Patent Description:
Heating and overheating are serious issues for electronics. In general, as electronics heat up, leakage currents increase, thermal noise increases, dopants may migrate, and/or the crystalline structure of Silicon components may break down. This can lead to malfunctioning components or a complete device failure. In addition, electronics at higher temperatures tend to require more power to operate.

This problem particularly acute in vehicle electronics systems, particularly those in or near the engine compartment, which tend to be exposed to high temperatures. Thus, cooling for these electronics is of particular importance.

Another problem in vehicle systems relates to the air conditioning system. Most vehicle air conditioning systems function by converting a refrigerant between vapor and liquid forms using a compressor. However, as the refrigerant is typically circulated around a closed-circuit loop, it is possible that liquid refrigerant can enter, and damage, the compressor. Therefore, an accumulator, or other liquid-gas separator device, is sometimes used to store or accumulate liquid refrigerant and prevent it from entering the compressor. By doing so, the accumulator helps prevent liquid refrigerant from entering the compressor. Over time, however, too much liquid refrigerant may accumulate in the liquid-gas separator device.

This for example is also addressed in <CIT> disclosing a refrigeration system having a compressor, a condenser, an evaporator, an accumulator, and electronics for controlling the compressor. The accumulator collects gaseous and liquid refrigerant passing from the evaporator to the compressor. The electronics are mounted to the accumulator to transfer heat from the electronics to the refrigerant located within the accumulator to cool the electronics.

Accordingly, there is a need for systems and/or devices with more efficient, compact, and cost-effective methods for cooling electronics and/or improving evaporation rates in an air-conditioning system. Such systems, devices, and methods optionally complement or replace conventional systems, devices, and methods for cooling electronics and/or improving evaporation rates in an air-conditioning system.

The invention is a refrigerant system with the features of claim <NUM> and a method of transferring heat to a refrigerant in accordance with claim <NUM>. (A1) Implementations include a refrigerant system comprising: a liquid-gas separator device including: (<NUM>) a refrigeration section configured to couple to a refrigeration loop, the refrigeration section comprising: (a) a refrigerant inlet configured to receive refrigerant from the refrigeration loop; (b) a refrigerant outlet configured to release vapor refrigerant to the refrigeration loop; and (c) a cavity coupled to the refrigerant inlet and the refrigerant outlet, the cavity configured to separate liquid refrigerant from vapor refrigerant; and (<NUM>) an electronics board thermally coupled to the refrigeration section, such that in use, heat from the electronics board is transferred to the refrigerant.

(A2) In some of the implementations above, the system further includes a compressor coupled downstream to the refrigerant outlet of the liquid-gas separator device, the compressor configured to compress refrigerant released by the liquid-gas separator device.

(A3) In some of the implementations above, the system further includes an evaporator coupled upstream to the refrigerant inlet of the liquid-gas separator device, the evaporator configured to evaporate refrigerant.

(A4) In some of the implementations above, the system further includes a condenser coupled upstream to the evaporator and downstream to the compressor, the condenser configured to condense refrigerant that has been compressed by the compressor.

(A5) In some of the implementations above, the electronics board is thermally coupled to the refrigeration section, such that in use, the heat transferred to the refrigerant converts at least a portion of the refrigerant from liquid refrigerant to vapor refrigerant.

(A6) In some of the implementations above, the electronics board is thermally coupled to the refrigeration section, such that in use, the heat transferred from the electronics boards cools electrical components on the electronics board.

(A7) In some of the implementations above, the liquid-gas separator device further includes compressor controller electronics mounted on the electronics board.

(A8) In some of the implementations above, the liquid-gas separator device further includes, mounted on the electronics board, at least one of: (a) a direct current (DC) to DC converter; (b) an alternating current (AC) to AC converter; (c) a DC to AC converter; (d) an AC to DC converter; (e) a power converter component; and (f) a transformer.

(A9) In some of the implementations above, the liquid-gas separator device further includes one or more additional electronics boards thermally coupled to the refrigeration section, such that in use heat from the one or more additional electronics boards is transferred to the refrigerant.

(A10) In some of the implementations above, the liquid-gas separator device further includes a liquid-vapor separator within the cavity, the liquid-vapor separator coupled to the refrigerant outlet and configured to impede the liquid refrigerant from being released via the refrigerant outlet.

(A11) In some of the implementations above, the liquid-vapor separator is configured to utilize gravity to prevent the liquid refrigerant from being released via the refrigerant outlet.

(A12) In some of the implementations above, the liquid-gas separator device includes connectors to mount to an inside of a vehicle engine compartment.

(A13) In some of the implementations above: (<NUM>) the liquid-gas separator device further includes one or more fasteners configured to secure the electronics board to the refrigeration section; and (<NUM>) the electronics board is thermally coupled to the first cavity via the one or more fasteners.

(A14) In some of the implementations above, the electronics board is thermally coupled to the first cavity via a thermal material.

(A15) In some of the implementations above, the refrigeration section is configured to withstand pressure exerted by refrigerant within the cavity.

(A16) In some of the implementations above, the liquid-gas separator device further includes a second refrigerant outlet distinct from the refrigerant outlet, the second refrigerant outlet configured to release liquid refrigerant from the cavity.

According to the invention, the refrigerant inlet and the refrigerant outlet are positioned on a first side of the liquid-gas separator device; and (<NUM>) the cavity includes: (a) an inlet sub-cavity coupled to the refrigerant inlet; (b) an outlet sub-cavity coupled to the refrigerant outlet, the outlet sub-cavity distinct from the inlet sub-cavity; and (c) a cap fluidly coupling the inlet sub-cavity to the outlet sub-cavity, the cap positioned on a second side of the liquid-gas separator device, opposite the first side.

(A18) In some of the implementations above, the cavity is formed from an extruded metal.

In another aspect, some implementations include a method of transferring heat to a refrigerant. The method includes: (<NUM>) receiving the refrigerant via a refrigerant inlet of a liquid-gas separator device; (<NUM>) separating, within a refrigerant cavity of the liquid-gas separator device, vapor refrigerant from liquid refrigerant; (<NUM>) operating one or more electronic components thermally coupled to the liquid-gas separator device, whereby the one or more electronic components generate heat during operation; (<NUM>) transferring the heat generated by the one or more electronic components to the refrigerant; and (<NUM>) releasing a substantially vapor refrigerant via a refrigerant outlet of the liquid-gas separator device. In some instances, transferring the heat generated by the one or more electronic components to the refrigerant converts at least a portion of the refrigerant from liquid refrigerant to vapor refrigerant. In some instances, transferring the heat generated by the one or more electronic components to the refrigerant cools the one or more electronic components.

Thus, devices and systems are provided with methods for cooling electronics and/or improving evaporation rates in an air-conditioning system, thereby increasing the effectiveness, efficiency, and user satisfaction with such systems. Such methods may complement or replace conventional methods for cooling electronics and/or improving evaporation rates in an air-conditioning system.

For a better understanding of the various described implementations, reference should be made to the Detailed Description below, in conjunction with the following drawings in which like reference numerals refer to corresponding parts throughout the figures.

Reference will now be made in detail to implementations, examples of which are illustrated in the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the various described implementations. However, it will be apparent to one of ordinary skill in the art that the various described implementations may be practiced without these specific details. In other instances, well-known methods, procedures, components, circuits, and networks have not been described in detail so as not to unnecessarily obscure aspects of the implementations.

Many modifications and variations of this disclosure can be made without departing from its scope, as will be apparent to those skilled in the art. The specific implementations described herein are offered by way of example only, and the disclosure is to be limited only by the terms of the appended claims.

Some implementations of the present disclosure are described in the context of air-conditioning systems for use in vehicles, and in particular, in the context of air-conditioning systems to cool different compartments or spaces of an over-the-road or off-road vehicle. In some implementations, the air-conditioning system includes, or is a component of, a heating, ventilation, and air-conditioning (HVAC) system. It is to be appreciated that the term vehicle as used herein may refer to trucks, such as tractor-trailer trucks or semitrailer trucks, the scope of the present teachings is not so limited. The present teachings are also applicable, without limitation, to cars, vans, buses, trailers, boats, planes, and any other suitable vehicle.

In some implementations, the air-conditioning system includes a refrigerant reservoir either before the evaporator or after the evaporator. In some implementations, the system uses a refrigerant reservoir after the evaporator and before the compressor. In some implementations, an accumulator, which stores the excess refrigerant that has not changed phase into a complete vapor (i.e., is a mixture of both vapor and liquid), is used as the refrigerant reservoir.

In some implementations, the compressor is an electric brushless DC (BLDC) motor driven compressor that uses an electronic controller to electrically commutate the compressor motor. In some implementations, this controller has certain electrical components that need to be cooled to function properly.

In some implementations, the system combines both the refrigerant accumulator and the electronics cooling system. As the refrigerant flows into the accumulator the mixture of liquid and vapor refrigerant functions as a heat sink and transfers heat from the electronic board and into the refrigerant. In some implementations, the two components are separated by a thermal barrier, such as an aluminum pressure vessel designed for heat transfer and as a pressure vessel for the refrigerant.

The added advantage of using this combined accumulator and electronics cooler is that more of the refrigerant is changed from a liquid to a vapor. This can reduce the amount of liquid stored in the accumulator thereby reducing the risk of liquid being drawn into the compressor and damaging the compressor during the compression cycle.

In some implementations, the air-conditioning system includes at least one compressor, at least one condenser, at least one evaporator, refrigerant lines, and an energy source, such as a battery system. In some implementations, the refrigerant lines fluidly connect the compressor, condenser and evaporators to form a refrigerant circuit. In some implementations, a condenser includes at least one condenser fan. In some implementations, an evaporator includes at least one evaporator fan (also sometimes called a blower fan).

In some implementations, the air-conditioning system includes at least one user interface (e.g., touch screen) and at least one sensor (e.g., a thermostat). In some implementations, the energy source includes at least one battery or power source and a battery monitoring system (also sometimes called a battery management system). In some implementations, the battery monitoring system includes at least one current sensor. In some implementations, the battery monitoring system includes a controller, such as an automatic temperature controller. In some implementations, the controller is electrically coupled to other components of the air-conditioning system (e.g., a compressor, a condenser, etc.) to control operation of these components.

<FIG> is a block diagram illustrating an air-conditioning system <NUM> (sometimes also called a refrigeration system or a refrigerant system) in accordance with some implementations. <FIG> shows the refrigeration system <NUM> including a compressor <NUM>, a condenser <NUM>, an evaporator <NUM>, and refrigerant lines <NUM> fluidly connecting the compressor <NUM>, condenser <NUM>, and evaporator <NUM> to form a refrigerant circuit for circulating a refrigerant. In accordance with some implementations, the refrigerant circuit shown in <FIG> includes a receiver drier unit <NUM> and a liquid-gas separator device <NUM>. In some implementations, the refrigerant circuit includes only one of the receiver drier unit <NUM> and the liquid-gas separator device <NUM>.

In <FIG>, the condenser <NUM> is disposed downstream of the compressor <NUM> and fluidly connected to the compressor <NUM> by a refrigerant line <NUM>-<NUM>. The receiver drier unit <NUM> is disposed downstream of the condenser <NUM> and fluidly connected to the condenser <NUM> by a refrigerant line <NUM>-<NUM>. In accordance with some implementations, the receiver drier unit <NUM> includes a receiver drier <NUM> and a first sensor <NUM>. The evaporator <NUM> is disposed downstream of the receiver drier unit <NUM> and fluidly connected to the receiver drier unit <NUM> by a refrigerant line <NUM>-<NUM>. As used herein, the term "downstream" refers to a position along a refrigerant line in the direction of the refrigerant flow. As used herein, the term "upstream" refers to a position along a refrigerant line opposite to the direction of the refrigerant flow.

In accordance with some implementations, the liquid-gas separator device <NUM> is disposed downstream of the evaporator <NUM> and fluidly connected to the evaporator <NUM> by a refrigerant line <NUM>-<NUM> and to the compressor <NUM> by a refrigerant line <NUM>-<NUM>, thus forming a refrigerant circuit for circulating the refrigerant. In some implementations, the liquid-gas separator device <NUM> includes an accumulator <NUM>, electronics <NUM>, and a second sensor <NUM>. In some implementations, the electronics <NUM> are thermally coupled to the accumulator <NUM> such that heat from the electronics <NUM> is transferred to refrigerant in the accumulator <NUM>. In some implementations, the liquid-gas separator device <NUM> includes one or more connectors to mount to an inside of a vehicle engine compartment.

In some implementations, the liquid-gas separator device <NUM> further includes one or more fasteners configured to secure electronics to the accumulator <NUM>. In some implementations, the electronics are thermally coupled to refrigerant in the accumulator <NUM> via the one or more fasteners. In some implementations, the electronics are thermally coupled to refrigerant in the accumulator <NUM> via a thermal material, such as thermal grease, thermal pad(s), and/or thermal paste. In some implementations, the electronics are thermally coupled to refrigerant in the accumulator <NUM> via the housing of the accumulator <NUM>, the one or more fasteners, and a thermal material.

The accumulator <NUM> includes a refrigerant inlet configured to receive refrigerant from the refrigeration loop (e.g., from the evaporator <NUM>); a refrigerant outlet configured to release vapor refrigerant to the refrigeration loop (e.g., to the compressor <NUM>); and a cavity coupled to the refrigerant inlet and the refrigerant outlet, the cavity configured to separate liquid refrigerant from vapor refrigerant. In some examples, the accumulator <NUM> includes a liquid-vapor separator within the cavity, the liquid-vapor separator coupled to the refrigerant outlet and configured to impede the liquid refrigerant from being released via the refrigerant outlet. In some examples, the accumulator <NUM> is configured to utilize gravity to prevent the liquid refrigerant from being released via the refrigerant outlet. In some examples, the accumulator <NUM> is configured to withstand pressure exerted by the refrigerant. In some examples, the accumulator <NUM> includes a second outlet configured to release liquid refrigerant from the accumulator (e.g., to the evaporator <NUM> or the reservoir <NUM>). The accumulator <NUM> includes an inlet cavity coupled to the refrigerant inlet; an outlet cavity coupled to the refrigerant outlet; and a cap fluidly coupling the inlet cavity to the outlet cavity. The refrigerant inlet and the refrigerant outlet are located on one side of the accumulator and the cap is positioned on the opposite side of the accumulator. In some examples, the accumulator is formed from an extruded metal.

In some implementations, the electronics <NUM> includes controller electronics for the compressor <NUM>. In some implementations, the electronics <NUM> includes controller electronics for the evaporator <NUM> and/or the condenser <NUM>. In some implementations, the electronics <NUM> includes one or more of: a direct current (DC) to DC converter; an alternating current (AC) to AC converter; a DC to AC converter; an AC to DC converter; a power converter component; and a transformer. In some implementations, the electronics <NUM> includes one or more electronics boards thermally coupled to the accumulator <NUM>, such that in use heat from the one or more electronics boards is transferred to refrigerant in the accumulator <NUM>.

In some implementations, the first sensor <NUM> and the second sensor <NUM> are optionally any type of sensor suitable to measure temperature and/or pressure of the refrigerant, including but not limited to combined pressure and temperature transducers. In some implementations, the first sensor <NUM> includes a first temperature sensor and a first pressure sensor; and the second sensor <NUM> includes a second temperature sensor and a second pressure sensor. In some implementations, the first sensor <NUM> is disposed on the high pressure side of the refrigerant circuit, and optionally installed at the receiver drier <NUM> such as at the inlet, outlet, interior or other suitable location of the receiver drier <NUM>. In some implementations, the second sensor <NUM> is disposed on the low pressure side of the refrigerant circuit, and optionally installed at the accumulator <NUM> such as at the inlet, outlet, interior or other suitable location of the accumulator <NUM>. Having the first sensor <NUM> installed at the receiver drier <NUM> and/or the second sensor <NUM> at the accumulator <NUM> provides several advantages, including packaging and installation convenience, original equipment time saving, and easier leakage testing.

In some implementations, during operation of the air-conditioning system, the compressor <NUM> compresses a refrigerant into a compressed refrigerant. The compressor <NUM> is optionally any type of compressor including but not limited to a reciprocating compressor or rotary compressor. The condenser <NUM> condenses the refrigerant that has been compressed by the compressor <NUM>. In some implementations, the receiver drier <NUM> of the receiver drier unit <NUM> temporarily stores the refrigerant and/or absorbs moisture, debris or other undesirable substances from the refrigerant that has been condensed by the condenser <NUM>. In some implementations, the first sensor <NUM> measures temperature and pressure of the refrigerant that has been condensed by the condenser <NUM>. The evaporator <NUM> vaporizes or evaporates the refrigerant that has been condensed by the condenser <NUM>, providing cooling for desired use. In some implementations, the accumulator <NUM> restricts liquid refrigerant from entering the compressor <NUM>, for example by temporarily storing excess liquid refrigerant at the accumulator <NUM>, to prevent damage to the compressor <NUM>. In some implementations, the second sensor <NUM> measures temperature and pressure of the refrigerant that has been vaporized/evaporated by the evaporator <NUM>. It should be noted that depending on the operation and performance of the air-conditioning system, the condensed refrigerant at the receiver drier <NUM> and the vaporized/evaporated refrigerant at the accumulator <NUM> is in the form of a liquid, a vapor, or a mixture of liquid and vapor.

The air-conditioning system <NUM> also includes a power source <NUM> for powering one or more components of the system, such as condenser <NUM>, evaporator <NUM>, compressor <NUM>, and the like. In some implementations, the power source <NUM> includes a solar cell, an electrical battery, an alternator, or the like. In some implementations, the power source <NUM> is belt driven from an internal combustion engine of a vehicle. In some implementations, the air-conditioning system <NUM> includes a battery management system <NUM> for managing various components of the system, such as power source <NUM>. In some implementations, the battery management system <NUM> governs an amount of power drawn by each component of the air-conditioning system <NUM>.

In some implementations, the battery management system <NUM> includes one or more controllers <NUM> and one or more current sensors <NUM>. In some implementations, the controller <NUM> is electrically coupled to one or more components of the air-conditioning system, such as condenser <NUM> (e.g., via connection <NUM>-<NUM>), evaporator <NUM> (e.g., via connection <NUM>-<NUM>), and/or compressor <NUM> (e.g., via connection <NUM>-<NUM>). In some implementations, the controller <NUM> is electrically coupled to a condenser blower <NUM> and an evaporator blower <NUM>. In some implementations, the controller <NUM> is configured to monitor and control the amount of the power drawn by the evaporator <NUM>, the amount of power drawn by the compressor <NUM>, the refrigerant level in the refrigeration system, and/or other operations. For example, in <FIG>, the controller <NUM> is electrically coupled via connection <NUM>-<NUM> to the first sensor <NUM> of the receiver drier unit <NUM> and coupled via connection <NUM>-<NUM> to the second sensor <NUM> of the liquid-gas separator device <NUM>. In some implementations, controller <NUM> includes memory, such as volatile memory or non-volatile memory. In some implementations, controller <NUM> includes one or more processors. In some implementations, the controller <NUM>, or components thereof, is thermally coupled to the liquid-gas separator device <NUM>, such that heat generated by the controller <NUM> is transferred to refrigerant in the liquid-gas separator device <NUM>.

In some implementations, the refrigeration system further includes an electronic valve <NUM> to inject refrigerant from a refrigerant reservoir <NUM> into the refrigeration system when the refrigerant charge level is below a predetermined refrigerant charge level. In some implementations, control of the electronic valve is controlled by the controller <NUM>. As an example, <FIG> illustrates the electronic valve <NUM> installed at the receiver drier <NUM>. In some implementations, the electronic valve <NUM> is selectively operated to allow flow of the refrigerant from the refrigerant reservoir <NUM> to the refrigerant circuit.

In some implementations, the battery management system <NUM> and/or the controller <NUM> is configured to calculate a compression ratio of the compressor <NUM>. If the calculated compression ratio exceeds a specific compression ratio for a given condition, the battery management system <NUM> determines that a blockage has occurred in the refrigerant circuit. In some implementations, the battery management system <NUM> then examines various factors to determine a location of the blockage. For example, an abnormal sub-cooling level indicates a blockage in the condenser <NUM> and an abnormal super-cooling indicates a blockage in the evaporator <NUM>.

In some implementations, the battery management system <NUM> and/or the controller <NUM> is configured to manage start-up of the air-conditioning system and detect any component failure during the start-up process. In some implementations, the controller <NUM> operates in conjunction with current sensor <NUM> to detect component failures. In some implementations, current sensor <NUM> is utilized to measure and/or monitor the current drawn from the power source <NUM> (e.g., current drawn by the condenser <NUM>, the evaporator <NUM>, and/or the compressor <NUM>). In some implementations, the battery management system <NUM> governs operation of the air-conditioning system based on the measurements by the current sensor <NUM>.

In some implementations, the battery management system <NUM> is communicatively coupled to an electronic device <NUM> and/or a server system (not shown). In some implementations, the electronic device includes a display, a user interface, a smartphone, and/or a computer. In some implementations, the electronic device <NUM> is located in proximity with the air-conditioning system. For example, the air-conditioning system is installed in a vehicle and the electronic device <NUM> is a display on the dashboard of the vehicle. In some implementations, the electronic device <NUM> is located remotely from the air-conditioning system. For example, the air-conditioning system is installed in a vehicle and the electronic device <NUM> is a device not connected with the vehicle, such as a smartphone or a computer at a dealer. The battery management system <NUM> outputs one or more signals to the electronic device <NUM>. In some implementations, the signals optionally include data (e.g., the current drawn by a particular component, the refrigerant charge level, and the like), alerts (e.g., excessive current drawn by a particular component), maintenance request, and the like.

In some implementations, the air-conditioning system includes one or more additional components such as air blowers, metering devices, flow control valves, and the like. In accordance with some implementations, <FIG> illustrates the air-conditioning system including a condenser blower <NUM> electrically coupled to the battery management system <NUM> and positioned proximate the condenser <NUM>. In some implementations, the condenser blower <NUM> includes one or more fans. In some implementations, the condenser blower <NUM> is a component of the condenser <NUM>. In some implementations, the condenser blower <NUM> is configured to blow ambient air and/or air from an air intake of the engine over the condenser <NUM>. The amount of airflow over the condenser <NUM> affects the temperature and pressure of the refrigerant at the high pressure side of the refrigerant circuit and hence the efficiency of the air-conditioning system. Accordingly, in some implementations, to enhance the efficiency of the air-conditioning system, the battery management system <NUM> controls a speed of the condenser blower <NUM> based at least in part on the temperature measured by the first sensor <NUM>, the pressure measured by the first sensor <NUM>, the temperature measured by the second sensor <NUM>, the pressure measured by the second sensor <NUM>, and/or the current measured by current sensor <NUM>.

In accordance with some implementations, <FIG> illustrates the air-conditioning system including an evaporator blower <NUM> electrically coupled to the battery management system <NUM> and positioned proximate the evaporator <NUM>. In some implementations, the evaporator blower <NUM> includes one or more fans. In some implementations, the evaporator blower <NUM> is a component of the evaporator <NUM>. In some implementations, the evaporator blower <NUM> is configured to blow air past the evaporator <NUM>, thereby cooling the air.

The air-conditioning system as illustrated in <FIG> also includes a metering device <NUM> disposed upstream of the evaporator <NUM> and configured for controlling flow of the refrigerant into the evaporator <NUM>. In some implementations, the metering device <NUM> includes a thermal expansion valve or a capillary tube. In some implementations, the air-conditioning system further includes a flow control valve <NUM> disposed upstream of the compressor <NUM> and configured to selectively restrict or permit flow of the refrigerant to the compressor <NUM>.

In some implementations, the battery management system <NUM>, or components thereof, is thermally coupled to the accumulator <NUM>, such that heat generated by the battery management system <NUM> is transferred to refrigerant in the accumulator <NUM>. For example, in accordance with some implementations, the battery management system <NUM>, or components thereof, are included in the electronics <NUM>. In some implementations, one or more controllers for the air-conditioning system, such as controller <NUM>, are thermally coupled to the accumulator <NUM>, such that heat generated by the controller(s) is transferred to refrigerant in the accumulator <NUM>. For example, in accordance with some implementations, the one or more controllers are included in the electronics <NUM>.

<FIG> is a block diagram illustrating an air-conditioning system <NUM> in a vehicle <NUM> in accordance with some implementations. The air-conditioning system <NUM> includes liquid-gas separator device <NUM>, compressor <NUM>, condenser <NUM> with condenser blower <NUM>, drier unit <NUM>, and a first evaporator (evaporator <NUM>) with evaporator blower <NUM>. The air-conditioning system <NUM> also includes a second evaporator <NUM> with evaporator blower <NUM>, metering devices <NUM> and <NUM> (e.g., expansion values), and shut-off valves <NUM> and <NUM>. In some implementations, metering device <NUM> is configured to control flow rate of the refrigerant into the first evaporator <NUM> and metering device <NUM> is configured to control flow rate of the refrigerant into the second evaporator <NUM>.

As shown in <FIG>, the vehicle <NUM> has a cab compartment <NUM> where an operator (e.g., driver) operates the vehicle and a sleeper compartment <NUM> where the operator can rest. In some implementations, the sleeper compartment <NUM> is physically partitioned from the cab compartment <NUM>. In some implementations, the first evaporator <NUM> is in thermal communication with the cab compartment <NUM>, while the second evaporator <NUM> is in thermal communication with the sleeper compartment <NUM>. In some implementations, the air-conditioning system <NUM> includes one or more thermal sensors located within the cab compartment <NUM> to monitor the ambient temperature in the cab compartment; and one or more thermal sensors located in the sleeper compartment <NUM> to monitor the ambient temperature in the sleeper compartment <NUM>. In some implementations, the air-conditioning system <NUM> includes a thermostat located within the cab compartment <NUM> to enable a user to set a desired temperature for the cab compartment <NUM>; and a thermostat located in the sleeper compartment <NUM> to enable a user to set a desired temperature for the sleeper compartment <NUM>. In some implementations, the condenser <NUM>, the compressor <NUM>, and/or the liquid-gas separator device <NUM> are located within an engine compartment of the vehicle.

In accordance with a determination that cooling is desired in both the cab compartment <NUM> and the sleeper compartment <NUM>, the first shut-off valve <NUM> and the second shut-off valve <NUM> are opened, either manually or automatically, so that the condensed refrigerant flows through both the first and second evaporators and provides cooling to both the cab and sleeper compartments. In accordance with a determination that cooling is only desired in the sleeper compartment (e.g., when the vehicle is parked and no one is in the cab compartment), the first and second shut-off valves are closed. In some implementations, the first and second shut-off valves <NUM> and <NUM> are installed at both the refrigerant inlet and outlet of the first evaporator <NUM>; and closing the first and second shut-off valves prevents the refrigerant from entering the first evaporator <NUM> from both sides and thus prevents the refrigerant from collecting or accumulating in the first evaporator <NUM>. As a result, the condensed refrigerant flows only through the second evaporator <NUM> and thus enhances the cooling effect of the second evaporator <NUM>. In some implementations, two or more shut-off valves (not shown) are used to shut-off flow to the second evaporator <NUM>. In some implementations, shut-off valves <NUM> and <NUM> are located and configured such that flow is selectively enabled/disabled to both the first evaporator <NUM> and the second evaporator <NUM>.

<FIG> is a block diagram illustrating a representative controller <NUM> in accordance with some implementations. In some implementations, the controller <NUM> includes one or more processing units (e.g., CPUs, ASICs, FPGAs, microprocessors, and the like) <NUM>, one or more communication interfaces <NUM>, memory <NUM>, and one or more communication buses <NUM> for interconnecting these components (sometimes called a chipset). In some implementations, the controller <NUM> includes one or more input devices, such as one or more buttons for receiving input. In some implementations, the controller <NUM> includes one or more output devices, such as one or more indicator lights, a sound card, a speaker, a small display for displaying textual information and error codes, etc. In some implementations, the controller <NUM> includes a location detection device, such as a GPS (global positioning satellite) or other geo-location receiver, for determining the location of the controller <NUM>. The controller <NUM> is coupled to the current sensor <NUM> and the power source <NUM>, as shown in <FIG>.

Communication interfaces <NUM> include, for example, hardware capable of data communications using any of a variety of custom or standard wireless protocols (e.g., IEEE <NUM>. <NUM>, Wi-Fi, ZigBee, 6LoWPAN, Thread, Z-Wave, Bluetooth Smart, ISA100.11a, WirelessHART, MiWi, etc.) and/or any of a variety of custom or standard wired protocols (e.g., Ethernet, HomePlug, etc.), or any other suitable communication protocol, including communication protocols not yet developed as of the filing date of this document.

Memory <NUM> includes high-speed random access memory, such as DRAM, SRAM, DDR SRAM, or other random access solid state memory devices; and, optionally, includes non-volatile memory, such as one or more magnetic disk storage devices, one or more optical disk storage devices, one or more flash memory devices, or one or more other non-volatile solid state storage devices. Memory <NUM>, or alternatively the non-volatile memory within memory <NUM>, includes a non-transitory computer-readable storage medium. In some implementations, memory <NUM>, or the non-transitory computer readable storage medium of memory <NUM>, stores the following programs, modules, and data structures, or a subset or superset thereof:.

Each of the above identified elements (e.g., modules stored in memory <NUM> of controller <NUM>) corresponds to a set of instructions for performing a function described herein. The above identified modules or programs (i.e., sets of instructions) need not be implemented as separate software programs, procedures, or modules, and thus various subsets of these modules may be combined or otherwise rearranged in various implementations. In some implementations, memory <NUM>, optionally, stores a subset of the modules and data structures identified above. Furthermore, memory <NUM>, optionally, stores additional modules and data structures not described above. For example, memory <NUM> optionally stores a heating module (not shown) for managing heating operations of the system.

<FIG> illustrate various views of a liquid-gas separator device <NUM> in accordance with some implementations. <FIG> shows the liquid-gas separator device <NUM> with refrigerant inlet <NUM>, refrigerant outlet <NUM>, casing <NUM>, and cover <NUM>. In some implementations, the casing <NUM> and/or the cover <NUM> is comprised of metal, such as aluminum or steel. <FIG> shows the liquid-gas separator device <NUM> without the cover <NUM> and housing electronics <NUM> (e.g., compressor controller electronics). In some implementations, the electronics <NUM> include a plurality of electrical connectors and/or a plurality of transistors, such as field-effect transistors (FETs). In some implementations, the electronics <NUM> are mounted on an electrical board. In some implementations, the cover <NUM> is affixed to the liquid-gas separator device <NUM> after the electronics <NUM> are housed within. <FIG> shows another view of the liquid-gas separator device <NUM> with electronics <NUM>, refrigerant outlet <NUM>, and refrigerant inlet <NUM> and without the cover <NUM>. In some implementations, the liquid-gas separator device <NUM> is configured to be mounted vertically without the refrigerant inlet <NUM> and the refrigerant outlet <NUM> on the bottom.

<FIG> shows the flow of refrigerant through the liquid-gas separator device <NUM>. The refrigerant enters the device via the refrigerant inlet <NUM>. The refrigerant then flows through the cooling cavity <NUM>. In the cooling cavity <NUM> heat is transferred from the electronics <NUM> to the refrigerant. In some cases, the transferred heat converts at least a portion of the liquid refrigerant in the cooling cavity <NUM> into vapor refrigerant. The refrigerant then flows into the cap <NUM> and into the accumulator cavity <NUM>. The liquid-vapor separator <NUM> in the accumulator cavity <NUM> separates the liquid refrigerant from the vapor refrigerant. The vapor refrigerant then exits the device via the refrigerant outlet <NUM>. <FIG> shows another view of the flow of refrigerant through the liquid-gas separator device <NUM>. <FIG> also shows the electronics <NUM> mounted within the device. <FIG> also shows the dual seal connections <NUM> in accordance with some implementations. In some implementations, the refrigerant inlet <NUM> and/or the refrigerant outlet <NUM> include one or more of: a refrigerant tube, one or more washers, and a connection point <NUM> for connecting a refrigerant hose.

<FIG> shows the liquid-gas separator device <NUM> without the casing <NUM> and with fasteners <NUM>. In some implementations, the fasteners <NUM> are configured to affix the electronics <NUM> (e.g., an electronics board with the electronics <NUM>) to the liquid-gas separator device <NUM>. In some implementations, the fasteners <NUM> are configured to transfer heat generated by the electronics <NUM> to refrigerant in the cooling cavity <NUM>. In some implementations, the fasteners <NUM> comprise screws, bolts, anchors, and the like.

<FIG> shows a cross-sectional view of the liquid-gas separator device <NUM>. <FIG> shows an electronics board <NUM> with electronics <NUM> mounted to the device via fastener <NUM>. <FIG> also shows a thermal material <NUM> applied between the electronics board <NUM> and the cooling cavity <NUM> of the liquid-gas separator device <NUM>. <FIG> also shows the accumulator cavity <NUM> with the liquid-vapor separator device <NUM>.

<FIG> illustrates a flowchart representation of a method <NUM> for cooling electronics in accordance with some implementations. In some implementations, the method <NUM> is performed by an air-conditioning system <NUM> or one or more components of the air-conditioning system, such as liquid-gas separator device <NUM>, <FIG>. In some implementations, method <NUM> is performed by a device coupled to the air-conditioning system <NUM>. In some implementations, the operations of the method <NUM> described herein are entirely interchangeable, and respective operations of the method <NUM> are performed by any of the aforementioned devices, systems, or combination of devices and/or systems. In some implementations, method <NUM> is governed by instructions that are stored in a non-transitory computer-readable storage medium and that are executed by one or more processors of an air-conditioning system, such as controller <NUM>, <FIG>. For convenience, method <NUM> is described below as being performed by a device, such as the liquid-gas separator device <NUM> in <FIG>.

The device receives (<NUM>) refrigerant via a refrigerant inlet (e.g., refrigerant inlet <NUM>, <FIG>). In some implementations, the refrigerant is received via a refrigerant hose coupled to the refrigerant inlet. In some implementations, the refrigerant is received from an evaporator coupled to the device, such as the evaporator <NUM>, <FIG>. In some implementations, the received refrigerant includes a mixture of liquid and vapor refrigerant. In some implementations, the refrigerant comprises ammonia, sulfur dioxide, hydroflourocarbons (e.g., R-134a), hydrofluoroolefins (e.g., or 1234yf), and/or hydrocarbons such as propane.

The device separates (<NUM>), within a refrigerant cavity of the liquid-gas separator device, vapor refrigerant from liquid refrigerant. In some implementations, the device utilizes a liquid-vapor separator <NUM> to separate the vapor refrigerant from the liquid refrigerant. In some implementations, the device utilizes gravity to separate the vapor refrigerant from the liquid refrigerant.

The device operates (<NUM>) one or more electronic components (e.g., electronics <NUM>) thermally coupled to the refrigerant cavity. In some implementations, the electronic components comprise controller electronics for a compressor (e.g., compressor <NUM>), an evaporator (e.g., evaporator <NUM>), and/or a condenser (e.g., condenser <NUM>). In some implementations, the electronic components include power generation and/or conversion electronics, such as electronics of battery management system <NUM>. The one or more electronics generate (<NUM>) heat during operation.

The device transfers (<NUM>) the heat generated by the one or more electronic components to the refrigerant. In some implementations the heat is transferred via one or more fasteners (e.g., fasteners <NUM>) and/or one or more thermal materials (e.g., thermal material <NUM>). In some cases, transferring the heat generated by the one or more electronic components to the refrigerant converts (<NUM>) at least a portion of the refrigerant from liquid refrigerant to vapor refrigerant. In some cases, transferring the heat generated by the one or more electronic components to the refrigerant cools (<NUM>) the one or more electronic components.

The device releases (<NUM>) a substantially vapor refrigerant via a refrigerant outlet (e.g., refrigerant outlet <NUM>). In some implementations, the device release the substantially vapor refrigerant to a compressor (e.g., compressor <NUM>). In some implementations, the device releases a substantially liquid refrigerant via a liquid outlet. In some implementations, the device releases the substantially liquid refrigerant to an evaporator (e.g., evaporator <NUM>) or a refrigerant reservoir (e.g., reservoir <NUM>).

Although some of various drawings illustrate a number of logical stages in a particular order, stages that are not order dependent may be reordered and other stages may be combined.

While some reordering or other groupings are specifically mentioned, others will be obvious to those of ordinary skill in the art, so the ordering and groupings presented herein are not an exhaustive list of alternatives. Moreover, it should be recognized that the stages could be implemented in hardware, firmware, software or any combination thereof.

It will also be understood that, although the terms first, second, etc. are, in some instances, used herein to describe various elements, these elements should not be limited by these terms. For example, a first condition could be termed a second condition, and, similarly, a second condition could be termed a first condition, without departing from the scope of the various described implementations. The first condition and the second condition are both conditions, but they are not the same condition.

The terminology used in the description of the various described implementations herein is for the purpose of describing particular implementations only and is not intended to be limiting. As used in the description of the various described implementations and the appended claims, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term "and/or" as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms "includes," "including," "comprises," and/or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

Claim 1:
A refrigerant system (<NUM>), comprising:
a liquid-gas separator device (<NUM>) including:
a refrigeration section configured to couple to a refrigeration loop, the refrigeration section comprising:
a refrigerant inlet (<NUM>) configured to receive refrigerant from the refrigeration loop;
a refrigerant outlet (<NUM>) configured to release vapor refrigerant to the refrigeration loop; and
a cavity coupled to the refrigerant inlet (<NUM>) and the refrigerant outlet (<NUM>), the cavity configured to separate liquid refrigerant from vapor refrigerant; and
an electronics board (<NUM>) thermally coupled to the refrigeration section, such that in use, heat from the electronics board (<NUM>) is transferred to the refrigerant;
characterized in that
the refrigerant inlet (<NUM>) and the refrigerant outlet (<NUM>) are positioned on a first side of the liquid-gas separator device (<NUM>), and wherein
the cavity comprises:
an inlet sub-cavity coupled to the refrigerant inlet (<NUM>);
an outlet sub-cavity coupled to the refrigerant outlet (<NUM>), the outlet sub-cavity distinct from the inlet sub-cavity; and
a cap fluidly coupling the inlet sub-cavity to the outlet sub-cavity, such that the refrigerant flows through the inlet sub-cavity into the cap and from the cap into the outlet sub-cavity, the cap positioned on a second side of the liquid-gas separator device, opposite the first side.