DE-112024002247-T5 - Thermal management module

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Abstract

A module comprises a first flow of refrigerant passing through a first flow path of the module, which passes through the high-pressure side of the internal heat exchanger; a second flow of refrigerant passing through a second flow path of the module, which passes through the evaporator, the accumulator, and the low-pressure side of the internal heat exchanger in sequence with the second flow; and a flow of coolant passing through a third flow path of the module, which passes through the evaporator.

Inventors

Orest Alexandru Dziubinschi
Devon Laird
Madison Paige Turner
Jeffrey LaPlante

Assignees

HANON SYSTEMS

Dates

Publication Date: 20260513
Application Date: 20240429
Priority Date: 20230524

Claims (20)

A module configured for installation in a thermal management system, comprising a refrigerant circuit configured to operate in heat pump mode, wherein the module has the following features: a mounting bracket; an internal heat exchanger attached to the mounting bracket, the internal heat exchanger comprising a high-pressure side and a low-pressure side; an evaporator attached to the mounting bracket; and an accumulator attached to the mounting bracket, wherein the module is configured to include a first flow of refrigerant passing through a first flow path of the module, which passes through the high-pressure side of the internal heat exchanger, and a second flow of refrigerant passing through a second flow path of the module, which, in sequence with the second flow, passes through the evaporator, the accumulator, and the low-pressure side of the internal heat exchanger, when the module is installed in the thermal management system and the refrigerant circuit is operational in heat pump mode.
The module according to Claim 1 , wherein the module is further configured to include a flow of coolant passing through a third flow path of the module passing through the evaporator when the module is installed in the thermal management system, wherein the flow of coolant is configured to exchange heat with the second flow of refrigerant within the evaporator.
The module according to Claim 2 , wherein the thermal management system comprises a coolant circuit that circulates the coolant through it, wherein the coolant circuit comprises a heat-generating component that transfers heat to the coolant.
The module according to Claim 2 , where the coolant is liquid water.
The module according to Claim 2 , wherein the first flow path, the second flow path and the third flow path within the module are provided independently of each other.
The module according to Claim 1 , where the temperature of the first flow of refrigerant within the internal heat exchanger is higher than the temperature of the second flow of refrigerant therein.
The module according to Claim 1 , wherein the second flow path of the module is arranged downstream of the first flow path of the module with respect to a flow of refrigerant through the refrigerant circuit when it is operable in heat pump mode.
The module according to Claim 1 , which furthermore has a first module fluid line that connects the evaporator to the accumulator along the second flow path.
The module according to Claim 8 , which furthermore has a second module fluid line that connects the accumulator to the low-pressure side of the internal heat exchanger.
The module according to Claim 9 , wherein the first module fluid line has at least a greater length than the second module fluid line and/or a greater number of flow direction changes along it than the second module fluid line in order to result in a pressure drop experienced by the refrigerant as it flows through the first module fluid line that is greater than a pressure drop experienced by the refrigerant as it flows through the second module fluid line.
The module according to Claim 1 , whereby the evaporator is not removable and is attached to the holder.
The module according to Claim 11 , wherein the internal heat exchanger is provided as a sub-module of the module, which is detachably attached to the holder to facilitate testing of the internal heat exchanger independently of the evaporator and the accumulator.
The module according to Claim 12 , wherein the internal heat exchanger is detachably attached to the bracket which is adjacent to an upper end of the evaporator with respect to a vertical direction.
The module according to Claim 1 , wherein at least one section of the first flow path is defined by a flow chamber formed within the holder.
The module according to Claim 1 , wherein at least one section of the second flow path is defined by a flow chamber formed within the holder.
The module according to Claim 15 , wherein the flow chamber fluidically couples an outlet of the evaporator to an inlet of the accumulator.
The module according to Claim 15 , wherein the flow chamber fluidically couples an outlet of the accumulator to an inlet of the low-pressure side of the internal heat exchanger.
The module according to Claim 1 , wherein the accumulator comprises a mounting section extending outwards from an outer circumferential surface of a cylindrical section thereof, the mounting section being configured to be attached to the support.
A thermal management system for a vehicle, wherein the thermal management system has the following features: a refrigerant circuit comprising, in a flow sequence of refrigerant through it during heat pump operation, a compressor, a condenser, a high-pressure side of an internal heat exchanger, an expansion element, an evaporator, an accumulator, and a low-pressure side of the internal heat exchanger; a coolant circuit comprising a coolant flowing through the evaporator of the refrigerant circuit to exchange heat between the refrigerant and the coolant within the evaporator, the coolant being in heat-exchange contact with a heat-generating component of the vehicle; wherein the internal heat exchanger, the evaporator and the accumulator are integrated into a module configured to be detachably coupled to each of the refrigerant circuit and the coolant circuit, the module having a mounting attached to each of the internal heat exchanger, the evaporator and the accumulator, the module being configured to include a first flow of refrigerant passing through a first flow path of the module passing through the high-pressure side of the internal heat exchanger, and a second flow of refrigerant passing through a second flow path of the module passing through the evaporator, the accumulator and the low-pressure side of the internal heat exchanger in sequence with the second flow, and the module being further configured to include a flow of coolant passing through a third flow path of the module passing through the evaporator.
The thermal management system according to Claim 19 , wherein the first flow path, the second flow path and the third flow path are provided independently of each other within the module.

Description

Technical field The invention relates to a thermal management system of a motor vehicle and in particular to a sub-module of the thermal management system, wherein the sub-module has integrated components of both a refrigerant circuit and a coolant circuit. Background technology A vehicle's thermal management system may comprise several different fluid circuits configured to manage the properties of one or more corresponding fluids. For example, a thermal management system may include at least one refrigerant circuit and/or at least one coolant circuit, each comprising several fluid delivery components arranged in a manner that necessitates the formation of fluid-tight seals at each connection point between them. Such fluid systems further require the use of fluid lines, provided as pipes, hoses, or the like, to fluidically connect the fluid delivery components of each associated fluid circuit. Disclosure of the invention Technical problem Accordingly, there is a growing desire for the components comprising a vehicle's thermal management system to be provided in modular form to facilitate vehicle manufacturing. Such a thermal management system module can include several components associated with the operation of the vehicle's corresponding coolant and/or refrigeration system. The thermal management module can be pre-assembled and then installed within a designated space in the vehicle, using a minimized number of couplings and connections. Solution to the problem According to the present disclosure, an integrated module of a thermal management system has surprisingly been discovered. According to an embodiment of the present invention, a module configured for installation in a thermal management system, which has a refrigerant circuit configured to operate in heat pump mode, comprises a mounting bracket, an internal heat exchanger attached to the mounting bracket (the internal heat exchanger comprising a high-pressure side and a low-pressure side), an evaporator attached to the mounting bracket, and an accumulator attached to the mounting bracket. The module is configured to include a first flow of refrigerant passing through a first flow path of the module, which passes through the high-pressure side of the internal heat exchanger, and a second flow of refrigerant passing through a second flow path of the module, which, in sequence with the second flow, passes through the evaporator, the accumulator, and the low-pressure side of the internal heat exchanger, when the module is installed in the thermal management system and the refrigerant circuit is operational in heat pump mode. According to a further embodiment of the invention, a thermal management system for a vehicle comprises a refrigerant circuit which, in the sequence of refrigerant flow through it during heat pump operation, includes a compressor, a condenser, a high-pressure side of an internal heat exchanger, an expansion element, an evaporator, an accumulator, and a low-pressure side of the internal heat exchanger. The thermal management system also includes a coolant circuit comprising a coolant that flows through the evaporator of the refrigerant circuit to exchange heat between the refrigerant and the coolant within the evaporator, the coolant being in heat exchange contact with a heat-generating component of the vehicle. The internal heat exchanger, the evaporator, and the accumulator are integrated into a module configured to be detachably coupled to each of the refrigerant circuits and the coolant circuit. The module includes a mounting bracket attached to each of the internal heat exchanger, the evaporator, and the accumulator. The module is configured to include a first refrigerant flow through a first flow path of the module, which passes through the high-pressure side of the internal heat exchanger, and a second refrigerant flow through a second flow path of the module, which, in sequence with the second flow, passes through the evaporator, the accumulator, and the low-pressure side of the internal heat exchanger. The module is further configured to include a refrigerant flow through a third flow path of the module, which passes through the evaporator. Brief description of the drawings 1 is a schematic view of a thermal management system with a thermal management module contained therein according to an embodiment of the invention;2 is a perspective rear view of the thermal management module;3 is a perspective front view of the thermal management module;4 is a perspective top view of the thermal management module;5 is a perspective rear view showing an isolated bracket of the thermal management module;6 is a top view of the bracket according to 5 ;7 is a perspective rear view of a device used to determine a fixed position of the thermal management module;8 is a perspective front view of the device according to 7 ;9 and 10 are perspective side views showing alternative configurations of a bracket and an accumulator of the thermal manag