Integrated Condenser-Evaporator Unit for Refrigerant Leak Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Compressor systems in vehicles with tiltable cabs face significant leakage risks due to high-pressure refrigerants like CO2, which require longer hoses and more connections, increasing the risk of refrigerant leakage, especially when using flammable refrigerants, and existing solutions do not effectively minimize hose length or connection numbers while maintaining efficiency.
Innovation Solution
A compact system where the condenser and evaporator are integrated as a plate heat exchanger with internal heat exchangers and a fixed constriction, reducing the number of connections and hoses, and allowing for adjustable expansion valves, thereby minimizing leakage risks and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If CO2 or high-pressure refrigerants are used to achieve efficient cooling, then cooling efficiency is improved, but the risk of refrigerant leakage increases due to higher operating pressures requiring longer hoses and more connections
Solution Approach 1:
The patent combines the condenser and evaporator into a single integrated plate heat exchanger unit. This merging eliminates the need for separate components and the long connecting hoses between them, thereby maintaining high cooling efficiency with CO2 while significantly reducing the number of connections and leakage risk points in the high-pressure refrigerant circuit
Solution Approach 2:
The patent introduces a secondary low-pressure cooling circuit that is segmented from the primary high-pressure refrigerant circuit. This secondary circuit uses water/glycol as coolant and operates at much lower pressures, providing an alternative cooling path that reduces reliance on long high-pressure hoses and multiple connections, thus reducing leakage risk while maintaining cooling performance
2Adaptability or versatility
If longer hoses and more connections are used to accommodate tiltable cabs, then adaptability to cab configuration is improved, but the risk of refrigerant leakage increases
Solution Approach 1:
By integrating the condenser and evaporator into one compact unit, the patent minimizes the length of refrigerant hoses required, even in vehicles with tiltable cabs. The reduced hose length and fewer connections directly reduce leakage risk while the unit can still be positioned to accommodate various cab configurations
Solution Approach 2:
The patent introduces a secondary low-pressure cooling circuit as an intermediary system that can be independently routed to the cab. This secondary circuit using water/glycol provides cooling capability without requiring long high-pressure refrigerant hoses, thus maintaining cab adaptability while reducing leakage risk in the primary refrigerant circuit
3Productivity
If flammable refrigerants like propane or R152a are used to improve efficiency, then cooling efficiency is improved, but safety risk increases due to potential leakage inside the driving cab
Solution Approach 1:
The patent segments the cooling function into two separate circuits: a primary high-pressure refrigerant circuit and a secondary low-pressure water/glycol circuit. This segmentation allows the system to use efficient flammable refrigerants in the primary circuit while the secondary circuit provides a safe backup that cannot leak flammable substances into the cab, thus maintaining cooling efficiency while reducing safety risk
Solution Approach 2:
The secondary low-pressure cooling circuit acts as an intermediary safety mechanism. It uses non-flammable water/glycol as coolant and operates at much lower pressures, providing a safe alternative cooling path that prevents flammable refrigerant leakage into the cab while maintaining the ability to achieve efficient cooling through the primary circuit
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 integrated system reduces the risk of refrigerant leakage, achieves efficient heat exchange, and simplifies assembly, making it safer, more efficient, and easier to manufacture, while allowing for both cooling and warming functions from a single unit.
Implementation Method 1
The condenser (4) and the evaporator (7) are combined in a single unit, i.e. integrated in a single unit (16), which takes the form of a plate heat exchanger
Implementation Method 2
At least one internal heat exchanger, i.e. a heat exchanger which exchanges heat between the high and low pressure sides of the refrigerant circuit, is integrated in the combined unit
Implementation Method 3
The liquid, usually water, is cooled in the evaporator of the refrigerant circuit
Implementation Method 4
the condenser (4) and the evaporator (7) are combined in a single unit
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a system and a device for cooling and/or warming which comprises at least a refrigerant circuit (2) with at least a compressor (3), a condenser (4), an evaporator (7) and an expansion means (6). The invention is effected by the evaporator and the condenser being combined/integrated in a single common unit (16) which comprises an internal heat exchanger (19).