Integrated refrigerant control modules
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Solution Overview
Problem
Current vehicle refrigeration systems lack an efficient and cost-effective solution for managing refrigerant flow and heat exchange, leading to increased complexity and potential leaks in HVAC and cooling systems.
Innovation Solution
A monolithic refrigerant control block with multiple openings and internal fluid paths that integrates expansion valves, vapor injection, and heat exchangers, reducing plumbing and assembly time while providing efficient refrigerant flow management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional separate components and plumbing are used for refrigerant flow management, then assembly and installation are straightforward, but the system complexity increases and leak paths multiply
Solution Approach 1:
The patent combines multiple separate refrigerant flow control components (expansion valves, heat exchangers, fluid paths) into a single integrated refrigerant control block. This consolidation eliminates numerous external plumbing connections and potential leak paths while maintaining all necessary refrigerant flow management functions within one monolithic structure.
Solution Approach 2:
The refrigerant control block serves multiple functions simultaneously: it acts as an expansion valve housing, contains internal heat exchangers, provides multiple fluid paths for different refrigerant flows, and interfaces with various system components (compressor, condenser, evaporator). This multi-functionality reduces the need for separate dedicated components.
2Ease of manufacture
If multiple separate components are used for heat exchange and refrigerant control, then manufacturing and assembly are simpler, but the overall system cost increases
Solution Approach 1:
The patent integrates heat exchanger coils, expansion valve mechanisms, and fluid distribution paths into a single molded refrigerant control block. This consolidation reduces the number of separate manufacturing steps and assembly operations required, as the integrated block can be produced as one piece and installed as a single unit.
Solution Approach 2:
While integrating multiple functions, the design maintains functional segmentation through internal separation of different refrigerant flow paths within the block. Each function (heat exchange, expansion, fluid distribution) is internally separated and optimized while remaining part of the unified structure, allowing modular functionality within integration.
3Ease of operation
If traditional plumbing connections are used between components, then installation is straightforward, but the number of potential leak paths increases
Solution Approach 1:
The refrigerant control block consolidates multiple connection points into a single installable unit. Instead of requiring separate plumbing connections for expansion valves, heat exchangers, and fluid paths, the integrated block provides all these functions through internal pathways, reducing external connections from numerous to minimal.
Solution Approach 2:
The patent converts the potential harm of multiple leak paths into a benefit by eliminating the need for numerous external connections. The internal fluid paths within the monolithic block eliminate external joints and seals that would create leak opportunities, while the integrated design maintains ease of installation through reduced connection requirements.
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 simplifies refrigerant flow management, reduces leak paths, and lowers costs by integrating heat exchange functions within a single solid block, enhancing the efficiency and reliability of vehicle refrigeration systems.
Implementation Method 1
The refrigerant control block provides an internal heat exchanger, which provides a first internal refrigerant path that receives refrigerant flowing from the vapor injection module to the chiller and a second internal refrigerant path receives refrigerant flowing from the chiller to the compressor
Data Source
AI summary
A vehicle refrigeration system includes a compressor, a condenser in fluid communication with the compressor, a chiller, a vapor injection module, and a refrigerant control block. The refrigerant control block includes a plurality of outer walls which provide a plurality of openings in fluid communication with a plurality of internal fluid paths. The plurality of openings include a VPI block outlet and a chiller block outlet. A first EXV opening receives a first EXV for modulating refrigerant flow out of the VPI block outlet through the vapor injection module to the compressor. A second EXV opening receives a second EXV for modulating refrigerant flow out of the chiller block outlet to the chiller.