Abstract: The present disclosure is directed to implementation of an environmental control unit using rotomolded techniques to fabricate the structures of the unit instead of the standard conventional sheet metal, extruded, forged, and punched parts. Such implementations will provide a lighter weight and more durable mechanical configuration that will also simplify inspection, simplify assembly/disassembly, and reduce fabrication costs. Implementations incorporate rotationally-molded interlocking structures to contain and attach the critical items of the ECU's mechanical components including the compressor, and the indoor and outdoor coils, as well as the fan and blower motor assembly. In one implementation, the rotomolded structure is strengthened and insulated (thermally and acoustically) by filling the interior void of the rotationally molded structure with a closed-cell foam.

Abstract: An apparatus and method are disclosed for ensuring adequate and uniform cooling for any heat-generating device that experiences large heat pulses by integrating parallel expansion devices and their control directly into each of a discrete cooling load or cold plate. One of the parallel expansion devices is an integrated cartridge thermostatic expansion valve (TXV) and the other is an electrically-actuated valve. The TXV is positioned such that a sensing element is located directly within an exit refrigerant stream, thereby improving time-response of the valve and eliminating the need for a capillary tube. The electrically-actuated valve provides a sudden burst of refrigerant while the TXV is responding to sudden heat pulses and operates at the command of the heat generating system or triggered by a temperature rise. The disclosed operational method leads to an order of magnitude reduction in settling time after a heat pulse.

Abstract: A flow control cartridge is used with a cold plate to form a cold plate assembly within which a refrigerant circulates for cooling at least one heat generating device. The cartridge includes a thermal expansion valve and a sensing portion that with a bellows-type actuator within the cartridge. The bellows-type actuator is located directly in a stream of the refrigerant exiting the cold plate. The thermal expansion valve is comprised of a main body having an inlet orifice arranged to receive refrigerant that has been subcooled from a condenser of a vapor compression system or a recuperative heat exchanger, and a needle arranged in an expanded section of the main body in association with discharge ports in the expanded section for discharging the refrigerant in a two-phase state into the cold plate.

Abstract: A method is disclosed for uniformly cooling a cooling plate of a heat generating device. Sub-cooled refrigerant is flowed through a thermal expansion valve and then into the cooling plate as a two-phase refrigerant where the refrigerant is superheated. Any refrigerant remaining in a fluid state before reaching a sensing portion associated with the thermal expansion valve and exiting the cooling plate can be completely vaporized by a recuperative heat exchanger. The superheated refrigerant is then passed to the sensing portion so that the superheated refrigerant directly transfers heat to a fluid within the sensing portion and causes a pressure change that is communicated to a needle of the thermal expansion valve.

Abstract: An apparatus for uniform cooling of a single power electronics device, an array of discrete power electronics devices or types of other heat-generating by integrating discrete thermostatic expansion devices (TXVs) and their control directly into each discrete cold plate. The thermostatic expansion device is positioned such that a sensing element is located directly within the exit refrigerant stream.

Abstract: A vapor compression thermal control system having at least one electrically powered evaporator fan and an apparatus for preventing compressor overloading apparatus having a sensor that measures temperature of air entering the evaporator. That measured temperature is compared with at least one predetermined temperature setting to activate a predetermined evaporator blower on/off duty cycle when the measured temperature exceeds the predetermined temperature. Alternatively, the apparatus can have a sensor that measures temperature of air being used to cool the condenser, and that measured temperature is then compared with at least one predetermined temperature setting to activate a predetermined evaporator blower on/off duty cycle when the measured temperature exceeds the predetermined temperature. In either case, it is evaporator air flow that is modulated when the system is operated as a heat pump. For liquid cooled evaporators, however the circulation pump instead of the fan is modulated.

Abstract: A method and apparatus are disclosed for inducing a supercavitating flow inside a fuel injection nozzle orifice to reduce the penetration length of the fuel spray, maintain high levels of fuel atomization, and improve uniformity of the fuel spray exiting the nozzle such that high-pressure injectors can be used on small engines. This reduction in penetration length is accomplished without any reduction in upstream fuel pressure.

Abstract: A compact and lightweight electric generator for portable power applications employs a new engine design and integration approach for reducing engine, generator, and starter weight. A unique flywheel alternator/starter configuration that generates electrical power, rotates the engine for starting, provides inertia for smooth engine operation, pressurized air for cooling, and inertia for the alternator. An engine cowling provides rotating component protection, a fan shroud mechanism, cooling air ducts, and a cooling mechanism for handling large quantities of heat produced by rectified power conversion. An electrical hook up that allows the generator to provide transient surge capacity for starting inductive loads, or improved load leveling and fuel efficiency.

Abstract: A compact and lightweight hybrid vehicle power source employs an integrated engine hybrid electric boost power design that operates on a single battery bank for all electrical functions. An integrated flywheel, cooling fan and a single hybrid electric motor drive, engine starter, electromagnetic regenerative braking device and battery charging alternator are combined. The flywheel alternator/starter/hybrid-drive configuration generates electrical power for battery recharging and parasitic loads, rotates the engine for starting, provides boost power for faster vehicle accelerations, provides regenerative braking for faster decelerations, provides inertia for smooth engine operation, and provides pressurized air for forced convection cooling.

Abstract: A retrofit arrangement for attacking an electrical lead to a terminal has a body consisting of a conductive central portion and a non-conductive portion substantially surrounding the central portion.

Abstract: A field-installable and removable moisture and/or acid test kit and method is used for a vapor compression system. A moisture and/or acid indicator is provided in the test kit which is installed at a single point location upstream or downstream of the system compressor in a region where the system working fluid is in a substantially vapor phase. The test kit can be connected to the system by a threaded connection or a quick disconnect fitting. The moisture/acid indicator in the test kit detects the presence of moisture and/or acid by a diffusion of moisture or acid to the indicator via diffusion. Some magnification is provided in the test kit because the lower transport rates from the vapor diffusion mechanism requires a smaller mass of indicator material than has been used in conventional flowing liquid systems.

Abstract: A retrofit arrangement using a non-conductive adaptor body is used to attach leads or lead spade terminations to deteriorated compressor terminals. A secure holding force between the leads or spades attached to the leads and the deteriorated terminals is obtained with a wedging force. A screw is arranged at an angle to the terminal to directly provide the wedging force. The screw can also be of non-conductive material.

Abstract: A compact, lightweight, and efficient evaporative spray cooling system is provided for removing high heat fluxes from surfaces of devices such as micro-electronic chips, metal, mirrors, and lasers. The system uses expanding metastable two-phase flow and a method of controlling the spray for optimum heat flux removal. Control includes spray atomization, fluid-phase, mass flow, and spray temperature.

Abstract: A method for controlling operation of a centrifugal cooling apparatus, which has at least one of an evaporator, a centrifugal compressor having a magnetic bearing system, a condenser, and an expansion device, includes monitoring an operating condition of the magnetic bearing system, and controlling compressor flow stability based upon the operating condition of the magnetic bearing system.

Abstract: A compact, lightweight, and efficient evaporative spray cooling system is provided for removing high heat fluxes from surfaces of devices such as micro-electronic chips, metal, mirrors, and lasers. The system uses expanding metastable two-phase flow and a method of controlling the spray for optimum heat flux removal. Control includes spray atomization, fluid-phase, mass flow, and spray temperature.

Abstract: A method for controlling magnetic bearings is disclosed. More specifically, this method moves the rotor position setpoint away from the center point between two opposing bearings and closer to one of the bearings. Assuming the force on the rotor is unidirectional, the bearings will be more stable and will be able to exert more force on the rotor. The bearings require less current, thereby allowing for the reduction of the winding size, and the power consumption of the bearing is decreased. The movement of the shaft in one direction or the other necessitates adaptive control, or the alteration of the dynamic control algorithm to maintain optimal performance by accounting for different system stability requirements.

Abstract: A compact, portable clothes washer and dryer system requires no direct water connection or drain line and includes a feed reservoir for holding hot or cold water; a basket for receiving clothes and said water from said feed reservoir; a filtration membrane unit that generates permeate for rinsing said clothes and retentate; a motor for operating said basket; a pump for circulating water from said feed reservoir through said membrane unit and to said basket; and a heating assembly for drying said clothes in said basket. The system reduces water usage and gray water generation for washing clothes. The system is particularly useful in dormitories, small apartments, or other remote dwellings where water is scarce or where there are no water feed lines or drains.

Abstract: A compact, portable clothes washer and dryer system requires no direct water connection or drain line and includes a feed reservoir for holding hot or cold water; a basket for receiving clothes and said water from said feed reservoir; a filtration membrane unit that generates permeate for rinsing said clothes and retentate; a motor for operating said basket; a pump for circulating water from said feed reservoir through said membrane unit and to said basket; and a heating assembly for drying said clothes in said basket. The system reduces water usage and gray water generation for washing clothes. The system is particularly useful in dormitories, small apartments, or other remote dwellings where water is scarce or where there are no water feed lines or drains.

Abstract: A compact, portable clothes washer and dryer system requires no direct water connection or drain line and includes a feed reservoir for holding hot or cold water; a basket for receiving clothes and said water from said feed reservoir; a filtration membrane unit that generates permeate for rinsing said clothes and retentate; a motor for operating said basket; a pump for circulating water from said feed reservoir through said membrane unit and to said basket; and a heating assembly for drying said clothes in said basket. The system reduces water usage and gray water generation for washing clothes. The system is particularly useful in dormitories, small apartments, or other remote dwellings where water is scarce or where there are no water feed lines or drains.