Modular chiller with pumped refrigerant economizer

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Solution Overview

Problem

Current pumped refrigerant economizer (PRE) systems in chillers lose efficiency at intermediate temperatures and fail to optimize performance across a wide range of cooling demands, as they either rely solely on compressors or thermosiphons, limiting opportunities for additional efficiency improvements.

Innovation Solution

A modular cooling system with multiple mixed mode refrigerant loops that can operate in either pumped or compressed refrigerant modes, dynamically adjusting based on cooling demand levels, allowing for flexible operation and efficient use of pumps and compressors to meet varying cooling requirements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If a pumped refrigerant economizer system is used, then efficiency is maintained at high ambient temperatures, but efficiency is lost at intermediate temperatures

Engineering Contradiction:

Improvesystem efficiencyVSAvoidtemperature range adaptability

Core Design Contradiction:

Use of energy by moving objectVSAdaptability or versatility

Solution Approach 1:

The system dynamically switches between pumped refrigerant economizer mode and compressor mode based on ambient temperature conditions and cooling demand. The control system monitors temperature levels and automatically transitions between operating modes to optimize efficiency across the full temperature range, resolving the contradiction between maintaining efficiency at high temperatures and adapting to intermediate temperatures.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The refrigerant loop is designed to perform multiple functions by operating in two distinct modes: pumped refrigerant economizer mode for high temperature conditions and compressor mode for intermediate and low temperature conditions. This multi-functionality allows the same hardware to adapt to varying temperature requirements without sacrificing efficiency in either regime.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Loss of energy

If a thermosiphon or pumped refrigerant economizer is used, then compressor operation is reduced, but opportunities for additional efficiency at intermediate temperatures are lost

Engineering Contradiction:

Improveenergy efficiencyVSAvoidoperational flexibility

Core Design Contradiction:

Loss of energyVSAdaptability or versatility

Solution Approach 1:

The system employs dynamic mode switching that allows transitions between pumped refrigerant economizer operation and compressor operation based on real-time cooling demand and temperature conditions. This dynamic adaptability ensures the system captures efficiency opportunities at intermediate temperatures by engaging the compressor when appropriate, while minimizing compressor operation when the pumped economizer mode is more efficient.

Inventive Principle:

Principle #15Dynamics

3Productivity

If multiple refrigerant loops are operated in pumped refrigerant mode, then cooling capacity is increased, but system complexity increases

Engineering Contradiction:

Improvecooling capacityVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The cooling system is divided into multiple independent refrigerant loops, each capable of operating in pumped refrigerant economizer mode or compressor mode. This segmentation allows the system to scale cooling capacity by activating additional loops while maintaining operational simplicity through standardized, modular loop designs that can be independently controlled.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The control system dynamically manages multiple refrigerant loops by selectively activating or deactivating individual loops based on cooling demand levels. This dynamic loop management allows the system to increase cooling capacity progressively by bringing online additional loops only when needed, rather than requiring all loops to operate simultaneously, thereby managing system complexity effectively.

Inventive Principle:

Principle #15Dynamics

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 system efficiently accommodates a wide range of cooling demands by optimizing the operation of refrigerant loops, maintaining efficiency across different temperature conditions, and enhancing overall performance by selectively using pumps or compressors as needed.

Implementation Method 1

pumping a first two-phase refrigerant through a first condenser and a first evaporator

Methodology Applied

Scientific EffectPhase change: Phase Change

Implementation Method 2

pumping a first two-phase refrigerant through a first condenser and a first evaporator

Methodology Applied

Scientific EffectHeat transfer: Heat Exchanger

Implementation Method 3

compressing the first two-phase refrigerant between the first evaporator and the first condenser

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS20260016197A1Modular chiller with pumped refrigerant economizer

Publication Date: 2026.01.15 VERTIV CORP

AI summary

A mixed mode modular cooling system can include two or more mixed mode refrigerant loops and plumbing to permit a working fluid to circulate through at least a portion of the loops. Each mixed mode refrigerant loop can include an evaporator, a condenser, a pump to pump a refrigerant through the evaporator and the condenser, and a compressor configured to compress the refrigerant between the evaporator and the condenser. As cooling demand varies, each mixed mode refrigerant loop can be brought online and operated in either compressed refrigerant mode or pumped refrigerant mode.