Integrated Secondary-Loop AC Assembly for Low Refrigerant Charge

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Solution Overview

Problem

Secondary loop air conditioning systems for vehicles are complex and require additional components, leading to packaging challenges and increased refrigerant usage, which can include flammable or toxic refrigerants entering the passenger compartment, causing noise and potential oil trapping issues.

Innovation Solution

An integrated air conditioning system with a condenser having spaced headers, a chiller mounted on one header, an expansion device adjacent to the chiller, and a receiver/dryer, minimizing refrigerant lines and usage, allowing for compact packaging and exclusion of refrigerant from the passenger compartment, enabling the use of previously unsuitable refrigerants and reducing noise.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a typical secondary loop air conditioning system is used with separate components, then flexibility in configuring and operating the system is provided, but extra components are added and packaging concerns arise when locating the components in the vehicle

Engineering Contradiction:

Improveflexibility in configuring and operatingVSAvoidextra components

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines the condenser, chiller, expansion device, and receiver/dryer into a single integrated assembly. This merging of previously separate components reduces the total number of discrete parts while maintaining the system's functional flexibility and adaptability.

Inventive Principle:

Principle #5Merging (Combining)

2Adaptability or versatility

If a typical secondary loop air conditioning system is used, then some additional flexibility in configuring and operating the air conditioning system is provided, but they add extra components and add additional packaging concerns when locating the components in the vehicle

Engineering Contradiction:

Improveflexibility in configuring and operatingVSAvoidpackaging space

Core Design Contradiction:

Adaptability or versatilityVSVolume of moving object

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated assembly nests multiple functional components within a compact structure. The chiller is mounted on the condenser header, the expansion device is positioned adjacent to the chiller, and the receiver/dryer is located within the assembly, creating a space-efficient nested arrangement.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Device complexity

If conventional single loop refrigerant systems are used, then simpler configuration is achieved, but nearly as much refrigerant is required in the primary loop

Engineering Contradiction:

Improveconfiguration simplicityVSAvoidrefrigerant charge

Core Design Contradiction:

Device complexityVSQuantity of substance

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent extracts the chiller from the traditional evaporator location and integrates it with the condenser assembly. This repositioning allows the refrigerant to be contained in a compact integrated assembly rather than extending through the passenger compartment, reducing the required refrigerant charge.

Inventive Principle:

Principle #2Taking out (Extraction)

4Ease of operation

If refrigerant lines extend into the passenger compartment, then cooling is provided, but flammable or toxic refrigerants may enter the passenger compartment causing safety concerns

Engineering Contradiction:

Improvecooling functionVSAvoidrefrigerant safety

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

By containing all refrigerant-containing components in an integrated assembly located outside the passenger compartment, the system creates an inert barrier that prevents refrigerant from entering the occupied space, enabling the use of flammable or toxic refrigerants.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

5Adaptability or versatility

If multiple cooling point systems are used, then broader cooling coverage is achieved, but potential oil trapping issues arise when rear units are turned off

Engineering Contradiction:

Improvecooling coverageVSAvoidoil trapping issues

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

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 provides a compact, efficient air conditioning system with reduced refrigerant usage and noise, allowing for the use of previously unsuitable refrigerants and eliminating oil trapping issues, while minimizing refrigerant in the passenger compartment.

Implementation Method 1

a condenser having a first condenser header spaced from a second condenser header, a condenser core extending between the first and second condenser headers

Methodology Applied

Scientific EffectHeat transfer: Heat Exchanger

Implementation Method 2

an expansion device in fluid communication with the condenser and mounted adjacent to the chiller for directing refrigerant into the chiller

Methodology Applied

Scientific EffectPressure drop: Pressure Drop

Implementation Method 3

a chiller mounted to the first condenser header and having a liquid inlet and a liquid outlet configured to be in fluid communication with a secondary loop

Methodology Applied

Scientific EffectHeat transfer: Heat Exchanger

Implementation Method 4

a pump in fluid communication with the liquid outlet

Methodology Applied

Scientific EffectPumping: Pump

Data Source

PatentUS9346338B2Low refrigerant charge secondary loop air conditioning system

Publication Date: 2016.05.24 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A secondary loop air conditioning system for a vehicle that includes a condenser and an integrated assembly is disclosed. The condenser has a first condenser header spaced from a second condenser header, a condenser core extending between the first and second condenser headers, and a refrigerant inlet operatively engaging the first condenser header. The integrated assembly includes a chiller mounted to the first condenser header and having a liquid inlet and a liquid outlet configured to be in fluid communication with a secondary loop of the air conditioning system, and an expansion device in fluid communication with the condenser and mounted adjacent to the chiller for directing refrigerant into the chiller, and a refrigerant outlet. Also, a receiver/dryer area may be located in one of the condenser and the integrated assembly.