Cooling system

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Solution Overview

Problem

Existing cooling systems face inefficiencies and increased costs due to the use of hot gas dump valves when low temperature loads are shut off or removed, leading to refrigerant temperature drops that can cause compressor foaming and shutdowns.

Innovation Solution

A heat exchanger is used to transfer heat from the discharge of the medium temperature compressor to the intake, eliminating the need for a hot gas dump valve by using flash gas to increase refrigerant superheat.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a hot gas dump valve is used to increase refrigerant superheat at the medium temperature compressor intake, then compressor foaming is prevented, but system efficiency decreases due to re-compression of already compressed refrigerant

Engineering Contradiction:

Improvecompressor operation stabilityVSAvoidsystem efficiency

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The system separates the flash gas handling function from the main refrigeration cycle by directing flash gas through a dedicated heat exchanger pathway. This segmentation allows the flash gas to be heated independently by the medium temperature compressor discharge without requiring re-compression, thus preventing compressor foaming while avoiding energy loss from re-compression cycles.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A heat exchanger is introduced as an intermediary component between the medium temperature compressor discharge and the flash gas. This intermediary transfers thermal energy from the hot compressor discharge to the flash gas, increasing the superheat of refrigerant at the compressor intake without requiring the hot gas dump valve that would cause re-compression and energy loss.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If a hot gas dump valve is installed to prevent compressor shutdown, then refrigerant superheat is increased, but system cost increases due to the expensive valve

Engineering Contradiction:

Improvecompressor operation stabilityVSAvoidsystem cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention replaces the expensive hot gas dump valve with a more economical heat exchanger configuration. The heat exchanger, which is a standard component in refrigeration systems, serves the dual purpose of cooling the compressor discharge and heating the flash gas, thereby preventing compressor shutdown without requiring costly specialized valves.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The heat exchanger is designed to perform multiple functions: it cools the medium temperature compressor discharge refrigerant and simultaneously heats the flash gas to increase superheat at the compressor intake. This multi-functionality eliminates the need for a dedicated hot gas dump valve, reducing system cost while maintaining compressor operation stability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Device complexity

If flash gas is directly introduced to the medium temperature compressor without heating, then system complexity is reduced, but refrigerant superheat is insufficient causing compressor foaming

Engineering Contradiction:

Improvesystem complexityVSAvoidcompressor operation stability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The invention merges the flash gas heating function with the existing heat exchanger that cools the medium temperature compressor discharge. By combining these two functions into a single heat exchanger unit, the system avoids adding complex separate heating equipment while ensuring sufficient refrigerant superheat at the compressor intake to prevent foaming and maintain operational reliability.

Inventive Principle:

Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution maintains compressor efficiency and prevents foaming by increasing refrigerant superheat without the need for expensive hot gas dump valves, thus improving system performance and reducing costs.

Implementation Method 1

The heat exchanger receives hot refrigerant discharged by the medium temperature compressor and a flash gas discharged by a flash tank. The heat exchanger transfers heat from the refrigerant from the medium temperature compressor to the flash gas.

Methodology Applied

Scientific EffectHeat transfer: Heat Exchanger

Implementation Method 2

The heat exchanger then directs the flash gas to the intake of the medium temperature compressor to increase the superheat of the refrigerant in the medium temperature compressor.

Methodology Applied

Scientific EffectSuperheating: Superheating

Data Source

PatentUS20250314406A1Cooling system

Publication Date: 2025.10.09 HEATCRAFT REFRIGERATION PRODUCTS LLC

AI summary

An apparatus includes a high side heat exchanger, a flash tank, a load, a compressor, and a heat exchanger. The high side heat exchanger removes heat from a refrigerant. The flash tank stores the refrigerant from the high side heat exchanger and to discharge a flash gas. The load uses the refrigerant from the cool a space proximate the load. The compressor compresses the refrigerant from the load. The heat exchanger transfers heat from the refrigerant from the compressor to the flash gas before the refrigerant from the compressor reaches the high side heat exchanger. The heat exchanger directs the flash gas to the compressor after heat from the refrigerant from the compressor is transferred to the flash gas and directs the refrigerant from the compressor to the high side heat exchanger after heat from the refrigerant from the compressor is transferred to the flash gas.