The present invention generally relates to thermal systems and work components, and more particularly, but not exclusively, to exchanging heat between a thermal system and a heat producing device.
Using thermal systems to exchange heat with work components remains an area of interest. Some existing systems have various shortcomings relative to certain applications. Accordingly, there remains a need for further contributions in this area of technology.
One embodiment of the present invention is a unique thermal system having an embedded electrical device. Other embodiments include apparatuses, systems, devices, hardware, methods, and combinations for exchanging heat between a working fluid of a thermal system and an electrical device. Further embodiments, forms, features, aspects, benefits, and advantages of the present application shall become apparent from the description and figures provided herewith.
For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Any alterations and further modifications in the described embodiments, and any further applications of the principles of the invention as described herein are contemplated as would normally occur to one skilled in the art to which the invention relates.
With reference to
The thermal system 50 can include a working fluid that circulates between the left and right side thermal system members 52 and 54, one embodiment of which is shown in
The thermal system 50 can include a container 56 that acts as a space for the receipt of a circulating working fluid from a passage, conduit, or other like device. In one form a cross sectional area at one or more locations in the container 56 relative to a cross sectional area of the passage leading to the container 56 permits the working fluid to flow through the container 56 at a lower speed. In such a manner the container 56 can be a large space relative to the passage which permits working fluid to collect and dwell longer than in the passage.
In one or more embodiments to be discussed further below the container 56 can be in contact with an electrical device. The electrical device can take many different forms and can be embedded, either in whole or in part, within the container. In one non-limiting form the electrical device can be an electrical motor, whether a relatively low powered motor or a relatively high powered motor. In other forms the electrical device can be a generator. In still other forms the electrical device can be power and/or control electronics. In still further non-limiting forms the electrical motor can be an electrical motor and the power and/or control electronics. Further details of embodiments incorporating the container 56 and electronics will be described further below.
In at least one non-limiting embodiment described above in which the thermal system 50 is in the form of a vapor-compression cycle, one of the left and right side thermal system members 52 and 54 can be an evaporator while the other can be a condenser. Though not depicted, the embodiment can also include a compressor, pump, or other device useful to increase the density of the working fluid upstream of the condenser. The container 56 in these embodiments can be located at a number of different positions relative to the components of the thermal system 50. In one non-limiting example the container 56 is located as an accumulator downstream of an evaporator and upstream of a compressor. In another non-limiting example the container 56 is located as a receiver tank downstream of a condenser and upstream of an evaporator.
Turning now to
The thermal system 50 can be used in conjunction with an internal combustion engine 60 that is associated with the vehicle 58. In one form the internal combustion engine 60 is a gas turbine engine, but other forms are also contemplated herein. The internal combustion engine 60 can be used with the vehicle 58 to provide power, whether in the form of propulsive or non-propulsive power, or a combination of the two.
The compressor 62 can take on a variety of forms suitable for increasing a pressure of the working fluid in the thermal system 50. In one non-limiting form the compressor 62 is a hermetic compressor that includes a pressure cutout 68 intended to regulate the compressor based upon pressures in the working fluid near an inlet to the compressor and near an outlet of the compressor. Not all forms of the compressor 62 need include a pressure cutout. Other forms of the compressor 62, as well as alternative and/or additional features such as the pressure cutout 68, are contemplated herein.
The condenser 64 can include a fan 70 that acts to increase heat transfer between the working fluid in the thermal system 50 and a mass conveyed by the fan 70. In some forms the condenser 64 may not include the fan 70, including those embodiments where a passing air stream is used to cool the condenser 64. Such a passing airstream could be provided by, or diverted from, a forward motion of the thermal system 50 relative to an air mass, such as if the system 50 were mounted in a moving vehicle. The passage/conduit that conveys the working fluid through the condenser can take a variety of forms and in one non-limiting embodiment shown in the Figure includes a number of bends and/or turns to increase the residence time of the working fluid within a heat transfer area of the condenser 64. The condenser can also include a finned or pin array heat exchanger that utilizes either bypass air from a gas turbine engine or ram air to condense working fluid in the vapor state to a liquid state. The fan 70 can be powered by an electric motor but other sources of power are contemplated herein.
The evaporator 66 in the illustrated embodiment is used to change the phase of the working fluid and in so doing absorb heat from its surroundings. In one form the evaporator 66 can include a restrictor or valve 71 used to reduce a pressure of the working fluid. In one form the restrictor or valve 71 can be used to change phase of the working fluid from a liquid to a vapor. The valve 71 can also be used to regulate a flow rate of the working fluid to the evaporator 66. The valve 71 can take a variety of forms such as an expansion valve or a capillary tube to set forth just two non-limiting examples. In one embodiment the liquid working fluid can be at a relatively high pressure while the vapor working fluid can be at a relatively low temperature and pressure. The evaporator can be used to receive a relatively low pressure working fluid and, if not already converted to a vapor through action of the restrictor or valve 71, can further be used to receive heat from the surroundings and change the phase of the working fluid. In such a manner the evaporator may be considered that portion of the thermal system 50 in which the working fluid is being changed from one physical state to the other. Different types of evaporators can be used to absorb heat from the surroundings are contemplated for use with the thermal system 50.
Also depicted in
A container 56a can be located between the condenser 64 and the evaporator 66 and in the illustrated embodiment is constructed to receive a liquid phase of the working fluid from the condenser 64. The container 56a can be any configuration and have any variety of shapes and sizes. In one form the container 56a is coupled with a liquid line valve 72 which can permit substantial passage of a liquid working fluid downstream of the container 56a to the evaporator 66. In the illustrated embodiment a liquid working fluid enters and exits the container 56a near the top of the container 56a, but other locations for either or both the inlet and exit are contemplated herein.
Alternatively and/or additionally, another container 56b can be located between the evaporator 66 and the compressor 62. In the illustrated embodiment the container 56b is constructed to receive a vapor phase working fluid from the evaporator 66. The container 56b can have any configuration and have any variety of shapes and sizes. In the illustrated embodiment a liquid working fluid enters and exits the container 56b near the top of the container 56b, but other locations for either or both the inlet and exit are contemplated herein. The containers 56a and 56b can have unique configurations. In some forms, however, the containers can have similar configurations. Furthermore, any given embodiment of the thermal system 50 can have one or both of the containers 56a and 56b. In other embodiments additional containers can be used.
Though not depicted in the illustrated embodiment of the thermal system 50, a recirculation pump can be used with the condenser 64 to account for variations in attitude and/or accelerations of the thermal system 50 that can be caused by a maneuvering vehicle 58. Such a recirculation pump can be used to suction liquid from the condenser, such as from the condenser coils in those embodiments that include coils, and deliver the liquid to the container 56a.
A relatively low pressure portion of the thermal system 50 can be placed into thermal communication with a relatively high pressure portion. In the illustrated embodiment a return line to the compressor 62 can be placed into thermal communication with a supply line to the evaporator 66 near the reference numeral 74, but other portions of the thermal system 50 different than those depicted can be placed into contact with each other. Not all embodiments need include a relatively low pressure portion in thermal communication with a relatively high pressure portion.
Turning now to
In any of the various embodiments described herein, the working fluid can remain in the physical state in which it entered the container 56 (e.g., liquid, vapor) but in some forms the working fluid may change state either in whole or in part as the working fluid is conveyed through the container 56 to other components of the thermal system 50. To set forth just a few non-limiting examples, the working fluid can remain in the same state as it exchanges heat with components located within the container 56, such as but not limited to the electric motor 76, while in other forms the working fluid can change state either in whole or in part within the container 56. In some embodiments it is envisioned that the primary mechanism through which the heat producing device is cooled (i.e. the electric motor 76 of the embodiment in
The container 56 in the illustrated embodiment includes an inlet 84 disposed near the top of the container 56 and an outlet 86 disposed near the bottom. Other configurations are also contemplated herein. The container 56 shown in
The container 56 can be any volume in the thermal system 50 in which working fluid can be used to transfer heat with the heat producing device, such as the electric motor 76. Though the embodiment of the container 56 is shown having a relatively distinct inlet 84, not all embodiments need have an opening into the volume that is as distinct. For example, the volume that is the container 56 can be a portion of the thermal system 50 in which a gradually widening of the passage occurs that leads to a portion containing the heat producing device. In this way the opening could be considered to be a location or area in proximity to the gradual widening of the passage, or it could be the transition from the gradual widening to the transition between it and the portion containing the heat producing device. In short, the opening can be a structure, or portion of the structure apart from a nominal passage for the working fluid as it flows between components. The exit of the container 56 can have similar characteristics as the opening.
One or more power conduits can be coupled between the power electronics 87 and the motor 76, though in some embodiments the power electronics 87 and motor 76 need not necessarily be coupled. Furthermore, one or more power conduits can be routed between either or both the motor 76 and the power electronics 87 and a device located external of the container 56. To set forth just a few non-limiting examples, an electrical conduit can be routed between a location external the container 56 and the power electronics 87, as well as another between the power electronics 87 and the motor 76. In another example a power conduit can be routed between a location external the container 56 and the motor 76, and another conduit between the motor 76 and the power electronics 87. In some forms the power electronics 87 can provide power to an electrically driven device located outside of the thermal system 50, while in other forms the power electronics 87 can provide power to the electrical device 76. Such a device external of the thermal system 50 driven by the motor 76 can be associated with the vehicle 58, such as, but not limited to, being carried by the vehicle 58.
The power conduits that couple the power electronics 87 and electrical motor 76, as well as any other device, can take the form of a conductive material and can be configured to carry a variety of electrical loads. Not all power conduits need be the same in any of configuration, size, material, etc. In some forms one or more portions of a power electronics 87 package associated with the electric motor 76 can be located outside of the container 56. In some forms the entire power electronics 87 can be found outside of the container 56 while the electric motor 76 is located within the container 56, among other possibilities.
One aspect of the present application includes an apparatus comprising a thermal system capable of transferring heat between a relatively warm region and a relatively cool region via passage of a working fluid, the thermal system structured to change the physical state of the working fluid, and a power electronics package disposed within the thermal system, wherein the power electronics package is in thermal communication with a substantially static physical state of the working fluid such that heat generated by the power electronics package can be dissipated with the working fluid.
A feature of the present application includes wherein the power electronics package is located in a portion of the thermal system where the working fluid is in a liquid state, and wherein the power electronics package includes passive components and a bus structure coupling the passive components.
Another feature of the present application further includes an electric motor coupled with the power electronics package, wherein the electric motor and the power electronics package are cooled by the working fluid of the thermal system, and wherein the power electronics package includes switching components.
Yet another feature of the present application includes wherein the electric motor is surrounded by working fluid one at least one side.
Still another feature of the present application includes wherein the thermal system is a refrigeration system having a condenser and evaporator, wherein the power electronics package is located in a low pressure side of the thermal system downstream of the evaporator, and wherein the power electronics package includes multiple components in electrical communication.
Yet still another feature of the present application includes wherein the power electronics package includes a laminated bus structure, and which further includes an electric motor disposed within the refrigeration system, a rotor of the electric motor separated from the working fluid by a wall.
Still yet another feature of the present application includes wherein a stator of the electric motor is immersed in the working fluid, and wherein the power electronics package includes a switching component and a controller.
Another aspect of the present application includes an apparatus comprising a refrigeration system having a working fluid that flows through a compressor, evaporator, and condenser, the evaporator configured to change state of the working fluid, a volume apart from the evaporator within the refrigeration system operable to receive the working fluid, and a power electronics device disposed within the volume wherein the refrigeration system working fluid is used to transfer heat with the power electronics device.
A feature of the present application includes wherein power electronic device includes a portion that is exposed to the working fluid.
Another feature of the present application includes wherein the power electronics device includes components coupled by an electrical bus, the working fluid substantially remaining in-state when exchanging heat with the power electronics device.
Still another feature of the present application includes wherein the electrical bus is part of a laminated bus structure, a first component of the components coupled to a first conductive layer and a second component of the components coupled to a second conductive layer.
Yet another feature of the present application includes wherein components of the power electronics device are exposed to the working fluid.
Still yet another feature of the present application includes wherein the power electronics device is coupled with an electrical device disposed within the volume, and wherein the working fluid remains in a single state while exchanging heat with the power electronics device.
A further feature of the present application includes wherein the electrical device is in a form of an electrical motor having a rotor and a stator, the stator in contact with the working fluid.
Yet a further feature of the present application includes wherein a power conduit is coupled between the power electronics device and an electrical device located external of the refrigeration system.
Yet another aspect of the present application includes a method comprising circulating a working fluid between a relatively high pressure side of a refrigeration system and a relatively low pressure side of a refrigeration system, routing an electrical power to a power electronics device disposed within a volume of the refrigeration system having the working fluid, and transferring heat between the power electronics device and the working fluid.
A feature of the present application further includes evaporating the working fluid in an evaporator of the refrigeration system.
Another feature of the present application includes wherein the evaporating occurs in a separate portion of the refrigeration system from the transferring heat between the power electronics device and the working fluid.
Still another feature of the present application includes wherein the working fluid substantially remains in a single physical state during the transferring heat between the power electronics device and the working fluid.
Yet still another feature of the present application further includes conveying an electrical current in a laminated bus of the power electronics device.
Still yet another feature of the present application further includes routing electrical power from the power electronics device, and which further includes powering an electrical motor.
A further feature of the present application further includes conveying heat between the electrical motor and the working fluid.
Yet a further feature of the present application includes wherein the conveying heat includes wetting a stator of the electrical motor with working fluid.
While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiments have been shown and described and that all changes and modifications that come within the spirit of the inventions are desired to be protected. It should be understood that while the use of words such as preferable, preferably, preferred or more preferred utilized in the description above indicate that the feature so described may be more desirable, it nonetheless may not be necessary and embodiments lacking the same may be contemplated as within the scope of the invention, the scope being defined by the claims that follow. In reading the claims, it is intended that when words such as “a,” “an,” “at least one,” or “at least one portion” are used there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim. When the language “at least a portion” and/or “a portion” is used the item can include a portion and/or the entire item unless specifically stated to the contrary.
The present application claims the benefit of U.S. Provisional Patent Application No. 61/477,199, filed Apr. 20, 2011, which is incorporated herein by reference.
Number | Date | Country | |
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61477199 | Apr 2011 | US |