Patent Grant
9840130
The disclosed embodiments relate to air conditioning systems, and more particularly, to air conditioning systems used in motor vehicles.
There have been various developments in recent years to make all aspects of motor vehicles more efficient. Such increases in efficiency reduce cost and have a positive environmental impact. Large vehicles such as tractor-trailers that are heavily relied on to handle contemporary shipping demands for goods and raw materials are no exception. Indeed, there have been many notable advances with these types of vehicles to make the same more efficient. However, as the cost of fuel continues to rise, there is a continuous effort to offset this increased operating cost and address the environmental impact of combusting excessive fossil fuels by utilizing leaner, lower-cost tractor-trailer type vehicles.
One aspect of the aforementioned tractor-trailer vehicles that has received a significant amount of attention from a cost reduction perspective is the heating, ventilation, and air conditioning (HVAC) system utilized therein. As one example, there has been a growing use of HVAC systems in tractor-trailers that utilize both an engine operated and an electrically operated configuration to provide heating/cooling. Such a system advantageously provides for HVAC service when the engine is running while a driver is operating the vehicle, as well as HVAC service when the engine is not running while a driver is resting in the vehicle. Such a system can be found at U.S. Pat. No. 6,889,762, the entire teachings and disclosure of which is hereby incorporated by reference in its entirety. As another example, there has been a growing desire to make each of the various components within an HVAC loop more efficient, by improving their thermal performance and reducing their power consumption.
While contemporary HVAC systems have vastly improved driver comfort and vehicle flexibility, there is an ongoing need to make such systems more efficient. The embodiments described herein provide various improvements upon the above described HVAC systems. These and other advantages will be apparent from the description provided herein.
In a vapor compression air conditioning system, refrigerant circulating through the air conditioning loop must be cooled at some point in the cycle so that the refrigerant can absorb heat when it is circulated through the space to be cooled. For example, in a conventional vapor compression air conditioning system, refrigerant is compressed by a compressor and is subsequently circulated to a condenser to be cooled. Typically, the condenser is a refrigerant-to-air heat exchanger, and a mechanical fan blows air over the heat exchanger to cool the refrigerant. After being cooled in the condenser, the refrigerant is circulated through an expansion device and to an evaporator, where the cooled refrigerant absorbs heat from the space to be cooled. The refrigerant is then circulated back to the compressor to continue the refrigeration cycle. In a simple sense, the heat that is absorbed by the refrigerant in the cooled space must be removed from the refrigerant by the condenser in order for the refrigeration cycle to provide effective cooling. Thus, the ability to remove the waste heat from the refrigerant is fundamental to the effectiveness of the air conditioning system. Thus, ways of improving the air conditioning system's ability to remove waste heat from refrigerant will help increase the effectiveness and efficiency of the system.
Many alternative fuel vehicles generate motive power using compressed fluids instead of traditional gasoline or diesel fuel. For example, some vehicles use compressed natural gas (or another appropriate hydrocarbon) to power an internal combustion engine that drives the vehicle. Other vehicles use compressed hydrogen to power a fuel cell that generates electricity, and the electricity is used to power an electric motor that drives the vehicle. When compressed fluids expand rapidly, such as when a compressed fluid leaves a high pressure storage tank, the temperature of the fluid decreases. Typically, the low temperature of the expanded or expanding fluid is not harnessed for any useful purpose. The present application, however, describes systems and apparatuses that use the lower temperature of the expanded fluid to cool the refrigerant in an air conditioning system. Capturing this source of cooling that would otherwise be unused results in more efficient and effective cooling by the air conditioning system. Moreover, the process of cooling the refrigerant causes a corresponding increase in the temperature of the expanded or expanding fluid, which can be beneficial for the operation of the engine or fuel cell which is being supplied by the storage tank. These and other benefits provided by the disclosed embodiments are discussed herein.
In accordance with some embodiments, a vehicle air conditioning system comprises a first vapor compression refrigeration loop. The first vapor compression refrigeration loop comprises a first refrigerant compressor and a first evaporator. In some embodiments, the first vapor compression refrigeration loop also includes a condenser. The vehicle air conditioning system also includes a tank for holding a compressed fluid, an outlet configured to carry expanding or expanded fluid from the tank, and a heat exchanger thermally coupled to the first vapor compression refrigeration loop and to the outlet. The heat exchanger is configured to transfer heat from refrigerant carried by the first vapor compression refrigeration loop to the expanding or expanded fluid, where the temperature of the fluid has been reduced as a result of expansion of the compressed fluid upon exiting the tank.
In order for the fluid to have dropped in temperature, it will either be in the process of expanding, or it may have recently expanded but not currently undergoing expansion. While the present application refers to expanded fluid, it is understood that this refers to fluid that is no longer expanding as well as fluid that is still expanding.
The embodiments disclosed herein and shown in the accompanying drawings are illustrated by way of example, and not by way of limitation. Like reference numerals refer to corresponding parts throughout the drawings.
In some embodiments the vehicle includes a cab 108. A vehicle operator may operate the vehicle 100 from within the cab 108. Some embodiments also include a sleeping area 104 containing one or more beds 110 on which the vehicle operator 112 or passenger may sleep or rest. In some embodiments, the sleeping area 104 is separated from the cab 108 by a retractable curtain or door, which may thermally separate the cab 108 from the sleeping area 104. In some embodiments, the sleeping area 104 is located within the outer shell of the vehicle cab between a back end wall 114 and a pair of sidewalls 118 extending generally perpendicular to the back end wall 114. The bed 110 is typically provided along the back end wall 114 of the sleeping area 104 with one side adjacent the back end wall 114 and two other sides or ends adjacent the sidewalls 118. Thus, three sides of the bed 110 are typically encompassed or surrounded by the shell of the sleeping area 104. This leaves an open side of the bed 110 along the front where a person can maneuver into and out of the bed 110. The bed 110 is typically elevated a few feet above the floor of the sleeping area 110.
In some embodiments, the thermal environment of the cab 108 is controlled with a primary air conditioning system 106 (e.g., a heater and/or air conditioner). In some embodiments, this air conditioning system uses a traditional belt-driven compressor that is mechanically coupled to the vehicle's engine 109 to operate the primary air conditioning system 106 when the engine 109 is running
In some embodiments, the vehicle 100 includes an auxiliary air conditioning system 102 (e.g. a heater and/or air conditioner) to control the thermal environment of the sleeping area 104. It should, however, be appreciated that the auxiliary air conditioning system 102 may heat or cool the cab 108 or any other area of the vehicle, with or without the assistance of the primary air conditioning system 106. Moreover, while the auxiliary air conditioning system 102 is shown in
The vehicle 100 includes one or more tanks 120 that store compressed fluid (e.g., a fuel such as compressed natural gas) that is used by the engine 109 (e.g., a compressed natural gas engine) to generate motive power for the vehicle 100. The vehicle 100 further includes one or more lines 122 that carry the fluid from the tank(s) 120 to the engine 109.
Both the primary air conditioning system 106 and the auxiliary air conditioning system 102 include refrigerant lines (lines 124 and 125, respectively) that are thermally coupled to a heat exchanger 126. The heat exchanger 126 is, in turn, thermally coupled to an outlet of the one or more tanks 120. As described herein, when fluid leaves the one or more tanks 120, it expands, causing the temperature of the fluid to drop. The cooling capacity generated by the expanded fluid can then be captured by the primary and/or the auxiliary air conditioning systems 106, 102 through the heat exchanger 126.
As depicted in the embodiment shown in
The air conditioning system 200 includes a first vapor compression air conditioning loop 202 (hereinafter “air conditioning loop 202”). The term “loop” as used herein includes the refrigerant lines, fittings, coils, compressors, pumps, valves, and other various components used in a vehicle-based vapor-compression air conditioning system. The air conditioning loop 202 includes a compressor 204, an evaporator 206, an expansion device 208, and an optional condenser 209.
In some embodiments, the compressor 204 is an engine-belt driven compressor that is mechanically coupled to an engine of the vehicle (e.g., the vehicle power source 212, discussed herein). In some embodiments, the compressor is an electrically-driven compressor that is not dependent on engine operation for its operation.
The air conditioning system 200 also includes a tank 210 that is configured to hold a compressed fluid. In some embodiments, the tank 210 is fluidly coupled to a vehicle power source 212. As described above, in some embodiments, the fluid is used by the vehicle power source 212 to generate motive power for the vehicle. For example, in some embodiments, the vehicle power source 212 is a combustion engine, and the fluid is a combustible fuel, such as a hydrocarbon. In some embodiments, the fuel is any of: liquefied natural gas (LNG), liquefied petroleum gas (LPG), compressed natural gas (CNG), or any other suitable fuel.
In some embodiments, the vehicle power source 212 is a fuel cell, and the fluid is hydrogen. A fuel cell uses hydrogen to generate electricity, which is then used to power one or more electric motors that drive the vehicle.
In some embodiments, the vehicle power source 212 is a pneumatic motor that generates motive power for the vehicle by harnessing mechanical energy produced by an expanding gas. For example, a pneumatic motor may be a rotary vane motor, piston motor, etc. In such cases, the fluid is air, nitrogen, or any other appropriate compressed fluid.
In some embodiments, the expanded fluid is passed through a turbine or other mechanism that generates mechanical work or electrical energy that is, in turn, used to drive a compressor (e.g., compressor 204). Thus, additional energy can be harnessed from the expanded fluid to reduce the thermal loading and/or increase the efficiency of the air conditioning system 200.
In some embodiments, the compressed fluid is not used by the vehicle 100 to generate motive power. Rather, the compressed fluid may be used for any suitable purpose. In some cases, the compressed fluid is used solely to provide the cooling benefits as described herein, and is not otherwise used by the vehicle 100 for any purpose.
The air conditioning system 200 also includes an outlet 214 that is configured to carry expanded fluid away from the tank 210 (e.g., to a power source 212). The outlet 214 is any portion of the tank, or any component coupled to the tank, that carries expanded fluid from the tank 210, including but not limited to pipes, tubes, lines, fittings, nozzles, valves, manifolds, and the like.
When the compressed fluid exits the tank 210, the fluid expands, which causes the temperature of the fluid to drop. This temperature drop causes components that carry the fluid (or that are thermally coupled to the fluid or to components carrying the fluid) to become cold. Accordingly, as shown in
The heat exchanger 216 is any appropriate heat exchanging mechanism, including, but not limited to, a tube-in-tube heat exchanger, a shell and tube heat exchanger, a plate heat exchanger, or the like. In some embodiments, the heat exchanger 216 is a refrigerant line that is coiled around a fuel line or outlet component of a tank (e.g., a regulator, valve, manifold, etc.). Other appropriate heat exchanging mechanisms or techniques are also contemplated.
As described above, the heat exchanger 216 is configured to transfer heat from refrigerant carried by the first air conditioning loop 202 to fluid carried by the outlet 214, where the temperature of the fluid carried by the outlet 214 has been reduced as a result of expansion of the fluid upon exiting the tank 210. In particular, the heat exchanger 216 is coupled to the air conditioning loop 202 at a point where waste heat absorbed by the refrigerant at another point in the refrigeration cycle needs to be removed from the refrigerant in order to provide effective cooling. Stated differently, the low temperature of expanded fluid is used to cool the refrigerant in the air conditioning loop 202. Typically, the waste heat is removed by a condenser (e.g., the condenser 209). With the heat exchanger 216, however, the cooling capacity of the cold, expanded fluid in the outlet 214 is used to remove some or all of the waste heat from the refrigerant in the air conditioning loop 202.
In some embodiments, the cooling effect provided by the expanded fluid (through the heat exchanger 216) reduces the thermal loading on the condenser 209 of the air conditioning loop 202 to which the heat exchanger is coupled. Thus, the air conditioning loop 202 can be supplied with a smaller, less efficient, and/or less costly condenser than would otherwise be necessary in order to provide the same cooling capacity.
In some embodiments, the cooling provided by the expanded fluid is sufficient to provide all of the waste heat removal required by the air conditioning loop 202, eliminating the need for a condenser entirely. Thus, in some embodiments, the air conditioning loop 202 does not include a condenser. In some embodiments where no condenser is used, the heat exchanger 216 is coupled to the air conditioning loop 202 between the compressor 204 and the expansion device 208.
In some embodiments, the cooling effect provided by the expanded fluid (through the heat exchanger 216) reduces the thermal loading on the air conditioning loop 202 such that a smaller or less costly compressor can be used while still providing adequate cooling capacity.
In some embodiments, the heat exchanger 216 is used as a pre-charger of the evaporator 206 of the air conditioning loop 202. In some embodiments, the heat exchanger 216 is used as a subcooler of the air conditioning loop 202. The particular location or portion of the air conditioning loop 202 to which the heat exchanger 216 is mechanically or functionally coupled is selected according to the particular function that the heat exchanger 216 is to serve.
In some embodiments, the heat exchanger 216 (or another heat exchanger that is thermally coupled to the outlet 214) is instead or additionally coupled to another portion of the air conditioning loop 202, another component of the air conditioning system 200, or another component of a vehicle (e.g., the vehicle 100,
Where additional components or portions of the air conditioning system 200 (or the vehicle) are to be cooled from the cooling capacity of the expanded fluid, additional heat exchanging mechanisms of any appropriate type or form can be coupled to the outlet 214. In some embodiments, a heat exchanging mechanism is simply a portion of a fuel line that is in thermal contact with another component to be cooled.
While
In some embodiments, the first compressor 304 is an engine-belt driven compressor, and the second compressor 314 is an electrically driven compressor that is not dependent upon engine operation for its operation. In some embodiments, the second compressor 314 is an engine-belt driven compressor, and the first compressor 304 is an electrically driven compressor that is not dependent upon engine operation for its operation. In other embodiments, both loops may include belt-driven, engine operated compressors, or electrically driven compressors.
The components of the first air conditioning loop 302 and the second air conditioning loop 312 are analogous to the components of the air conditioning loop 202 described above with respect to
Both the first air conditioning loop 302 and the second air conditioning loop 312 are coupled to a heat exchanger 322. The heat exchanger 322 in
The dual-loop air conditioning system 300 also includes a plurality of tanks 330 that are configured to hold a compressed fluid. In some embodiments, the tanks 330 are coupled to a vehicle power source 332, and provide the fluid to the vehicle power source 332. As described above, the fluid is used by the vehicle power source 332 to generate motive power for the vehicle. Once again, tanks and vehicle power sources are described above with respect to
While
In some embodiments, in order to share the heat exchanger 322 between two air conditioning loops, the dual-loop air conditioning system 300 includes one or more valves 324 (e.g., valves 324-1, 324-2) for controlling the flow of refrigerant through the first air conditioning loop 302 and the second air conditioning loop 312. Specifically, the one or more valves 324 are configured to allow refrigerant to flow through either the first air conditioning loop 302 or the second air conditioning loop 312, or both, depending on the particular operational state of the air conditioning system 300.
In some embodiments, the dual-loop air conditioning system 300 does not include all of the valves 324 shown in
As shown in
The components of the air conditioning loop 402 are analogous to the components of the air conditioning loop 202 described above with respect to
The auxiliary cooling loop 420 includes a heat exchanger 422, a pump 424, and one or more coolant lines, fittings, coils, compressors, pumps, valves, and other various components used in a cooling loop. In some embodiments, the auxiliary cooling loop 420 is configured to circulate coolant (e.g., liquid coolant such as water, antifreeze, mixtures of water and antifreeze, or any other appropriate coolant) using a pump 424 (e.g., a centrifugal pump, lobe pump, scroll pump, screw pump, peristaltic pump, piston pump, etc.). The coolant is circulated through a heat exchanger 422 in order to deliver cooling (or heating) to an appropriate component or space.
The air conditioning system 400 also includes a tank 410 that is configured to hold a compressed fluid. In some embodiments, the tank 410 is coupled to a vehicle power source 412, and provides the fluid to the vehicle power source 412. As described above, the fluid is used by the vehicle power source 412 to generate motive power for the vehicle. Once again, tanks and vehicle power sources are described above with respect to
As shown in
In
For example, in some embodiments, the heat exchanger 422 is a coolant-to-air heat exchanger that is located near (or coupled to) the evaporator 406. Thus, when the air conditioning loop 402 is in operation (e.g., cooling an interior compartment of a vehicle), the auxiliary cooling loop 420 provides additional cooling capacity for the air conditioning system 400.
In some embodiments, both the air conditioning loop 402 and the auxiliary cooling loop 420 are configured to operate at the same time. Thus, due of the additional cooling capacity provided by the auxiliary cooling loop 420, an air conditioning loop 402 with a smaller cooling capacity (and, thus, a cheaper, smaller, lighter, and more efficient air conditioning system) can be selected. Even if the thermal capacity of the air conditioning loop 402 is not reduced (e.g., when the auxiliary cooling loop 420 is included as an aftermarket addition to an existing air conditioning loop 402), the additional cooling capacity of the auxiliary cooling loop 420 can result in greater efficiencies because the air conditioning loop 402 will not have to run as often or produce as much cooling as it otherwise would.
In some embodiments, the auxiliary cooling loop 420 is configured to operate when the air conditioning loop 402 is not operating. For example, the auxiliary cooling loop 420 may be configured to operate alone if the auxiliary cooling loop 420 is able to satisfy the cooling demand, such as when only a small amount of cooling is required. If the demand increases beyond the capabilities of the auxiliary cooling loop 420, the air conditioning loop 402 is activated in order to provide the additional required cooling capacity.
In some embodiments, the auxiliary cooling loop 420 is not used to cool the same space or components as the air conditioning loop 402. For example, whereas the air conditioning loop 402 may be primarily configured to cool an interior portion of a vehicle (e.g., the cab 108 of the vehicle 100,
In some embodiments, the method further includes using the expanded fluid to power an engine of a vehicle (504). In some embodiments, the engine of the vehicle is a fuel cell, and the fluid is hydrogen. In some embodiments, the engine of the vehicle is a combustion engine, and the fluid is selected from the group consisting of: liquefied natural gas (LNG), liquefied petroleum gas (LPG), and compressed natural gas (CNG). In some embodiments, the engine of the vehicle is a pneumatic motor, and the fluid is air.
The method further includes transferring, to the expanded fluid, heat from refrigerant of a vapor compression refrigeration loop, wherein the heat is transferred due to a temperature difference between the expanded fluid and the refrigerant (506). In some embodiments, the heat is transferred from the refrigerant to the expanded fluid via a refrigerant-to-liquid heat exchanger (508).
The method further includes providing cooling to an interior portion of the vehicle with the refrigerant of the vapor compression refrigeration loop (510). For example, the vapor compression refrigeration loop can correspond to a vapor-compression air conditioning system of a vehicle, where refrigerant is passed through an evaporator (e.g., evaporator 206,
In some embodiments, the method further includes powering a vehicle engine with the expanded fluid (512). For example, after the expanded fluid has passed through the heat exchanger, it is used by an engine (e.g., a fuel cell, combustion motor, or pneumatic motor) to generate motive power for the vehicle.
In the foregoing discussion, plural instances are, optionally provided for components, operations, or structures described herein as a single instance. Finally, boundaries between various components, operations, and data stores are somewhat arbitrary, and particular operations are illustrated in the context of specific illustrative configurations. Other allocations of functionality are envisioned and optionally fall within the scope of the embodiment(s). In general, structures and functionality presented as separate components in the example configurations are, optionally, implemented as a combined structure or component. Similarly, structures and functionality presented as a single component are, optionally, implemented as separate components. These and other variations, modifications, additions, and improvements fall within the scope of the embodiment(s).
It will also be understood that, although the terms “first,” “second,” are, in some circumstances, used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first contact could be termed a second contact, and, similarly, a second contact could be termed a first contact, which changing the meaning of the description, so long as all occurrences of the “first contact” are renamed consistently and all occurrences of the second contact are renamed consistently. The first contact and the second contact are both contacts, but they are not the same contact.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the claims. As used in the description of the embodiments and the appended claims, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term “and/or” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof
As used herein, the term “if” is, optionally, construed to mean “when” or “upon” or “in response to determining” or “in accordance with a determination” or “in response to detecting,” that a stated condition precedent is true, depending on the context. Similarly, the phrase “if it is determined (that a stated condition precedent is true)” or “if (a stated condition precedent is true)” or “when (a stated condition precedent is true)” is, optionally, construed to mean “upon determining” or “in response to determining” or “in accordance with a determination” or “upon detecting” or “in response to detecting” that the stated condition precedent is true, depending on the context.
The foregoing description included example systems, methods, techniques, instruction sequences, and computing machine program products that embody illustrative embodiments. For purposes of explanation, numerous specific details were set forth in order to provide an understanding of various embodiments of the inventive subject matter. It will be evident, however, to those skilled in the art that embodiments of the inventive subject matter is, optionally, practiced without these specific details. In general, well-known instruction instances, protocols, structures and techniques have not been shown in detail.
The foregoing description, for purpose of explanation, has been described with reference to specific embodiments. However, the illustrative discussions above are not intended to be exhaustive or to limit the embodiments to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings. The embodiments were chosen and described in order to best explain the principles and their practical applications, to thereby enable others skilled in the art to best utilize the embodiments and various embodiments with various modifications as are suited to the particular use contemplated.
This application claims priority to U.S. Provisional Application No. 61/778,760, filed Mar. 13, 2013, the contents of which are incorporated herein by reference in its entirety.
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