INTEGRATED REFRIGERANT CHARGE COLLECTOR FOR HEAT PUMPS

An integrated refrigerant charge collector for a heat pump system is provided. The charge collector includes an elongated housing, and a divider plate disposed within the elongated housing to define an accumulator compartment and a receiver compartment. A horizontal plane of the divider plate is perpendicular to a longitudinal axis of the elongated housing. The accumulator compartment is in fluid communication with a reversing valve and a compressor of the heat pump system, and allows a desired flow of a refrigerant charge into the compressor during a heating mode and a cooling mode. The receiver compartment is in fluid communication with an indoor coil and an outdoor coil of the heat pump system, and extracts a liquid refrigerant from a circuit of the heat pump system during the heating mode, and adds the liquid refrigerant to the circuit during the cooling mode.

TECHNICAL FIELD

The present disclosure relates, in general, to heat pumps and, more specifically, relates to an integrated refrigerant charge collector for heat pump systems.

BACKGROUND

Generally, air conditioning systems are used for conditioning air within a closed space, and such air conditioning systems are designed and developed to heat or cool the air within the closed space more efficiently. In an example, an air conditioning system may be a heat pump for heating or cooling the closed space. As heat pumps are widely used nowadays, matching system volume ratio is critical to improve operational efficiency in both heating and cooling modes. Typically, heat exchangers define the majority of volume in the system and to make the operational performance of the heat exchangers more efficient, smaller diameter tubes and louvered fins are designed and developed to improve boiling and condensing performance.

However, such smaller diameter tubes and louvered fins make design of the system volume ratio complex and cumbersome. Utilizing smaller diameter tubes for better heat exchanger efficiency reduces an amount of liquid refrigerant that a heat exchanger can actually hold, and therefore causes higher system pressure in the opposite mode of operation. In an example, if the system is charged optimally for cooling mode with a heat exchanger having tubes with larger diameter, then the system will be severely overcharged in heating mode. Therefore, there is a need remains to develop a heat pump system that is cost effective and can operate more efficiently in both the heating and cooling modes.

SUMMARY

According to one aspect of the present disclosure, an integrated refrigerant charge collector for a heat pump system is disclosed. The integrated refrigerant charge collector includes an elongated housing defining a longitudinal axis, and a divider plate disposed within the elongated housing. The divider plate is configured to define an accumulator compartment and a receiver compartment within the elongated housing. A horizontal plane of the divider plate is perpendicular to the longitudinal axis of the elongated housing. The accumulator compartment is in fluid communication with a reversing valve and a compressor of the heat pump system. The accumulator compartment is configured to allow a desired flow of a refrigerant charge into the compressor during a heating mode and a cooling mode of the heat pump system. The receiver compartment is in fluid communication with an indoor coil and an outdoor coil of the heat pump system. The receiver compartment is configured to (i) extract a liquid refrigerant from a circuit of the heat pump system during the heating mode, and (ii) add the liquid refrigerant to the circuit of the heat pump system during the cooling mode.

In some embodiments, the accumulator compartment includes an inlet configured to fluidly communicate with the outdoor coil, an outlet configured to fluidly communicate with the compressor, and a J-tube having a top end configured to couple with the outlet and a bottom end configured to receive a refrigerant charge therethrough.

In some embodiments, the accumulator compartment includes a top end plate at a top end of the elongated housing, and a first side wall extending from a periphery of the top end plate. The divider plate, the top end plate, and the first side wall together define an accumulator volume to receive the refrigerant charge therein.

In some embodiments, the inlet and the outlet are defined in the top end plate and spaced apart from each other.

In some embodiments, the receiver compartment comprises a first port configured to fluidly communicate with the indoor coil and a second port configured to fluidly communicate with the outdoor coil.

In some embodiments, the receiver compartment includes a bottom end plate at a bottom end of the elongated housing, and a second side wall extending from a periphery of the bottom end plate. The divider plate, the bottom end plate, and the second side wall together define a receiver volume to receive the liquid refrigerant therein.

In some embodiments, the first port and the second port are defined in the second side wall, and are proximate a top edge and a bottom edge of the receiver compartment, respectively.

In some embodiments, the divider plate includes a top surface defining the accumulator compartment and a bottom surface defining the receiver compartment.

In some embodiments, the divider plate includes one or more protrusions extending downward from the bottom surface thereof.

In some embodiments, the divider plate is made of a metal or a metal alloy.

In some embodiments, an outer diameter of the elongated housing is in a range of 4 to 6 inches.

In some embodiments, a length of the elongated housing is in a range of 8 to 18 inches.

In some embodiments, the divider plate is located at a distance of 30% to 35% of the length of the elongated housing from a bottom end thereof.

In another aspect of the present disclosure, a heat pump system is disclosed. The heat pump system includes an indoor coil configured to condition air in a closed space, an outdoor coil configured to exchange heat with ambient air, a compressor in fluid communication with the indoor coil and the outdoor coil, and a reversing valve in fluid communication with the indoor coil, the outdoor coil, and the compressor. The reversing valve is configured to switch operation of the heat pump system between a heating mode and a cooling mode. The heat pump system further includes an integrated refrigerant charge collector in fluid communication with the indoor coil, the outdoor coil, the compressor, and the reversing valve. The integrated refrigerant charge collector is configured to (i) extract a liquid refrigerant from a circuit of the heat pump system during the heating mode, (ii) add the liquid refrigerant to the circuit during the cooling mode, and (iii) allow desired flow of a refrigerant charge into the compressor during the heating mode and the cooling mode. The integrated refrigerant charge collector includes an elongated housing, and a divider plate disposed within the elongated housing. The divider plate is configured to define an accumulator compartment and a receiver compartment. The accumulator compartment is in fluid communication with the reversing valve and the compressor, and the receiver compartment is in fluid communication with the indoor coil and the outdoor coil.

In some embodiments, the accumulator compartment includes a top end plate at a top end of the elongated housing, and a first side wall extending vertically downward from a periphery of the top end plate. The divider plate, the top end plate, and the first side wall together define an accumulator volume to receive the refrigerant charge therein.

In some embodiments, the accumulator compartment includes an inlet defined in the top end plate and configured to fluidly communicate with the reversing valve, an outlet defined in the top end plate and configured to fluidly communicate with the compressor, and a J-tube having a top end configured to couple with the outlet and a bottom end configured to receive the refrigerant charge therethrough.

In some embodiments, the receiver compartment includes a bottom end plate at a bottom end of the elongated housing, and a second side wall extending vertically upward from a periphery of the bottom end plate. The divider plate, the bottom end plate, and the second side wall together define a receiver volume to receive the liquid refrigerant therein.

In some embodiments, the receiver compartment includes a first port defined in the second side wall and configured to fluidly communicate with the indoor coil, and a second port defined in the second side wall and configured to fluidly communicate with the outdoor coil.

In some embodiments, the divider plate includes a top surface defining the accumulator compartment, a bottom surface defining the receiver compartment, and one or more protrusions extending downward from the bottom surface of the divider plate.

These and other aspects and features of non-limiting embodiments of the present disclosure will become apparent to those skilled in the art upon review of the following description of specific non-limiting embodiments of the disclosure in conjunction with the accompanying drawings.

DETAILED DESCRIPTION

Reference will now be made in detail to specific embodiments or features, examples of which are illustrated in the accompanying drawings. Wherever possible, corresponding or similar reference numbers will be used throughout the drawings to refer to the same or corresponding parts. Moreover, references to various elements described herein, are made collectively or individually when there may be more than one element of the same type. However, such references are merely exemplary in nature. It may be noted that any reference to elements in the singular may also be construed to relate to the plural and vice-versa without limiting the scope of the disclosure to the exact number or type of such elements unless set forth explicitly in the appended claims.

Although various aspects of the disclosed technology are explained in detail herein, it is to be understood that other aspects of the disclosed technology are contemplated. Accordingly, it is not intended that the disclosed technology is limited in its scope to the details of construction and arrangement of components expressly set forth in the following description or illustrated in the drawings. The disclosed technology can be implemented and practiced or carried out in various ways. Accordingly, when the present disclosure is described as a particular example or in a particular context, it will be understood that other implementations can take the place of those referred to.

It should also be noted that, as used in the specification and the appended claims, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. References to a composition containing “a” constituent is intended to include other constituents in addition to the one named.

Also, in describing the disclosed technology, terminology will be resorted to for the sake of clarity. It is intended that each term contemplates its broadest meaning as understood by those skilled in the art and includes all technical equivalents which operate in a similar manner to accomplish a similar purpose.

Ranges may be expressed herein as from “about” or “approximately” or “substantially” one particular value and/or to “about” or “approximately” or “substantially” another particular value. When such a range is expressed, the disclosed technology can include from the one particular value and/or to the other particular value. Further, ranges described as being between a first value and a second value are inclusive of the first and second values. Likewise, ranges described as being from a first value and to a second value are inclusive of the first and second values.

It is also to be understood that the mention of one or more method steps does not preclude the presence of additional method steps or intervening method steps between those steps expressly identified. Moreover, although the term “step” can be used herein to connote different aspects of methods employed, the term should not be interpreted as implying any particular order among or between various steps herein disclosed unless and except when the order of individual steps is explicitly required. Further, the disclosed technology does not necessarily require all steps included in the methods and processes described herein. That is, the disclosed technology includes methods that omit one or more steps expressly discussed with respect to the methods described herein.

The components described hereinafter as making up various elements of the disclosed technology are intended to be illustrative and not restrictive. Many suitable components that would perform the same or similar functions as the components described herein are intended to be embraced within the scope of the disclosed technology. Such other components not described herein can include, but are not limited to, similar components that are developed after development of the presently disclosed subject matter.

Referring toFIG.1, a schematic block diagram of a heat pump system100is illustrated, according to an embodiment of the present disclosure. The heat pump system100includes an indoor coil102configured to condition air in a closed space. The closed space may be defined as a room which is closed to maintain a desired room temperature. The indoor coil102may be otherwise known as an indoor heat exchanger placed inside the closed space to extract heat from or add heat to air contained within the closed space using a refrigerant. The heat pump system100further includes an outdoor coil104configured to exchange heat with ambient air. The outdoor coil104may be otherwise known as an outdoor heat exchanger placed outside the closed space to extract heat from or release heat to the ambient air. The heat pump system100further includes a compressor106in fluid communication with the indoor coil102and the outdoor coil104. The compressor106is fluidly coupled with the indoor coil102and the outdoor coil104using fluid conduits to allow flow of the refrigerant therethrough. The compressor106is configured to receive a low pressure refrigerant through an inlet port106A and discharge a high pressure and high temperature refrigerant through an outlet port106B.

The heat pump system100further includes a reversing valve108in fluid communication with the indoor coil102, the outdoor coil104, and the compressor106. The reversing valve108is configured to switch operation of the heat pump system100between a heating mode and a cooling mode. As such, the indoor coil102, the outdoor coil104, the compressor106, and the reversing valve108along with the fluid conduits together constitute a circuit110to form a closed loop system to cyclically operate the heat pump system100. In the heating mode and the cooling mode of the heat pump system100, the inlet port106A of the compressor106is configured to fluidly communicate with the outdoor coil104and the indoor coil102, respectively, and the outlet port106B is configured to fluidly communicate with the reversing valve108. As such, during the heating mode and the cooling mode, a high pressure high temperature refrigerant flows through the indoor coil102and the outdoor coil104, respectively, through the outlet port106B. The heating mode of the heat pump system100is shown inFIG.1, and the reversing valve108is configured to be in a heating mode position during the heating mode. In the heating mode, the high pressure high temperature refrigerant flows through the indoor coil102to exchange heat energy with the air contained in the closed space.

The heat pump system100further includes an integrated refrigerant charge collector112, hereinafter alternatively referred to as the “charge collector112,” in fluid communication with the indoor coil102, the outdoor coil104, the compressor106, and the reversing valve108. The charge collector112is configured to (i) extract a liquid refrigerant from the circuit110of the heat pump system100during the heating mode, (ii) add the liquid refrigerant to the circuit110during the cooling mode, and (iii) allow desired flow of the refrigerant charge into the compressor106during the heating mode and the cooling mode. The charge collector112includes an elongated housing114and a divider plate116disposed within the elongated housing114. The divider plate116is configured to define an accumulator compartment118and a receiver compartment120within the elongated housing114. The accumulator compartment118is in fluid communication with the reversing valve108and the compressor106. Particularly, during the heating mode and the cooling mode, the accumulator compartment118is configured to fluidly communicate with the outdoor coil104and the indoor coil102, respectively, though the reversing valve108, and the receiver compartment120is in fluid communication with the indoor coil102and the outdoor coil104.

Referring toFIG.2, a schematic side view of the charge collector112is illustrated, according to an embodiment of the present disclosure. The charge collector112includes the elongated housing114defining a longitudinal axis ‘A’. The elongated housing114has a top end114A and a bottom end114B defining a length1′ therebetween. In some embodiments, the length ‘L’ of the elongated housing114is in a range of 8 to 18 inches. The elongated housing114includes a wall202defining a cylindrical or other suitable shape having an outer diameter or dimension ‘D’. In some embodiments, the outer diameter or dimension ‘D’ of the elongated housing114is in a range of 4 to 6 inches. The charge collector112further includes the divider plate116disposed within the elongated housing114. The divider plate116is configured to define the accumulator compartment118and the receiver compartment120within the elongated housing114. The divider plate116is disposed within the elongated housing114such that a horizontal plane of the divider plate116is perpendicular to the longitudinal axis ‘A’ of the elongated housing114.

The accumulator compartment118includes a top end plate204disposed at the top end114A of the elongated housing114and a first side wall202A extending from a periphery of the top end plate204. Particularly, the first side wall202A extends vertically downward from the periphery of the top end plate204. The first side wall202A is otherwise referred to as a portion of the wall202of the elongated housing114. Thus, the divider plate116, the top end plate204, and the first side wall202A together define an accumulator volume to receive the refrigerant charge therein. The accumulator compartment118further includes an inlet206defined in the top end plate204and configured to fluidly communicate with the reversing valve108. The accumulator compartment118further includes an outlet208defined in the top end plate204and configured to fluidly communicate with the compressor106. The inlet206and the outlet208of the accumulator compartment118are defined in the top end plate204such that they are spaced apart from each other. The accumulator compartment118further includes a J-tube210having a top end210A configured to couple with the outlet208and a bottom end210B configured to receive the refrigerant charge therethrough.

The receiver compartment120includes a bottom end plate214disposed at the bottom end114B of the elongated housing114and a second side wall202B extending from a periphery of the bottom end plate214. Particularly, the second side wall202B extends vertically upward from the periphery of the bottom end plate214. The second side wall202B is otherwise referred to as a remaining portion of the wall202of the elongated housing114. As such, the first side wall202A and the second side wall202B together constitute the wall202of the elongated housing114. The divider plate116, the bottom end plate214, and the second side wall202B together define a receiver volume to receive the liquid refrigerant therein. The receiver compartment120further includes a first port216configured to fluidly communicate with the indoor coil102and a second port218configured to fluidly communicate with the outdoor coil104. In some embodiments, the first port216and the second port218are defined in the second side wall202B, and are proximate a top edge120A and a bottom edge120B, respectively, of the receiver compartment120. In certain embodiments, the top edge120A and the bottom edge120B of the receiver compartment120defines a length therebetween which is 30% to 35% of the length ‘L’ of the elongated housing114. As such, the divider plate116may be located at a distance of 30% to 35% of the length ‘L’ of the elongated housing114from the bottom end114B thereof.

The divider plate116includes a top surface116A defining the accumulator compartment118and a bottom surface116B defining the receiver compartment120. In some embodiments, the divider plate116is made of a metal or a metal alloy. In some embodiments, the divider plate116includes one or more protrusions (not shown) extending downward from the bottom surface116B thereof. Particularly, the one or more protrusions extend vertically downward from the bottom surface116B of the divider plate116such that heat from vapor gas may conduct through the protrusions to make the divider plate116cold. That is, cold gas may conduct through the protrusions to make the divider plate cold. Beneficially, the divider plate being cold may encourage attraction of refrigerant to the surface thereof and the liquid may collect there. In some embodiments, the one or more protrusions may be individual components separately attached to the bottom surface116B of the divider plate116. In some embodiments, the one or more protrusions may be formed integral to the divider plate116.

During the heating mode of the heat pump system100, referring toFIG.1andFIG.2, the reversing valve108is in the heating mode position such that the high pressure high temperature refrigerant (represented by solid arrow lines inFIG.1) from the compressor106flows through the indoor coil102to exchange heat energy with the air contained in the closed space. The accumulator compartment118is in fluid communication with the outdoor coil104and the compressor106of the heat pump system100. Particularly, the inlet206of the accumulator compartment118is fluidly coupled to the outdoor coil104though the reversing valve108and the outlet208is fluidly coupled to the compressor106. The receiver compartment120is in fluid communication with the indoor coil102and the outdoor coil104of the heat pump system100. Particularly, the indoor coil102is fluidly coupled to the first port216of the receiver compartment120to allow the high pressure high temperature refrigerant to flow therethrough. The second port218of the receiver compartment120is fluidly coupled to the outdoor coil104via a first expansion valve220A such that the high pressure high temperature refrigerant flows from the indoor coil102to the first expansion valve220A through the receiver compartment120. The receiver compartment120is configured to extract the liquid refrigerant from the circuit110of the heat pump system100during the heating mode. At the first expansion valve220A, the high pressure high temperature refrigerant expands to become low pressure low temperature refrigerant (represented by dotted arrow lines inFIG.1) and flows through the outdoor coil104and to the accumulator compartment118of the charge collector112via the reversing valve108. The accumulator compartment118is configured to allow the desired flow of the refrigerant charge into the compressor106during the heating mode of the heat pump system100.

During the cooling mode of the heat pump system100, referring toFIG.2andFIG.3, the reversing valve108is configured to be in a cooling mode position such that the high pressure high temperature refrigerant (represented by solid arrow lines) from the compressor106flows through the outdoor coil104via the reversing valve108to exchange heat energy with the ambient air. The accumulator compartment118of the charge collector112is in fluid communication with the indoor coil102and the compressor106of the heat pump system100. Particularly, the inlet206of the accumulator compartment118is fluidly coupled to the indoor coil102via the reversing valve108and the outlet208is fluidly coupled to the compressor106. The receiver compartment120is in fluid communication with the indoor coil102and the outdoor coil104of the heat pump system100. Particularly, the outdoor coil104is fluidly coupled to the second port218of the receiver compartment120to allow flow of the high pressure high temperature refrigerant to flow therethrough. The first port216of the receiver compartment120is fluidly coupled to the indoor coil102via a second expansion valve220B such that the high pressure high temperature refrigerant flows from the outdoor coil104to the second expansion valve220B through the receiver compartment120. The receiver compartment120is configured to add the liquid refrigerant to the circuit110of the heat pump system100during the cooling mode. At the second expansion valve220B, the high pressure high temperature refrigerant expands to become low pressure low temperature refrigerant (represented by dotted arrow lines inFIG.3) and flows through the indoor coil102and to the accumulator compartment118of the charge collector112via the reversing valve108. The accumulator compartment118is configured to allow the desired flow of the refrigerant charge into the compressor106during the cooling mode of the heat pump system100. In some embodiments, the high pressure high temperature refrigerant coming through the outdoor coil104may be bypassed from entering into the receiver compartment120using a bypass conduit222to communicate with the second expansion valve220B. In such a case, a check valve may be disposed in the bypass conduit222.

The present disclosure relates to the heat pump system100having the integrated refrigerant charge collector112to facilitate operation of the heat pump system100more efficiently during both the heating mode and the cooling mode. Typically, the indoor coil102is made smaller than the outdoor coil104in terms of volume by reducing diameter of tubes to operate the heat pump more efficiently. However, such design of the heat pump leads to a mismatch in the volume ratio. Therefore, the integrated refrigerant charge collector112further improves the operational efficiency of the heat pump system100during the heating and cooling modes. By making the accumulator compartment118and the receiver compartment120into a single unit, such as the integrated refrigerant charge collector112, the design and development of the heat pump system100become more cost effective. Further, the receiver volume of the receiver compartment120can be increased based on the application of the heat pump system100as the receiver compartment120is defined at bottom of the accumulator compartment118. Since the second port218of the receiver compartment120is defined proximate the bottom edge120B thereof, the collected liquid refrigerant along with the oil may entirely flow through the second port218.