Unitary heat pump air conditioner having a heat exchanger with an integral accumulator

• US 9,109,840 B2
• Filed: 04/23/2012
• Issued: 08/18/2015
• Est. Priority Date: 02/17/2011
• Status: Active Grant

• Current Assignee: Mahle International GmbH (MAHLE-STIFTUNG GmbH)
• Original Assignee: Delphi Technologies, Inc. (Aptiv PLC)
• Inventors: Kadle, Prasad S., Vreeland, Gary S., Oddi, Frederick V.
• Primary Examiner(s): Tyler, Cheryl J
• Assistant Examiner(s): VAZQUEZ, ANA M
• Application Number:
  US13/453,550
• Publication Number:
  US 20120216562A1
• Time in Patent Office: 1,212 Days
• Field of Search: 624/34, 624/98, 625/09, 625/13, 625/07, 623/246, 165/166
• US Class Current: 1/1
• CPC Class Codes: B60H 1/00899 Controlling the flow of liquid in a heat pump system controlling the properties of the refrigerant liquid, e.g. pressure or temperature, B60H1/3204
• CPC Class Codes: B60H 1/32284 comprising two or more secondary circuits, e.g. at evaporator and condenser side
• 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 2339/047 Water-cooled condensers
• CPC Class Codes: F25B 25/005 using primary and secondary systems
• CPC Class Codes: F25B 30/02 of the compression type
• CPC Class Codes: F25B 39/00 Evaporators; Condensers
• CPC Class Codes: F28D 2021/0068 for refrigerant cycles
• CPC Class Codes: F28D 2021/0084 Condensers
• CPC Class Codes: F28D 2021/0085 Evaporators
• CPC Class Codes: F28D 9/005 the plates having openings therein for both heat-exchange media
• CPC Class Codes: F28D 9/0093 Multi-circuit heat-exchangers, e.g. integrating different heat exchange sections in the same unit or heat-exchangers for more than two fluids

Abstract

The disclosure relates to a unitary heat pump air conditioner (Unitary HPAC) having a plate type exchanger assembly, an electrically driven compressor, and coolant pumps. The plate heat exchanger assembly includes a plurality of plates stacked and hermetically sealed between an upstream end plate and a downstream end plate. The stacked plates define a condenser/chiller portion adjacent the upstream end plate, an accumulator portion adjacent the downstream end plate, and an evaporator/chiller portion sandwiched between the condenser/chiller portion and the accumulator portion. A refrigerant passageway extends through the plate type heat exchanger assembly, a hot coolant passageway extends through the condenser/chiller portion, and a cold coolant passageway extends through the evaporator/chiller portion. The cold coolant passageway and the hot coolant passageway are in non-contact thermal communication with the refrigerant passageway.

Claims

1. A unitary heat pump air conditioner (HPAC), comprising:

a plate type heat exchanger assembly having a plurality of plates stacked and hermetically sealed between an upstream end plate and a downstream end plate, defining;

a condenser/chiller portion adjacent said upstream end plate, wherein said upstream end plate includes a refrigerant inlet, a hot coolant inlet, and a hot coolant outlet;

an accumulator portion adjacent said downstream end plate, wherein said downstream end plate includes a refrigerant outlet, a cold coolant inlet, and a cold coolant outlet;

an evaporator/chiller portion sandwiched between said condenser/chiller portion and said accumulator portion;

a refrigerant passageway extending through said plate type heat exchanger assembly and in hydraulic communication with said refrigerant inlet and said refrigerant outlet;

a hot coolant passageway extending through said condenser/chiller portion and in hydraulic communication with said hot coolant inlet and said hot coolant outlet; and

a cold coolant passageway extending through said evaporator/chiller portion and in hydraulic communication with said cold coolant inlet and said cold coolant outlet;

wherein said hot coolant passageway and said cold coolant passageway are in non-contact thermal communication with said refrigerant passageway, such that a two phase refrigerant flowing through said refrigerant passageway as part of a refrigerant loop transfers heat energy from a cold side coolant flowing through said cold coolant passageway to a hot side coolant flowing through said hot coolant passageway.

2. The unitary heat pump air conditioner of claim 1, wherein said plate type heat exchanger assembly includes:

a first boundary plate separating said condenser/chiller portion and evaporator/chiller portion; and

a second boundary plate separating said evaporator/chiller portion and accumulator portion;

wherein said evaporator/chiller portion defines a refrigerant expansion chamber extending between said first boundary plate and said second boundary plate.

3. The unitary heat pump air conditioner of claim 2, wherein said plate type heat exchanger assembly further includes:

a refrigerant expansion device having an entry end and an exit end, wherein said refrigerant expansion device is disposed within said refrigerant expansion chamber such that said entry end extends through said first boundary plate and is in hydraulic communication with said refrigerant passageway within said condenser/chiller portion, and said exit end extends into said refrigerant expansion chamber toward said second boundary plate.

4. The unitary heat pump air conditioner of claim 3, wherein said refrigerant expansion device is a tube and said refrigerant expansion chamber is substantially cylindrical, said tube and said refrigerant expansion chamber cooperate to define an annular refrigerant passageway.

5. The unitary heat pump air conditioner of claim 4, wherein said annular refrigerant passageway communicates with said refrigerant passageway within said evaporator/chiller at a location adjacent to said first boundary plate.

6. The unitary heat pump air conditioner of claim 1, wherein said accumulator portion includes an oil pick-up tube in hydraulic communication with said refrigerant outlet and lower volume of accumulator portion.

7. The unitary heat pump air conditioner of claim 6, wherein said downstream end plate includes an interior surface defining a channel depression extending from said refrigerant outlet to a bottom portion of said downstream end plate, and wherein said channel depression cooperates with an immediate adjacent plate to define said oil pick-up tube.

8. The unitary heat pump air conditioner of claim 7, wherein said accumulator portion is defined by said plurality of stacked metallic plates, wherein at least one of said stacked metallic plates includes a lower portion having at least one aperture for hydraulic communication between said stacked metallic plates.

9. The unitary heat pump air conditioner of claim 8, wherein said at least one aperture is in hydraulic communication with said oil pick-up tube.

10. The unitary heat pump air conditioner of claim 9, further comprising an electrically driven compressor having a high pressure discharge side hydraulically connected to said refrigerant inlet and a low pressure intake side hydraulically connected to said refrigerant outlet.

11. The unitary heat pump air conditioner of claim 9, further comprising an electrically driven hot side coolant pump and an electrically driven cold side coolant pump in hydraulic communication with said hot coolant inlet and said cool coolant inlet, respectively.

12. The unitary heat pump air conditioner of claim 11, wherein said plate type heat exchanger assembly, and said electrically driven compressor and said coolant pumps are mounted on a single platform.

13. A plate-type heat exchanger comprising:

an upstream end plate having a refrigerant inlet, a hot coolant inlet, and a hot coolant outlet;

a downstream end plate having a refrigerant outlet, a cold coolant inlet, and a cold coolant outlet, wherein said downstream end plate is axially spaced from said upstream end plate;

a condenser/chiller portion adjacent said upstream end plate, wherein said condenser/chiller portion includes a hot coolant passageway in hydraulic communication with said hot coolant inlet and said hot coolant outlet;

an accumulator portion adjacent said downstream end plate having a coolant inlet header and a coolant outlet header in hydraulic communication with said cold coolant inlet and said cold coolant outlet, respectively;

an evaporator/chiller portion sandwiched between said condenser/chiller portion and said accumulator portion, wherein said evaporator/chiller portion includes a cold coolant passageway in hydraulic communication with said coolant inlet and outlet headers;

a refrigerant passageway extending through said plate-type heat exchanger and in hydraulic communication with said refrigerant inlet and said refrigerant outlet;

wherein said hot coolant passageway and said cold coolant passageway are in non-contact thermal communication with said refrigerant passageway such that a two phase refrigerant flowing through said refrigerant passageway as part of refrigerant loop transfers heat energy from a cold side coolant flowing through said cold coolant passageway to a hot side coolant flowing through said hot coolant passageway.

14. The plate-type heat exchanger of claim 13, further comprising:

a first boundary plate separating said condenser/chiller portion and evaporator/chiller portion; and

a second boundary plate separating said evaporator/chiller portion and accumulator portion;

wherein said evaporator/chiller portion defines a refrigerant expansion chamber extending between said first boundary plate and said second boundary plate.

15. The plate-type heat exchanger of claim 14, further comprising:

a refrigerant expansion device having an entry end and an exit end, wherein said refrigerant expansion device is disposed within said refrigerant expansion chamber such that said entry end extends through said first boundary plate and is in hydraulic communication with said refrigerant passageway within said condenser/chiller portion, and said exit end extends into said refrigerant expansion chamber toward said second boundary plate.

16. The plate-type heat exchanger of claim 15, wherein said refrigerant expansion device is a tube and said refrigerant expansion chamber is substantially cylindrical, said tube and said refrigerant expansion chamber cooperate to define an annular refrigerant passageway.

17. The plate-type heat exchanger of claim 16, wherein said annular refrigerant passageway communicates with said refrigerant passageway within said evaporator/chiller at a location adjacent to said first boundary plate.

18. The plate-type heat exchanger of claim 13, wherein said accumulator portion includes an oil pick-up tube in hydraulic communication with said refrigerant outlet and lower volume of accumulator portion.

19. The plate-type heat exchanger of claim 18, wherein said downstream end plate includes an interior surface defining a channel depression extending from said refrigerant outlet to a bottom portion of said downstream end plate, and wherein said channel depression cooperates with an immediate adjacent plate to define said oil pick-up tube.

20. The plate-type heat exchanger of claim 19, wherein said accumulator portion is defined by said plurality of stacked metallic plates, wherein at least one of said stacked metallic plates includes a lower portion having at least one aperture for hydraulic communication between said stacked metallic plates and said oil pick-up tube.