AIR-CONDITIONING SYSTEM WITH INTEGRATED SORBENT BODY
An air conditioning system for a vehicle includes a refrigerant circulating through a closed system including a condenser, a compressor, and an evaporator. A sorbent body, which may be a desiccant-entrained polymer, is disposed inside the compressor to remove moisture from the refrigerant passing therethrough.
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Conventional cooling systems for vehicles, such as automobiles and airplanes, generally include a compressor, an evaporator, and a condenser fluidly connected with each other to provide a closed, sealed fluid system through which a refrigerant circulates. In many such systems, the condenser is modified to include a desiccant chamber carrying a sachet filled with a desiccant material. The desiccant chamber is part of the fluid path defined by the condenser, such that as the fluid flows over the desiccant sachet, unwanted moisture in the refrigerant is absorbed and therefore removed from the closed system. However, this conventional configuration may have drawbacks. For example, the desiccant chamber increases the footprint of the condenser and adds weight to the system. Moreover, conventional sachets are susceptible to dusting such that while the desiccant may remove moisture from the refrigerant, it may also introduce particulate matter which may also be harmful to the system. Furthermore, conventional sachets consist of a non-woven fabric, typically polyester. The non-woven fibers, although needle punched, can migrate out of the sachet and become lodged in small orifices or in valves in the system adversely impacting system performance and reliability. The present disclosure is intended to address at least some of the foregoing or other drawbacks in conventional systems.
The following detailed description is directed generally to air conditioning systems for vehicles, such as land, sea, and/or air-borne vehicles. Such vehicles often have heating, ventilation, and air-conditioning (HVAC) systems that allow drivers and/or passengers to control ambient temperatures. One key aspect of many HVAC systems is the air-conditioning unit, which acts to output relatively cold air, e.g., to lower the temperature in the vehicle. Aspects of this disclosure relate specifically to improvements to the air-conditioning unit. For example, some aspects of this disclosure describe integrating a sorbent into a compressor. For example, a molded sorbent body may be secured in a fluid path inside the compressor to remove moisture from the sealed system. Various improvements described herein may result in a space-saving design, a cleaner system, reduced system weight, and/or a reduction in cost associated with air-conditioning systems. These and other improvements will be described in more detail below.
As also illustrated in
However, this conventional arrangement has drawbacks. For example, the desiccant chamber 116 increases the footprint of the condenser 104. Moreover, the desiccant chamber 116 requires additional raw materials that both increase the cost of the condenser 104 and increase the weight of the condenser 104. Accordingly, the conventional air-conditioning system 100 is bulkier than may be necessary. However, vehicle manufacturers often look to reduce the size and/or weight of vehicles, to improve fuel efficiency and for other considerations.
While the air-conditioning system 200 does not include the desiccant chamber 116, it does include a material configured to remove moisture from the air-conditioning system 200. However, as will be described in further detail below in connection with
As illustrated, the compressor 300 generally also includes a suction port or inlet 308 and a discharge port or outlet 310. Refrigerant enters the compressor 300 through the inlet 308 and exits the compressor 300 at the outlet 310. Accordingly, the housing 302 generally also defines an internal fluid channel or passageway 312. A plurality of pistons 314 are disposed in the passageway 312. More specifically, the pistons act on refrigerant entering the compressor 300 via the inlet 308 to compress the refrigerant. Compressed refrigerant is then passed out of the compressor 300 via the outlet 310. In the illustrated compressor 300, the pistons 314 are arranged in an array about a shaft 316. Rotation of the shaft 316 causes the pistons to stroke in a predetermined manner to compress the refrigerant. As also illustrated, the compressor 300 includes a pulley 318 communicatively coupled to the shaft 316. Although not illustrated, the pulley may be driven by a belt connected to a driving force, such as a motor or engine.
The housing 302 of the compressor 300 may be cast, e.g., from a metal or metal alloy, and the casting process may create a number of voids generally defining the passageway 312. Arrows 320 generally show the flow of refrigerant through the compressor. As illustrated, after the refrigerant is compressed by the pistons 314, it may be passed through a discharge cavity 322 formed in the endcap 306.
Thus, as will be appreciated, the discharge cavity 406 generally includes the individual cavity portions 408a-408g and channels 412 connecting those cavity portions 408a-408g. The discharge cavity 406 has a predetermined volume resulting from the size and shape of the cavity portions 408a-408g and the channels 410. As described above, high-pressure refrigerant output from the pistons is received in the discharge cavity 406 where it then passes via an orifice 414 into an outlet chamber 416. The outlet chamber 416 is in fluid communication with an outlet of the compressor. In the illustrated embodiment, the outlet may be formed as a portion of the housing not illustrated.
As illustrated in
In implementations of this disclosure, the sorbent member is formed of a desiccant-entrained polymer. For example, the inventors have found by forming the illustrated sorbent body 500 from a mixture of polymer and a desiccant, sufficient water-vapor absorption is achieved to alleviate the need for a conventional desiccant in a desiccant chamber associated with the condenser. For example, implementations of this disclosure may completely obviate the desiccant chamber 116.
In some examples, the sorbent material may be formed from polymer present in an amount of from at least about 30% by weight to about 70% by weight, balance desiccant. In implementations of this disclosure, the polymer may be polypropylene, and the desiccant may be a molecular sieve, such as zeolite, for example. Both of these materials are acceptable for use with conventional refrigerants. In other embodiments, other polymers and/or sorbents may be used. For example, and not by way of limitation, other polymers that could be used may include polyesters or polycarbonates. In some instances, polymers that are hydroscopic may be chosen. The desiccant may be any hygroscopic substance that absorbs or adsorbs water. Other known desiccants that could be used in embodiments of this disclosure may include activated charcoal, calcium chloride or silica gel. Other sorbents also could be used.
In operation, refrigerant flowing through the compressor, and more specifically through the discharge cavity 322, 406, contacts the sorbent body where moisture is absorbed by the desiccant entrained in the polymer. As will be appreciated, the efficacy of the sorbent body 500 may be altered depending upon the desired moisture absorption of the body. For instance, the loading of the desiccant in the body, i.e., the amount of desiccant included, the volume of the sorbent body, and the exposed surface area of the sorbent body may all impact the amount of moisture absorbed by the sorbent body and/or the speed at which the moisture is absorbed.
As in the embodiment of
In implementations of this disclosure, the sorbent body is secured in the compressor. For example, in the embodiment of
More specifically,
Modifications to the sorbent body 604 also are contemplated. For example, although the sorbent body 604 is illustrated as touching sidewalls of the cavity 602, the sorbent body may be dimensioned so as to be spaced from the sidewalls. For example, the sorbent body may be configured to only touch a bottom surface, e.g., a surface into which the bolts 606 are threadably received, of the cavity 602. Such an arrangement may be beneficial to improve the flow of fluid through the cavity 602 and/or to increase a surface area of the sorbent body 604 that is exposed to the fluid. As will be appreciated by those having ordinary skill in the art, the greater the surface area of the sorbent body, the better its moisture absorbing capabilities (absorption rate).
In still other modifications of the example of
Although examples illustrated herein generally show the use of press-fitting, fasteners and clips to retain a sorbent body in a cavity of a compressor, other techniques and systems also are contemplated. For example, a vapor permeable cover may be secured over the sorbent body. Alternatively, retention features, similar to the clips 708 illustrated in
Moreover, although not illustrated, additional features may also be provided in the compressor and/or sorbent body according to examples of this disclosure. For instance, a dye tracer may be entrained in the sorbent body and/or may be provided separated in the compressor. For instance, the dye tracer may be used to detect leaks in the air conditioning system.
The novel air conditioning systems and compressors described herein may provide many benefits over conventional systems. For example, and as discussed above, the disclosed embodiments may obviate the desiccant chambers that are conventionally appended to condensers. The removal of the desiccant chamber may reduce the footprint, size, and/or cost of the condenser. Moreover, removing the conventional desiccant sachet may result in a cleaner system. Specifically, the conventional desiccant generally includes a particulate or granular desiccant in a porous sachet. Such desiccant may be prone to dusting, i.e., the release of small particles, which can migrate through the sachet and into the refrigerant and/or other components of the air conditioning system. Moreover, removing the sachet-based desiccant may improve the system because the textile making up the sachet may absorb, e.g., by wicking, oil in the cooling system. For example, compressor oil may be present in the compressor to lubricate surfaces and components. Aspects of the present disclosure may reduce the amount of oil necessary, and therefore the cost of the system, because the sorbent body will not absorb the oil.
The present disclosure may also reduce costs associated with manufacturing. For instance, operations associated with filling and sealing the desiccant chamber, as well as re-filling and re-sealing in some instances, are no longer needed in aspects of this disclosure. Instead, the sorbent body may be secured in the compressor, and the compressor packed for delivery. In some current packaging techniques, the inlet and outlet ports of the compressor are sealed between manufacture and use, and thus the integrity of the sorbent body would be maintained. Other features and benefits will also be understood by those having ordinary skill in the art, with the benefit of this disclosure.
While one or more embodiments have been described, various alterations, additions, permutations and equivalents thereof are included within the scope of the disclosure.
In the description of embodiments, reference is made to the accompanying drawings that form a part hereof, which show by way of illustration specific embodiments of the claimed subject matter. It is to be understood that other embodiments may be used and that changes or alterations, such as structural changes, may be made. Such embodiments, changes or alterations are not necessarily departures from the scope with respect to the intended claimed subject matter. While the steps herein may be presented in a certain order, in some cases the ordering may be changed so that certain inputs are provided at different times or in a different order without changing the function of the systems and methods described. The disclosed procedures could also be executed in different orders. Additionally, various computations that are herein need not be performed in the order disclosed, and other embodiments using alternative orderings of the computations could be readily implemented. In addition to being reordered, the computations could also be decomposed into sub-computations with the same results.
Furthermore, although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described. Rather, the specific features and acts are disclosed as exemplary forms of implementing the claims.
Claims
1. An air conditioning system for a vehicle, the air conditioning system comprising:
- an evaporator;
- a condenser; and
- a compressor comprising: a housing defining an inlet in fluid communication with the evaporator, a fluid outlet in fluid communication with the condenser, and at least one interior fluid path fluidly connecting the inlet and the outlet; at least one piston disposed in the housing and configured to compress fluid in the interior fluid path; and a sorbent body disposed in the interior fluid path.
2. The air conditioning system of claim 1, wherein the sorbent body comprises an injection molded sorbent.
3. The air-conditioning system of claim 1, wherein the housing comprises an end cap comprising at least one cavity defining a portion of the internal fluid path, the sorbent body being disposed in the at least one cavity.
4. The air-conditioning system of claim 3, wherein the sorbent body is an injection molded sorbent configured to be retained in the at least one cavity.
5. The air-conditioning system of claim 4, further comprising a retention mechanism configured to retain the injection molded sorbent in the at least one cavity.
6. The air-conditioning system of claim 4, wherein the injection molded sorbent is configured to be press fit into the at least one cavity.
7. The air-conditioning system of claim 4, wherein the injection molded sorbent comprises a body and a hole extending through the body, the compressor further comprising a fastener extending at least partially through the hole to retain the injection molded sorbent in the at least one cavity.
8. A compressor comprising:
- a housing;
- an inlet port;
- an outlet port;
- an internal channel fluidly connecting the inlet port and the outlet port;
- at least one piston disposed in fluid communication with the internal channel, a first portion of the internal channel between the inlet port and the at least one piston comprising a low-pressure portion and a portion of the internal channel between the at least one piston and the outlet port comprising a high-pressure portion; and
- a molded sorbent body disposed in the high-pressure portion of the internal channel.
9. The compressor of claim 8, wherein:
- the housing includes a main body and an end cap removably sealable to the main body;
- the at least one piston is disposed in the main body;
- the high-pressure portion is at least partially defined by a cavity in the cap; and
- the molded sorbent body is disposed in the cavity in the cap.
10. The compressor of claim 8, wherein the molded sorbent body is secured in the cavity.
11. The compressor of claim 10, wherein the molded sorbent body is press fit into the cavity.
12. The compressor of claim 10, further comprising a fastener configured to secure the molded sorbent body in the cavity, the fastener comprising at least one of a tab, a threaded fastener, or a flange.
13. The compressor of claim 8, wherein the molded sorbent body is an injection molded desiccant-entrained polymer.
14. The compressor of claim 8, wherein the molded sorbent body comprises a polymer and at least one of zeolite or molecular sieve.
15. An air conditioning system for a vehicle, the air conditioning system comprising:
- an evaporator;
- a condenser; and
- a compressor,
- wherein the evaporator, the condenser and the compressor are in fluid communication and comprise a closed fluid system through which a refrigerant circulates, the compressor comprising: a housing defining an inlet in fluid communication with the evaporator, an outlet in fluid communication with the condenser, and at least one interior fluid path fluidly connecting the inlet and the outlet; a plurality of pistons disposed in the housing and configured to compress the refrigerant in the interior fluid path, a first portion of the internal fluid path between the inlet port and the plurality of pistons comprising a low-pressure portion and a second portion of the internal fluid path between the plurality of pistons and the outlet port comprising a high-pressure portion; and a molded sorbent body disposed in the high-pressure portion of the interior fluid path.
16. The air conditioning system of claim 15, wherein the molded sorbent body comprises an injection-molded, desiccant-entrained polymer configured for retention in the high-pressure portion.
17. The air conditioning system of claim 16, wherein the sorbent body comprises from about 30% to about 70% desiccant and from about 30% to about 70% polymer.
18. The air condition system of claim 17, wherein the molded sorbent body comprises at least one of molecular sieve, zeolite or activated carbon.
19. The air conditioning system of claim 15, wherein the molded sorbent body is press-fit into the high-pressure portion of the interior fluid path.
20. The air conditioning system of claim 15, wherein the compressor further comprises a fastener configured to secure the molded sorbent body in the high-pressure portion of the interior fluid path.
Type: Application
Filed: Nov 16, 2017
Publication Date: May 16, 2019
Applicant: Multisorb Technologies, Inc. (Buffalo, NY)
Inventor: Samuel Alexander Incorvia (Buffalo, NY)
Application Number: 15/814,974