Refrigerant liquid-gas separator with electronics cooling

{
  "publication_number": "US10369863B2",
  "country": "US",
  "kind": "B2",
  "title": "Refrigerant liquid-gas separator with electronics cooling",
  "abstract": "The refrigerant liquid-gas separator is thermally coupled to electronics to transfer heat away from the electronics, and assist in vaporizing the liquid refrigerant. The liquid-gas separator device includes a refrigeration section configured to couple to a refrigeration loop, and an electronics board thermally coupled to the refrigeration section. The refrigeration section includes: (a) a refrigerant inlet configured to receive refrigerant from the refrigeration loop; (b) a refrigerant outlet configured to release vapor refrigerant to the refrigeration loop; and (c) a cavity coupled to the refrigerant inlet and the refrigerant outlet, the cavity configured to separate liquid refrigerant from vapor refrigerant. In use, heat from the electronics board is transferred to the refrigerant.",
  "claims": [
    "1. A refrigerant system, comprising: a liquid-gas separator device including: a refrigeration section configured to couple to a refrigeration loop, the refrigeration section comprising: a refrigerant inlet positioned on a first side of the liquid-gas separator and configured to receive refrigerant from the refrigeration loop; a refrigerant outlet positioned on the first side of the liquid-gas separator and configured to release vapor refrigerant to the refrigeration loop; a cavity coupled to the refrigerant inlet and the refrigerant outlet, the cavity configured to separate liquid refrigerant from vapor refrigerant, the cavity comprising an inlet sub-cavity, an outlet sub-cavity, and a cap sub-cavity, wherein: the inlet sub-cavity is coupled to the refrigerant inlet; the outlet sub-cavity is coupled to the refrigerant outlet; the outlet sub-cavity is separated from the inlet sub-cavity by a first wall; and the cap sub-cavity is positioned on a second side of the liquid-gas separator device, opposite the first side, and fluidly couples the inlet sub-cavity with the outlet sub-cavity; and an electronics board mounted on a second wall of the refrigeration section such that the electronics board spans, and is thermally coupled to, at least a portion of the inlet sub-cavity and at least a portion of the outlet sub-cavity so that, in use, heat from the electronics board is transferred to the refrigerant.",
    "2. The refrigerant system of claim 1, further comprising a compressor coupled downstream to the refrigerant outlet of the liquid-gas separator device, the compressor configured to compress refrigerant released by the liquid-gas separator device.",
    "3. The refrigerant system of claim 2, further comprising an evaporator coupled upstream to the refrigerant inlet of the liquid-gas separator device, the evaporator configured to evaporate refrigerant.",
    "4. The refrigerant system of claim 3, further comprising a condenser coupled upstream to the evaporator and downstream to the compressor, the condenser configured to condense refrigerant that has been compressed by the compressor.",
    "5. The refrigerant system of claim 1, wherein the electronics board is thermally coupled to the refrigeration section, such that in use, the heat transferred to the refrigerant converts at least a portion of the refrigerant in the inlet sub-cavity, and at least a portion of the refrigerant in the outlet sub-cavity, from liquid refrigerant to vapor refrigerant.",
    "6. The refrigerant system of claim 1, wherein the electronics board is thermally coupled to the refrigeration section, such that in use, the heat transferred from the electronics boards cools electrical components on the electronics board.",
    "7. The refrigerant system of claim 1, wherein the liquid-gas separator device further includes compressor controller electronics mounted on the electronics board.",
    "8. The refrigerant system of claim 1, wherein the liquid-gas separator device further includes, mounted on the electronics board, at least one of: a direct current (DC) to DC converter; an alternating current (AC) to AC converter; a DC to AC converter; an AC to DC converter; a power converter component; a power transistor; and a transformer.",
    "9. The refrigerant system of claim 1, wherein the liquid-gas separator device further includes one or more additional electronics boards thermally coupled to the refrigeration section, such that in use heat from the one or more additional electronics boards is transferred to the refrigerant.",
    "10. The refrigerant system of claim 1, wherein the liquid-gas separator device further includes a liquid-vapor separator component within the outlet sub-cavity, the liquid-vapor separator component coupled to the refrigerant outlet and configured to impede the liquid refrigerant from being released via the refrigerant outlet.",
    "11. The refrigerant system of claim 10, wherein the liquid-vapor separator component is configured to utilize gravity to prevent the liquid refrigerant from being released via the refrigerant outlet.",
    "12. The refrigerant system of claim 1, wherein the liquid-gas separator device includes one or more connectors to mount to an inside of a vehicle engine compartment.",
    "13. The refrigerant system of claim 1, wherein the liquid-gas separator device further includes one or more thermally-conductive fasteners configured to secure the electronics board to the refrigeration section, wherein the electronics board is thermally coupled to the cavity via the one or more thermally-conductive fasteners.",
    "14. The refrigerant system of claim 13, wherein the electronics board is thermally coupled to the cavity via a thermal material.",
    "15. The refrigerant system of claim 13, wherein one or more thermally-conductive fasteners includes: a first fastener securing, and thermally-coupling, the electronics board to a portion of the second wall adjacent to the inlet sub-cavity, and a second fastener securing, and thermally-coupling, the electronics board to a portion of the second wall adjacent to the outlet sub-cavity.",
    "16. The refrigerant system of claim 1, wherein the refrigeration section is configured to withstand pressure exerted by refrigerant within the cavity.",
    "17. The refrigerant system of claim 1, wherein the liquid-gas separator device further includes a second refrigerant outlet distinct from the refrigerant outlet, the second refrigerant outlet configured to release liquid refrigerant from the cavity.",
    "18. The refrigerant system of claim 1, wherein the cavity is formed from at least one of: an extruded metal; a diecast metal; and a machined housing.",
    "19. The refrigerant system of claim 1, wherein the liquid-gas separator device is configured and arranged such that, in use, refrigerant enters via the refrigerant inlet and flows through the inlet sub-cavity to the outlet sub-cavity via the cap sub-cavity prior to exiting via the refrigerant outlet.",
    "20. The refrigerant system of claim 1, wherein the liquid-gas separator device further comprises a casing configured and arranged to enclose at least a portion of each of the refrigeration section and the electronics board."
  ],
  "description_excerpt": "This relates generally to air-conditioning systems, including but not limited to, a vehicle air-conditioning system having a refrigerant liquid-gas separator with integrated controller electronics.\n\nHeating and overheating are serious issues for electronics. In general, as electronics heat up, leakage currents increase, thermal noise increases, dopants may migrate, and/or the crystalline structure of Silicon components may break down. This can lead to malfunctioning components or a complete device failure. In addition, electronics at higher temperatures tend to require more power to operate.\n\nThis problem particularly acute in vehicle electronics systems, particularly those in or near the engine compartment, which tend to be exposed to high temperatures. Thus, cooling for these electronics is of particular importance.\n\nAnother problem in vehicle systems relates to the air conditioning system. Most vehicle air conditioning systems function by converting a refrigerant between vapor and liquid forms using a compressor. However, as the refrigerant is typically circulated around a closed-circuit loop, it is possible that liquid refrigerant can enter, and damage, the compressor. Therefore, an accumulator, or other liquid-gas separator device, is sometimes used to store or accumulate liquid refrigerant and prevent it from entering the compressor. By doing so, the accumulator helps prevent liquid refrigerant from entering the compressor. Over time, however, too much liquid refrigerant may accumulate in the liquid-gas separator device.",
  "cpc": [
    "B60H 1/00271",
    "B60H 1/00378",
    "B60H 2001/00307",
    "F25B 2400/051",
    "F25B 2400/23",
    "F25B 31/006",
    "F25B 43/00",
    "F25B 43/006",
    "H05K 7/20936",
    "H10W 40/73"
  ],
  "ipc": [
    "B60H 1/32",
    "B60H 1/00",
    "H10W 40/73",
    "F25B 31/00",
    "F25B 43/00"
  ],
  "assignees": [
    "Bergstrom Inc"
  ],
  "inventors": [
    "Brett S. Connell",
    "Brett Herrmann",
    "Aaron D. Sullivan",
    "Terry Zeigler"
  ],
  "filing_date": "2016-09-30",
  "publication_date": "2019-08-06",
  "grant_date": "2019-08-06",
  "priority_date": "2016-09-30",
  "application_number": "US-201615283150-A",
  "family_id": "57570185",
  "cited_by_count": 13,
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