] 14 cases

[0062] 15 plate elements

[0063] 16 Power Electronics

[0064] 16' connection element

[0065] 17th wave

[0066] 18 Fluid line

[0067] 19 oil separators

[0068] 20 Seal

[0069] 21 Bearing intake

Claims

ZF Friedrichshafen AG File 30551 1 Friedrichshafen 2024-09-26 Patent claims 1. A circulating process device (10), in particular a heat pump, for a vehicle, in particular an electric vehicle or a hybrid vehicle, comprising at least the following functional components: at least a first heat exchanger (1 1 a) and a second heat exchanger (1 1 b) for transferring thermal energy, a compressor unit (12) for compressing a fluid, an expansion valve (13) for adjusting the pressure of a fluid, a housing (14) for receiving at least the compressor unit (12), a plate element (15) arranged on the housing (14) and wherein at least one of the functional components is at least partially integrated into the plate element (15).

2. Circular process device (10) according to claim 1, wherein the at least one plate element (15) is positively connected and / or force-fit and / or materially connected to the housing (14).

3. Circular process device (10) according to claim 1 or 2, wherein the at least one plate element (15) is arranged at an axial end of the housing (14).

4. Circular process device (10) according to one of the preceding claims, wherein the plate element (15) is at least partially part of a housing wall.

5. Cyclic process device (10) according to one of the preceding claims, wherein the functional component is a fluid line for guiding a fluid through the plate element (15) and / or a seal for sealing the housing to the outside and / or a bearing receptacle for supporting a shaft of the compressor unit (12) and / or ZF Friedrichshafen AG File 305511 Friedrichshafen 2024-09-26 includes an oil separator for separating oil from a fluid 6. Cyclic process device (10) according to one of the preceding claims, wherein the functional component comprises a sensor for obtaining pressure information and / or temperature information and / or a line for transmitting an electrical signal or electrical energy 7. Circular process device (10) according to one of the preceding claims, wherein the circular process device (10) comprises three plate elements (15), wherein two plate elements (15) are arranged opposite axial ends of the housing and one plate element (15) is arranged between a compressor and a drive unit of the compressor unit (12).

8. Circular process device (10) according to one of the preceding claims, wherein the at least one plate element (15) is formed integrally with the housing (14).

9. Thermal management system with a cycle process device (10) according to one of claims 1 to 8.

10. Vehicle with a thermal management system according to claim 9 and / or a cycle process device (10) according to any one of claims 1 to 8.

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