MUFFLERS FOR CLIMATE CONTROL SYSTEMS

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Non-provisional Application of U.S. Provisional Application No. 62/707,775 filed Oct. 16, 2024 and entitled “MUFFLERS FOR CLIMATE CONTROL SYSTEMS”, the entire contents of which is incorporated herein by reference.

BACKGROUND

A climate control system, such as a heating, air-conditioning, and ventilation (HVAC) system, may be used to condition the climate of an interior space. The interior space may be an interior space of a house, apartment, building, retail store, storage unit, office, refrigerator, freezer, vehicle, etc. Some climate control systems may exchange heat between the interior space and an outdoor ambient environment by use of a refrigerant. Specifically, the refrigerant may be circulated between a pair of heat exchangers so as to transfer heat between the interior space and the outdoor ambient environment via the refrigerant during operations. A compressor may be used to circulate the refrigerant during operation.

BRIEF SUMMARY

The present disclosure includes, without limitation, the following examples.

Some example implementations disclosed herein are directed to a muffler for a climate control system. The muffler comprises a body including an inlet, an outlet, a central axis extending between the inlet and the outlet, and a cavity within the body, between the inlet and the outlet, that includes a converging surface that converges toward the central axis. The converging surface includes has a convex curvature within the cavity.

Another example implementations disclosed herein are directed to an outdoor unit for a climate control system. The outdoor unit comprises a compressor capable of a plurality of operating speeds, a heat exchanger configured to exchange heat between an ambient environment and an A2L designated refrigerant, a refrigerant line for conveying the A2L designated refrigerant from the compressor to the heat exchanger, and a muffler positioned along the refrigerant line to attenuate pressure pulsations imparted by the compressor on the refrigerant. The muffler is configured to impart a transmission loss of at least 10 dB across a frequency range of from 500 Hz to 2700 Hz, and potentially a broader range of 110 Hz to 3720 Hz or more.

These and other features, aspects, and advantages of the disclosure will be apparent from a reading of the following detailed description together with the accompanying drawings, which are briefly described below. The disclosure includes any combination of two, three, four, or more of the above-noted embodiments, examples, or implementations as well as combinations of any two, three, four, or more features or elements set forth in this disclosure, regardless of whether such features or elements are expressly combined in a specific example description herein. This disclosure is intended to be read holistically such that any separable features or elements of the disclosed disclosure, in any of its various aspects, embodiments, examples, or implementations, should be viewed as intended to be combinable unless the context clearly dictates otherwise.

BRIEF DESCRIPTION OF THE DRAWINGS

For a detailed description of various embodiments, reference will now be made to the accompanying drawings in which:

FIG. 1 is a cross-sectional view of a conventional muffler for attenuating pressure pulsations in a refrigerant line of a climate control system;

FIG. 2 is a plot illustrating an estimated pulsation attenuation for the conventional muffler of FIG. 1 across a range of frequencies;

FIG. 3 is a perspective view of a muffler for attenuating pressure pulsations in a refrigerant line of a climate control system according to some embodiments disclosed herein;

FIG. 4 is a cross-sectional view of the muffler of FIG. 3 according to some embodiments disclosed herein;

FIG. 5 is a plot illustrating an estimated pulsation attenuation for the muffler of FIG. 3 across a range of frequencies according to some embodiments disclosed herein;

FIG. 6 is a perspective view of a muffler for attenuating pressure pulsations in a refrigerant line of a climate control system according to some embodiments disclosed herein;

FIG. 7 is a cross-sectional view of the muffler of FIG. 6 according to some embodiments disclosed herein;

FIG. 8 is a plot illustrating an estimated pulsation attenuation for the muffler of FIG. 6 across a range of frequencies according to some embodiments disclosed herein;

FIG. 9 is a perspective view of a muffler for attenuating pressure pulsation in a refrigerant line of a climate control system according to some embodiments disclosed herein;

FIG. 10 is a cross-sectional view of the muffler of FIG. 9 according to some embodiments disclosed herein;

FIG. 11 is a plot illustrating an estimated pulsation attenuation for the muffler of FIG. 9 across a range of frequencies according to some embodiments disclosed herein;

FIG. 12 is a perspective view of a muffler for attenuating pressure pulsations in a refrigerant line of a climate control system according to some embodiments disclosed herein;

FIG. 13 is a cross-sectional view of the muffler of FIG. 12 according to some embodiments disclosed herein;

FIG. 14 is a plot illustrating an estimated pulsation attenuation for the muffler of FIG. 12 across a range of frequencies according to some embodiments disclosed herein;

FIG. 15 is a perspective view of a muffler for attenuating pressure pulsations in a refrigerant line of a climate control system according to some embodiments disclosed herein;

FIG. 16 is a cross-sectional view of the muffler of FIG. 15 according to some embodiments disclosed herein;

FIG. 17 is a plot illustrating an estimated pulsation attenuation for the muffler of FIG. 15 across a range of frequencies according to some embodiments disclosed herein; and

FIGS. 18 and 19 are schematic diagrams of a climate control system using an embodiment of a muffler for attenuating pressure pulsations according to some embodiments disclosed herein.

DETAILED DESCRIPTION

A climate control system may circulate a refrigerant between a pair of heat exchangers via a refrigerant compressor (or more simply “compressor”) to exchange heat between an interior space and an ambient environment. The ambient environment may be an outdoor ambient environment that at least partially surrounds the interior space (or a structure defining the interior space). During operation, the compressor may generate pressure pulsations that are conducted through one or more refrigerant lines of the climate control system with the flowing refrigerant. These pressure pulsations can result in excess vibrations of the refrigerant lines of the climate control system, which may result in undesirable noise and potential failure (e.g., due to fatigue, abrasive contact with the vibrating refrigerant lines, etc.). In addition, the pressure pulsations may cause inefficiencies in the flow through the climate control system, which may negatively affect heat transfer rates during operations. Many climate control systems may include variable speed or multi-speed compressors that are operated at a plurality of different operating speeds. Each different operating speed of the compressor may induce different pulsation frequencies into the flow of refrigerant. Thus, there is a desire for systems to attenuate or dampen pressure pulsations in the refrigerant lines of a climate control system, particularly for climate control systems that utilize a variable speed or multi-speed compressor.

Accordingly, embodiments disclosed herein include mufflers for reducing pressure pulsations in a refrigerant line of a climate control system. In some embodiments, the muffler of the disclosed embodiments may include relatively complex inner cavities that are configured to attenuate pressure pulsations across a wider range of frequencies when compared to conventional designs (which may generally comprise interior cavities shaped as a simple right circular cylinder). Thus, use of mufflers according to the embodiments disclosed herein may more effectively attenuate the pressure pulsations generated by a multi-speed or variable speed compressor.

FIG. 1 illustrates a cross-sectional view of a conventional muffler 600 for attenuating pressure pulsations in a refrigerant line of a climate control system. The muffler 600 includes a body 610 that defines a cavity 620 therein. The cavity 620 is shaped as a simple right-circular cylinder. Specifically, the body 610 includes a central or longitudinal axis 605, an upstream end 610a, and a downstream end 610b spaced axially from the upstream end 610a along axis 605. The cylindrically-shaped cavity 620 includes a pair of axially-spaced planar surfaces 622, 626 that extend radially relative to the axis 605, and a cylindrical surface 624 that extends axially between the planar surfaces 622, 626 and circumferentially about axis 605. Because the cavity 620 is shaped as a simple right-circular cylinder, the cylindrical surface 624 is maintains a constant inner diameter along its axial length.

FIG. 2 shows a plot 640 of the estimated pressure pulsation attenuation (or transmission loss) for the conventional muffler 600 of FIG. 1 over a range of frequencies. The plot 640 was generated assuming use of the refrigerant R454B. The speed of sound through this refrigerant is nominally approximately 170 meters per second (m/s); however, as is understood the speed of sound may vary based on multiple factors including temperature. The plot 640 shows an estimated transmission loss (in decibels or “dB”) over a range of frequencies (in Hertz or “Hz”) for the muffler 600.

The plot 640 illustrates a spike in sound pressure reduction between 2500 Hz and 3000 Hz. However, the plot 640 also indicates that the muffler 600 suffers from reduced sudden (or sharp) drops in sound pressure reduction performance substantially below 10 dB (such as down to 0 dB) between 500 Hz and 1000 Hz, and between 1500 Hz and 2000 Hz. Moreover, the plot 640 also shows a substantial drop in sound pressure reduction below 10 dB between about 3000 Hz and 3700 Hz. Thus, the plot 640 indicates that while the conventional muffler 600 can be “tuned” to effectively reduce sound pressure in a flow of refrigerant at a particular frequency or narrow band of frequencies (e.g., such as between 2500 Hz and 3000 Hz in this particular example), it also suffers poor performance at several other frequencies along an operating range. As a result, the conventional muffler 600 may be less effective when employed with a variable speed compressor which may induce pressure pulsations over a large range of different frequencies as previously described.

Referring now to FIGS. 3 and 4, a muffler 100 for attenuating pressure pulsations in a refrigerant line of a climate control system is shown according to some embodiments. As is described in more detail herein, the muffler 100 may be configured to more effectively attenuate pressure pulsations along a wider range of frequencies than the conventional muffler 600 of FIG. 1.

The muffler 100 may be in fluid communication with a compressor of the climate control system (not shown, but see compressor 30 in the climate control system 10 of FIGS. 18 and 19). For instance, the muffler 100 may be positioned downstream of the compressor so that the muffler 100 may receive refrigerant that is discharged from the compressor during operations.

The muffler 100 may have a body 110 that includes a first or upstream end 110a, and a second or downstream end 110b opposite the upstream end 110a. The upstream end 110a may be coupled to an upstream refrigerant line 101 that may be further coupled to the compressor (not shown). The downstream end 110b may be coupled to a downstream refrigerant line 103. During operations, refrigerant may flow into the muffler 100 via the upstream refrigerant line 101 and may be discharged from the muffler 100 into the downstream refrigerant line 103.

With specific reference to FIG. 4, the body 110 may include a central or longitudinal axis 105 that extends between the ends 110a, 110b. The central axis 105 may be aligned with the central axes (not shown) of both the upstream refrigerant line 101 and the downstream refrigerant line 103. In addition, the body 110 includes or defines a cavity 120 therein, so that the body 110 has a first or radially inner surface 110c extending between the ends 110a, 110b and a second or radially outer surface 110d also extending between the ends 110a, 110b. An inlet 102 is defined in the body 110 at the upstream end 110a that is coupled to the upstream refrigerant line 101 so that refrigerant flowing along the upstream refrigerant line 101 may flow into the cavity 120. In addition, an outlet 104 is defined in the body 110 at the downstream end 110b that is coupled to the downstream refrigerant line 103 so that refrigerant flowing out of the cavity 120 may enter the downstream refrigerant line 103.

In some embodiments, the body 110 may be integrated (e.g., co-manufactured with, etc.) with the refrigerant lines 101, 103 so that the body 110 and lines 101, 103 may define a single-piece, monolithic body. In some embodiments, one or both of the refrigerant lines 101, 103 may be separately formed and connected to the body 110 via any suitable method or system (e.g., welding, coupling, connector, etc.) capable of containing the pressurized refrigerant passing through the muffler.

The radially inner surface 110c defines the shape of the cavity 120 within the body 110. In some embodiments, the radially inner surface 110c includes a first or upstream planar surface 122 at the upstream end 110a and a second or downstream planar surface 128. The planar surfaces 122, 128 may extend radially relative to the central axis 105. The inlet 102 may be positioned or defined on the upstream planar surface 122, and the outlet 104 may be positioned or defined on the downstream planar surface 128.

The cavity 120 may have an axial length L₁₂₀ that extends axially from the upstream planar surface 122 to the downstream planar surface 128. In addition, the radially inner surface 110c includes a cylindrical surface 124 extending axially from the upstream planar surface 122, and an inner converging surface 126 that extends from the cylindrical surface 124 to the downstream planar surface 128. The cylindrical surface 124 may extend circumferentially about the central axis 105 at a first inner diameter D₁₂₄, and the converging surface 126 may converge from the first inner diameter D₁₂₄ down to a second inner diameter D₁₂₈ at the downstream planar surface 128. Both the first inner diameter D₁₂₄ and the second inner diameter D₁₂₈ may extend radially relative to the central axis 105.

Both the diameters D₁₂₄, D₁₂₈ may be greater than the inner diameters of the upstream refrigerant line 101 and the downstream refrigerant line 103 in order to attenuate pressure pulsations during operations. In addition, the inner diameters of the upstream refrigerant line 101 and downstream refrigerant line 103 may be the same or different. For instance, in some embodiments, the diameter D₁₂₄ may be at least two-times larger than the inner diameter of the inlet refrigerant line 101, such as at least four-times larger than the inner diameter of the inlet refrigerant line 101, or such as at least six-times larger than the inner diameter of the inlet refrigerant line 101.

In some embodiments, the diameter D₁₂₄ may be in a range of about 2 inches to about 4 inches, such as about 2.5 inches to about 3.5 inches, or such as about 2.99 inches. In some embodiments, the diameter D₁₂₈ may be in a range from 0.5 inches to about 2.0 inches, such as from about 0.75 to about 1.5 inches, or such as about 1.0 inch. In some embodiments, the axial length L₁₂₀ may be in a range of about 1.0 inches to about 3 inches, such as about 2 inches to about 3 inches, or such as about 2.275 inches. These values may be selected based on the refrigerant flowing through the muffler 100 (and particularly the speed of sound through the refrigerant) during operations. In this case, these values and ranges may correspond to use of refrigerant R454B. However, other refrigerants are contemplated, and the use of alternative refrigerants may correspond with different dimensions of muffler 100. Thus, these example dimensions of muffler are merely characteristic of some embodiments.

In some embodiments, the converging surface 126 may have a profile in cross-section (FIG. 4) that has a convex curvature. For instance, in some embodiments, the converging surface 126 may have a circular curvature in the axial cross-section of FIG. 4. Specifically, in some embodiments, the converging surface 126 may have a radius of curvature R that is half of the difference between the diameters D₁₂₄, D₁₂₈ (R=½*(D₁₂₄−D₁₂₈)). However, other curvatures are contemplated for converging surface 126, such as parabolic, elliptical, linear, etc.

In some embodiments, the radially outer surface 110d may mirror the radially inner surface 110c. Thus, the radially outer surface 110d may include an upstream planar surface 132, a cylindrical surface 134, a converging surface 136, and a downstream planar surface 138, that may correspond with the upstream planar surface 122, cylindrical surface 124, converging surface 126, and downstream planar surface 128, respectively, of the radially inner surface 110c. The converging surface 136 of the radially outer surface 110d may have a concave curvature in axial cross-section (FIG. 4) that corresponds with the convex curvature of the converging surface 126.

However, it should be appreciated that the radially outer surface 110d may not correspond with the radially inner surface 110c in some embodiments. For instance, in some embodiments, the radially outer surface 110d may include a continuous cylindrical surface that extends between planar surfaces at the ends 110a, 110b, while the radially inner surface 110c may be substantially as shown in FIG. 4 and previously described. Thus, in some embodiments, the wall thickness of the body 110 of muffler 100 may vary along the axis 105 between the ends 110a, 110b to define the radially inner surface 110c and cavity 120.

Referring now to FIG. 5, a plot 140 showing the estimated pressure pulsation attenuation (or transmission loss) for the muffler 100 shown in FIGS. 3 and 4 and previously described above. As shown in FIG. 5, the plot 150 illustrates that the muffler 100 of FIGS. 3 and 4 may have generally elevated pressure pulsation reduction performance above about 10 dB between 500 Hz and 3500 Hz, and lacks the sudden, sharp drops in sound pressure reduction that are shown in the plot 640 of FIG. 2 for the conventional muffler 600 (e.g., between 500 and 1000 Hz and between 1500 and 2000 Hz as previously described). Thus, the muffler 100 of FIGS. 3 and 4 may reduce pressure pulsations over a wide range of frequencies, and thus may provide a more effective muffler for a variable speed compressor, when compared to the conventional muffler 600 of FIG. 1.

Referring now to FIGS. 6 and 7, a muffler 200 for attenuating pressure pulsations in a refrigerant line of a climate control system is shown according to some embodiments. As is described in more detail herein, the muffler 200 may also be configured to more effectively attenuate pressure pulsations along a wider range of frequencies than the conventional muffler 600 of FIG. 1.

The muffler 200 may be in fluid communication with a compressor of the climate control system (not shown, but see compressor 30 in the climate control system 10 of FIGS. 18 and 19). For instance, the muffler 200 may be positioned downstream of the compressor so that the muffler 200 may receive refrigerant that is discharged from the compressor during operations.

The muffler 200 may have a body 210 that includes a first or upstream end 210a, and a second or downstream end 210b opposite the upstream end 210a. The upstream end 210a may be coupled to the upstream refrigerant line 101 that may be further coupled to the compressor (not shown). The downstream end 210b may be coupled to the downstream refrigerant line 103. During operations, refrigerant may flow into the muffler 200 via the upstream refrigerant line 101 and may be discharged from the muffler 200 into the downstream refrigerant line 103.

With specific reference to FIG. 7, the body 210 may include a central or longitudinal axis 205 that extends between the ends 210a, 210b. The central axis 205 may be aligned with the central axes (not shown) of both the upstream refrigerant line 101 and the downstream refrigerant line 103. In addition, the body 210 includes or defines a cavity 220 therein, so that the body 210 has a first or radially inner surface 210c extending between the ends 210a, 210b and a second or radially outer surface 210d also extending between the ends 210a, 210b. An inlet 202 is defined in the body 210 at the upstream end 210a that is coupled to the upstream refrigerant line 101 so that refrigerant flowing along the upstream refrigerant line 101 may flow into the cavity 220. In addition, an outlet 204 is defined in the body 210 at the downstream end 210b that is coupled to the downstream refrigerant line 103 so that refrigerant flowing out of the cavity 220 may enter the downstream refrigerant line 103.

In some embodiments, the body 210 may be integrated (e.g., co-manufactured with, etc.) with the refrigerant lines 101, 103 so that the body 210 and lines 101, 103 may define a single-piece monolithic body. In some embodiments, one or both of the refrigerant lines 101, 103 may be separately formed and connected to the body 210 via any suitable method or system (e.g., welding, coupling, connector, etc.).

The radially inner surface 210c defines the shape of the cavity 220 within the body 210. In some embodiments, cavity 220 may have a generally conical shape. As a result, the radially inner surface 210c includes a first or upstream planar surface 222 at the upstream end 210a and a frustoconical surface 226 extending from the upstream planar surface 222 and the downstream end 210b. The upstream planar surface 222 may extend radially relative to the central axis 205. The inlet 202 may be positioned or defined on the upstream planar surface 222, and the outlet 204 may be positioned or defined at intersection of the frustoconical surface 226 and the downstream refrigerant line 103.

The cavity 220 may have an axial length L₂₂₀ that extends axially from the upstream planar surface 222 to the outlet 204 at the downstream end 210b. In addition, the frustoconical surface 210c converges radially inward toward the central axis 105 when moving axially from the upstream end 210a toward the downstream end 210b. Accordingly, the cavity 220 may have an inner diameter D₂₂₀ extending radially relative to central axis 205 that ranges from a maximum value at the upstream planar surface 222 to a minimum at the outlet 204.

In some embodiments, the length L₂₂₀ may be in a range of about 2 inches to about 3 inches, such as about 2 inches to about 2.5 inches, or such as about 2.275 inches. In addition, in some embodiments, the maximum value of the inner diameter D₂₂₀ at upstream planar surface may be in a range of about 2 inches to about 4 inches, such as about 2.5 inches to about 3.5 inches, or such as about 2.99 inches. As previously described, these values may be selected based on the refrigerant flowing through the muffler 200 (and particularly the speed of sound through the refrigerant) during operations. In this case, these values and ranges may correspond to use of refrigerant R454B. However, other refrigerants are contemplated, and the use of alternative refrigerants may correspond with different dimensions of muffler 200. Thus, these example dimensions of muffler are merely characteristic of some embodiments.

As previously described for the muffler 100 shown in FIGS. 1 and 2, in some embodiments, the radially outer surface 210d may mirror the radially inner surface 210c. Thus, the radially outer surface 210d may include an upstream planar surface 232 and a frustoconical surface 236 that may correspond with the upstream planar surface 222 and frustoconical surface 226, respectively, of the radially inner surface 210c. However, it should be appreciated that the radially outer surface 210d may not correspond with the radially inner surface 210c in some embodiments. For instance, in some embodiments, the radially outer surface 210d may include a continuous cylindrical surface that extends between the ends 210a, 210b, while the radially inner surface 210c may be substantially as shown in FIG. 6 and previously described. Thus, in some embodiments, the wall thickness of the body 210 of muffler 200 may vary along the axis 205 between the ends 210a, 210b to define the radially inner surface 210c and cavity 220.

Referring now to FIG. 8, a plot 240 showing an estimated pressure pulsation attenuation (or transmission loss) (in dB) over a range of frequencies (in Hz) for the muffler 200 shown in FIGS. 5 and 6 and previously described above is shown. As previously described, the plot 240 in FIG. 8, was generated assuming use of the refrigerant R454B; however, the use of other refrigerants is also contemplated. As shown in FIG. 8, the plot 240 illustrates that the muffler 200 of FIGS. 6 and 7 may have generally elevated pulsation attenuation performance above about 10 dB between 500 Hz and 2700 Hz, and lacks the sudden, sharp drops in sound pressure reduction that are shown in the plot 640 of FIG. 2 for the conventional muffler 600 (e.g., between 500 and 1000 Hz and between 1500 and 2000 Hz as previously described). Thus, like the muffler 100 of FIGS. 3 and 4, the muffler 200 may reduce pressure pulsations over a wide range of frequencies, and thus may provide an effective muffler for a variable speed compressor, when compared to the conventional muffler 600 of FIG. 1.

Referring now to FIGS. 9 and 10, a muffler 300 for attenuating pressure pulsations in a refrigerant line of a climate control system is shown according to some embodiments. The muffler 300 may be in fluid communication with a compressor of the climate control system (not shown, but see compressor 30 in the climate control system 10 of FIGS. 18 and 19). For instance, the muffler 300 may be positioned downstream of the compressor so that the muffler 300 may receive refrigerant that is discharged from the compressor during operations.

The muffler 300 may have a body 310 that includes a first or upstream end 310a, and a second or downstream end 310b opposite the upstream end 310a. The upstream end 310a may be coupled to the upstream refrigerant line 101 that may be further coupled to the compressor (not shown). The downstream end 310b may be coupled to the downstream refrigerant line 103. During operations, refrigerant may flow into the muffler 300 via the upstream refrigerant line 101 and may be discharged from the muffler 300 into the downstream refrigerant line 103.

With specific reference to FIG. 10, the body 310 may include a central or longitudinal axis 305 that extends between the ends 310a, 310b. The central axis 305 may be aligned with the central axes (not shown) of both the upstream refrigerant line 101 and the downstream refrigerant line 103. In addition, the body 310 includes or defines a cavity 320 therein, so that the body 310 has a first or radially inner surface 310c extending between the ends 310a, 310b and a second or radially outer surface 310d also extending between the ends 310a, 310b. An inlet 302 is defined in the body 310 at the upstream end 310a that is coupled to the upstream refrigerant line 101 so that refrigerant flowing along the upstream refrigerant line 101 may flow into the cavity 320. In addition, an outlet 304 is defined in the body 310 at the downstream end 310b that is coupled to the downstream refrigerant line 103 so that refrigerant flowing out of the cavity 320 may enter the downstream refrigerant line 103.

In some embodiments, the body 310 may be integrated (e.g., co-manufactured with, etc.) with the refrigerant lines 101, 103 so that the body 310 and lines 101, 103 may define a single-piece monolithic body. In some embodiments, one or both of the refrigerant lines 101, 103 may be separately formed and connected to the body 310 via any suitable method or system (e.g., welding, coupling, connector, etc.).

The radially inner surface 310c defines the shape of the cavity 320 within the body 310. In some embodiments, cavity 320 may have a generally cylindrical shape with convex and concave ends. Specifically, the radially inner surface 410c includes an inner convex hemispherical surface 322 positioned at the upstream end 310a and projecting axially away from the upstream end 310a and toward the downstream end 310b. In addition, the radially inner surface 310c includes an inner concave hemispherical surface 326 positioned at the downstream end 310a and projecting axially away from the upstream end 310a. Thus, the inlet 302 may be positioned or defined on the inner convex hemispherical surface 322, and the outlet 304 may be positioned or defined on inner concave hemispherical surface 326. A cylindrical surface 334 may extends axially from the inner convex hemispherical surface 322 and the inner concave hemispherical surface 326 and circumferentially about the axis 305. The cylindrical surface 334 may have a constant inner diameter D₃₂₀ extending radially relative to central axis 305.

In some embodiments, the diameter D₃₂₀ may be in a range of about 2 inches to about 4 inches, such as about 2.5 inches to about 3.5 inches, or such as about 2.99 inches. As previously described, these values may be selected based on the refrigerant flowing through the muffler 300 (and particularly the speed of sound through the refrigerant) during operations. In this case, these values and ranges may correspond to use of refrigerant R454B. However, other refrigerants are contemplated, and the use of alternative refrigerants may correspond with different dimensions of muffler 300. Thus, these example dimensions of muffler are merely characteristic of some embodiments.

One or both of the inner convex hemispherical surface 322 and the inner concave hemispherical surface 326 may have a spherical curvature in some embodiments. In other embodiments, one of both of the surfaces 322, 326 may have non-spherical curvatures, such as a paraboloid curvature, an ellipsoid curvature, a linear curvature (e.g., conical), etc.

As previously described for the muffler 100 shown in FIGS. 3 and 4, in some embodiments, the radially outer surface 310d may mirror the radially inner surface 310c. Thus, the radially outer surface 310d may include an outer concave hemispherical surface 332, a cylindrical surface 334, and an outer convex hemispherical surface 326 that correspond with the inner convex hemispherical surface 322, the cylindrical surface 324, and the inner concave hemispherical surface 326, respectively, of the radially inner surface 310c. However, it should be appreciated that the radially outer surface 310d may not correspond with the radially inner surface 310c in some embodiments. For instance, in some embodiments, the radially outer surface 310d may include a continuous cylindrical surface that extends between the ends 310a, 310b, while the radially inner surface 310c may be substantially as shown in FIG. 10 and previously described. Thus, in some embodiments, the wall thickness of the body 310 of muffler 300 may vary along the axis 305 between the ends 310a, 310b to define the radially inner surface 310c and cavity 320.

Referring now to FIG. 11, a plot 340 showing an estimated pressure pulsation attenuation (or transmission loss) (in dB) over a range of frequencies (in Hz) for the muffler 300 shown in FIGS. 9 and 10 and previously described above is shown. As previously described, the plot 340 in FIG. 11, was generated assuming use of the refrigerant R454B; however, the use of other refrigerants is also contemplated. As shown in FIG. 11, the plot 340 illustrates that the muffler 300 of FIGS. 9 and 10 may have generally elevated pulsation attenuation performance above about 10 dB between 500 Hz and 2700 Hz, and lacks the sudden, sharp drops in sound pressure reduction that are shown in the plot 640 of FIG. 2 for the conventional muffler 600 (e.g., between 500 and 1000 Hz and between 1500 and 2000 Hz as previously described). In addition, the plot 340 also shows that the muffler 300 may provide enhanced attenuation of pressure pulsations at about 1500 Hz (e.g., about 75 dB) and at about 1800 Hz (e.g., about 60 dB), which may provide particular benefits for addressing higher frequency pulsations. Thus, like the muffler 100 of FIGS. 3 and 4, the muffler 300 may reduce pressure pulsations over a wide range of frequencies, and thus may provide an effective muffler for a variable speed compressor, when compared to the conventional muffler 600 of FIG. 1.

Referring now to FIGS. 12 and 13, a muffler 400 for attenuating pressure pulsations in a refrigerant line of a climate control system is shown according to some embodiments. The muffler 400 may be in fluid communication with a compressor of the climate control system (not shown, but see compressor 30 in the climate control system 10 of FIGS. 18 and 19). For instance, the muffler 400 may be positioned downstream of the compressor so that the muffler 400 may receive refrigerant that is discharged from the compressor during operations.

The muffler 400 may have a body 410 that includes a first or upstream end 410a, and a second or downstream end 410b opposite the upstream end 410a. The upstream end 410a may be coupled to an upstream refrigerant line 101 that may be further coupled to the compressor (not shown). The downstream end 410b may be coupled to a downstream refrigerant line 103. During operations, refrigerant may flow into the muffler 400 via the upstream refrigerant line 101 and may be discharged from the muffler 400 into the downstream refrigerant line 103.

With specific reference to FIG. 13, the body 410 may include a central or longitudinal axis 405 that extends between the ends 410a, 410b. The central axis 405 may be aligned with the central axes (not shown) of both the upstream refrigerant line 101 and the downstream refrigerant line 103. In addition, the body 410 includes or defines a cavity 420 therein, so that the body 410 has a first or radially inner surface 410c extending between the ends 410a, 410b and a second or radially outer surface 410d also extending between the ends 410a, 410b. An inlet 402 is defined in the body 410 at the upstream end 410a that is coupled to the upstream refrigerant line 101 so that refrigerant flowing along the upstream refrigerant line 101 may flow into the cavity 420. In addition, an outlet 404 is defined in the body 410 at the downstream end 410b that is coupled to the downstream refrigerant line 103 so that refrigerant flowing out of the cavity 420 may enter the downstream refrigerant line 103.

In some embodiments, the body 410 may be integrated (e.g., co-manufactured with, etc.) with the refrigerant lines 101, 103 so that the body 410 and lines 101, 103 may define a single-piece monolithic body. In some embodiments, one or both of the refrigerant lines 101, 103 may be separately formed and connected to the body 410 via any suitable method or system (e.g., welding, coupling, connector, etc.).

The radially inner surface 410c defines the shape of the cavity 420 within the body 410. In some embodiments, the radially inner surface 410c includes a first or upstream planar surface 422 at the upstream end 410a, a second or downstream planar surface 428, and a third or middle planar surface 425 axially positioned between the upstream planar surface 422 and the downstream planar surface 428. The planar surfaces 422, 425, 428 may each extend radially relative to the central axis 405. The inlet 402 may be positioned or defined on the upstream planar surface 422, and the outlet 404 may be positioned or defined on the downstream planar surface 428.

The cavity 420 may have an axial length L₄₂₀ that extends axially from the upstream planar surface 422 to the downstream planar surface 428. In addition, the radially inner surface 410c includes a first or upstream cylindrical surface 424 extending axially from the upstream planar surface 422 to the middle planar surface 425, and a second or downstream cylindrical surface 425 that extends from the middle planar surface 425 to the downstream planar surface 428. Each of the cylindrical surfaces 424, 426 may each extend circumferentially about the central axis 405. The upstream cylindrical surface 424 may extend radially outward from the central axis 405 to a first inner diameter D₄₂₄, and the downstream cylindrical surface 426 may extend radially outward from the central axis 405 to a second inner diameter D₄₂₆. The first inner diameter D₄₂₄ may be greater than the downstream inner diameter D₄₂₆ so that the middle planar surface 425 may define an annular shoulder within the cavity 420 that faces (or opposes) the upstream end 410a. Both the first inner diameter D₄₂₄ and the second inner diameter D₄₂₆ may be larger than the inner diameters (not shown specifically) of the upstream refrigerant line 101 and the downstream refrigerant line 103.

In addition, in some embodiments, the upstream cylindrical surface 424 and the downstream cylindrical surface 426 may each occupy about 50% (or half) of the total axial length L₄₂₀. However, in some embodiments, the upstream cylindrical surface 424 or the downstream cylindrical surface 426 may occupy a majority of the axial length L₄₂₀.

In some embodiments, the diameter D₄₂₄ may be in a range of about 2 inches to about 4 inches, such as about 2.5 inches to about 3.5 inches, or such as about 2.75 inches. In some embodiments, the diameter D₄₂₆ may be in a range from 0.5 inches to about 2.0 inches, such as from about 0.75 to about 1.5 inches, or such as about 1.0 inches. In some embodiments, the total axial length L₄₂₀ may be in a range of about 1.5 inches to about 4 inches, such as about 2 inches to about 3 inches, or such as about 2.3 inches. As previously described, these values may be selected based on the refrigerant flowing through the muffler 400 (and particularly the speed of sound through the refrigerant) during operations. In this case, these values and ranges may correspond to use of refrigerant R454B. However, other refrigerants are contemplated, and the use of alternative refrigerants may correspond with different dimensions of muffler 400. Thus, these example dimensions of muffler are merely characteristic of some embodiments.

As previously described for the muffler 100 shown in FIGS. 3 and 4, in some embodiments, the radially outer surface 410d may mirror the radially inner surface 410c. Thus, the radially outer surface 410d may include an upstream planar surface 432, an upstream cylindrical surface 424, a middle planar surface 435, a downstream cylindrical surface 436, and a downstream planar surface 438 that may correspond with the upstream planar surface 422, upstream cylindrical surface 424, middle planar surface 425, downstream cylindrical surface 426, and downstream planar surface 428, respectively, of the radially inner surface 410c. However, it should be appreciated that the radially outer surface 410d may not correspond with the radially inner surface 410c in some embodiments. For instance, in some embodiments, the radially outer surface 410d may include a continuous cylindrical surface that extends between the ends 410a, 410b, while the radially inner surface 410c may be substantially as shown in FIG. 13 and previously described. Thus, in some embodiments, the wall thickness of the body 410 of muffler 400 may vary along the axis 405 between the ends 410a, 410b to define the radially inner surface 410c and cavity 420.

Referring now to FIG. 14, a plot 440 showing an estimated pressure pulsation attenuation (or transmission loss) (in dB) over a range of frequencies (in Hz) for the muffler 400 shown in FIGS. 12 and 13 and previously described above is shown. As previously described, the plot 440 in FIG. 14, was generated assuming use of the refrigerant R454B; however, the use of other refrigerants is also contemplated. As shown in FIG. 14, the plot 440 illustrates that the muffler 400 of FIGS. 12 and 13 may have generally elevated pulsation attenuation performance above about 10 dB between 500 Hz and 3000 Hz, and lacks the sudden, sharp drops in sound pressure reduction that are shown in the plot 640 of FIG. 2 for the conventional muffler 600 (e.g., between 500 and 1000 Hz and between 1500 and 2000 Hz as previously described). In particular, the plot 440 also shows that the muffler 400 may provide enhanced attenuation of pressure pulsations between about 2400 Hz and about 3000Hz (between about 30 dB and about 80 dB), which may provide particular benefits for addressing higher frequency pulsations. Thus, like the muffler 100 of FIGS. 3 and 4, the muffler 400 may reduce pressure pulsations over a wide range of frequencies, and thus may provide an effective muffler for a variable speed compressor, when compared to the conventional muffler 600 of FIG. 1.

Referring now to FIGS. 15 and 16, a muffler 500 for attenuating pressure pulsations in a refrigerant line of a climate control system is shown according to some embodiments. The muffler 500 may be in fluid communication with a compressor of the climate control system (not shown, but see compressor 30 in the climate control system 10 of FIGS. 18 and 19). For instance, the muffler 500 may be positioned downstream of the compressor so that the muffler 500 may receive refrigerant that is discharged from the compressor during operations.

The muffler 500 may have a body 510 that includes a first or upstream end 510a, and a second or downstream end 510b opposite the upstream end 510a. The upstream end 510a may be coupled to the upstream refrigerant line 101 that may be further coupled to the compressor (not shown). The downstream end 510b may be coupled to the downstream refrigerant line 103. During operations, refrigerant may flow into the muffler 500 via the upstream refrigerant line 101 and may be discharged from the muffler 500 into the downstream refrigerant line 103.

With specific reference to FIG. 16, the body 510 may include a central or longitudinal axis 505 that extends between the ends 510a, 510b. The central axis 505 may be aligned with the central axes (not shown) of both the upstream refrigerant line 101 and the downstream refrigerant line 103. In addition, the body 510 includes or defines a cavity 520 therein, so that the body 510 has a first or radially inner surface 510c extending between the ends 510a, 510b and a second or radially outer surface 510d also extending between the ends 510a, 510b. An inlet 502 is defined in the body 510 at the upstream end 510a that is coupled to the upstream refrigerant line 101 so that refrigerant flowing along the upstream refrigerant line 101 may flow into the cavity 520. In addition, an outlet 504 is defined in the body 510 at the downstream end 510b that is coupled to the downstream refrigerant line 103 so that refrigerant flowing out of the cavity 520 may enter the downstream refrigerant line 103.

In some embodiments, the body 510 may be integrated (e.g., co-manufactured with, etc.) with the refrigerant lines 101, 103 so that the body 310 and lines 101, 103 may define a single-piece monolithic body. In some embodiments, one or both of the refrigerant lines 101, 103 may be separately formed and connected to the body 510 via any suitable method or system (e.g., welding, coupling, connector, etc.).

The radially inner surface 510c defines the shape of the cavity 520 within the body 510. In some embodiments, cavity 520 may have a generally spherical shape. Thus, the cavity 520 may be referred to as a “spherical cavity.” As a result, the radially inner surface 510c includes an inner concave spherical surface 522 that extends axially from the inlet 502 to the outlet 504. Thus, the inlet 502 may be positioned or defined on the inner concave spherical surface 522 at the upstream end 510a, and the outlet 504 may be positioned or defined on inner concave spherical surface 522 at the downstream end 510b.

The cavity 520 may have an axial length L₅₂₀ that extends axially from the inlet 502 to the outlet 504. In addition, the cavity 520 may have an inner diameter D₅₂₀ extending radially relative to central axis 505 that is at a maximum value substantially midway between the inlet 502 and outlet 504 along axis 505, and decreases when moving axially toward both the inlet 502 and the outlet 504. Due to the spherical shape of cavity 520, the axial length L₅₂₀ may generally equal the maximum diameter D₅₂₀ midway between the inlet 502 and outlet 504.

In some embodiments, the length L₅₂₀ and the maximum diameter D₅₂₀ may be in a range of about 2 inches to about 3 inches, such as about 2 inches to about 2.5 inches, or such as about 2.131 inches. As previously described, these values may be selected based on the refrigerant flowing through the muffler 500 (and particularly the speed of sound through the refrigerant) during operations. In this case, these values and ranges may correspond to use of refrigerant R454B. However, other refrigerants are contemplated, and the use of alternative refrigerants may correspond with different dimensions of muffler 500. Thus, these example dimensions of muffler 500 are merely characteristic of some embodiments.

As previously described for the muffler 100 shown in FIGS. 3 and 4, in some embodiments, the radially outer surface 510d may mirror the radially inner surface 510c. Thus, the radially outer surface 510d may include an outer convex spherical surface 532 that corresponds with the inner concave spherical surface 522 of the radially inner surface 510c. However, it should be appreciated that the radially outer surface 510d may not correspond with the radially inner surface 510c in some embodiments. For instance, in some embodiments, the radially outer surface 510d may include a continuous cylindrical surface that extends between the ends 510a, 510b, while the radially inner surface 510c may be substantially as shown in FIG. 16 and previously described. Thus, in some embodiments, the wall thickness of the body 510 of muffler 500 may vary along the axis 505 between the ends 510a, 510b to define the radially inner surface 510c and cavity 520.

Referring now to FIG. 17, a plot 540 showing an estimated pressure pulsation attenuation (or transmission loss) (in dB) over a range of frequencies (in Hz) for the muffler 500 shown in FIGS. 15 and 16 and previously described above is shown. As previously described, the plot 540 in FIG. 17 was generated assuming use of the refrigerant R454B; however, the use of other refrigerants is also contemplated. As shown in FIG. 17, the plot 540 illustrates that the muffler 500 of FIGS. 15 and 16 may have generally elevated pulsation attenuation performance between 0 Hz and 2000 Hz, as well as additional ranges of elevated pulsation attenuation performance between 2000 Hz and 3500 Hz and between 3500 Hz and 5000 Hz. Thus, like the muffler 100 of FIGS. 3 and 4, the muffler 500 may reduce pressure pulsations over a wide range of frequencies, and thus may provide an effective muffler for a variable speed compressor, when compared to the conventional muffler 600 of FIG. 1.

Referring now to FIGS. 18 and 19, a climate control system 10 for conditioning an interior space 12 is shown according to some embodiments disclosed herein. The interior space 12 is shown to include the interior space of a house or dwelling 14; however, as previously described, the interior space 12 may comprise any other suitable interior space that may be conditioned by a climate control system. For instance, the interior space 12 may comprise the interior space of a building, office, retail space, storage unit, refrigerator, freezer, etc.

The climate control system 10 may be configured to circulate a refrigerant through a fluid circuit (or refrigerant circuit) 58 to transfer heat between the interior space 12 and an outdoor ambient environment 5 (or “outdoor environment” 5). The outdoor environment 5 may comprise an environment that at least partially surrounds the interior space 12. For instance, in the embodiment illustrated in FIG. 17, the interior space 12 is an interior space of a house 14, and the outdoor environment comprises the outdoor environment that surrounds the house 14.

The climate control system 10 may include a compressor 30, a first heat exchanger 32, a pair of expansion devices 36, 42, a second heat exchanger 44, and a reversing valve 28 that are interconnected by a plurality of refrigerant lines 56 to at least partially define the fluid circuit 58. The fluid circuit 58 may circulate any suitable refrigerant (or refrigerants) during operations. For instance, in some embodiments, the refrigerant circulated through the fluid circuit 58 is R454B. However, other refrigerants are contemplated. For instance, the refrigerant circulated through fluid circuit 58 may include other refrigerant(s) that may have a relatively low Global Warming Potential (GWP), such as other so called “A2L” designated refrigerants including hydrofluoroolefins (HFOs) and blends thereof (e.g., R-1234fy, R-1234ze, R-452B, etc.). Also, in some embodiments, the fluid circuit 58 may circulate other refrigerants, such as one or more refrigerants that may comprise hydrofluorocarbons (HFCs), chlorofluorocarbons (CFCs), hydrochlorofluorocarbons (HCFCs), fluorocarbons (FCs), hydrocarbons (HCs), Ammonia (NH₃), carbon dioxide (CO₂), or some combination thereof.

In addition, the climate control system 10 may include a muffler 700 for attenuating pressure pulsations in the refrigerant discharged from the compressor 30 during operations. The muffler 700 may be configured the same or similarly to any of the mufflers 100, 200, 300, 400, 500 previously described herein. Thus, the muffler 700 may be positioned along the refrigerant line 56 extending between the compressor 30 and the reversing valve 28, so that the portion of the refrigerant line 56 positioned between the compressor 30 and the muffler 700 maybe the upstream refrigerant line 101 previously described, and the portion of the refrigerant line 56 extending between the muffler 700 and the reversing valve 28 may be the downstream refrigerant line 103 previously described.

The compressor 30 may include any suitable type of refrigerant compressor design. For instance, in some embodiments, the refrigerant compressor may comprise a reciprocating compressor, a scroll compressor, a screw compressor, a rotary compressor, centrifugal compressor, etc. Some compressor types, such as a reciprocating compressor, may be more prone to generate stronger pressure pulsations in the flow of refrigerant in the fluid circuit 58. Thus, in some embodiments, the muffler 700 may be particularly useful for use with climate control systems (such as climate control system 10) that include a compressor that may be predisposed to generation of significant pressure pulsations, such as a reciprocating compressor.

In the embodiment illustrated in FIGS. 18 and 19, the climate control system 10 may comprise a heat pump that may be operated to selectively cool or heat the interior space 12 via the fluid circuit 58 during operations. Thus, during a cooling mode operation of the climate control system 10 illustrated in FIG. 18, the climate control system 10 may generally transfer heat from the interior space 12 to the outdoor environment 5 via the fluid circuit 58, and during a heating mode operation of the climate control system illustrated in FIG. 18, the climate control system 10 may generally transfer heat from the outdoor environment 5 to the interior space 12 via the fluid circuit 58. Each of the cooling mode operation (FIG. 18) and heating mode operation (FIG. 19) will be described in more detail.

As shown in FIG. 18, during a cooling mode operation to cool the interior space 12, the compressor 30 compresses the refrigerant in a gaseous state and outputs the compressed refrigerant through the muffler 700 to attenuate pressure pulsations as previously described. Thereafter, the refrigerant flows to the reversing valve 28, which may then route the compressed refrigerant to the first heat exchanger 32. In the cooling mode operation of FIG. 18, the first heat exchanger 32 is configured to facilitate heat transfer from the refrigerant to the outdoor environment 5. Specifically, the refrigerant may flow through one or more coils 34 of the first heat exchanger 32, while a fan 38 generates an airflow 40 that is flowed over and around the one or more coils 34 to thereby draw heat away from the refrigerant flowing therein. The airflow 40 is then directed away from the first heat exchanger 32 and into the outdoor environment 5. The transfer of heat from the refrigerant to the airflow 40 via the first heat exchanger 32 may cause the refrigerant to at least partially condense to a liquid, such that the first heat exchanger 32 may function as a “condenser”when operating in the cooling mode of FIG. 18.

The liquid (or substantially liquid) refrigerant is then directed through the first expansion device 36 and then the second expansion device 42. In the cooling mode operation of FIG. 18, the first expansion device 36 may be positioned or actuated as to not substantially restrict or meter the flow of refrigerant therethrough. However, the second expansion device 42 may be actuated or set so as to controllably constrict and expand the flow of refrigerant so as to reduce a temperature thereof. The first expansion device 36 and second expansion device 42 may comprise orifices or expansion valves, such as electronic expansion valves (EEVs) that are actuated by a controller (e.g., controller 80 described herein). Alternatively, the first expansion device 36 and the second expansion device 42 may comprise a thermostatic expansion valve (TXV) that is configured to adjust in position (that is, in opening position) in response to one or more pressures and/or temperatures of the refrigerant flowing in the fluid circuit 58 (or a portion thereof).

The expanded, cold refrigerant is then directed through the second heat exchanger 44 which is configured to transfer heat from an airflow 50 generated by a blower 48 to the refrigerant. Specifically, the refrigerant may flow through one or more coils 46 of the second heat exchanger 44, while the blower 48 generates the airflow 50 that is flowed over and around the one or more coils 46 to thereby draw heat away from the airflow 50 and into the refrigerant. The blower 48 may also be driven by an electric motor; however, that motor is not specifically depicted so as to simplify the drawings.

The cooled airflow 50 is then discharged from the second heat exchanger 44 to the interior space 12 so as to reduce a temperature (and relatively humidity) therein. The airflow 50 may be discharged from the second heat exchanger 44 to the interior space 12 via suitable ducting 52 (e.g., rigid ducts, flexible hoses, or any other suitable fluid conveyance system).

The transfer of heat from the airflow 50 to the refrigerant via the second heat exchanger 44 may cause the refrigerant to vaporize or at least partially vaporize to a gas, such that the second heat exchanger 44 may function as an “evaporator” when operating in the cooling mode of FIG. 18. The vaporized (or partially vaporized) refrigerant may progress from the second heat exchanger 44 back to the compressor 30 via the reversing valve 28 so as to restart the cycle described above.

Referring now to FIG. 19, during a heating mode operation of the climate control system 10 the flow direction of the refrigerant in the fluid circuit 58 is generally reversed from that described for the cooling mode operation (FIG. 18). Specifically, during a heating mode operation, the reversing valve 28 is actuated so as to route the compressed refrigerant emitted from the compressor 30 to the second heat exchanger 44 rather than the first heat exchanger 32. As a result, in the heating mode operation shown in FIG. 19, the second heat exchanger 44 is configured to transfer heat from the refrigerant to the interior space 12 via airflow 50 so as to condense the refrigerant. Thus, in the heating mode operation of FIG. 19, the second heat exchanger 44 functions as a “condenser” for the refrigerant. The condensed refrigerant is then directed through the second expansion device 42 and the first expansion device 36; however, in the heating mode operation of FIG. 19, the second expansion device 42 is positioned or actuated so as to not substantially restrict or meter the flow of refrigerant therethrough, and the first expansion device 36 is actuated so as to controllably constrict and expand the flow of refrigerant so as to reduce a temperature thereof.

The expanded, cold refrigerant is then directed through the first heat exchanger 32 which is configured to transfer heat form the airflow 40 to the refrigerant to thereby vaporize the refrigerant and cool the airflow 40. Thus, in the heating mode operation, the first heat exchanger 32 functions the “evaporator” for the refrigerant. Finally, the vaporized refrigerant is routed back to the compressor 30 via the reversing valve 28 to restart the cycle described above.

While the climate control system 10 illustrated in FIGS. 18 and 19 has been described as a heat pump that is configured to both heat or cool the interior space 12 via circulation of a refrigerant, it should be appreciated that climate control system 10 may be differently configured in other embodiments. For instance, in some embodiments, the climate control system 10 may be configured as an air conditioning system that is configured to run in cooling mode (FIG. 18) only. Thus, in these embodiments, the reversing valve 28 may be omitted and the climate control system 10 may be configured to circulate the refrigerant in the direction illustrated in FIG. 18 so as to cool the interior space 12. In some of these embodiments, where the climate control system 10 is configured as an air conditioning system, a supplemental heating device (e.g., an electrically resistive heater, a combustion furnace, etc.) may be used to selectively heat the airflow 50. Thus, references to the climate control system 10 as a heat pump as shown in FIGS. 18 and 19 is merely illustrative of some embodiments disclosed herein.

In both the cooling mode operation (FIG. 18) and the heating mode operation (FIG. 19), the climate control system 10 may be configured to deliver either a single, set cooling or heating capacity, respectively, or a plurality of different cooling or heating capacities. Specifically, the climate control system 10 may be operable to deliver a single cooling or heating capacity by circulating the refrigerant through the refrigerant circuit 58 at single flow rate via a single speed of the compressor 30, and by outputting set flow rates for the airflows 40, 50 via single operating speeds of the fan 38 and blower 48, respectively.

Conversely, the climate control system 10 may be operable to deliver a plurality of cooling or heating capacities by circulating the refrigerant through the refrigerant circuit 58 at a plurality of different flow rates via a plurality of speeds of the compressor 30 and by outputting a plurality of different flow rates for the airflows 40, 50 via a plurality of different operating speeds of the fan 38 and blower 48, respectively. For embodiments of climate control system 10 that are configured to provide a plurality of different cooling or heating capacities, the different speeds of the compressor 30, fan 38, and blower 48 may be configured in a plurality of set stages or levels (e.g., such a low stage and high stage), or may be configured as a continuous series of potential speeds along defined ranges (e.g., such as for a fully variable climate control system 10).

Referring again to FIGS. 18 and 19, in some embodiments, the second heat exchanger 44, second expansion device 42, and blower 48 may be embodied as an at least partially integrated first unit 60. In addition, in some embodiments, the first heat exchanger 32, first expansion device 36, fan 38, fan motor 39, reversing valve 28, and compressor 30 may be embodied as an at least partially integrated second unit 70. In some embodiments, the first unit 60 may be positioned in any suitable indoor space that may or may not be the same (or connected to) the interior space 12. For instance, the first unit 60 may be positioned in an attic, storage room, basement, building, enclosure, that is proximate to, connected to, or at least partially integrated (or inside of) the interior space 12. Likewise, the second unit 70 may be positioned in the outdoor environment 5. Thus, in some embodiments, the first unit 60 may be referred to herein as an “indoor unit” and the second unit 70 may be referred to as an “outdoor unit.”

However, these example positions of the units 60, 70 are not intended to limit a particular location of either of the units 60, 70 in various embodiments. For example, in some embodiments, the first unit 60 and second unit 70 may be at least partially integrated with one another and co-located in single location. For instance, in some embodiments, the first unit 60 and the second unit 70 may be integrated with one another as a so-called “packaged unit” and located in the outdoor environment 5. In some embodiments, the at least partially integrated units 60, 70 (e.g., as a packaged unit) may be positioned on a rooftop of the house 14, dwelling, building, etc. that defines the interior space 12. Thus, in these embodiments, the climate control system 10 may be referred to as a so-called “rooftop unit.”

The embodiments disclosed herein include mufflers for reducing pressure pulsations in a refrigerant line of a climate control system. In some embodiments, the muffler of the disclosed embodiments may include relatively complex inner cavities that are configured to attenuate pressure pulsations across a wider range of frequencies when compared to conventional designs (which may generally comprise simple cavities shaped as a right circular cylinder). Thus, use of mufflers according to the embodiments disclosed herein may more effectively attenuate the pressure pulsations generated by a multi-seed or variable speed compressor.

In addition to the benefits and functions described above, it should also be appreciated that embodiments of the mufflers 100, 200, 300, 400, 500 described herein do not include internal baffles, dividers, or other flow restrictions or obstructions in the corresponding cavities. Thus, embodiments of mufflers disclosed herein (e.g., mufflers 100, 200, 300, 400, 500) may induce a reduced or minimal pressure drop in the flow of refrigerant (e.g., such as refrigerant discharged from compressor 30 shown in FIGS. 18 and 19).

Further, while the central axes 105, 205, 305, 405, 505 of the mufflers 100, 200, 300, 400, 500, respectively, have been described as being aligned with the central axes of the refrigerant lines 101, 103, it should be appreciated that the central axes 105, 205, 305, 405, 505 may be misaligned in some embodiments. For instance, in some embodiments, the central axes 105, 205, 305, 405, 505 of embodiments of one or more of the mufflers 100, 200, 300, 400, 500, respectively, may be parallel with the central axis of one or both of the refrigerant lines 101, 103.

While embodiments of mufflers for attenuating pressure pulsations in a climate control system have been described as being positioned downstream of a refrigerant compressor, it should be appreciated that embodiments of a muffler disclosed herein may be positioned in other locations of a climate control system. For instance, a muffler according to some embodiments disclosed herein may be positioned upstream of a compressor of a climate control system.

Also, in addition to the benefits and functions described above, it should be appreciated that one or more of the cavities 120, 220, 320, 420, may have a mis-match in shape at the corresponding inlets 102, 202, 302, 402, respectively, and the outlets 104, 204, 304, respectively. Specifically, as shown in at least FIGS. 4, 7, 13, one or more of the inlets 102, 202, 302, 402, 502 of the mufflers 100, 200, 300, 400, 500, respectively, may have a relatively sharper or more rapid flow area expansion than the flow area constriction at the corresponding outlets 104, 204, 304, 504, respectively. For instance, the flow area expansion at the inlet 102 and planar surface 122 of muffler 100 (FIG. 4) is sharper (or more rapid) than the flow area constriction of the converging surface 126. Similarly, the flow area expansion at the inlet 202 and planar surface 222 of the muffler 200 (FIG. 7) is sharper (or more rapid) than the flow area constriction of the frustoconical surface 226. Further, the flow area expansion at the inlet 402 and planar surface 422 of the muffler 400 (FIG. 13) is sharper (or more rapid) than the stepped flow area constriction of the planar surfaces 425, 428. Without being limited to this or any other theory, it is believed that combining the sharper flow area expansion at the inlet with the more gradual flow area constriction at the outlet of one or more embodiments of a muffler disclosed herein may help to attenuate pressure pulsations and thereby at least contributes to the general performance previously described.

In addition, in some embodiments, one or more embodiments of a muffler disclosed herein may be placed in series with another muffler (e.g., another muffler according to the embodiments disclosed herein or a conventional muffler) along a refrigerant line. Without being limited to this or any other theory, placing a muffler according to the embodiments disclosed herein in series with another muffler may layer and combine the pressure pulsation attenuation performance of both mufflers to thereby better attenuate pressure pulsations across the wider range of frequencies.

The preceding discussion is directed to various exemplary embodiments. However, one of ordinary skill in the art will understand that the examples disclosed herein have broad application, and that the discussion of any embodiment is meant only to be exemplary of that embodiment, and not intended to suggest that the scope of the disclosure, including the claims, is limited to that embodiment.

The drawing figures are not necessarily to scale. Certain features and components herein may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in interest of clarity and conciseness.

Clause 1. A muffler for a climate control system, the muffler comprising: a body including an inlet, an outlet, a central axis extending between the inlet and the outlet, and a cavity within the body, between the inlet and the outlet, that includes a converging surface that converges toward the central axis, wherein the converging surface includes has a convex curvature within the cavity.

Clause 2. The muffler of any of the clauses, wherein the converging surface converges toward the central axis at the outlet.

Clause 3. The muffler of any of the clauses, wherein the converging surface has a convex circular curvature within the cavity.

Clause 4. The muffler of any of the clauses, wherein the cavity also includes a planar surface that extends radially relative to the central axis and a cylindrical surface extending from the planar surface to the converging surface.

Clause 5. The muffler of any of the clauses,, wherein the inlet is defined on the planar surface.

Clause 6. The muffler of any of the clauses, wherein the body includes a radially outer surface that mirrors the cavity.

Clause 7. The muffler of any of the clauses, wherein the converging surface comprises a convex hemispherical surface at the inlet, the convex hemispherical surface projecting axially toward the outlet relative to the central axis.

Clause 8. The muffler of any of the clauses, wherein the cavity also includes an concave hemispherical surface at the outlet, wherein the concave hemispherical surface projects axially away from the inlet relative to the central axis.

Clause 9. The muffler of any of the clauses, wherein the cavity also includes a cylindrical surface extending from the convex hemispherical surface to the concave hemispherical surface.

Clause 10. The muffler of any of the clauses, wherein the body includes a radially outer surface that mirrors the cavity.

Clause 11. An outdoor unit for a climate control system, the outdoor unit comprising: a compressor capable of a plurality of operating speeds, a heat exchanger configured to exchange heat between an ambient environment and an A2L designated refrigerant, a refrigerant line for conveying the A2L designated refrigerant from the compressor to the heat exchanger, and a muffler positioned along the refrigerant line to attenuate pressure pulsations imparted by the compressor on the refrigerant, wherein the muffler is configured to impart a transmission loss of at least 10 dB across a frequency range of from 500 Hz to 2700 Hz.

Clause 12. The outdoor unit of any of the clauses, wherein the muffler comprises: a body including: an inlet, an outlet, a central axis extending between the inlet and the outlet, and a cavity within the body, between the inlet and the outlet, that includes a converging surface that converges toward the central axis, wherein the converging surface includes has a convex curvature within the cavity.

Clause 13. The outdoor unit of any of the clauses, wherein the converging surface converges toward the central axis at the outlet.

Clause 14. The outdoor unit of any of the clauses, wherein the converging surface has a convex circular curvature within the cavity.

Clause 15. The outdoor unit of any of the clauses, wherein the cavity also includes a planar surface that extends radially relative to the central axis and a cylindrical surface extending from the planar surface to the converging surface

Clause 16. The outdoor unit of any of the clauses, wherein the inlet is defined on the planar surface

Clause 17. The outdoor unit of any of the clauses, wherein the body includes a radially outer surface that mirrors the cavity.

Clause 18. The outdoor unit of any of the clauses, wherein the converging surface comprises a convex hemispherical surface at the inlet, the convex hemispherical surface projecting axially toward the outlet relative to the central axis.

Clause 19. The outdoor unit of any of the clauses, wherein the cavity also includes an concave hemispherical surface at the outlet, wherein the concave hemispherical axially toward the outlet relative to the central axis.

Clause 20. The outdoor unit of any of the clauses, wherein the cavity also includes a cylindrical surface extending from the convex hemispherical surface to the concave hemispherical surface.

Clause 21. The outdoor unit of any of the clauses, wherein the body includes a radially outer surface that mirrors the cavity.

Clause 22. A muffler for a climate control system, the muffler comprising: a body including: an inlet, an outlet, a central axis extending between the inlet and the outlet; and a cavity within the body, between the inlet and the outlet, that includes: a planar surface that extends radially relative to the central axis; and a frustoconical surface extending from the planar surface to the outlet.

Clause 23. The muffler of any of the clauses, wherein the inlet is defined on the planar surface.

Clause 24. The muffler of any of the clauses, wherein the body includes a radially outer surface that mirrors the cavity.

Clause 25. A muffler for a climate control system, the muffler comprising: a body including: an inlet, an outlet, a central axis extending between the inlet and the outlet, and a spherical cavity within the body, between the inlet and the outlet.

Clause 26. A muffler for a climate control system, the muffler comprising: a body including: an inlet, an outlet, a central axis extending between the inlet and the outlet; and a cavity within the body, between the inlet and the outlet, that includes: a first cylindrical surface having a first inner diameter; and a second cylindrical surface having a second inner diameter, the second inner diameter being less than the first inner diameter.

Clause 27. The muffler of any of the clauses, wherein the body includes a radially outer surface that mirrors the cavity.

In the discussion herein and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to.” Also, the term “couple” or “couples” is intended to mean either an indirect or direct connection. Thus, if a first device couples to a second device, that connection may be through a direct connection of the two devices, or through an indirect connection that is established via other devices, components, nodes, and connections. In addition, as used herein, the terms “axial” and “axially” generally mean along or parallel to a given axis (e.g., central axis of a body or a port), while the terms “radial” and “radially” generally mean perpendicular to the given axis. For instance, an axial distance refers to a distance measured along or parallel to the axis, and a radial distance means a distance measured perpendicular to the axis. Further, when used herein (including in the claims), the words “about,” “generally,” “substantially,” “approximately,” and the like, when used in reference to a stated value mean within a range of plus or minus 10% of the stated value.

While exemplary embodiments have been shown and described, modifications thereof can be made by one skilled in the art without departing from the scope or teachings herein. The embodiments described herein are exemplary only and are not limiting. Many variations and modifications of the systems, apparatus, and processes described herein are possible and are within the scope of the disclosure. Accordingly, the scope of protection is not limited to the embodiments described herein, but is only limited by the claims that follow, the scope of which shall include all equivalents of the subject matter of the claims. Unless expressly stated otherwise, the steps in a method claim may be performed in any order. The recitation of identifiers such as (a), (b), (c) or (1), (2), (3) before steps in a method claim are not intended to and do not specify a particular order to the steps, but rather are used to simplify subsequent reference to such steps.