SYSTEM AND METHOD FOR VARYING REFRIGERANT FLOW IN A REVERSING VALVE

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to Indian Patent Application No. 202011010821, filed Mar. 13, 2020, the contents of which are incorporated by reference herein in their entirety.

BACKGROUND

The present invention generally relates to heating, ventilation, and air conditioning (HVAC) systems. More particularly, the invention relates to a system and a method for varying refrigerant flow using a flow diverter of a reversing valve in the HVAC systems.

With the advent of climate control systems for controlling temperature of a particular area, the earlier known separate systems for cooling and heating are being dispensed with. The development of climate control technology has resulted in introduction of heat pumps that can be used for heating as well as cooling the same area.

In order to use the same heat pump for heating operation, defrosting operation as well as cooling operation, a reversible valve is used in the heat pumps that can perform heating, defrosting, and cooling operations through the same device. Such reversible valve eliminates the requirement of using separate devices for heating, defrosting and cooling operations. In particular, the reversible valve has a solenoid valve which triggers shifting of the reversible valve for reversing the operation. However, the solenoid valve needs to be energized at all times based on required operation, thereby resulting in wastage of energy. Furthermore, the reversible valve sometimes fails to shift from heating operation to cooling operation or vice-versa, or from defrosting operation to heating operation and does not completely reverse the operation. Moreover, the reversible valve also suffers leakage while reversing operation. In addition, only one reversing valve can be used for each tonnage.

In view of the afore-mentioned problems in the existing reversible valve, there is a need of an efficient and effective system and method for eliminating leakage while reversing operation in a reversing valve. There is also a need of a valve that completely reverses an operation. There is also a need of a valve that does not fail to shift the operation. In order to solve problems in the existing reversible valve, a system and a method are disclosed.

SUMMARY

Various embodiments of the invention describe a system for varying the refrigerant flow using a flow diverter of a reversing valve in HVAC systems. The system comprises a reversing valve, a control circuit and a stepper motor. The reversing valve is adapted to operate in a plurality of modes. Also, the reversing valve comprises a first tube, a second tube, a third tube and a fourth tube. The control circuit is adapted to receive a command for operating the reversing valve in the plurality of modes and determine a tonnage profile for refrigerant to flow in the reversing valve. The control circuit is also adapted to generate a signal based on the command and the tonnage profile. The stepper motor is adapted to rotate a flow diverter of the reversing valve based on the signal received from the control circuit. The rotation of the flow diverter allows the refrigerant to flow in one of the plurality of modes.

In an embodiment of the invention, the plurality of modes correspond to a cooling mode, a defrost mode, and a heating mode.

In another embodiment of the invention, the tonnage profile for refrigerant is determined based on a temperature defined by a user.

In yet another embodiment of the invention, the flow diverter is rotated from 0° angle to 90° angle in a clockwise or a counter-clockwise direction based on the tonnage profile and/or change from one mode to another mode.

In another embodiment of the invention, the flow diverter is rotated from 0° angle to 10° angle in the cooling mode or in the defrost mode. Also, the flow diverter is rotated from 70° angle to 90° angle in the heating mode.

In still another embodiment of the invention, the flow diverter is rotated to a first position for a first tonnage profile, to a second position for a second tonnage profile, to a third position for a third tonnage profile and/or to a fourth position for a fourth tonnage profile.

In a different embodiment of the invention, the flow diverter is rotated at the first position of 0° angle for the first tonnage profile in the cooling mode or in the defrost mode, wherein the flow diverter is rotated to the second position of 10° angle for the second tonnage profile in the cooling mode or the defrost mode.

In yet another embodiment of the invention, the flow diverter is rotated at the third position of 70° angle for the third tonnage profile in the heating mode, wherein the flow diverter is rotated to the fourth position of 90° angle for the fourth tonnage profile in the heating mode.

In another embodiment of the invention, the first tube is connected to a discharge port of a compressor, the second tube is connected to an outdoor coil, the third tube is connected to an indoor coil, and the fourth tube is connected to a return port of the compressor.

In an embodiment of the invention, the refrigerant flows from the discharge port of the compressor to the first tube, from the first tube to the second tube, from the second tube to the outdoor coil, from the outdoor coil to the indoor coil, from the indoor coil to the third tube, from the third tube to the fourth tube, and from the fourth tube to the return port of the compressor in the cooling mode or in the defrost mode.

In yet another embodiment of the invention, the refrigerant flows from the discharge port of the compressor to the first tube, from the first tube to the third tube, from the third tube to the indoor coil, from the indoor coil to the outdoor coil, from the outdoor coil to the second tube, from the second tube to the fourth tube, and from the fourth tube to the return port of the compressor in the heating mode.

Various embodiments of the invention describe a method for varying the refrigerant flow using a flow diverter of a reversing valve in HVAC systems. The method comprises the step of receiving, by a control circuit, a command for operating a reversing valve in a plurality of modes. The reversing valve comprises a first tube, a second tube, a third tube and a fourth tube. The method also comprises the steps of determining a tonnage profile for refrigerant to flow in the reversing valve and generating a signal based on the command and the tonnage profile. The method also comprises the steps of communicating the signal to a stepper motor and rotating a flow diverter of the reversing valve by the stepper motor based on the signal. Accordingly, the rotation of the flow diverter allows the refrigerant to flow in one of the plurality of modes.

In an embodiment of the invention, the plurality of modes correspond to a cooling mode, a defrost mode, and a heating mode.

In still another embodiment of the invention, the flow diverter is rotated at a first position of 0° angle for a first tonnage profile in the cooling mode or in the defrost mode, wherein the flow diverter is rotated to a second position of 10° angle for a second tonnage profile in the cooling mode or the defrost mode.

In yet another embodiment of the invention, the flow diverter is rotated at a third position of 70° angle for a third tonnage profile in the heating mode, wherein the flow diverter is rotated to a fourth position of 90° angle for a fourth tonnage profile in the heating mode

In an embodiment of the invention, the first tube is connected to a discharge port of a compressor, the second tube is connected to an outdoor coil, the third tube is connected to an indoor coil, and the fourth tube is connected to a return port of the compressor.

In another embodiment of the invention, the refrigerant flows from the compressor to the first tube, from the first tube to the second tube, from the second tube to the outdoor coil, from the outdoor coil to the indoor coil, from the indoor coil to the third tube, from the third tube to the fourth tube, and from the fourth tube to the compressor in the cooling mode or in the defrost mode.

In still another embodiment of the invention, the refrigerant flows from the compressor to the first tube, from the first tube to the third tube, from the third tube to the indoor coil, from the indoor coil to the outdoor coil, from the outdoor coil to the second tube, from the second tube to the fourth tube, and from the fourth tube to the compressor in the heating mode.

This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

Other aspects, advantages, and salient features of the invention will become apparent to those skilled in the art from the following detailed description, which taken in conjunction with the annexed drawings, discloses exemplary embodiments of the invention. The foregoing features and elements may be combined in various combinations without exclusivity, unless expressly indicated otherwise. These features and elements as well as the operation thereof will become more apparent in light of the following description and the accompanying drawings. It should be understood, however, that the following description and drawings are intended to be illustrative and explanatory in nature and non-limiting.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter is particularly pointed out and distinctly claimed at the conclusion of the specification. The foregoing and other features, and advantages of the present disclosure are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:

FIG. 1A depicts an external view of an exemplary reversing valve, FIG. 1B depicts an internal view of the exemplary reversing valve and FIG. 1C depicts an exemplary flow diverter of the exemplary reversing valve according to an exemplary embodiment of the invention.

FIG. 1D depicts an exemplary flow diverter at 0° angle and FIG. 1E depicts an exemplary flow diverter at 90° angle according to an exemplary embodiment of the invention. FIG. 1F depicts an exemplary flow diverter with holes C1 and C2 in a cooling mode or a defrost mode. FIG. 1G depicts a cross-sectional view of the flow diverter with the holes C1 and C2 in the cooling mode or the defrost mode. FIG. 1H depicts rotation/position of the flow diverter with the holes C1 and C2 in the cooling mode or the defrost mode.

FIG. 1I depicts an exemplary flow diverter with holes H1, H2, C1 and C2 in a heating mode. FIG. 1J depicts a cross-sectional view of the flow diverter with the holes H1, H2, C1 and C2 in the heating mode. FIG. 1K depicts rotation/position of the flow diverter with the holes in the heating mode.

FIG. 2A depicts an exemplary reversing valve operating in a cooling mode and/or a defrost mode according to an exemplary embodiment of the invention.

FIG. 2B depicts flow of refrigerant in an exemplary reversing valve operating in a cooling mode and/or a defrost mode, according to an exemplary embodiment of the invention.

FIG. 2C depicts a cross-sectional view of first & second tubes of the reversing valve operating in a cooling mode and/or a defrost mode, and FIG. 2D depicts a cross-sectional view of third and fourth tubes of the reversing valve operating in a cooling mode and/or a defrost mode, according to an exemplary embodiment of the invention. FIG. 2E depicts an exemplary port opening of tube/s for a first tonnage profile and FIG. 2F depicts an exemplary port opening of tube/s for a second tonnage profile in a cooling mode and/or a defrost mode, according to an exemplary embodiment of the invention.

FIG. 3A depicts an exemplary reversing valve operating in a heating mode according to an exemplary embodiment of the invention. FIG. 3B depicts flow of refrigerant in an exemplary reversing valve operating in a heating mode, according to an exemplary embodiment of the invention.

FIG. 3C depicts a cross-sectional view of first and second tubes of the reversing valve operating in a heating mode, and FIG. 3D depicts a cross-sectional view of third and fourth tubes of the reversing valve operating in a heating mode, according to an exemplary embodiment of the invention. FIG. 3E depicts an exemplary port opening of tube/s for a third tonnage profile and FIG. 3F depicts an exemplary port opening of tube/s for a fourth tonnage profile in a heating mode, according to an exemplary embodiment of the invention.

FIG. 4 depicts an exemplary flowchart illustrating a method to perform the invention according to an exemplary embodiment of the invention.

FIG. 5 depicts an exemplary flow diverter with different O-Rings according to an exemplary embodiment of the invention.

Corresponding reference numerals indicate corresponding parts throughout the drawings.

DETAILED DESCRIPTION

Described herein is the technology with a system and a method for varying refrigerant flow using a flow diverter of a reversing valve in HVAC systems. The reversing valve may comprise a first tube, a second tube, a third tube and a fourth tube. Further, the reversing valve may be connected with a compressor, an indoor coil, an outdoor coil and an expansion through ends of these four tubes. Furthermore, the reversing valve may operate in a plurality of modes based on a command. The command may be provided by a user through a thermostat for operating the reversing valve in one of the plurality of modes.

Moreover, the command may be received by a control circuit and the control circuit may determine a tonnage profile for refrigerant to flow in the reversing valve. The control circuit may generate a signal based on the command and the tonnage profile and then, communicate the signal to a stepper motor. Then, the stepper motor may rotate a flow diverter of the reversing valve based on the signal in order to make the refrigerant flow in one of the plurality of modes. The flow diverter may be rotated from 0° angle to 90° angle in a clockwise or a counter-clockwise direction based on the command and the tonnage profile. Various tonnage profiles for rotating the flow diverter from 0° angle to 90° angle have been explained in detail throughout the specification.

As used herein, the reversing valve may use the flow diverter to control the flow of refrigerant through the reversing valve based on the plurality of modes. The plurality of modes may be a heating mode, a cooling mode and/or a defrost mode. The details of flow of the refrigerant in the reversing valve operating in various modes have been explained in detail below. The reversing valve may be any rotational reversing valve that is well known in the art.

As used herein, the control circuit may be an electronic circuitry or a printed circuit board communicably coupled and/or attached with the reversing valve and/or a thermostat. The control circuit may be present inside or outside the reversing valve. The control circuit may also be communicably coupled with the thermostat to receive a command. The command may be provided by a user to operate the reversing valve in any of the plurality of modes. The control circuit may further be communicably coupled and/or attached with a stepper motor.

As used herein, the stepper motor may be communicably coupled and/or attached with the reversing valve and/or the control circuit. The stepper motor may be present inside or outside the reversing valve. Further, the stepper motor may be programmed in such a way that the stepper motor may rotate the flow diverter inside the reversing valve based on the signal received from the control circuit. The stepper motor may be any stepper motor that is well known in the art.

FIG. 1A depicts an external view of an exemplary reversing valve according to an exemplary embodiment of the invention. As depicted, an external view 100A of a reversing valve 102 in FIG. 1A, the reversing valve 102 may comprise a first tube 104A, a second tube 104B, a third tube 106A, and a fourth tube 106B. Further, the reversing valve 102 also comprises a stepper motor 108 present inside/outside a housing of the reversing valve 102.

FIG. 1B depicts an internal view of the exemplary reversing valve according to an exemplary embodiment of the invention. As depicted, an internal view 100B in FIG. 1B, the reversing valve 102 may comprise a flow diverter 110 adapted to make refrigerant flow in the reversing valve 102 through the first tube 104A, the second tube 104B, the third tube 106A, and the fourth tube 106B based on a command from a user. As can be seen, the flow diverter 110 may comprise cavities (i.e. holes) through which the refrigerant may pass from the tubes which has been described in details below.

FIG. 1C depicts an exemplary flow diverter of the exemplary reversing valve according to an exemplary embodiment of the invention. Also, the flow diverter 110 may be rotated from 0° angle to 90° angle in a clockwise or a counter-clockwise direction based on a command from a user and a tonnage profile.

FIG. 1D depicts an exemplary view 100D showing the flow diverter 110 at 0° angle and FIG. 1E depicts an exemplary view 100E showing the flow diverter 110 at 90° angle. These act as a stopper at 0° angle and 90° angle for restricting the rotation of the flow diverter 110.

FIG. 1F depicts an exemplary flow diverter 110 with holes C1 and C2 in a cooling mode or a defrost mode. Particularly, the first tube 104A gets connected to hole C1 and the third tube 106A gets connected to hole C2. The flow of refrigerant through these holes have been explained in detail in FIGS. 2A and 2B. FIG. 1G depicts a cross-sectional view 100G of the flow diverter 110 with the holes C1 and C2 in the cooling mode or the defrost mode. FIG. 1H depicts rotation/position of the flow diverter 110 with the holes C1 and C2 in the cooling mode or the defrost mode.

FIG. 1I depicts an exemplary flow diverter 110 with holes H1, H2, C1 and C2 in a heating mode. Particularly, the first tube 104A gets connected to hole H1 and the second tube 104B gets connected to hole H2. The flow of refrigerant through these holes have been explained in detail in FIGS. 3A and 3B. FIG. 1J depicts a cross-sectional view 100J of the flow diverter 110 with the holes H1, H2, C1 and C2 in the heating mode. FIG. 1K depicts rotation/position of the flow diverter 110 with the holes in the heating mode.

FIG. 2A depicts an exemplary reversing valve operating in a cooling mode and/or a defrost mode according to an exemplary embodiment of the invention. A user (not shown) may select an option in a thermostat 124 (installed in a home 122) to operate the reversing valve 102 in the cooling mode and/or the defrost mode. For this, the user may use a soft button or hard button provided on an interface of the thermostat 124 to give a command for operating the reversing valve 102 in the cooling mode and/or the defrost mode. Alternatively, the user may provide a command through an application of the thermostat 124 stored in a device. Before the user provides the command, a heat pump of the reversing valve 102 may be powered-on for starting its functioning or the reversing valve 102 may be already operating in a heating mode and the user may provide a command for mode reversal. In a different exemplary embodiment, the user may set temperature in the thermostat 124 and based on the set temperature, a system may automatically decide the mode of the reversing valve 102. When the user selects the option to operate the reversing valve 102 in the cooling mode and/or the defrost mode, the thermostat 124 may transmit a command to a control circuit 120 through a wired network or a wireless network. The control circuit 120 may be communicably coupled or connected with the thermostat 124 and/or the reversing valve 102. The control circuit 120 may be present inside or outside the building/home 122.

When the control circuit 120 receives the command from the thermostat 124 to operate the reversing valve 102, the control circuit 120 may determine a tonnage profile for refrigerant to flow in the reversing valve 102. For this, the tonnage profile for refrigerant is determined by the control circuit 120 based on a temperature defined by the user in the thermostat 124 and/or a temperature inside the building/home 122. In specific, the user may define the temperature based on number of people/occupants present in the building/home 122. If there are multiple occupants in the building/home 122 which may exceed temperature, then the system may decide to run at full load condition, depending upon the heat generated by multiple occupants in the building/home 122. Alternatively, the control circuit may automatically acquire a temperature setpoint based on the number of occupants and current temperature. In an exemplary embodiment, the control circuit 120 may request the thermostat 124 to provide a current temperature inside the building/home 122. In another exemplary embodiment, the control circuit 120 may determine a current temperature inside the building/home 122.

After the control circuit 120 determines the current temperature inside the building/home 122, the control circuit 120 may accordingly determine a tonnage profile for refrigerant to flow in the reversing valve 102. The control circuit 120 may determine a first tonnage profile or a second tonnage profile for the cooling/defrost mode. The control circuit 120 may determine the first tonnage profile when a difference between the current temperature inside the building/home 122 and a pre-defined cooling temperature threshold is high. Similarly, the control circuit 120 may determine the second tonnage profile when a difference between the current temperature inside the building/home 122 and the pre-defined cooling temperature threshold is low. Then, the control circuit 120 may generate a signal based on the command and the determined tonnage profile. The control circuit 120 may communicate the signal to the stepper motor 108 for operating the reversing valve 102 in the cooling/defrost mode as per the determined tonnage profile. In an exemplary embodiment, the pre-defined cooling temperature threshold may be defined by the user of the thermostat 124 and may be the temperature which is desired to be maintained inside the building/home 122.

When the stepper motor 108 receives the signal from the control circuit 120, the stepper motor 108 may rotate the flow diverter 110 based on the signal. The stepper motor 108 may rotate as per the command and the determined tonnage profile defined in the signal. In particular, the stepper motor 108 may be programmed in such a manner that the stepper motor 108 may rotate the flow diverter 110 to a first position for the first tonnage profile or to a second position for the second tonnage profile. At the first position for the first tonnage profile, the stepper motor 108 may rotate the flow diverter 110 to 0° angle. And, at the second position for the second tonnage profile, the stepper motor 108 may rotate the flow diverter 110 to 10° angle. In particular, when the flow diverter 110 is positioned at 0° angle in the first tonnage profile, the flow of refrigerant is maximum inside the tubes. And, when the flow diverter 110 is positioned at 10° angle in the second tonnage profile, the flow of refrigerant is minimum inside the tubes.

The determination of the tonnage profile and the rotation of the flow diverter 110 with respect to the tonnage profile in the cooling/defrost mode have been explained in greater details below with examples in exemplary Table 1.

TABLE 1

Cooling Mode or Defrost Mode

Current
Pre-defined

Opening of

Temper-
Cooling

First and
Rotation
Angle of

ature inside
Temperature
Tonnage
Second
of Flow
Flow

Building
threshold
Profile
Tubes
Diverter
Diverter

40° Celsius
18° Celsius
First
Fully Open
First
0° angle

Tonnage

Rotation

Profile

Position

22° Celsius
18° Celsius
Second
Partially
Second
10° angle

Tonnage
Open
Rotation

Profile

Position

As can be seen in Table 1 above, the first tonnage profile may be determined by the control circuit 120 when the difference between the current temperature (i.e. 40° Celsius) inside the building/home 122 and the pre-defined cooling temperature threshold (i.e. 18° Celsius) is high (i.e. 22° Celsius). For the first tonnage profile, the stepper motor 108 may rotate the flow diverter 110 at the first position of 0° angle such that the opening of the first tube 104A, the second tube 104B, the third tube 106A and the fourth tube 106B are maximum (i.e. fully open). Similarly, the second tonnage profile may be determined by the control circuit 120 when the difference between the current temperature (i.e. 22° Celsius) inside the building/home 122 and the pre-defined cooling temperature threshold (i.e. 18° Celsius) is low (i.e. 4° Celsius). For the second tonnage profile, the stepper motor 108 may rotate the flow diverter 110 at the second position of 10° angle such that the opening of the first tube 104A, the second tube 104B, the third tube 106A and the fourth tube 106B are minimum (i.e. partially open). The full opening of these tubes allow the maximum refrigerant to flow inside the tubes. And, the partial opening of the first tube 104A, the second tube 104B, the third tube 106A and the fourth tube 106B allow the minimum refrigerant to flow inside the tubes. By determining the tonnage profile, this embodiment of the present invention provides a technical advantage of precise/fine rotation of the flow diverter 110 and varying the flow of the refrigerant. Such variations in rotation of the flow diverter 110 may help in effective cooling inside the building/home 122.

Furthermore, as depicted in FIG. 2A and FIG. 2B, the first tube 104A may be connected to a discharge/outlet port of a compressor 114. The second tube 104B may be connected to an outdoor coil 112 and the third tube 106A may be connected to an indoor coil 118. And, the fourth tube 106B may be connected to a return/inlet port of the compressor 114.

Moreover, as depicted in FIG. 2A and FIG. 2B in the cooling mode or in the defrost mode of the reversing valve 102, the refrigerant may flow from the discharge/outlet port of the compressor 114 to the first tube 104A and from the first tube 104A to the second tube 104B. Then, from the second tube 104B to the outdoor coil 112, from the outdoor coil 112 to the indoor coil 118 through an expansion 116, and from the indoor coil 118 to the third tube 106A. From the third tube 106A to the fourth tube 106B, from the fourth tube 106B to the return/inlet port of the compressor 114 in the cooling mode or in the defrost mode. In an exemplary embodiment, the indoor coil 118 may be adapted to absorb the heat inside the building/home 122 and the outdoor coil 112 may be adapted to reject the heat outside the building/home 122.

FIG. 2C depicts a cross-sectional view of a first and second tubes of the reversing valve operating in a cooling mode and/or a defrost mode according to an exemplary embodiment of the invention. As depicted, a cross-sectional view 200C of the first tube 104A and the second tube 104B in the flow diverter 110 and Section A-A of the first tube 104A and the second tube 104B in the flow diverter 110. As explained above in FIGS. 2A and 2B, the first tube 104A and the second tube 104B are fully open (i.e. maximum refrigerant flow) when the flow diverter 110 is at the first rotation position of 0° angle and is partially open (i.e. minimum refrigerant flow) when the flow diverter 110 is at the second rotation position of 10° angle.

FIG. 2D depicts a cross-sectional view of a third and fourth tubes of the reversing valve operating in a cooling mode and/or a defrost mode according to an exemplary embodiment of the invention. As depicted, a cross-sectional view 200D of the third tube 106A and the fourth tube 106B in the flow diverter 110 and Section B-B of the third tube 106A and the fourth tube 106B in the flow diverter 110. As explained above in FIGS. 2A and 2B, the third tube 106A and the fourth tube 106B are fully opened (i.e. maximum refrigerant flow) when the flow diverter 110 is at the first rotation position of 0° angle and is partially open (i.e. minimum refrigerant flow) when the flow diverter 110 is at the second rotation position of 10° angle.

FIG. 2E depicts an exemplary port opening of tube/s for a first tonnage profile in a cooling mode and/or a defrost mode, according to an exemplary embodiment of the invention. In the first tonnage profile, the flow diverter 110 may be at the first rotation position of 0° angle. Also, a port opening (circled) is shown in FIG. 2E in the first tonnage profile. Such port opening would allow the maximum refrigerant to pass through the tubes.

FIG. 2F depicts an exemplary port opening of tube/s for a second tonnage profile in a cooling mode and/or a defrost mode, according to an exemplary embodiment of the invention. In the second tonnage profile, the flow diverter 110 may be at the second rotation position of 10° angle. Also, a port opening (circled) is shown in FIG. 2F in the second tonnage profile. Such port opening would allow the minimum refrigerant to pass through the tubes.

FIG. 3A depicts an exemplary reversing valve operating in a heating mode according to an exemplary embodiment of the invention. A user (not shown) may select an option in a thermostat 124 to operate a reversing valve 102 in a heating mode as explained above in FIG. 3A. Before the user provides the command, heat pump of the reversing valve 102 may be powered-on for starting its functioning or the reversing valve 102 which may be already operating in a cooling/defrost mode. The user may provide a command for mode reversal. In a different exemplary embodiment, the user may set temperature in the thermostat 124 and based on the set temperature, a system may automatically decide the mode of the reversing valve 102. When the user selects the option to operate a reversing valve 102 in a heating mode, the thermostat 124 may transmit a command to a control circuit 120 through a wired network or a wireless network. The control circuit 120 may be communicably coupled or connected with the thermostat 124 and the reversing valve 102. The control circuit 120 may be present inside or outside the building/home 122.

When the control circuit 120 receives the command from the thermostat 124 to operate the reversing valve 102 in the heating mode, the control circuit 120 may determine a tonnage profile for refrigerant to flow in the reversing valve 102. For this, the tonnage profile for refrigerant is determined by the control circuit 120 based on a temperature defined by the user and/or a temperature inside the building/home 122. In specific, the user may define the temperature based on number of people/occupants present in the building/home 122 as explained above in FIG. 3A. Alternatively, the control circuit may automatically acquire a temperature setpoint based on the number of occupants and current temperature.

After the control circuit 120 determines the current temperature inside the building/home 122, the control circuit 120 may accordingly determine a tonnage profile for the refrigerant to flow into the reversing valve 102. The control circuit 120 may determine a third tonnage profile or a fourth tonnage profile. The control circuit 120 may determine the third tonnage profile when a difference between the current temperature inside the building/home 122 and a pre-defined heating temperature threshold is low. Similarly, the control circuit 120 may determine the fourth tonnage profile when a difference between the current temperature inside the building/home 122 and a pre-defined heating temperature threshold is high. Then, the control circuit 120 may generate a signal based on the command and the determined tonnage profile. The control circuit 120 may then communicate the signal to a stepper motor 108 for operating the reversing valve 102 in the heating mode as per the determined tonnage profile. In an exemplary embodiment, the pre-defined heating temperature threshold may be defined by the user of the thermostat 124 and may be the temperature that is desired to be maintained inside the building/home 122.

When the stepper motor 108 receives the signal generated by the control circuit based on the determined tonnage profile, the stepper motor 108 may rotate a flow diverter 110 based on the signal. In particular, the stepper motor 108 may be programmed to rotate in such a manner that the stepper motor 108 may rotate the flow diverter 110 to a third position for the third tonnage profile or to a fourth position for the fourth tonnage profile. At the third position for the third tonnage profile, the stepper motor 108 may rotate the flow diverter 110 to 70° angle. And at the fourth position for the fourth tonnage profile, the stepper motor 108 may rotate the flow diverter 110 to 90° angle. In particular, when the flow diverter 110 is positioned at 70° angle in the third tonnage profile, the flow of refrigerant is minimum inside the tubes. And, when the flow diverter 110 is positioned at 90° angle in the fourth tonnage profile, the flow of refrigerant is maximum inside the tubes. This embodiment of the present invention provides a technical advantage of eliminating the requirement of continuously energizing a valve for heating and providing complete reversal of from cooling mode to heating mode. The determination of the tonnage profile and the rotation of the flow diverter 110 with respect to the tonnage profile in the heating mode have been explained in greater details below with examples in exemplary Table 2.

TABLE 2

Heating Mode

Pre-

Current
defined

Opening of
Rotation

Tempera-
Heating

First and
of
Angle of

ture Inside
Temperature
Tonnage
Second
Flow
Flow

Building
threshold
Profile
Tubes
Diverter
Diverter

24° Celsius
30° Celsius
Third
Partially
Third
70° angle

Tonnage
Open
Rotation

Profile

Position

2° Celsius
30° Celsius
Fourth
Fully Open
Fourth
90° angle

Tonnage

Rotation

Profile

Position

As can be seen in Table 2 above, the third tonnage profile may be determined by the control circuit 120 when the difference between the current temperature (i.e. 24° Celsius) inside the building/home 122 and the pre-defined temperature threshold (i.e. 30° Celsius) is low (i.e. 6° Celsius). For the third tonnage profile, the stepper motor 108 may rotate the flow diverter 110 at the third position of 70° angle such that the opening of the first tube 104A, the second tube 104B, the third tube 106A and the fourth tube 106B are minimum (i.e. partially open). Similarly, the fourth tonnage profile may be determined by the control circuit 120 when the difference between the current temperature (i.e. 2° Celsius) inside the building/home 122 and the pre-defined temperature threshold (i.e. 30° Celsius) is high (i.e. 28° Celsius). For the fourth tonnage profile, the stepper motor 108 may rotate the flow diverter 110 at the fourth position of 90° angle such that the opening of the first tube 104A, the second tube 104B, the third tube 106A and the fourth tube 106B are maximum (i.e. fully open). The full opening of these tubes allow the maximum refrigerant to flow inside the tubes. And, the partial opening of the first tube 104A, the second tube 104B, the third tube 106A and the fourth tube 106B allow the minimum refrigerant to flow inside the tubes. By determining the tonnage profile, this embodiment of the present invention provides a technical advantage of precise/fine rotation of the flow diverter 110 and varying the flow of the refrigerant. Such variations in rotation of the flow diverter 110 may help in effective heating inside the building/home 122.

Furthermore, as depicted in FIG. 3A and FIG. 3B, the first tube 104A may be connected to a discharge/outlet port of a compressor 114. The second tube 104B may be connected to an outdoor coil 112. Also, the third tube 106A may be connected to an indoor coil 118. And, the fourth tube 106B may be connected to a return/inlet port of the compressor 114.

As depicted in FIG. 3A and FIG. 3B in the heating mode of the reversing valve 102, the refrigerant may flow from the discharge/outlet port of the compressor 114 to the first tube 104A and from the first tube 104A to the third tube 106A. Then, from the third tube 106A to the indoor coil 118 and from the indoor coil 118 to the outdoor coil 112 through an expansion 116. From the outdoor coil 112 to the second tube 104B and from the second tube 104B to the fourth tube 106B. Then, from the fourth tube 106B to the return port of the compressor 114 in the heating mode. In an exemplary embodiment, the indoor coil 118 may be adapted to reject heat from inside the building/home 122 and the outdoor coil 112 may be adapted to absorb heat.

FIG. 3C depicts a cross-sectional view of first and second tube of the reversing valve operating in a heating mode according to an exemplary embodiment of the invention. As depicted, a cross-sectional view 300C of the first tube 104A and the second tube 104B in the flow diverter 110 and Section C-C of the first tube 104A and the second tube 104B in the flow diverter 110. As explained above in FIGS. 3A and 3B, the first tube 104A and the second tube 104B are partially open (i.e. minimum refrigerant flow) when the flow diverter 110 is at the third rotation position of 70° angle and is fully open (i.e. maximum refrigerant flow) when the flow diverter 110 is at the fourth rotation position of 90° angle.

FIG. 3D depicts a cross-sectional view of third tube and the fourth tube of the reversing valve operating in a heating mode according to an exemplary embodiment of the invention. As depicted, a cross-sectional view 300D of the third tube 106A and the fourth tube 106B in the flow diverter 110 and Section D-D of the third tube 106A and the fourth tube 106B in the flow diverter 110. As explained above in FIGS. 3A and 3B, the third tube 106A and the fourth tube 106B are partially open (i.e. minimum refrigerant flow) when the flow diverter 110 is at the third rotation position of 70° angle and are fully open (i.e. maximum refrigerant flow) when the flow diverter 110 is at the fourth rotation position of 90° angle.

FIG. 3E depicts an exemplary port opening of tube/s for a third tonnage profile in a heating mode, according to an exemplary embodiment of the invention. In the third tonnage profile, the flow diverter 110 may be at the third rotation position of 70° angle. Also, a port opening (circled) is shown in FIG. 3E in the third tonnage profile. Such port opening would allow the minimum refrigerant to pass through the tubes.

FIG. 3F depicts an exemplary port opening of tube/s for a fourth tonnage profile in a heating mode, according to an exemplary embodiment of the invention. In the fourth tonnage profile, the flow diverter 110 may be at the fourth rotation position of 90° angle. Also, a port opening (circled) is shown in FIG. 3F in the fourth tonnage profile. Such port opening would allow the maximum refrigerant to pass through the tubes.

The present invention further encompasses the stepper motor 108 and/or the control circuit 120 may determine an error associated with the rotation position of the flow diverter 110. For this, the stepper motor 108 and/or the control circuit 120 may determine an incorrect rotation position of the flow diverter 110 based on a current location (or co-ordinates) of the flow diverter 110 on the holes. Further, the stepper motor 108 may communicate the incorrect rotation position of the flow diverter 110 to the control circuit 120. The control circuit 120 may verify the incorrect position of the flow diverter 110 by comparing the incorrect position to a programmed location of the flow diverter 110. In an exemplary embodiment, the programmed location of the flow diverter 110 is already preprogrammed or configured in the control circuit 120. Accordingly, the control circuit 120 may provide a command to the stepper motor 108 to rotate the flow diverter 110 to a desired location based on the comparison. This would help in error correction of the rotation position of the flow diverter 110 with respect to the programmed location of the flow diverter 110. Moreover, the logs of error correction and rotation position of the flow diverter 110 with respect to the programmed location may be captured/stored by the control circuit 120 for error control and diagnostics purpose.

Although a limited number of tonnage profiles (i.e. 4 tonnage profiles) and flow diverter rotation positions (i.e. 4 positions) have been explained herein in the specification for the cooling mode, the defrost mode or in the heating mode, however, any number and any other possible variations/alterations in the tonnage profiles and flow diverter rotation positions are within the scope of this invention. As used herein, the definition of the terms “low” and “high” in the cooling mode, the defrost mode or in the heating mode may vary from case to case and in each scenario. The choice of deciding whether a difference between a pre-defined temperature threshold (for cooling, defrost or heating) and a current temperature inside the building/home 122 is “low” and “high” resides with the control circuit 120 or any device within proximity to the system. In an exemplary embodiment, the control circuit 120 may decide that a difference between a pre-defined temperature threshold (for cooling or heating) and a temperature inside the building/home 122 is “low” when such a temperature difference lies in the range of 2° Celsius to 8° Celsius. Similarly, the control circuit 120 may decide that a difference between a pre-defined temperature threshold (for cooling, defrost or heating) and a current temperature inside the building/home 122 is “high” when such a temperature difference lies in the range of 21° Celsius to 35° Celsius. It is to be noted that the temperature ranges and the pre-defined temperature threshold (for cooling or heating) provided herein are exemplary and any other possible variations/alterations in the temperature ranges as well as the defined temperature threshold are within the scope of this invention.

FIG. 4 depicts a flowchart outlining the features of the invention in an exemplary embodiment of the invention. The method flowchart 400 describes a method for varying the refrigerant flow using a flow diverter of a reversing valve in heat pumps. The method flowchart 400 starts at step 402.

At step 404, a control circuit 120 of a system 200A or a system 300A may receive a command for operating a reversing valve 102 in a plurality of modes. The reversing valve 102 comprises a first tube 104A, a second tube 104B, a third tube 106A and a fourth tube 106B.

At step 406, the control circuit 120 of the system 200A, 300A may determine a tonnage profile for refrigerant to flow in the reversing valve 102. This has been explained in greater details in FIGS. 2A, 2B, 3A and 3B and Tables 1 and 2.

At step 408, the control circuit 120 of the system 200A or the system 300A may generate a signal based on the command and the tonnage profile and then may communicate the signal to a stepper motor 108. This has been explained in greater details in FIGS. 2A, 2B, 3A and 3B and Tables 1 and 2.

At step 410, the stepper motor 108 may rotate a flow diverter 110 of the reversing valve 102 based on the signal. The rotation of the flow diverter 110 may allow the refrigerant to flow in one of the plurality of modes. This has been explained in greater details in FIGS. 2A, 2B, 3A and 3B and Tables 1 and 2. Then, the method flowchart 400 may end at 412.

The present invention encompasses the reserving valve 102 comprising three O-Rings as shown in FIG. 5, namely, a first O-Ring, a second O-Ring and a third O-Ring. Such O-Rings may be installed on the flow diverter 110 of the reserving valve 102. Further, the reserving valve 102 may also comprise circlip/s 126 (as shown in FIG. 2B) at one of the end of the reserving valve 102 for assembling and/or disassembling of flow diverter 110 for maintenance and/or replacement purpose.

The present invention is applicable to various fields such as, but not limited to, residential homes, hospitality industry, museums, libraries, colleges, universities, hospitals, offices and any such building that is well known in the art and where the heat pump/s having the reversing valve is used.

The order of execution or performance of the operations in examples of the invention illustrated and described herein is not essential, unless otherwise specified. That is, the operations may be performed in any order, unless otherwise specified, and examples of the invention may include additional or fewer operations than those disclosed herein. For example, it is contemplated that executing or performing a particular operation before, contemporaneously with, or after another operation is within the scope of aspects of the invention.

When introducing elements of aspects of the invention or the examples thereof, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. The term “exemplary” is intended to mean “an example of” The phrase “one or more of the following: A, B, and C” means “at least one of A and/or at least one of B and/or at least one of C”.

Having described aspects of the invention in detail, it will be apparent that modifications and variations are possible without departing from the scope of aspects of the invention as defined in the appended claims. As various changes could be made in the above constructions, products, and methods without departing from the scope of aspects of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

Although the subject matter has been described in language specific to structural features and/or acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as examples of implementing the claims and other equivalent features and acts are intended to be within the scope of the claims.

SYSTEM AND METHOD FOR VARYING REFRIGERANT FLOW IN A REVERSING VALVE

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