Patent Application
20190128573
This document relates generally to heat pumps, and more specifically to vapor injection heat pumps.
Driven by direct and indirect legislations, electrification will be required for compliance in the future automotive world. For hybrid and electric vehicles, heat pump systems represent a proven solution to extend the driving range of electrified vehicles and hold significant potential in meeting the increasing demands on electrification. Compared to heating methods using high voltage positive temperature coefficient (HV-PTC) heaters or phase-change material (PCM) heat storage, for example, a heat pump system may extend the driving range by up to 30% (FTP drive cycle at −10° C.; supplier data).
Since technological advances allow many electrified vehicles to routinely travel over 200 miles without recharging, the improvement to the driving range afforded these vehicles through utilization of heat pump systems may not, alone, be sufficient to justify the use of these systems. This is particularly true given the fact that most electrified vehicles with heat pump systems are also equipped with HV-PTC heaters as a supplemental heating source in low ambient conditions (e.g., an ambient temperature below approximately a minus seven degrees Celsius (−7° C.). When combined with the required valves, controls, and expansion device(s) required to make the system operate, the overall cost of heat pump systems is greater than desired.
For plug-in hybrid electric vehicles where engine heating is available, some organizations have attempt to eliminate the need for HV-PTC heaters and the like in low ambient conditions utilizing a vapor injection heat pump. However, the vapor injection feature or mode of operation is only activated in a heating mode of operation. In order to overcome these issues, a need exists for such a vapor injection heat pump system that is capable of activation in more modes of operation than just a heating mode (e.g., a cooling mode of operation). Such a design would take full benefits of vapor injection and address degradation performance issues in both high and low ambient conditions, making it a more competitive solution for use in vehicle climate control and thermal management.
In accordance with the purposes and benefits described herein, a vapor injection heat pump is provided. The heat pump may be broadly described as comprising a compressor for compressing a refrigerant, a first valve directing at least one of a first portion of the refrigerant output by the compressor to a first heat exchanger and a second portion of the refrigerant output by the compressor to a second air-to-refrigerant heat exchanger dependent upon a mode of operation, a first expansion device receiving at least one of the first portion of the refrigerant directed through the first heat exchanger and the second portion of the refrigerant directed through the second air-to-refrigerant heat exchanger, a vapor generator receiving a liquid and vapor refrigerant mix from the first expansion device and directing a vapor component of the liquid and vapor refrigerant mix to a first input port of the compressor and a liquid component of the liquid and vapor refrigerant mix to a second valve, the second valve directing the liquid component to the second air-to-refrigerant heat exchanger or a third air-to-refrigerant heat exchanger dependent upon the mode of operation, wherein a second input of the compressor receives an output refrigerant of the at least one of the second air-to-refrigerant heat exchanger and the third air-to-refrigerant heat exchanger dependent upon the mode of operation, and a control module for controlling at least the first and second valves and the first expansion device dependent upon the mode of operation.
In another possible embodiment, the heat pump includes an accumulator receiving the refrigerant output by the second air-to-refrigerant heat exchanger or the third air-to-refrigerant heat exchanger dependent upon the mode of operation and directing the vapor component of the refrigerant output by the second air-to-refrigerant heat exchanger or the third air-to-refrigerant heat exchanger to the second input port of the compressor.
In still another possible embodiment, the first heat exchanger is an air-to-refrigerant heat exchanger.
In another possible embodiment, the first valve directs the refrigerant output by the compressor to the second air-to-refrigerant heat exchanger, and the second valve directs the liquid component of the liquid and vapor refrigerant mix to the third air-to-refrigerant heat exchanger, in a cooling mode of operation.
In yet another possible embodiment, the first valve directs the refrigerant output by the compressor to the first air-to-refrigerant heat exchanger, and the second valve directs the liquid component of the liquid and vapor refrigerant mix to the second air-to-refrigerant heat exchanger, in a heating mode of operation.
In another possible embodiment, the first valve directs the refrigerant output by the compressor to the first air-to-refrigerant heat exchanger, and the second valve directs the liquid component of the liquid and vapor refrigerant mix to the third air-to-refrigerant heat exchanger, in a reheating mode of operation.
In still yet another possible embodiment, the first valve directs the refrigerant output by the compressor to the first air-to-refrigerant heat exchanger and the second air-to-refrigerant heat exchanger, and the second valve directs the liquid component of the liquid and vapor refrigerant mix to the third air-to-refrigerant heat exchanger, in a reheating mode of operation.
In still another possible embodiment, the first valve directs the refrigerant output by the compressor to the second air-to-refrigerant heat exchanger. The control module operates the first expansion device in an open mode providing minimal refrigerant flow restriction. The vapor component of the liquid and vapor refrigerant mix received by the vapor generator is directed to the first suction port of the compressor, in a deicing mode of operation.
In another possible embodiment, the first valve and the second valve direct the refrigerant output by the compressor through the second air-to-refrigerant heat exchanger and a second expansion device, the second valve directs refrigerant output by the second expansion device through a fourth valve to the second input port of the compressor, and the control module further controls the second expansion device, in a deicing mode of operation.
In one other possible embodiment, the first heat exchanger is a refrigerant-to-coolant heat exchanger.
In another possible embodiment, the heat pump further includes a coolant loop including the refrigerant-to-coolant heat exchanger and a fourth air-to-coolant heat exchanger through which a coolant is pumped dependent upon the mode of operation.
In yet another possible embodiment, the heat pump further includes a refrigerant loop including the compressor, the first valve, the second air-to-refrigerant heat exchanger, the first expansion device, the vapor generator, the second valve, and the third air-to-refrigerant heat exchanger.
In still another possible embodiment, the first valve directs the refrigerant output by the compressor to the second air-to-refrigerant heat exchanger and the second valve directs the liquid component of the liquid and vapor refrigerant mix to the third air-to-refrigerant heat exchanger, in a cooling mode of operation.
In another possible embodiment, the first valve directs the refrigerant output by the compressor to the refrigerant-to-coolant heat exchanger, the second valve directs the liquid component of the liquid and vapor refrigerant mix to the second air-to-refrigerant heat exchanger, and the pump pumps coolant through the refrigerant-to-coolant heat exchanger and the fourth air-to-coolant heat exchanger within the coolant loop, in a heating mode of operation.
In yet still another possible embodiment, the first valve directs the refrigerant output by the compressor to the first refrigerant-to-coolant heat exchanger, the second valve directs the liquid component of the liquid and vapor refrigerant mix to the third air-to-refrigerant heat exchanger, and the pump pumps coolant through the first refrigerant-to-coolant heat exchanger and the fourth air-to-coolant heat exchanger within the coolant loop, in a reheating mode of operation.
In still another possible embodiment, the first valve directs the refrigerant output by the compressor to the first refrigerant-to-coolant heat exchanger and the second air-to-refrigerant heat exchanger, the second valve directs the liquid component of the liquid and vapor refrigerant mix to the third air-to-refrigerant heat exchanger, and the pump pumps coolant through the first refrigerant-to-coolant heat exchanger and the fourth air-to-coolant heat exchanger within the coolant loop, in a reheating mode of operation.
In one other possible embodiment, the first valve directs the refrigerant output by the compressor to the second air-to-refrigerant heat exchanger. The control module operates the first expansion device in an open mode providing minimal refrigerant flow restriction. The vapor component of the liquid and vapor refrigerant mix received by the vapor generator is directed to the first suction port of the compressor, in a deicing mode of operation.
In still another possible embodiment, the first valve and the second valve direct the refrigerant output by the compressor through the second air-to-refrigerant heat exchanger and a second expansion device, the second valve directs refrigerant output by the second expansion device through a fourth valve to the second input port of the compressor, and the control module further controls the second expansion device, in a deicing mode of operation.
In other possible embodiments, the vapor generator is a separator.
In still other possible embodiments, the vapor generator is a refrigerant-to-refrigerant heat exchanger, the refrigerant-to-refrigerant heat exchanger receiving (1) a first portion of the refrigerant output by the at least one of the first heat exchanger and the second air-to-refrigerant heat exchanger and expanded within the first expansion device to the liquid and vapor refrigerant mix and directs the vapor component of the liquid and vapor refrigerant mix to the first input port of the compressor and (2) a second portion of the refrigerant output by the at least one of the first heat exchanger and the second air-to-refrigerant heat exchanger dependent upon the mode of operation.
In accordance with another possible embodiment, a vapor injection heat pump includes a compressor for compressing a refrigerant, a first valve directing the refrigerant output by the compressor, the first valve directing the refrigerant to a first heat exchanger in a heating mode of operation and to a second air-to-refrigerant heat exchanger in a cooling mode of operation, a first expansion device receiving the refrigerant directed through the first heat exchanger in the heating mode of operation and the refrigerant directed through the second air-to-refrigerant heat exchanger in the cooling mode of operation, a vapor generator receiving a liquid and vapor refrigerant mix from the first expansion device and directing a vapor component of the liquid and vapor refrigerant mix to a first input port of the compressor and a liquid component of the liquid and vapor refrigerant mix to a second valve, the second valve directing the liquid component to the second air-to-refrigerant heat exchanger in the heating mode of operation and to a third air-to-refrigerant heat exchanger in the cooling mode of operation, wherein a second input of the compressor receives an output refrigerant of the second air-to-refrigerant heat exchanger in the heating mode of operation and the third air-to-refrigerant heat exchanger in the cooling mode of operation, and a control module for controlling at least the first and second valves and the first expansion device dependent upon the mode of operation.
In accordance with yet another possible embodiment, a vapor injection heat pump includes a compressor for compressing a refrigerant, a first valve directing the refrigerant output by the compressor to an air-to-refrigerant heat exchanger, an expansion device receiving the refrigerant directed to the air-to-refrigerant heat exchanger, a vapor generator receiving a liquid and vapor refrigerant mix from the first expansion device and directing a vapor component of the liquid and vapor refrigerant mix to a first input port of the compressor in a deicing mode of operation, and a control module for controlling the first valve and the expansion device.
In another possible embodiment, the control module operates the first expansion device in an open mode providing minimal refrigerant flow restriction. The vapor component of the liquid and vapor refrigerant mix received by the vapor generator is directed to the first suction port of the compressor, in a deicing mode of operation.
In yet another possible embodiment, the heat pump further includes second and fourth valves directing the refrigerant output by the compressor through the second air-to-refrigerant heat exchanger and a second expansion device, the second valve directs refrigerant output by the second expansion device through a fourth valve to the second input port of the compressor, and the control module further controls the second expansion device, in a deicing mode of operation.
In the following description, there are shown and described several embodiments of a vapor injection heat pump and related methods of heating and cooling a passenger compartment of a vehicle. As it should be realized, the methods and vapor injection heat pumps are capable of other, different embodiments and their several details are capable of modification in various, obvious aspects all without departing from the methods and vapor injection heat pumps as set forth and described in the following claims. Accordingly, the drawings and descriptions should be regarded as illustrative in nature and not as restrictive.
The accompanying drawing figures incorporated herein and forming a part of the specification, illustrate several aspects of the vapor injection heat pump and related methods and together with the description serve to explain certain principles thereof. In the drawing figures:
Reference will now be made in detail to the present embodiments of the vapor injection heat pump and related methods of heating and cooling a passenger compartment, examples of which are illustrated in the accompanying drawing figures, wherein like numerals are used to represent like elements.
Reference is now made to
The high temperature, high pressure vapor refrigerant leaves the compressor 16 via a discharge port as shown by action arrow 18, and flows into a valve 20. In the described embodiment, the valve 20 is a three-way valve (one input and two outputs) electrically connected to a control module 22 as shown by dashed line. The valve 20 directs the refrigerant output by the compressor 16 through a first, refrigerant-to-coolant, heat exchanger 24 and/or a second, air-to-refrigerant, heat exchanger 26 dependent upon a mode of operation via a check valve 32, to an expansion device 28 in all modes of operation except a second deicing mode wherein a vapor generator 36, described below, is bypassed. As will be described in more detail below, the second air-to-refrigerant heat exchanger 26 may function as a condenser or an evaporator depending on the mode of operation.
The expansion device 28 has three operating modes, including an open mode providing minimal flow restriction, a closed mode blocking refrigerant flow, and an intermediate open mode causing a certain degree of expansion of refrigerant flow, dependent upon the mode of operation. When operating in the expansion mode, a cooled, high-pressure refrigerant from the refrigerant-to-coolant heat exchanger 24 and/or the second air-to-refrigerant heat exchanger 26 is expanded to become an intermediate-pressure, intermediate-temperature liquid and vapor refrigerant mixture which is supplied to the vapor generator 36. A vapor generator includes any device used to generate a vapor and supply the vapor to one input port of the compressor. For example, vapor generators include a flash tank or a heat exchanger among other known devices. The vapor generator 36 directs, or injects, a vapor component of a liquid and vapor refrigerant mix to the first suction port (or intermediate-pressure input port) of the compressor 16 as shown by action arrow 38 in
The first expansion device 28 is an electronic expansion device with an adjustable opening size. However, similar functions can be achieved using a fixed orifice tube, or a thermal expansion device, combined with extra valves (not shown). When the expansion device 28 is an electronic expansion device having an opening therein through which the refrigerant passes, as in the described embodiment, regulation of the flow of refrigerant, or throttling, is used to control a temperature of the refrigerant provided to the vapor generator 36. Increasing the pressure drop necessarily lowers the temperature of the refrigerant entering the vapor refrigerant 36. The control module 22 is electrically connected to the expansion device 28 (as shown by dashed line) and operates to control a size of the opening within the expansion device 28 which determines refrigerant status moving through the device.
A liquid component of the liquid and vapor refrigerant mix exiting the vapor generator 36 is directed by a combination of a valve 40, a second expansion device 42, and a stop valve 51 to the second air-to-refrigerant heat exchanger 26, as shown by action arrow 44, or to a third air-to-refrigerant heat exchanger 46 via a third expansion device 48, as shown by action arrow 50, dependent upon the mode of operation. In the described embodiment, the valve 40 is a three-way valve (two inputs and one output) electrically connected to the control module 22 as shown by dashed line.
In all but the deicing modes of operation in the described embodiment, an accumulator 70 receives low-pressure, low-temperature, mostly vapor, refrigerant exiting either the second air-to-refrigerant heat exchanger 26, via valves 40 and 51, or the third air-to-refrigerant heat exchanger 46. The accumulator 70 functions to store excessive refrigerant and provide only vapor refrigerant to the compressor 16. In another possible embodiment, the accumulator may not be required when the second expansion device 42 and the third expansion device 48 are thermal expansion devices with calibrated superheat. In the described embodiment, the accumulator 70 provides vapor refrigerant to the second suction port (or low-pressure input port) of the compressor 16 as shown by action arrow 52. As described above, the refrigerant entering the second suction port is compressed in the low-pressure stage, combined with the refrigerant entering the first suction port, and compressed in the intermediate-pressure stage into the high-pressure, high-temperature gas refrigerant.
As further shown in
Other components connected to the control module 22, in the described embodiment, include each of the valves and expansion devices, whether or not connected to the control module by dashed lines, in the figures. While the described embodiment utilizes a single control module 22 to control the plurality of components within the vapor injection heat pump 10, any of a plurality of control modules connected to a vehicle computer via a controller area network (CAN) bus in the vehicle, as is known in the art, could be utilized to control one or more of the plurality of components of the vapor injection heat pump 10. The control module 22 is responsive to a switch (or other input means) operated by an operator of a vehicle in the described embodiment. The switch (e.g., an air conditioning on/off switch) changes a mode of operation from, for example, a cooling mode to an off mode, a heating mode, or other modes of operation.
As eluded to above, the refrigerant loop 12 interacts with the secondary or coolant loop 14 primarily through heat transfers occurring within the refrigerant-to-coolant heat exchanger 24. Within the coolant loop 14, control module 22 controls coolant flows through an air-to-coolant heat exchanger 54, a reservoir 25 (e.g., a degas tank), and the refrigerant-to-coolant heat exchanger 24 dependent upon the mode of operation of the vapor injection heat pump 10. As shown in FIG. 1, a pump 56 pumps the coolant through the coolant loop 14, as shown by action arrow 58. The control module 22 controls the pump 56 and necessarily a rate of coolant flow dependent upon the mode of operation and a desired output. It should be noted that the pump 56 may be turned off in certain modes of operation as described below.
In the described embodiment, the coolant loop 14 further includes an auxiliary coolant loop 60 for utilizing heat from at least one component or member 62 (e.g., an engine, electronics, one or more heating elements, and/or brakes, etc.). Whether coolant flow exiting the air-to-coolant heat exchanger 54 is directed through the auxiliary coolant loop 60 or not is controlled by an auxiliary loop valves 61 and 63. The valves 61 and 63 operate to bypass the auxiliary coolant loop 60 or direct the coolant flow through the auxiliary coolant loop 60 as directed by the control module 22. The utilization of an auxiliary coolant loop 60, however, is not required in all embodiments while other embodiments may utilize one or more auxiliary coolant loops.
In a cooling mode of operation, as shown in
The liquid component of the liquid and vapor refrigerant mix exiting the vapor generator 36 is directed by the valve 40 to the third air-to-refrigerant heat exchanger 46 via the third expansion device 48. In the cooling mode, the third air-to-refrigerant heat exchanger 46 functions as an evaporator as is known in the art. In the described embodiment, the third air-to-refrigerant heat exchanger 46 is positioned within a heating, ventilation, and air conditioning (HVAC) case 66 of a vehicle and used to cool or dehumidify a passenger compartment (not shown).
Warm, moist air flowing across the third air-to-refrigerant heat exchanger 46 (as shown by arrow 68) transfers its heat to the cooler refrigerant within the third air-to-refrigerant heat exchanger. The byproducts are a lowered temperature air and condensation from the air which is routed from the third air-to-refrigerant heat exchanger 46 to an exterior of the vehicle. A blower (not shown) may blow air across the third air-to-refrigerant heat exchanger 46. This process results in the passenger compartment having a cooler, drier air therein.
Within the third air-to-refrigerant heat exchanger 46, the low-pressure, low-temperature liquid and vapor refrigerant mixture boils to a vapor, or mostly vapor (with some liquid), state due to the heat removed from the air. The resulting low-pressure, low-temperature vapor refrigerant exits the third air-to-refrigerant heat exchanger 46, as shown by action arrow 72, and is received by the accumulator 70. In the described embodiment, the accumulator 70 functions to store excessive refrigerant and provide vapor refrigerant to the second suction port of the compressor 16. As described above, the accumulator 70 may not be required in other embodiments, for example when thermal expansion devices are used.
In a heating mode of operation, as shown in
The liquid component of the liquid and vapor refrigerant mix exiting the vapor generator 36, on the other hand, is directed by the valve 40 to the second air-to-refrigerant heat exchanger 26 via the second expansion device 42. In the heating mode, the second air-to-refrigerant heat exchanger 26 functions as an evaporator as is known in the art. In this instance, an intermediate-temperature, intermediate-pressure liquid refrigerant discharged from the vapor generator 36 is expanded within the second expansion device 42 to a low-temperature, low-pressure liquid refrigerant. The low-temperature, low-pressure liquid refrigerant boils to a vapor due to heat transferred from warm air flowing across the second air-to-refrigerant heat exchanger 26 to the cooler refrigerant within the second air-to-refrigerant heat exchanger. The low-pressure, low-temperature vapor refrigerant exits the second air-to-refrigerant heat exchanger 26, as shown by action arrow 76, and is directed by the valve 40 and the valve 51 to the accumulator 70, as shown by action arrow 78, to the second suction port (or low-pressure input port) of the compressor 16. The third expansion device 48 remains fully closed.
In the described heating mode, the control module 22 directs the pump 56 to pump coolant within the coolant loop 14 through the first, refrigerant-to-coolant, heat exchanger and the fourth, air-to-coolant, heat exchanger 54 which functions as a heater core. As is known in the art, the fourth air-to-coolant heat exchanger 54 is positioned within the HVAC case 66 of the vehicle and is used to warm the passenger compartment. Cold air flowing across the fourth air-to-coolant heat exchanger 54 (as shown by arrow 80) absorbs heat from the warm coolant thereby increasing the temperature of the air. The blower (not shown) blows air across the fourth air-to-coolant heat exchanger 54 and into the passenger compartment. This process results in the passenger compartment having a warmer air therein.
Within the fourth air-to-coolant heat exchanger 54, the warm coolant is cooled due to the heat given to the air and directed back to the first refrigerant-to-coolant heat exchanger 24 (as shown by action arrow 82). In the first refrigerant-to-coolant heat exchanger 24, the cooled coolant is again warmed by absorbing heat from the refrigerant in the refrigerant loop 12, and cycled through the coolant loop 14. In the heating mode of operation, an auxiliary coolant loop 60 may be utilized as a supplemental heat source to further heat the coolant in the manner described above.
As noted above, the control module 22 is electrically connected to the pump 56 and the compressor 16 and controls one or both in varying embodiments to adjust or regulate the heating capacity of the fourth air-to-coolant heat exchanger 54. Increasing the pumping rate raises the coolant flow rate in the coolant loop 14 and increasing the compressor speed raises the refrigerant flow rate in the refrigerant loop 12, thereby increasing heating capacity. The opposite is true when the pumping rate and/or the compressor speed is lowered and heating capacity is decreased.
In a dehumidification and reheat mode of operation, as shown in
The liquid component of the liquid and vapor refrigerant mix exiting the vapor generator 36, however, is directed by the valve 40, and closure of the second expansion device 42, to the third air-to-refrigerant heat exchanger 46, as shown by action arrow 45, via the third expansion device 48. In this instance, the intermediate-temperature, intermediate-pressure liquid refrigerant discharged from the vapor generator 36 is expanded within the third expansion device 48 to a low-temperature, low-pressure liquid and vapor refrigerant mixture received by the third air-to-coolant heat exchanger 46. In this mode of operation, the second air-to-refrigerant heat exchanger 26 is idle and the third air-to-refrigerant heat exchanger 46 functions as an evaporator as in the cooling mode. More specifically, the third air-to-refrigerant heat exchanger 46 is used to cool and dehumidify the moist, warm air flowing across the third air-to-refrigerant heat exchanger (shown by action arrow 84). Within the third air-to-refrigerant heat exchanger 46, the now low-pressure, low-temperature liquid and vapor refrigerant mixture boils to a vapor due to the heat removed from the air and is directed to the accumulator 70 as shown by action arrow 86.
While the third air-to-refrigerant heat exchanger 46 functions to lower the humidity of the air within the passenger compartment for the comfort of the passengers or to defog one or more of the windows/windshield within the passenger compartment, the air in the passenger compartment is also cooled through this process. In this scenario, it may be desired to re-heat or warm the air in the passenger compartment to ensure the comfort of the passengers. Accordingly, in the dehumidification and reheat mode of operation, warmed coolant within the coolant loop 14 is concurrently pumped through the air-to-coolant heat exchanger 54.
As in the heating mode, the control module 22 directs the pump 56 to pump coolant within the coolant loop 14 through the first refrigerant-to-coolant heat exchanger 24 and the fourth air-to-coolant heat exchanger 54 which functions as a heater core within the HVAC case 66 to heat the cooled, dehumidified air and supply tempered or warm air to the passenger compartment. The cold air flowing across the fourth air-to-coolant heat exchanger 54 (as shown by arrow 88) absorbs heat from the warm coolant thereby increasing the temperature of the air. This process results in the passenger compartment having a warmer air therein.
Within the fourth air-to-coolant heat exchanger 54, the warm coolant is cooled due to the heat given to the air and directed back to the first refrigerant-to-coolant heat exchanger 24 (as shown by action arrow 82). In the first refrigerant-to-coolant heat exchanger 24, the cooled coolant is again warmed by absorbing heat from the refrigerant in the refrigerant loop 12, and cycled through the coolant loop 14. In the dehumidification and reheat mode of operation, an auxiliary coolant loop 60 may be utilized as a supplemental heat source to further heat the coolant in the manner described above.
As described above, the control module 22 may be utilized to control one, or both, of the pump 56 and the compressor 16 in varying embodiments to adjust or regulate the heating capacity of the fourth air-to-coolant heat exchanger 54 and, in certain embodiments, through the auxiliary cooling loop 60. In the dehumidification and reheat mode of operation, varying one or both components may be utilized to adjust a heating capacity of the fourth air-to-coolant heat exchanger 54 allowing the temperature of air flowing into the passenger compartment to be controlled without the need for a blend door or other mechanical means as described above.
In a second reheat or defrost mode of operation, as shown in
As in the above-described heating mode, the first refrigerant-to-coolant heat exchanger 24 functions to cool the first portion of the high-pressure, high-temperature vapor refrigerant discharged from the compressor 16. The cooled, high-pressure refrigerant is sent to the expansion device 28 as shown by action arrow 92. Concurrently, the second air-to-refrigerant heat exchanger 26 functions to cool the second portion of the high-pressure, high-temperature vapor refrigerant discharged from the compressor 16 due primarily to the effect of outside air as in the above-described cooling mode. The cooled, high-pressure refrigerant is then directed through the valve 32 (shown by action arrow 94) to combine with the cooled, high-pressure refrigerant exiting the first refrigerant-to-coolant heat exchanger 24 prior to entering the first expansion device 28. Within the first expansion device 28, the recombined refrigerant is expanded to become the intermediate-pressure, intermediate-temperature liquid and vapor refrigerant mixture supplied to the vapor generator 36. As described above, the vapor component of the liquid and vapor refrigerant mix is injected into the first suction port of the compressor 16 as shown by action arrow 38.
As in the first dehumidification and reheat mode of operation, the liquid component of the liquid and vapor refrigerant mix exiting the vapor generator 36 is directed by the valve 40, and closure of the second expansion device 42, to the third air-to-refrigerant heat exchanger 46, via the third expansion device 48. Again, the intermediate-temperature, intermediate-pressure liquid refrigerant discharged from the vapor generator 36 is expanded within the third expansion device 48 to a low-temperature, low-pressure liquid and vapor refrigerant mixture received by the third air-to-refrigerant heat exchanger 46. The second air-to-refrigerant heat exchanger 26 now receives high-temperature refrigerant vapor from the compressor 16, thereby melting frost that may accumulate on the heat exchanger surface during the heating mode of operation. The third air-to-refrigerant heat exchanger 46 functions as an evaporator and is used to cool and dehumidify the moist, warm air flowing across the third air-to-refrigerant heat exchanger as shown by action arrow 96. Within the third air-to-refrigerant heat exchanger 46, the now low-pressure, low-temperature liquid and vapor refrigerant mixture boils to a vapor due to the heat removed from the air and is directed to the accumulator 70 as shown by action arrow 98.
While the third air-to-refrigerant heat exchanger 46 functions to lower the humidity of the air within the passenger compartment for the comfort of the passengers or to defog one or more of the windows/windshield within the passenger compartment, the air in the passenger compartment is also cooled through this process. Again, it may be desired to re-heat or warm the air in the passenger compartment to ensure the comfort of the passengers. Accordingly, in the second reheat or defrost mode of operation, warmed coolant within the coolant loop 14 is concurrently pumped through the fourth air-to-coolant heat exchanger 54.
As in the heating mode, the control module 22 directs the pump 56 to pump coolant within the coolant loop 14 through the first refrigerant-to-coolant heat exchanger 24 and the fourth air-to-coolant heat exchanger 54 which functions as a heater core within the HVAC case 66 to heat the cooled, dehumidified air and supply tempered or warm air to the passenger compartment. Cold air flowing across the fourth air-to-coolant heat exchanger 54 (as shown by arrow 100) absorbs heat from the warm coolant thereby increasing the temperature of the air. This process results in the passenger compartment having a warmer air therein.
Within the fourth air-to-coolant heat exchanger 54, the warm coolant is cooled due to the heat given to the air and directed back to the first refrigerant-to-coolant heat exchanger 24 (as shown by action arrow 82) where the cooled coolant is again warmed by absorbing heat from the refrigerant in the refrigerant loop 12, and cycled through the coolant loop 14. In the second reheat and defrost mode of operation, the auxiliary coolant loop 60 may be utilized as a supplemental heat source to further heat the coolant in the manner described above.
Again, the control module 22 controls the pump 56 and the compressor 16 and may be used to adjust or regulate the heating capacity of the fourth air-to-coolant heat exchanger 54 and, in certain embodiments, through the auxiliary coolant loop 60. In the second reheat and defrost mode of operation, varying one or both components may be utilized to adjust a heating capacity of the air-to-coolant heat exchanger 54 allowing the temperature of air flowing into the passenger compartment to be controlled without the need for a blend door or other mechanical means as described above.
Under certain ambient conditions, after the heat pump system operates in the heating mode for a period of time, ice or frost may build up on the first outside air-to-refrigerant heat exchanger 26, resulting in a loss or reduction in the ability of the heat pump 10 to provide heat. In such situations, the vapor injection heat pump 10 may be required to provide a deicing function. In this, a deicing mode of operation shown in
The cooled, high-pressure refrigerant is then directed through valve 32 (shown by action arrow 104) to the first expansion device 28 as shown by action arrow 106. In this deicing mode of operation, the first expansion device 28 is open such that the refrigerant is minimally or not expanded prior to entering the vapor generator 36. As described above, the vapor component of the liquid and vapor refrigerant mix is injected into the first suction port of the compressor 16 as shown by action arrow 38. In this mode of operation, the valve 40 and second expansion device 42 are closed such that the liquid component of the liquid and vapor refrigerant mix, if any, does not exit the vapor generator 36. In addition, there is no refrigerant entering the second suction port of the compressor 16 for compression in a first stage to be combined with the refrigerant entering the first suction port. Thus, the refrigerant entering the first suction port is simply compressed into a high-pressure, high-temperature gas refrigerant which is recirculated back through the system 10.
In a second deicing mode of operation, shown in
The cooled, high-pressure refrigerant is then directed, by closing the first expansion device 28, through the second expansion device 42 as shown by action arrow 110. In this second deicing mode of operation, the second expansion device 42 is open such that the refrigerant is minimally or not expanded. In other words, the cooled, high pressure refrigerant exiting the second expansion device 42 is substantially unchanged and directed by the valve 40 and the valve 51, as shown by action arrow 114, to the second suction port of the compressor 16 via the accumulator 70.
In this mode of operation, the first expansion device 28 is fully closed such that the refrigerant does not reach the vapor generator 36 and a vapor component does not exit the vapor generator 36. As a result, there is no refrigerant entering the first suction port of the compressor 16 to be combined with the refrigerant entering the second suction port for compression in a low-pressure stage. Thus, the cooled, high pressure refrigerant entering the second suction port is simply compressed into a high-pressure, high-temperature gas refrigerant which is recirculated back through the system 10.
In another embodiment of a vapor injection heat pump 116, the vapor generator 36 of the above-described vapor injection heat pump 10 is a fifth, refrigerant-to-refrigerant, heat exchanger 118. In this embodiment, the refrigerant-to-refrigerant heat exchanger 118 receives a first portion of the cooled, high-pressure refrigerant output by the at least one of the first refrigerant-to-coolant heat exchanger 24 and the second air-to-refrigerant heat exchanger 26 via a first expansion device 122 and valve 120 (shown by action arrow 126), and a second portion of the cooled, high-pressure refrigerant output by the at least one of the first refrigerant-to-coolant heat exchanger and the second air-to-refrigerant heat exchanger directly (shown by action arrow 128) in all modes of operation except the second deicing mode wherein the vapor generator 36 is bypassed. The remaining elements of the above-described vapor injection heat pump 10 are unchanged, as evidenced by use of the same reference numerals, and each of the various modes described above function in the same manner. The difference is that the first portion of the refrigerant directed through the fifth refrigerant-to-refrigerant heat exchanger 118 via the first expansion device 122 is heated up by the second portion of the refrigerant flowing directly into the refrigerant-to-refrigerant heat exchanger.
Within the refrigerant-to-refrigerant heat exchanger 118, the now intermediate-pressure, intermediate-temperature first portion of the liquid and vapor refrigerant mixture after the first expansion device 122 boils to a vapor due to the heat removed from the second portion of refrigerant passing through the refrigerant-to-refrigerant heat exchanger. The now substantially vapor refrigerant exiting the refrigerant-to-refrigerant heat exchanger 118 is injected into the first suction port of the compressor 16 as shown by action arrow 38. The second portion of the refrigerant is now a further-cooled, high-pressure liquid, or substantially liquid, refrigerant exiting the refrigerant-to-refrigerant heat exchanger 118 as shown by action arrow 130. As suggested above, the substantially liquid refrigerant is directed to one or more of the second air-to-refrigerant heat exchanger 26, the accumulator 70, and the third air-to-refrigerant heat exchanger 46, dependent upon the mode of operation.
Whether the cooled, high-pressure refrigerant passing through node 124 comes from the first refrigerant-to-coolant heat exchanger 24 in a heating or reheating mode of operation, the second air-to-refrigerant heat exchanger 26 in a cooling or deicing mode of operation, or both the first refrigerant-to-coolant heat exchanger 24 and the second air-to-refrigerant heat exchanger 26 in another reheating mode of operation, the fifth refrigerant-to-refrigerant heat exchanger 118 functions to direct a first component, including a substantially vapor refrigerant, to the first suction port of the compressor 16 and a second component, including a substantially liquid refrigerant, downstream to one or more of the second air-to-refrigerant heat exchanger 26 and/or the accumulator 70, or through the third air-to-refrigerant heat exchanger 46 dependent upon the mode of operation. As indicated above, other than the utilization of the refrigerant-to-refrigerant heat exchanger as a vapor generator, the vapor injection heat pump 116 functions the same as the above-described vapor injection heat pump 10 in all modes of operation.
The foregoing has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the embodiments to the precise form disclosed. Obvious modifications and variations are possible in light of the above teachings. For example, the valves utilized in the heat pump can be different types of valves and/or combinations of different types of valves. In the described embodiment, for example, the valves 20 and 40 are three-way valves which could be replaced in alternate embodiments by a series of one-way and/or two-way valves sufficient to direct the refrigerant flows in desired directions dependent upon the mode of operation. Again, the valves receive signals from and are controlled by the control module 22. The varying directions the valves direct the refrigerant flows are described in more detail for the various modes of operation above.
In still other embodiments, a vapor injection heat pump 132 may include a plurality of check valves. In this embodiment, the control module 22 controls each of the check valves to direct refrigerant through the refrigerant loop 12 depending upon the mode of operation. It should be noted that each check valve is in a normally closed state. In other words, absent a signal from the control module 22, the check valves will not allow refrigerant to flow through them. When a check valve is in an open state, the check valve only allows refrigerant to flow in a single, designated direction.
In this embodiment, shown in
In operation, first, second, and third check valves 32, 134, and 136 are utilized to direct the high-pressure, high-temperature refrigerant directed by valve 20 toward the second air-to-coolant heat exchanger 26, in the cooling, reheating, and deicing modes of operation, through the second air-to-refrigerant heat exchanger to the first expansion device 28. In addition, the expanded low-pressure, low-temperature refrigerant exiting the second expansion device 144 is directed by a combination of second, third, and fourth check valves 134, 136, and/or 138 through the second air-to-refrigerant heat exchanger 26 in a heating mode of operation. In the cooling and reheating modes of operation, the low-pressure, low-temperature refrigerant is directed by check valves 140 and 142 through the third air-to-refrigerant heat exchanger 46 to the compressor 16. The check valves 140 and 142 are further and similarly utilized in the heating mode of operation to direct low-pressure, low-temperature refrigerant exiting the second air-to-refrigerant heat exchanger 26 to the compressor 16. Even more, in a first deicing mode of operation, the first, second, and third check valves 32, 134, and 136 are utilized to direct the high-pressure, high-temperature refrigerant, directed by valve 20 toward the second air-to-refrigerant heat exchanger 26, through the second air-to-refrigerant heat exchanger and on to the vapor generator 36.
One additional alternate embodiment of a vapor injection heat pump 150 is shown in
In the expansion device 28, the cooled, high-pressure refrigerant from the first air-to-refrigerant heat exchanger 152 and/or the second air-to-refrigerant heat exchanger 26 is expanded in all but a first deicing mode of operation (described in detail below). More specifically, the refrigerant is expanded to become an intermediate-pressure, intermediate-temperature liquid and vapor refrigerant mixture which is supplied to a vapor generator 36. The vapor generator 36 directs, or injects, a vapor component of the liquid and vapor refrigerant mix to the first suction port (or intermediate-pressure input port) of the compressor 16 as shown by action arrow 38 in
The liquid component of the liquid and vapor refrigerant mix exiting the vapor generator 36 is directed by a combination of a valve 40, a second expansion device 42, and a stop valve 51 to the second air-to-refrigerant heat exchanger 26 via, as shown by action arrow 44, or to a third air-to-refrigerant heat exchanger 46 via a third expansion device 48, as shown by action arrow 50, dependent upon the mode of operation. In the described embodiment, the valve 40 is a three-way valve (two inputs and one output) electrically connected to the control module 22 as shown by dashed line.
In all but the deicing modes of operation in the described embodiment, an accumulator 70 receives low-pressure, low-temperature, mostly vapor, refrigerant exiting either the second air-to-refrigerant heat exchanger 26, via valves 40 and 51, or the third air-to-refrigerant heat exchanger 46. The accumulator 70 functions to store excessive refrigerant and provide only vapor refrigerant to the compressor 16. In the described embodiment, the accumulator 70 provides vapor refrigerant to the second suction port (or low-pressure input port) of the compressor 16 as shown by action arrow 52. As described above, the refrigerant entering the second suction port is compressed in the low-pressure stage, combined with the refrigerant entering the first suction port, and compressed in the intermediate-pressure stage into the high-pressure, high-temperature gas refrigerant.
As further shown in
All such modifications and variations are within the scope of the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled.
