Integrated condenser and compressor system

• US 10,589,598 B2
• Filed: 03/09/2016
• Issued: 03/17/2020
• Est. Priority Date: 03/09/2016
• Status: Active Grant

• Current Assignee: Bergstrom Incorporated
• Original Assignee: Bergstrom Incorporated
• Inventors: Connell, Brett S., Zeigler, Terry
• Primary Examiner(s): Crenshaw, Henry T
• Assistant Examiner(s): Tavakoldavani, Kamran
• Application Number:
  US15/065,745
• Publication Number:
  US 20170259645A1
• Time in Patent Office: 1,469 Days
• CPC Class Codes: B60H 1/00428 electric
• CPC Class Codes: B60H 1/0045 mechanical power take-offs from the vehicle propulsion unit
• CPC Class Codes: B60H 1/00885 Controlling the flow of heating or cooling liquid, e.g. valves or pumps B60H1/00899 takes precedence; constructions of valves B60H1/00485
• CPC Class Codes: B60H 1/3223 characterised by the arrangement or type of the compressor B60H1/3222 takes precedence
• CPC Class Codes: B60H 1/3227 characterised by the arrangement or the type of heat exchanger, e.g. condenser, evaporator condensed liquid drainage means B60H1/3233
• CPC Class Codes: B60H 1/3229 characterised by constructional features, e.g. housings, mountings, conversion systems B60H1/3227, B60H1/3233 take precedence
• CPC Class Codes: F25B 2400/071 Compressor mounted in a housing in which a condenser is integrated
• CPC Class Codes: F25B 2400/075 with parallel compressors
• CPC Class Codes: F25B 31/00 Compressor arrangements
• CPC Class Codes: F25B 39/00 Evaporators; Condensers
• CPC Class Codes: F25B 39/04 Condensers
• CPC Class Codes: F25B 49/02 for compression type machines, plants or systems
• CPC Class Codes: F28F 9/002 with fastening means for other structures

Abstract

Disclosed is an integrated compressor system configured to be integrated with existing air conditioning systems. The integrated compressor system generally includes a mounting assembly, a first compressor and a valve. The mounting assembly can be mounted directly on a condenser of an existing air conditioning system. The first compressor and the valve are mounted directly on the mounting assembly. The valve has a first valve inlet, a second valve inlet and a valve outlet. When assembly and integrated with an existing AC system, the first valve inlet is fluidly coupled to a compressor outlet of the first compressor, the second valve inlet is fluidly coupled to a compressor outlet of the compressor of existing AC system, and a valve outlet is fluidly connected to a condenser inlet of the condenser.

Claims

1. An aftermarket compressor system for coupling to an existing vehicle air-conditioning system, comprising:

an electric compressor configured to mount directly to a condenser of the existing vehicle air-conditioning system via a first condenser bracket and compress a refrigerant, the electric compressor comprising a compressor inlet and a compressor outlet; and

a valve configured to mount directly to the condenser of the existing vehicle air-conditioning system via a second condenser bracket, the valve comprising;

a first valve inlet fluidly coupled to the compressor outlet of the electric compressor;

a second valve inlet configured to be fluidly coupled to a compressor outlet of an engine-driven compressor of the existing vehicle air-conditioning system; and

a valve outlet to be fluidly connected to a condenser inlet of the condenser.

2. The system of claim 1, wherein the compressor inlet of the electric compressor is configured to be fluidly connected to a compressor inlet of the engine-driven compressor.

3. The system of claim 1, wherein a largest cross-sectional dimension of the electric compressor is less than 3.5 inches, less than 4 inches, less than 4.5 inches or less than 5 inches.

4. The system of claim 1, wherein the electric compressor comprises one or more mounting brackets welded onto a wall of the electric compressor and configured to be coupled to the condenser.

5. The system of claim 1, wherein the valve is selected from the group consisting of a magnetic valve, a spring-load valve, electronic solenoid valve, and electronic stepper valve.

6. The system of claim 1, wherein the electric compressor comprises the first condenser bracket.

7. The system of claim 1, wherein the electric compressor comprises the second condenser bracket.

8. A system, comprising:

an engine-driven compressor, of an existing vehicle air-conditioning system, configured to compress a refrigerant, the engine-driven compressor comprising a compressor outlet;

a condenser having a condenser inlet;

an electric compressor configured to compress a refrigerant, the electric compressor mounted directly to the condenser via a first condenser bracket and comprising a compressor inlet and a compressor outlet; and

a valve mounted directly to the condenser via a second condenser bracket, the valve comprising;

a first valve inlet fluidly connected to the compressor outlet of the electric compressor;

a second valve inlet fluidly connected to the compressor outlet of the engine-driven compressor; and

a valve outlet fluidly connected to the condenser inlet of the condenser.

9. The system of claim 8, further comprising one or more of the following:

a first refrigerant tube connecting the compressor outlet of the electric compressor to the first valve inlet of the valve;

a second refrigerant tube for connecting the valve outlet of the valve to the condenser inlet of the condenser;

a controller electrically coupled to the electric compressor and the engine-driven compressor and configured to selectively control operation of the electric compressor and the engine-driven compressor; and

an electric fan disposed adjacent to the condenser, the electric fan being configured and positioned to blow air over the condenser.

10. The system of claim 8, further comprising:

a valve mounting assembly configured to hold the valve, wherein the valve mounting assembly is directly and fixedly coupled to one or more of the following;

the edge of the condenser, and

the second condenser bracket; and

a compressor mounting assembly configured to hold the electric compressor, wherein the compressor mounting assembly is directly and fixedly coupled to one or more of the following;

the edge of the condenser,

a middle mounting bracket, and

the first condenser bracket.

11. The system of claim 10, wherein the middle mounting bracket is identical to the first condenser bracket or the second condenser bracket.

12. The system of claim 10, wherein:

the valve mounting assembly comprises one or more of the following;

a plurality of spacers directly and fixedly coupled to the edge of the condenser;

a manifold directly and fixedly coupled to one or more of the spacers;

a first bracket directly and fixedly coupled to one or more of the following;

the second condenser bracket and one or more of the spacers;

a plurality of machined rings configured to enhance strength of the valve mounting assembly and facilitate positioning and sealing of the valve, wherein the plurality of machined rings includes a first ring directly and fixedly coupled to the first bracket and a second ring;

a plurality of cylindrical pipes comprising one or more of the following;

a first cylindrical pipe fixedly coupled to the first ring, a second cylindrical pipe fixedly coupled to the second ring, and a third cylindrical pipe or rod;

a stamped PC disposed below the first cylindrical pipe; and

a junction PC directly and fixedly coupled to one or more of the following;

the second cylindrical pipe, the third cylindrical pipe or rod, the first bracket, and one or more of the plurality of the spacers;

the compressor mounting assembly comprises one or more of the following;

a second bracket directly and fixedly coupled to one or more of the following;

the edge of the condenser, the middle mounting bracket and the first condenser bracket;

a U-shaped bracket directly and fixedly coupled to the second bracket, and configured to accommodate the electric compressor; and

one or more vibration dampeners.

13. The system of claim 12, wherein:

the electric compressor comprises one or more mounting brackets welded onto a wall of the electric compressor and configured to be coupled to the U-shaped bracket of the compressor mounting assembly; and

the one or more vibration dampeners comprise a plurality of rubber vibration mounts coupling the one or more mounting brackets welded onto the wall of the electric compressor to the U-shaped bracket of the compressor mounting assembly.

14. The system of claim 8, wherein the condenser comprises the first condenser bracket and the second condenser bracket, and the system further comprises:

a third bracket fixedly coupled to the first and second condenser brackets;

a valve mounting assembly configured to hold the valve, wherein the valve mounting assembly is fixedly coupled to one or more of the following;

the edge of the condenser and an upper portion of the third bracket; and

a compressor mounting assembly configured to hold the electric compressor, wherein the compressor mounting assembly is fixedly coupled a lower portion of the third bracket.

15. The system of claim 14, wherein:

the valve mounting assembly comprises one or more of the following;

a plurality of spacers directly and fixedly coupled to the edge of the condenser;

a manifold directly and fixedly coupled to one or more of the spacers;

a first bracket directly and fixedly coupled to one or more of the following;

the upper portion of the third bracket and one or more of the spacers;

a plurality of machined rings configured to enhance strength of the valve mounting assembly and facilitate positioning and sealing of the valve, wherein the plurality of machined rings includes a first ring directly and fixedly coupled to the first bracket and a second ring;

a plurality of cylindrical pipes comprising one or more of the following;

a first cylindrical pipe fixedly coupled to the first ring, a second cylindrical pipe fixedly coupled to the second ring, and a third cylindrical pipe or rod;

a stamped PC disposed below the first cylindrical pipe; and

a junction PC directly and fixedly coupled to one or more of the following;

the second cylindrical pipe, the third cylindrical pipe or rod, the first bracket, and one or more of the plurality of the spacers; and

the compressor mounting assembly comprises one or more of the following;

a U-shaped bracket fixedly coupled to the lower portion of the third bracket and configured to accommodate the electric compressor;

one or more vibration dampeners; and

a pad disposed between the U-shaped bracket and the third bracket and configured to provide one or more of the following;

reducing vibration, distributing pressure evenly, and preventing the coupling of the U-shaped bracket to the third bracket from loosening.

16. The system of claim 8, further comprising a mounting assembly, wherein the mounting assembly comprises:

a plurality of mounting brackets directly and fixedly coupled to an edge of the condenser and extruded from the edge of the condenser, wherein the plurality of mounting brackets comprises;

(i) an upper mounting bracket directly and fixedly coupled to an upper portion of the edge of the condenser;

(ii) a middle mounting bracket directly and fixedly coupled to a middle portion of the edge of the condenser; and

(iii) a lower mounting bracket directly and fixedly coupled to a lower portion of the edge of the condenser;

a third bracket fixedly coupled to the upper, middle and lower mounting brackets;

a valve mounting assembly configured to hold the valve, wherein the valve mounting assembly is fixedly coupled to one or more of the following;

the edge of the condenser, and an upper portion of the third bracket; and

a compressor mounting assembly configured to hold the electric compressor, wherein the compressor mounting assembly is fixedly coupled to a lower portion of the third bracket.

17. The system of claim 16, wherein:

the valve mounting assembly comprises one or more of the following;

a plurality of spacers directly and fixedly coupled to the edge of the condenser;

a manifold directly and fixedly coupled to one or more of the spacers;

a first bracket directly and fixedly coupled to one or more of the following;

the upper portion of the third bracket and one or more of the spacers;

a plurality of machined rings configured to enhance strength of the valve mounting assembly and facilitate positioning and sealing of the valve, wherein the plurality of machined rings includes a first ring directly and fixedly coupled to the first bracket and a second ring;

a plurality of cylindrical pipes comprising one or more of the following;

a first cylindrical pipe fixedly coupled to the first ring, a second cylindrical pipe fixedly coupled to the second ring, and a third cylindrical pipe or rod;

a stamped PC disposed below the first cylindrical pipe; and

a junction PC directly and fixedly coupled to one or more of the following;

the second cylindrical pipe, the third cylindrical pipe or rod, the first bracket, and one or more of the plurality of the spacers; and

the compressor mounting assembly comprises one or more of the following;

a U-shaped bracket fixedly coupled to the lower portion of the third bracket and configured to accommodate the electric compressor;

one or more vibration dampeners; and

a pad disposed between the U-shaped bracket and the third bracket and configured to provide one or more of the following;

reducing vibration, distributing pressure evenly, and preventing the coupling of the U-shaped bracket to the third bracket from loosening.

18. The system of claim 17, wherein:

the electric compressor comprises one or more mounting brackets welded onto a wall of the electric compressor and configured to be coupled to the U-shaped bracket of the compressor mounting assembly; and

the one or more vibration dampeners comprise a plurality of rubber vibration mounts coupling the one or more mounting brackets welded onto the wall of the electric compressor to the U-shaped bracket of the compressor mounting assembly.