SUCTION LINE HEAT EXCHANGER

Description

RELATED APPLICATION

This application claims priority to U.S. Provisional Application Ser. No. 63/705,327, filed Oct. 9, 2024, entitled “Suction Line Heat Exchanger,” which is incorporated herein by reference.

TECHNICAL FIELD

This relates generally to a suction line heat exchanger, more specifically, an integrated accumulator, receiver dryer, and suction line heat exchanger for use in a refrigerant system.

BACKGROUND

Conventional refrigerant systems, such as vapor-compression refrigerant systems, use dryer devices and/or accumulator devices to store refrigerant and/or treat a refrigerant as it flows through the conventional refrigerant systems. Untreated refrigerant can lead to malfunctioning components or device failure. For example, liquid refrigerant entering a compressor can damage the compressor. Additionally, debris or other contaminants in the refrigerant can decrease performance of conventional refrigerant systems. Moreover, dryer devices and/or accumulator devices can occupy a large footprint, which results in design constraints that limit flexibility in refrigerant systems.

Accordingly, there is a need for systems and/or devices that address the above-identified drawbacks.

SUMMARY

The devices and systems disclosed herein allow for refrigerant systems with improved efficiency. The devices and systems described herein provide an integrated accumulator and dryer device that is compact and cost-effective. Additionally, the integrated accumulator and dryer device disclosed herein improves performance of refrigerant systems (e.g., vapor-compression refrigerant systems) by operating as a suction line heat exchanger. The integrated accumulator and dryer device, referred to herein as a suction line heat exchanger, improves performance of condensers and/or evaporators. The disclosed suction line heat exchanger is configured to filter a refrigerant, remove moisture from a refrigerant, and/or convert a refrigerant into a gas before providing the refrigerant to a compressor. Moreover, the disclosed suction line heat exchanger allows for reduced condenser sizing, increases subcooling,

In one aspect, a suction line heat exchanger (HX) includes an outer chamber including a first refrigerant channel, and an inner chamber including a second refrigerant channel distinct from the first refrigerant channel. The inner chamber is disposed within the outer chamber. The suction line HX further includes a first set of ports fluidically coupling a first HX with a second HX via the second refrigerant channel, and a second set of ports fluidically coupling the second HX with a compressor via the first refrigerant channel. The inner chamber receives a first portion of refrigerant from the first HX and guides the first portion of refrigerant toward the second HX, the outer chamber receives a second portion of refrigerant from the second HX and guides the second portion of refrigerant toward the compressor, and the second portion of refrigerant substantially fills the outer chamber and surrounds the inner chamber such that heat transfers between the first portion of refrigerant and the second portion of refrigerant.

In another aspect, a refrigerant system (e.g., climate control system) includes a compressor fluidically coupled between a suction line HX and a first HX. The first HX is fluidically coupled between the compressor and the suction line HX. The refrigerant system further includes a second HX and a suction line HX, the second HX fluidically coupled with the suction line HX. The suction line HX includes an outer chamber including a first refrigerant channel and an inner chamber including a second refrigerant channel distinct from the first refrigerant channel. The inner chamber is disposed within the outer chamber. The suction line HX further includes a first set of ports fluidically coupling the first HX with the second HX via the second refrigerant channel, and a second set of ports fluidically coupling the second HX with the compressor via the first refrigerant channel. The inner chamber receives a first portion of refrigerant from the first HX and guides the first portion of refrigerant toward the second HX, the outer chamber receives a second portion of refrigerant from the second HX and guides the second portion of refrigerant toward the compressor, and the second portion of refrigerant substantially fills the outer chamber and surrounds the inner chamber such that heat transfers between the first portion of refrigerant and the second portion of refrigerant.

In yet another aspect, a method of manufacturing a suction line HX includes providing an outer chamber including a first refrigerant channel. The method includes providing an inner chamber including a second refrigerant channel distinct from the first refrigerant channel. The method also includes disposing the inner chamber within the outer chamber such that the inner chamber is exposed to a refrigerant receiver within the outer chamber. The method includes providing a first set of ports for receiving and providing the refrigerant via the second refrigerant channel and providing a second set of ports for receiving and providing the refrigerant via the first refrigerant channel.

The features and advantages described in the specification are not necessarily all inclusive and, in particular, certain additional features and advantages will be apparent to one of ordinary skill in the art in view of the drawings, specification, and claims. Moreover, it should be noted that the language used in the specification has been principally selected for readability and instructional purposes.

Having summarized the above example aspects, a brief description of the drawings will now be presented.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the various described embodiments, reference should be made to the Detailed Description below, in conjunction with the following drawings in which like reference numerals refer to corresponding parts throughout the figures.

FIG. 1 is a block diagram of climate control system including a suction line heat exchanger, in accordance with some embodiments.

FIGS. 2A-2C illustrate a suction line heat exchanger, in accordance with some embodiments.

FIGS. 3A and 3B illustrate cross-sections of an example suction line heat exchanger, in accordance with some embodiments.

FIG. 4 illustrates different views of a suction line heat exchanger, in accordance with some embodiments.

FIG. 5 illustrates improvements to a climate cooling system using a suction line heat exchanger, in accordance with some embodiments.

FIG. 6 is a block diagram illustrating a representative controller, in accordance with some embodiments.

FIG. 7 illustrates a flowchart of a method for manufacturing a suction line heat exchanger, in accordance with some embodiments.

DETAILED DESCRIPTION

Reference will now be made in detail to embodiments, examples of which are illustrated in the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the various described embodiments. However, it will be apparent to one of ordinary skill in the art that the various described embodiments may be practiced without these specific details. In other instances, well-known methods, procedures, components, circuits, and networks have not been described in detail so as not to unnecessarily obscure aspects of the embodiments.

Many modifications and variations of this disclosure can be made without departing from its spirit and scope, as will be apparent to those skilled in the art. The specific embodiments described herein are offered by way of example only, and the disclosure is to be limited only by the terms of the appended claims, along with the full scope of equivalents to which such claims are entitled.

As used herein, a “refrigerant” is a fluid adapted to undergo phase transitions between liquid and gas during operation of a corresponding refrigerant system. For example, the refrigerant has a liquid-to-gas transition point below a target operating temperature of the refrigerant system. In various embodiments, the refrigerant can be classified according to different flammability classes, such as a class 1, class 2, class 2L, or class 3 refrigerants.

Some embodiments of the present disclosure are described in the context of air-conditioning systems. In some embodiments, the air-conditioning system includes, or is a component of, a heating, ventilation, and air-conditioning (HVAC) system. The embodiments of the present disclosure can be used in vehicles, buildings, rooms, or compartments. For example, embodiments of the present disclosure can be used in the context of an air-conditioning systems to cool different compartments or spaces of an over-the-road or off-road vehicle. It is to be appreciated that the term vehicle as used herein may refer to trucks, such as tractor-trailer trucks or semi-trailer trucks, the scope of the present teachings is not so limited. The present teachings are also applicable, without limitation, to cars, vans, buses, trailers, boats, planes, and any other suitable vehicle. Similarly, the present teachings are also applicable, without limitation, to offices, homes, bedrooms, classrooms, and any other industrial, commercial, private and/or public buildings.

FIG. 1 is a block diagram of climate control system 100 including a suction line heat exchanger, in accordance with some embodiments. The climate control system 100 (e.g., a heating, ventilation, and air conditioning (HVAC) system, an air-conditioning system, etc.) includes a compressor 102 (e.g., any type of compressor including but not limited to a reciprocating compressor, rotary compressor, scrolling compressor, centrifugal compressor, screw compressor, heat pump, etc.), a first heat exchanger (HX) 104 (e.g., a condenser to absorb or remove heat), a second HX 106 (e.g., an evaporator to absorb heat from air in a compartment), the suction line HX 114, and refrigerant lines 122 fluidly coupling the different components. In some embodiments, the climate control system 100 includes an expansion device 132 (e.g., a metering device, thermal expansion valve, etc.) and/or one or more valves (e.g., a first valve 126 and/or a second valve 134, such as flow control valve, check valves, pressure valves, etc.). In some embodiments, the climate control system 100 includes a reservoir 128. In some embodiments, the climate control system 100 includes one or more sensors and a controller 124.

For example, as shown by the climate control system 100, a first refrigerant line 122-1 fluidically couples the compressor 102 and the first HX 104; a second refrigerant line 122-2 fluidically couples the first HX 104 and the suction line HX 114; a third refrigerant line 122-3 fluidically couples the suction line HX 114, the first valve 126, and the reservoir 128; a fourth refrigerant line 122-4 fluidically couples the first valve 126, the reservoir 128, and the expansion device 132; a fifth refrigerant line 122-5 fluidically couples the expansion device 132 and the second HX 106; a sixth refrigerant line 122-6 fluidically couples the second HX 106 and the suction line HX 114; a seventh refrigerant line 122-7 fluidically couples the suction line HX 114 and the second valve 134; and an eighth refrigerant line 122-8 fluidically couples the second valve 134 and the compressor 102. In some embodiments, the one or more sensors are coupled to one or more components and/or along the refrigerant line 122 to obtain operational data. For example, a first sensor 108 is disposes along the first refrigerant line 122-1 and/or on the first HX 104, a second sensor 110 is disposes along the sixth refrigerant line 122-6 and/or on the second HX 106, and third and fourth sensors 116 and 118 are disposed on the suction line HX 114 and/or the second and seventh refrigerant lines 122-2 and 122-7, respectively. Although not shown, one or more sensors can be included on devices, compartments, cabins, rooms buildings, etc. thermally coupled with the climate control system 100.

The climate control system 100 can include a first air-mover device 130 (e.g., a fan, blower, and/or other air moving device) and/or a second air-mover device 135 (e.g., a fan, blower, and/or other air moving device) for facilitating airflow within the climate control system 100 and/or outside of the climate control system 100 (e.g., to a thermally coupled compartment, cabin, room, building, etc.). In some embodiments, the climate control system 100 includes one or more heating elements (not shown) configured to change a temperature of air that passes through the one or more heating elements.

The climate control system 100 can include a power source 138 for powering one or more components, such as the first air-mover device 130, the second air-mover device 135, the compressor 102, the first HX 104, the second HX 106, and the like. In some embodiments, the power source 138 includes a solar cell, an electrical battery, an alternator, or the like. In some embodiments, the power source 138 is belt driven from an internal combustion engine of a vehicle. In some embodiments, the controller 124 manages various components of the climate control system 100. In some embodiments, the controller 124 manages an amount of power drawn by each component of the climate control system 100.

The one or more sensors can include one or more temperature sensors, pressure sensors, CO2 sensors, thermometers, thermostats, humidity sensors, etc. The sensors obtain operations data from the climate control system 100 and/or thermally coupled devices, compartments, cabins, rooms buildings, etc. The operation data can include temperature, pressure, charge levels, air-mover device speeds, compressor speeds, compression rations, ambient temperature, room temperature, device temperature, current or power usage, humidity levels, CO2 levels, and/or other data that is used to adjust operation of the components within or thermally coupled to the climate control system 100.

The controller 124 is communicatively coupled with the compressor 102, the first HX 104, the expansion device 132, one or more valves, the second HX 106, the first air-mover device 130, the second air-mover device 135, the one or more sensors, and/or the suction line HX 114. The controller 124 is configured to control operation of the different communicatively coupled components. In some embodiments, the controller 124 adjusts operation of one or more components based on the operational data obtained by the sensors and/or operational information provided by one or more communicatively coupled components (e.g., compressor on, first air-mover device on, etc.). For example, the controller 124 can use operational data to adjust a speed of the compressor 102, the first air-mover device 130, and/or the second air-mover device 135. Additionally, the controller 124 can be configured to identify one or more errors in the climate control system 100 based on the operational data and/or operational information. For example, the climate control system 100 can calculate a compression ratio of the compressor 102 to determine whether a blockage is present and/or a location of the blockage (e.g., based on various factors such an abnormal sub-cooling level, abnormal super-cooling, etc.).

In some embodiments, the controller 124 operates the one or more valves (e.g., the first valve 126) to inject refrigerant from the (refrigerant) reservoir 128 into the climate control system 100 when the refrigerant charge level is below a predetermined refrigerant charge level. In some embodiments, the controller 124 selectively operates the first valve 126 allow flow of a refrigerant from the reservoir 128 to the climate control system 100. In some embodiments, the second valve 134 selectively restricts or permits flow of the refrigerant to the compressor 102.

In some embodiments, the controller 124 is electrically or wirelessly coupled to an electronic device 136 including but not limited to a display, a receiver, a smartphone or a computer. The controller 124 can provide one or more notifications or signals to be presented or used by the electronic device. For example, the notifications can include audio notifications, such as a beep, alarm, or tune, or visual notifications, such a text or graphic displayed on a screen. The signals include but are not limited to data (e.g., a cooling level, a super-heating level and a refrigerant charge level), warning signals (e.g., a refrigerant charge level is below a predetermined refrigerant charge level), maintenance request or the like. In some embodiments, the controller 124 is configured to receive one or more instructions from the electronic device for adjusting operation of the climate control system 100. For example, the controller 124 can receive one or more instructions for adjusting a temperature of a compartment, defining a desired temperature, defining a desired temperature threshold, adjusting an air-mover speed, adjusting a compressor speed, adjusting a pump speed, etc.

The suction line HX 114 can include a dryer component 160 and an accumulator component 170. In particular, the suction line HX 114 integrates the dryer component 160 and an accumulator component 170 into a single device. As shown and described below in reference to FIGS. 2A-4, the dryer component 160 is disposed within the accumulator component 170. By integrating the dryer component 160 and the accumulator component 170 into a single device, heat can transfer between the refrigerants stored within the dryer component 160 and the accumulator component 170 (e.g., thermal conduction can take place through an inner barrier wall, which operates as a suction line HX). For example, thermal conduction can take place through an inner wall between a high-pressure and/or high-temperature (liquid) refrigerant stored and/or flowing through the dryer component 160 and a low-temperature and/or low-pressure gas refrigerant stored and/or flowing through the accumulator component 170.

The dryer component 160 receives refrigerant from the first HX 104 and guides the refrigerant toward the second HX 106. In some embodiments, the dryer component 160 temporarily stores refrigerant and/or absorbs moisture, debris or other undesirable substances from the refrigerant that has received by the dryer component 160. In some embodiments, the refrigerant received by the dryer component 160 is a high-temperature and/or high-pressure refrigerant. In some embodiments, the refrigerant received by the dryer component 160 is liquid (subcooled) refrigerant. The dryer component 160 contains and/or stores the refrigerant. The dryer component 160 can remove moisture and filter the refrigerant. For example, the dryer component 160 can include a desiccant to remove moisture from the refrigerant and a filter to remove small particles within the refrigerant.

The accumulator component 170 receives refrigerant from the second HX 106 and guides the refrigerant toward the compressor 102. In some embodiments, the accumulator component 170 restricts a liquid refrigerant from entering the compressor 102 (e.g., by temporarily storing excess liquid refrigerant at the accumulator component 170, which prevents or reduces damage to the compressor 102). In some embodiments, the refrigerant received by the accumulator component 170 is a low-temperature and/or low-pressure refrigerant. In some embodiments, the refrigerant received by the accumulator component 170 is a mixed phase refrigerant. The accumulator component 170 changes a received refrigerant into gas before providing the refrigerant to the compressor 102. For example, the accumulator component 170 can boil off refrigerant to prevent liquid refrigerant from returning to the compressor 102. The accumulator component 170 can contain and/or store the refrigerant.

The suction line HX 114 increases subcooling, heats (cool) gas refrigerant to ensure phase change occurs within the accumulator component 170, enhances performance, provides return gas refrigerant to compressor 102 (e.g., reduces or prevents liquid refrigerant from being returned to the compressor 102), and allows for the use of smaller HXs (e.g., allows reduced condenser sizing).

FIGS. 2A-2C illustrate a suction line heat exchanger, in accordance with some embodiments. The suction line HX 114 includes an outer chamber (e.g., accumulator chamber 220), an inner chamber (e.g., dryer chamber 201), a first set of ports (e.g., a dryer inlet 217-1 and a dryer outlet 217-2), and a second set of ports (e.g., an accumulator inlet 227-1 and an accumulator outlet 227-2). The outer chamber 220 forms, in part, an accumulator, and the inner chamber 201 forms, in part, a dyer. FIG. 2A shows portions of a dyer component 160 (FIG. 1) of the suction line HX 114. FIGS. 2B and 2C show an accumulator component 170 (FIG. 1) of the suction line HX 114.

Turning to FIG. 2A, the dryer component 160 is disposed within the accumulator component 170. For example, the dryer chamber 201 is disposed within the accumulator chamber 220. The dryer chamber 201 includes a refrigerant channel 207 for guiding a refrigerant received from a first HX 104 (e.g., via the dryer inlet 217-1 and the second refrigerant line 122-2) towards a second HX 106 (e.g., via the dryer outlet 217-2 and the third refrigerant line 122-3), as described above in reference to FIG. 1. For example, a refrigerant is received via the dryer inlet 217-1, flows along a first direction 219-1 (e.g., a longitudinal direction) of the dryer chamber 201, reaches a first end (e.g., end 203) of the dryer chamber 201, flows from the first end of the dryer chamber 201 along a second direction 219-2, opposite the first direction 219-1, and is released via the dryer outlet 217-2. The refrigerant flowing through the dryer chamber 201 can be high-side (e.g., high-pressure and/or high-temperature) refrigerant. In some embodiments, the refrigerant flowing through the dryer chamber 201 is a liquid refrigerant. In some embodiments, the dryer component allows bidirectional flow of refrigerant through the dryer chamber 201 (e.g., in addition to the flow direction described above, the refrigerant may be received via the dryer outlet 217-2, flow along a third direction, opposite the first direction 219-1, reaches the end 203 of the dryer chamber 201, flows from the end 203 of the dryer chamber 201 along a fourth direction, opposite the third direction, and is released via the dryer inlet 217-1).

The dryer chamber 201 can include a desiccant for removing moisture from the refrigerant. In some embodiments, the dryer chamber 201 stores a predetermined amount of desiccant (e.g., 40 grams). The desiccant can be liquid and/or solid. For example, the desiccant can be formed of silica gel, natural zeolites, molecular sieves, activated alumina, synthetic polymers, calcium chloride, tri-ethylene glycol, and/or lithium chloride. In some embodiments, the dyer component 160 includes a filter 210 for removing particles from the refrigerant. The dyer component 160 can include a removable member (e.g., cap 215). The removable member seals the desiccant 205 within the dryer chamber 201 when coupled to the suction line HX 114. The removable member allows the dyer component 160 to be serviceable. For example, the cap 215 can be removed from the suction line HX 114 such that the desiccant 205 can be replaced.

FIG. 2B show a first view of the accumulator component 170 and FIG. 2C show a second view of the accumulator component 170. The accumulator chamber 220 of the accumulator component 170 houses the dyer component 160 (e.g., the dryer chamber 201). The accumulator chamber 220 includes another refrigerant channel (e.g., tube 225), separate and distinct from the refrigerant channel 207 of the dryer chamber 201, for guiding a refrigerant received from the second HX 104 (e.g., via the accumulator inlet 227-1 and the sixth line 122-6) towards a compressor 102 (e.g., via the accumulator outlet 227-2 and the seventh refrigerant line 122-7), as described above in reference to FIG. 1. For example, a refrigerant is received via the accumulator inlet 227-1, fills or substantially fills the accumulator chamber 220, a liquid or mixed phase refrigerant is changed into a gas refrigerant, the gas refrigerant flows through the tube 225, and flows from the tube 225 to the compressor 102 via the accumulator outlet 227-2. In some embodiments, the tube 225 includes an anti-syphon hole 230. The refrigerant flowing through the accumulator chamber 220 can be low-side (e.g., low-pressure and/or low-temperature) refrigerant. In some embodiments, the refrigerant flowing through the accumulator chamber 220 is a mixed phase refrigerant.

In some embodiments, the accumulator chamber 220 includes a liquid-vapor separator (e.g., the other refrigerant channel (e.g., tube 225) within the outer chamber). The liquid-vapor separator is fluidically coupled to the accumulator outlet 227-2 and impedes a liquid refrigerant from being released via the accumulator outlet 227-2. In some embodiments, the accumulator chamber 220 uses gravity to prevent the liquid refrigerant from being released via the accumulator outlet 227-2. For example, the accumulator chamber 220 temporarily stores a liquid refrigerant, the liquid refrigerant remains on a bottom portion of the accumulator chamber 220 until the liquid refrigerant is changed into a gas refrigerant (e.g., boiled), the tube 225 is disposed at a top portion, opposite the bottom portion, of the accumulator chamber 220 such that the gas refrigerant is able enter the tube 225. In some embodiments, the tube 225 forms a U-shape such that a liquid refrigerant entering the tube 225 is unable to be released via the accumulator outlet 227-2 (until boiled). The accumulator chamber 220 is configured to withstand pressure exerted by the refrigerant.

The accumulator chamber 220 and the dryer chamber 201 of the suction line HX 114 allow for thermal conduction between a refrigerant flowing through the accumulator chamber 220 and a refrigerant flowing through the dryer chamber 201. In particular, conduction takes place through an inner wall (e.g., a wall of or surrounding the dryer chamber 201) between high-pressure and/or high-temperature liquid refrigerant and low-temperature and/or low-pressure gas refrigerant. The accumulator chamber 220 is substantially filled or filled with a refrigerant such that the dryer chamber 201 is surrounded or, at least partially, submerged in refrigerant (facilitating heat transfer (e.g., thermal conduction)).

FIGS. 3A and 3B illustrate cross-sections of an example suction line heat exchanger, in accordance with some embodiments. FIG. 3A shows a cross-section of a dyer component 160 of the suction line HX 114 and FIG. 3B shows a cross-section of an accumulator component 170 of the suction line HX 114.

FIG. 3A shows a dryer chamber 201, a dryer inlet 217-1, a dryer outlet 217-2, a refrigerant channel 207, a filter 210, a desiccant 205, and a cap 215 of the dyer component 160. The dyer component 160 is disposed within the accumulator component 170. A high-side refrigerant enters the dryer chamber 201 via the dryer inlet 217-1, flows through the dryer chamber 201 and exits the dryer chamber 201 via the dryer outlet 217-2. In some embodiments, the dryer chamber 201 allows for bidirectional flow (e.g., as described in reference to FIG. 2A), and the high-side refrigerant may also enter the dryer chamber 201 via the dryer outlet 217-2, flow through the dryer chamber 201 and exit the dryer chamber 201 via the dryer inlet 217-1. The high-side refrigerant is filtered by the filter 210, and moisture is removed from the high-side refrigerant by the desiccant 205.

FIG. 3B shows an accumulator chamber 220, an accumulator inlet 227-1, an accumulator outlet 227-2, another refrigerant channel (not shown). The accumulator component 170 houses the dyer component 160. A low-side refrigerant enters the accumulator chamber 220 via the accumulator inlet 227-1, substantially fills the accumulator chamber 220, flows through the other refrigerant channel (e.g., tube 225), and exits the accumulator chamber 220 via the accumulator outlet 227-2. The low-side refrigerant changed from a mixed phase refrigerant into a gas refrigerant.

FIG. 4 illustrates different views of a suction line heat exchanger, in accordance with some embodiments. The perspective views of the suction line HX 114 show a dryer chamber 201, a dryer inlet 217-1, a dryer outlet 217-2, a desiccant 205, an accumulator chamber 220, an accumulator inlet 227-1, an accumulator outlet 227-2, tube 225, and oil return filter 310.

FIG. 5 illustrates improvements to a climate cooling system using a suction line heat exchanger, in accordance with some embodiments. FIG. 5 shows a pressure-enthalpy diagram for an example refrigerant (e.g., R-134a). Solid lines in the pressure-enthalpy diagram represents a conventional vapor compression cycle for a climate cooling system and dashed lines represent a vapor compression cycle of a climate cooling system using a suction line HX 114. As shown by the pressure-enthalpy diagram, the vapor compression cycle of the climate cooling system using the suction line HX 114 results in an increase in enthalpy deltas across a first HX (e.g., a condenser) and a second HX (e.g., an evaporator).

FIG. 6 is a block diagram illustrating a representative controller 124 in accordance with some embodiments. In some embodiments, the controller 124 includes one or more processing units (e.g., CPUs, ASICs, FPGAs, microprocessors, and the like) 602, one or more communication interfaces 604, memory 608, and one or more communication buses 606 for interconnecting these components (sometimes called a chipset). In some embodiments, the controller 124 includes one or more input devices, such as one or more buttons for receiving input. In some embodiments, the controller 124 includes one or more output devices, such as one or more indicator lights, a sound card, a speaker, a small display for displaying textual information and error codes, etc. In some embodiments, the controller 124 includes a location detection device, such as a GPS (global positioning satellite) or other geo-location receiver, for determining the location of the controller 124. The controller 124 is coupled to one or more sensors 640 and a power source 138, as shown and described above in reference to FIG. 1.

Communication interfaces 604 include, for example, hardware capable of data communications using any of a variety of custom or standard wireless protocols (e.g., IEEE 802.15.4, Wi-Fi, ZigBee, 6LoWPAN, Thread, Z-Wave, Bluetooth Smart, ISA100.11a, WirelessHART, MiWi, etc.) and/or any of a variety of custom or standard wired protocols (e.g., Ethernet, HomePlug, etc.), or any other suitable communication protocol, including communication protocols not yet developed as of the filing date of this document.

Memory 608 includes high-speed random-access memory, such as DRAM, SRAM, DDR SRAM, or other random-access solid-state memory devices; and, optionally, includes non-volatile memory, such as one or more magnetic disk storage devices, one or more optical disk storage devices, one or more flash memory devices, or one or more other non-volatile solid state storage devices. Memory 608, or alternatively the non-volatile memory within memory 608, includes a non-transitory computer-readable storage medium. In some embodiments, memory 608, or the non-transitory computer readable storage medium of memory 608, stores programs, modules, data structures, or a subset or superset thereof. Example programs, modules, and/or data structures include operating logic 610, a communication module 612, a state module 614, a cooling module 616, an error module 618, and database 620.

The operating logic 610 includes procedures for handling various system services and for performing hardware dependent tasks. The communication module 612 is used to connect to and/or communicate with other network devices connected to one or more networks via the one or more communication interfaces 604 (e.g., wired or wirelessly connected). The state module 614 determine an operating state of the system (e.g., of air-conditioning system 100, FIG. 1) and/or sets/adjusts the operating state of the system. The cooling module 616 manages cooling operations of the system (e.g., temperature settings, fan speeds, power settings, etc.). The error module 618 determines whether one or more error conditions are present and/or conveys the one or more error conditions to a user of the system and/or initiates remedial actions in response to the one or more error conditions. The database 620, includes, but is not limited to, sensor information 622 for storing and managing data received, detected, and/or transmitted by one or more sensors of the system (e.g., sensors 108, 110, 116, 118; FIG. 1); component settings 624 for storing and managing operational settings for one or more components of the system (e.g., first HX 104, compressor 102, air-mover devices, and/or second HX 106); and timing information 626 for storing and managing timing information related to operation and/or testing of the system.

Each of the above identified elements (e.g., modules stored in memory 608 of controller 124) corresponds to a set of instructions for performing a function described herein. The above identified modules or programs (i.e., sets of instructions) need not be implemented as separate software programs, procedures, or modules, and thus various subsets of these modules may be combined or otherwise rearranged in various embodiments. In some embodiments, memory 608, optionally, stores a subset of the modules and data structures identified above. Furthermore, memory 608, optionally, stores additional modules and data structures not described above. For example, memory 608 optionally stores a heating module (not shown) for managing heating operations of the system.

FIG. 7 illustrates a flowchart of a method 700 for manufacturing a suction line heat exchanger, in accordance with some embodiments. In some embodiments, the suction line HX manufactured using method 700 is used in vapor-compression refrigerant systems. In some embodiments, the suction line HX manufactured using method 700 can be used in any climate control system described above in reference to FIGS. 1-6.

• • (A1) The method 700 includes providing (710) an outer chamber including a first refrigerant channel. For example, providing an accumulator chamber 220 including tube 225. The method 700 includes providing (720) an inner chamber including a second refrigerant channel distinct from the first refrigerant channel. For example, providing a dryer chamber 201 including a refrigerant channel 207. The method 700 also includes disposing (730) the inner chamber within the outer chamber such that the inner chamber is exposed to a refrigerant receive within the outer chamber. For example, as shown in FIGS. 2A-4, the dryer chamber 201 is housed within the accumulator chamber 220. The method 700 includes providing (740) a first set of ports (e.g., dryer inlet 217-1 and dryer outlet 217-2) for receiving and providing the refrigerant via the second refrigerant channel and providing (750) a second set of ports (e.g., accumulator inlet 227-1 and accumulator outlet 227-2) for receiving and providing the refrigerant via the first refrigerant channel.
  • (A2) In some embodiments of A1, the method 700 further includes forming a service port on the inner chamber, the service port providing access to the inner chamber.
  • (A3) In some embodiments of any one of A1-A2, the method 700 includes providing a desiccant within the inner chamber.
  • (A4) In some embodiments of any one of A1-A3, the method 700 includes providing a filter within the inner chamber.
  • (B1) In accordance with some embodiments, a suction line HX includes an outer chamber including a first refrigerant channel, and an inner chamber including a second refrigerant channel distinct from the first refrigerant channel. The inner chamber is disposed within the outer chamber. The suction line HX further includes a first set of ports fluidically coupling a first HX with a second HX via the second refrigerant channel, and a second set of ports fluidically coupling the second HX with a compressor via the first refrigerant channel. The inner chamber receives a first portion of refrigerant from the first HX and guides the first portion of refrigerant toward the second HX, the outer chamber receives a second portion of refrigerant from the second HX and guides the second portion of refrigerant toward the compressor, and the second portion of refrigerant substantially fills the outer chamber and surrounds the inner chamber such that heat transfers between the first portion of refrigerant and the second portion of refrigerant.
  • (B2) In some embodiments of B1, the inner chamber includes a desiccant for removing moisture from the refrigerant.
  • (B3) In some embodiments of any one of B1-B2, the inner chamber includes a filter for removing particles from the refrigerant.
  • (B4) In some embodiments of any one of B1-B3, the inner chamber includes removable member, the removable member sealing a desiccant within the inner chamber when coupled to the suction line HX.
  • (B5) In some embodiments of any one of B1-B4, an expansion device is fluidically coupled between the suction line HX and the second HX.
  • (B6) In some embodiments of any one of B1-B5, the outer chamber prevents a liquid refrigerant from returning to the compressor.
  • (B7) In some embodiments of any one of B1-B6, the first portion of refrigerant is a liquid refrigerant; the second portion of refrigerant is a mixed refrigerant; and the mixed refrigerant is converted into to a gas refrigerant within the outer chamber.
  • (B8) In some embodiments of any one of B1-B7, the first portion of refrigerant is high-side refrigerant; and the second portion of refrigerant is low-side refrigerant.
  • (B9) In some embodiments of any one of B1-B8, the outer chamber is an accumulator; and the inner chamber is dryer.
  • (C1) In accordance with some embodiments, a refrigerant system (e.g., climate control system 100; FIG. 1) includes a compressor fluidically coupled between a suction line HX and a first HX. The first HX is fluidically coupled between the compressor and the suction line HX. The refrigerant system further includes a second HX and a suction line HX, the second HX fluidically coupled with the suction line HX. The suction line HX includes an outer chamber including a first refrigerant channel and an inner chamber including a second refrigerant channel distinct from the first refrigerant channel. The inner chamber is disposed within the outer chamber. The suction line HX further includes a first set of ports fluidically coupling the first HX with the second HX via the second refrigerant channel, and a second set of ports fluidically coupling the second HX with the compressor via the first refrigerant channel. The inner chamber receives a first portion of refrigerant from the first HX and guides the first portion of refrigerant toward the second HX, the outer chamber receives a second portion of refrigerant from the second HX and guides the second portion of refrigerant toward the compressor, and the second portion of refrigerant substantially fills the outer chamber and surrounds the inner chamber such that heat transfers between the first portion of refrigerant and the second portion of refrigerant.
  • (C2) In some embodiments of C1, the refrigerant system further includes an expansion device fluidically coupled between the suction line HX and the second HX.
  • (C3) In some embodiments of any one of C1-C2, the inner chamber includes a desiccant for removing moisture from the refrigerant.
  • (C4) In some embodiments of any one of C1-C3, the inner chamber includes a filter for removing particles from the refrigerant.
  • (C5) In some embodiments of any one of C1-C4, the inner chamber includes removable member, the removable member sealing a desiccant within the inner chamber when coupled to the suction line HX.
  • (C6) In some embodiments of any one of C1-C5, the first portion of refrigerant is a liquid refrigerant; the second portion of refrigerant is a mixed refrigerant; and the mixed refrigerant is converted into to a gas refrigerant within the outer chamber.
  • (C7) In some embodiments of any one of C1-C6, the first portion of refrigerant is high-side refrigerant; and the second portion of refrigerant is low-side refrigerant.
  • (C8) In some embodiments of any one of C1-C7, the refrigerant system further includes one or more sensors and a controller. The controller includes one or more instructions for causing the performance of receiving operational data from the one or more sensors, and adjusting operation of at least the compressor based on the operational data.
  • (C9) In some embodiments of any one of C8, the refrigerant system further includes one or more air-mover devices, and the controller further includes instructions for causing the performance of adjusting operation of the one or more air-mover devices based on the operational data.
  • (C10) In some embodiments of any one of C8-C9, the refrigerant system further includes a reservoir communicatively coupled between the suction line HX and the second HX, and the controller further includes instructions for causing the performance of adjusting a charge level of the refrigerant based on the operating data.
  • (C11) In some embodiments of any one of C8-C10, the operating data includes one or more of a temperature of the first portion of refrigerant, a temperature of the second portion of refrigerant, a pressure of the first portion of refrigerant, a pressure of the second portion of refrigerant, a compressor speed, a compression ratio, and an air-mover device speed.
  • (C12) In some embodiments of any one of C1-C11, wherein the suction line HX is configured in accordance with any of A1-B9.
  • (D1) In accordance with some embodiments, a method performed by a refrigerant system in accordance with any of C1-C12 and configured to perform one or more operations of C1-C12.
  • (D1) In accordance with some embodiments, a method performed by a refrigerant system in accordance with any of C1-C12 and configured to perform or caused performance of operations corresponding to any of C1-C12.
  • (E1) In accordance with some embodiments, a non-transitory computer readable storage medium including instructions that, when executed by a controlled in communication with a refrigerant system in accordance with any of C1-C12, cause the controller to perform operations corresponding to any of C1-C12.

Although some of various drawings illustrate a number of logical stages in a particular order, stages that are not order dependent may be reordered and other stages may be combined or broken out. While some reordering or other groupings are specifically mentioned, others will be obvious to those of ordinary skill in the art, so the ordering and groupings presented herein are not an exhaustive list of alternatives. Moreover, it should be recognized that the stages could be implemented in hardware, firmware, software or any combination thereof.

It will also be understood that, although the terms first, second, etc. are, in some instances, used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first condition could be termed a second condition, and, similarly, a second condition could be termed a first condition, without departing from the scope of the various described embodiments. The first condition and the second condition are both conditions, but they are not the same condition.

The terminology used in the description of the various described embodiments herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term “and/or” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms “includes,” “including,” “comprises,” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

As used herein, the term “if” is, optionally, construed to mean “when” or “upon” or “in response to determining” or “in response to detecting” or “in accordance with a determination that,” depending on the context. Similarly, the phrase “if it is determined” or “if [a stated condition or event] is detected” is, optionally, construed to mean “upon determining” or “in response to determining” or “upon detecting [the stated condition or event]” or “in response to detecting [the stated condition or event]” or “in accordance with a determination that [a stated condition or event] is detected,” depending on the context.

The foregoing description, for purpose of explanation, has been described with reference to specific embodiments. However, the illustrative discussions above are not intended to be exhaustive or to limit the scope of the claims to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings. The embodiments were chosen in order to best explain the principles underlying the claims and their practical applications, to thereby enable others skilled in the art to best use the embodiments with various modifications as are suited to the particular uses contemplated.