The preferred invention is related to a flow control valve (FCV). More specifically, the
5 preferred invention is related to a flow control valve automotive air conditioning system (ACS),
a Battery Thermal Management System (BTMS), or an Electric Vehicle Thermal Management
System (EVTMS).
BACKGROUND OF THE INVENTION
10 Background description includes information that may be useful in understanding the present
invention. It is not an admission that any of the information provided herein is prior art or
relevant to the presently claimed invention, or that any publication specifically or implicitly
referenced is prior art.
15 Conventional refrigeration systems in EVTMS or HP ACS encounters a problem where the
refrigerant circuit has excess number of pipes and connections, which increases the cost of
construction and increases the packing space required. Therefore, there is a need to simplify
the refrigerant circuit, to reduce the number of pipes and connections from vapour compression
refrigeration cycle of EVTMS or HP ACS, since this simplification of the refrigerant circuit
20 contributes to reduce not only cost and packaging space but also the refrigerant pressure drop
in the cycle so that the system efficiency is improved.
If vehicle thermal system uses refrigerant circuit for both cooling and heating, changing
refrigerant flow direction as necessary, 2 to 4-way FCV is necessary for Electric vehicle (EV)
25 or Hybrid Electric Vehicle (HEV) application. Electronic expansion valve (EXV) function also
is sometimes used and sometimes not used, depending on operation mode. Since the number
of valves and pipes/hoses are increasing for such applications, this becomes a problem.
Therefore, it is highly desired to integrate valves and to reduce number of pipes and hoses as
result of valve integration.
30
SUMMARY OF THE INVENTION
It is intended that all such features, and advantages be included within this description, be
within the scope of the present invention, and be protected by the accompanying claims. The
3
following summary is provided to facilitate an understanding of some of the innovative features
unique to the disclosed embodiment and is not intended to be a full description. A full
appreciation of the various aspects of the embodiments disclosed herein can be gained by
taking the entire specification, claims, drawings, and abstract as a whole.
5
An integrated flow control valve disclosed here addresses the need to integrate valves to reduce
number of pipes and hoses. The integrated flow control valve comprises a valve body, a rotating
flap disposed within the valve body, and a motor and a solenoid positioned at opposing ends
of the valve body to rotate the rotating flap. The integrated flow control valve also comprises
10 a valve stem, where refrigerant super heat control is performed with movement of the valve
stem and changing area of cross section of an orifice present on the rotating flap for refrigerant
flow between an inlet pipe and an outlet pipe. The integrated flow control valve also comprises
bypassable electronic expansion valves axially integrated within the rotating flap, which reduce
protruding volume occupied by surface of the rotating flap, and this reduction in protruding
15 volume reduces refrigerant pressure drop. In an embodiment, the rotating flap is disposed
within the valve body to change a mode between operational mode of the expansion valve and
bypassed mode of the expansion valve. In an embodiment, the rotating flap oriented in a as
bypassed mode to sustain flow area for the refrigerant equivalent as compared to the inlet pipe
and the outlet pipe by increasing inner diameter of the valve body.
20
In another embodiment, the integrated flow control valve comprises a valve body, a rotating
flow control unit, a motor and a solenoid, and a valve stem. The rotating flow control unit and
a fixed flap are disposed within the valve body. The motor and the solenoid are positioned at
opposing ends of the valve body, where the motor rotates the rotating flow control unit from
25 bottom of the valve body and the solenoid actuates the fixed flap from top of the valve body.
Refrigerant super heat control is performed by movement of the valve stem and changing
area of cross section of an orifice present on the fixed flap, which is separately allocated from
the rotating flow control unit, for refrigerant flow between an inlet pipe and an outlet pipe.
30 In an embodiment, a first expansion valve defined by the orifice present on the fixed flap and
an evaporator are bypassed for a heating mode in a Heating, Ventilation, and Air
Conditioning (HVAC) heater. In an embodiment, the first expansion valve that is positioned
between a first flow control valve defined by the rotating flow control unit and an air-cooled
4
condenser, is used as an expansion valve when a refrigerant cycle is both in the cooling mode
and in Hot Gas Pre-Heating (HGPH) mode, which are differently controlled under the
Electric Vehicle Thermal Management System (EVTMS) control logic. In an embodiment,
the first expansion valve that is integrated in the first flow control valve is positioned between
5 a water-cooled condenser and the air-cooled condenser, which switches one of the refrigerant
flow to the air-cooled condenser for the cooling mode and to a compressor for the heating
mode, and wherein the integrated first flow control valve and the compressor are used to
maintain required inlet superheat to the compressor.
10 In an embodiment, integrated flow control valve is a third flow control valve comprising an
inlet pipe, a first outlet pipe, a second outlet pipe, and a ball valve, wherein the fixed flap is
modified with an orifice, wherein the second outlet pipe and the orifice that are defined as a
variable expansion device is completely closed, and the ball valve rotates to one of change
between the cooling mode and the heating mode, and set an intermediate position to balance
15 both the cooling mode and the heating mode. In an embodiment, a third expansion valve is
integrated at outlet side of the flow control valve, to control the refrigerant superheat for both
the cooling mode and the heating mode. In an embodiment, the third flow control valve that
is positioned between the water-cooled condenser and the air-cooled condenser switches the
refrigerant direction to flow towards the compressor through the water-cooled condenser and
20 by-passing the air-cooled condenser before the compressor if heating is required and bypassing the water-cooled condenser towards the air-cooled condenser if the cooling mode is
required, to avoid pressure drop in the water-cooled condenser.
In other words, an expansion device integrated flow control valve (FCV) is disclosed here for
25 air conditioning system or battery thermal management system or integrated thermal
management system which is using the basic principles of vapour compression refrigerant
cycle, having refrigerant expansion function and flow direction control function in one
package. The expansion device comprises of expansion valve part and flow control part rotated
by electric motor to change refrigerant flow direction. In an embodiment, FCV function has 2
30 ways, refrigerant inlet, and outlet. Its expansion device is integrated into centre portion of
butterfly type flap. Flap shaft axis and expansion actuation axis are common or almost
common.
5
In an embodiment, FCV function has 3 ways. Refrigerant inlet has integrated expansion device
whose actuation axis is different from flow control part axis. In an embodiment, FCV function
has 3 ways. One of refrigerant outlet has integrated expansion device whose actuation axis is
different from flow control part axis. In an embodiment, FCV function has 3 ways. One of
5 refrigerant outlet has integrated fixed expansion device having refrigerant flow rate control
function by regulating flow control part opening through its rotation control. In an embodiment,
FCV function has 4 ways. Adjacent two ways are interconnected with pipes and/or hoses
having at least one heat exchanger in between. Expansion device is integrated in inlet side of
said two adjacent ways. Rotating flow control part, two control modes is set. One is passing
10 through said two adjacent ways and the other is bypassing said two adjacent ways.
In an embodiment, FCV function has 4 ways. One of refrigerant outlet has integrated expansion
device whose actuation axis is different from flow control part axis. In an embodiment, FCV
function has 4 ways. One of refrigerant outlet has integrated fixed expansion device having
15 refrigerant flow rate control function by regulating flow control part opening through its
rotation control. In an embodiment, flow control part axis and expansion actuation axis are
parallel each other and two actuators are located opposite end of axis. In an embodiment, cross
section of refrigerant flow passage from inlet to outlet is nearly the same when the butterfly
type flap position is parallel to refrigerant flow direction as bypass mode. In different
20 embodiments, flow control part is butterfly type, flow control part is ball type, and flow control
part is gate type.
The preferred invention is focused on the development of Flow Control Valve (FCV), which
has a structure of Electric Expansion Valve (EXV) integrated in the FCV, for typically
25 automotive air conditioning system (ACS) or Battery Thermal Management System (BTMS)
or Electric Vehicle Thermal Management System (EVTMS). Current systems in vehicle
electrification are changing vapour compression refrigeration cycle to adapt heating solution.
Traditionally, heat source for ACS was engine cooling coolant in ICE vehicle. However, for
non-ICE vehicle, there is no engine cooling coolant available. Therefore, new heating solutions
30 were demanded and identified. They are typically Heat Pump (HP) heating ACS and EVTMS,
as energy efficient systems.
6
Since these systems are using FCVs to switch between or change refrigerant direction for HP
system and EVTMS, and are using expansion devices for evaporators, with bypass passages,
in order to manage cooling and heating functions with one refrigerant circuit, it was desired to
simplify the circuit. This disclosure describes a simplified refrigerant distribution device
5 having expansion device integrated. The solution having features listed below;
- Integration of EXV and FCV into one, reducing number of bypass circuits or
eliminating bypass circuit completely depending on the different systems.
- This EXV integrated FCV serves all basic functions of an EXV without compromise
on performance for expansion and generating same super heat as was the case with
10 standalone EXV.
- FCV also prevents liquid back flow to electric compressor
- FCV uses a butterfly valve flap concept to minimize internal pressure drop.
- EXV is integrated either in centre axis of butterfly valve flap or in one of ways to
connect to refrigerant circuit.
15 - FCV and EXV comprises electric actuators respectively.
- FCV actuator allows butterfly flap to rotate around the centre axis.
- EXV actuator allows shaft with plug, which are opening and closing orifice, to move
up and down along the shaft axis.
- To have above EXV and FCV in a compact packaging, two axis are parallel and two
20 actuators are positioned in opposite sides each other.
- This EXV integrated FCV application is used for all EXV applications which require
EXV function and its bypassing function as 2-way FCV, 3 way FCV and 4 way FCV.
- 2-way FCV is applied for EVTMS HP Option. It is allocated in between water
condenser and air condenser.
25 - 3-way FCV is applied for EVTMS Hot Gas Bypass Heating (HGBH) option. It is
allocated in between HVAC Evaporator and Compressor to switch the refrigerant direction
from EXV to HVAC Evaporator or Compressor.
- 3-way FCV can be applied for HP ACS. It is allocated in between HVAC Evaporator
and Accumulator to switch the refrigerant direction from Condenser/Evaporator to HVAC
30 Evaporator or Accumulator.
- 3-way REF-EXV/FCV is applied for EVTMS Hot Gas By-Pass option. It is allocated
in between water condenser and air condenser to by-pass the refrigerant from air condenser to
7
compressor either 100% or partially based on system heating and cooling demand. This EXV
function is either variable orifice or fixed orifice.
- 4-way FCV is applied for HP ACS and is allocated in between Compressor and Heater
(Inner Condenser) – Condenser/Evaporator to switch the refrigerant direction to flow in the
5 Heater with EXV function or bypassing them directly to Condenser/Evaporator.
- 4-way REF-EXV/FCV is applied for EVTMS HGBH Option. It is allocated in
between water condenser and air condenser to switch the refrigerant direction to flow in
Compressor with REF-EXV/FCV function through water condenser by-passing air condenser
and the rest of components before Compressor, if heating required and By-pass water
10 condenser to air condenser if cooling mode requires to avoid pressure drop of water
condenser.
- In case to reduce butterfly valve flap operation torque, it may stop compressor once
during distribution switching period.
15 BRIEF DESCRIPTION OF DRAWINGS
The invention can be better understood with reference to the following drawings. The
components in the drawings are not necessarily to scale, emphasis instead being placed upon
clearly illustrating the principles of the present invention. Moreover, in the drawings, like
reference numerals designate corresponding parts throughout the several views.
20
Fig. 1 exemplarily illustrates an EVTMS HP Heating Option.
Fig. 2 exemplarily illustrates an EVTMS – Hot Gas Pre-Heating (HGPH) option
25 Fig. 3 exemplarily illustrates an HP ACS with Battery thermal management system.
Fig. 4 exemplarily illustrates an EVTMS HGBH (Using 3-Way Valve) option.
Fig. 5 exemplarily illustrates an EVTMS HGBH (Using 4-Way Valve) option.
30
Figs. 6A and 6B exemplarily illustrate a 2-way FCV for EVTMS HGPH option (EXV Mode).
8
Figs. 7A and 7B exemplarily illustrate a 2-way FCV for EVTMS for HGPH option (Bypass
Mode).
Figs. 8A and 8B exemplarily illustrate a 3/4-way FCV for EVTMS or HP AC application.
5
Fig. 9 exemplarily illustrates a 3-way FCV for EVTMS HGPH application (Heating Mode).
Fig. 10 exemplarily illustrates a 3-way FCV for EVTMS HGPH application (Cooling Mode).
10 Fig. 11 exemplarily illustrates a 3-way FCV for HP ACS application / AccumulatorEvaporator (Heating Mode).
Fig. 12 exemplarily illustrates a 3-way FCV for HP ACS application / AccumulatorEvaporator (Cooling Mode).
15
Fig. 13A and 13B exemplarily illustrate a 3-way ball valve REF-EXV/FCV for EVTMS HGBH
(Heating Mode) and a graph showing pressure drop in inlet and outlet pipes, respectively.
Fig. 14 exemplarily illustrates a 4-way FCV for EVTMS HP ACS Application / Heater-Bypass
20 (Heating Mode).
Fig. 15 exemplarily illustrates a 4-way FCV for EVTMS HP ACS Application / Heater-Bypass
(Cooling Mode).
25 Figs. 16A and 16B exemplarily illustrate a 4-way ball valve REF-EXV/FCV for EVTMS
HGBH (Heating Mode).
Fig. 16C exemplarily illustrates graph showing pressure drop in inlet and outlet pipes,
respectively, based on embodiments in Figs. 16A and 16B.
30
DESCRIPTION OF THE INVENTION
The following description with reference to the accompanying drawings is provided to assist
in a comprehensive understanding of exemplary embodiments of the invention. It includes
9
various specific details to assist in that understanding but these are to be regarded as merely
exemplary. Accordingly, persons skilled in the art will recognize that various changes and
modifications to the embodiments described herein can be made without departing from the
scope and spirit of the invention. In addition, descriptions of well-known functions and
5 constructions are omitted for clarity and conciseness.
The terms and words used in the following description are not limited to the bibliographical
meanings, but, are merely used by the inventor to enable a clear and consistent understanding
of the invention. Accordingly, it should be apparent to the person skilled in the art that the
10 following description of exemplary embodiments of the present invention are provided for
illustration purpose only. It is to be understood that the singular forms “a,” “an,” and “the”
include plural referents unless the context clearly dictates otherwise.
The present invention aims to provide a thermal management system for cabin cooling of pure
15 electric commercial vehicles used in hot and humid climate region, in which all AC System
loops run simultaneously to provide effective cooling to the passenger cabin. The foregoing
advantages, as well as the working of the thermal management system, will become more
noticeable and understandable from the following detail description thereof when read in
conjunction with the accompanying drawings.
20
Fig. 1 illustrates an EVTMS HP Heating option. In a first embodiment of the EVTMS 100, the
EVTMS 100 uses the basic principles of vapour compression refrigerant cycle and single-phase
coolant cycle. The first closed cycle includes electric compressor 102, water-cooled condenser
104, air-cooled condenser 106, electronic expansion valve (EXV) 108, a first FCV 110,
25 evaporator 112 and connecting pipes. The electric compressor 102, which is powered by a
battery 114, compresses the refrigerant vapour thereby increasing temperature and pressure of
refrigerant. The two condensers, for example, the water-cooled condenser 104 and air-cooled
condenser 106, are condensing high pressure and high temperature refrigerant using coolant
and air respectively, which are coming from the second closed cycle, and ambient air
30 respectively. The first EXV 108 is controlling refrigerant pressure, temperature, and refrigerant
flow before the electric compressor 102 under EVTMS 100 controlling logic. Pressure and
temperature sensors, for example, low pressure temperature sensor (LPTS) and high-pressure
temperature sensor (HPTS) respectively as shown in Fig. 1, which are positioned before and
10
after the electric compressor 102 are used as controller input data. The first FCV 110 that is
positioned in between first EXV 108 and the air-cooled condenser 106 is switching refrigerant
flow to evaporator 112 for cooling mode, or in another embodiment, by-passing first EXV 108
and evaporator 112 for heating mode via HVAC heater 116. This EVTMS 100 is designed to
5 define the above described first EXV 108 integrated into the first FCV 110 function.
The second closed cycle includes electric water pump 202, battery heat exchanger 204, watercooled condenser 104, heater core or HVAC Heater 116, surge tank 206, chiller 208 and second
connecting pipes. The electric water pump 202 that is powered by a battery unit 114 pumps the
10 coolant, which is typically a mixture of water, ethylene glycol and some additives thereby
flowing it through heat exchangers in the cycle. The water-cooled condenser 104 is the
common heat exchanger between two closed cycles. For the coolant cycle, the water-cooled
condenser 104 acts as a coolant heater uses waste heat from first closed cycle, providing hot or
warm coolant to HVAC heater 116 and to battery pack thermal management heat exchanger
15 (BTM HEX) 204 to warm up the battery unit 114 when desired. Using the second FCV 210
that is positioned before the water-cooled condenser 104, the coolant flow is controlled based
on input temperature data before or after HVAC heater 116, based on EVTMS 100 controlling
logic to give minimum required heating energy.
20 Temperature control of the battery unit 114 is performed with EVTMS 100 controlling logic.
Inlet and outlet coolant temperature sensors, for example BITS and BOTS respectively, are
used for the controller input data. Since this coolant cycle operates in parallel to refrigerant
cycle, HVAC has temperature control, which is cooling and is dehumidifying by evaporator
112 first and then re-heating by HVAC heater 116. Battery heat exchanger (BTM HEX) 204 is
25 also controlled with respect to temperature, for example, heating. Concerning higher load
heating function: when cooling load is small or not required, in addition to heat recovery
heating using water-cooled condenser 104, HP system in refrigerant cycle, heating up coolant
more powerfully by water-cooled condenser 104 is be used. For HP heating mode, it can absorb
the energy from ambient air for better COP. But for the evaporator 112 mode being activated
30 on the air-cooled condenser 106, it requires additional second EXV 212 which is inoperative
during cooling mode. This EVTMS 100 is designed to define the above-described function.
11
Referring to Figs. 6A, 6B, 7A and 7B, a first EXV 108 integrated 2-way FCV 110 is described
therein, for EXV mode in Figs. 6A-6B, and for bypass mode in Figs. 7A-7B. Basic structure is
butterfly type motor drive FCV 110, rotating flap 602a disposed within a valve body 612
around 90 degrees to change the mode between EXV mode and bypass mode. Refrigerant super
5 heat control is performed with valve stem 610 movement, the changing orifice 608 area cross
section for refrigerant flow, which is the same or similar axis direction as the rotation axis of
the rotating flap 602a, for example, a butterfly valve flap. Motor 604 to rotate the rotating flap
602a and solenoid 606 are allocated in the opposite end of control axis to have compact
packaging to rotate the rotating flap 602a. In case of this 2-way FCV 110, orifice 608, stem
10 610, valve body 612, consisting of expansion function, are allocated in butterfly valve flap axis
area.
This structure of the first FCV 110 is with minimized protruding profile from surface of the
rotating flap 602a to minimize the refrigerant pressure drop. And the flow passage between the
15 valve body 612 inside and the protruding profile area is designed to have similar cross section
area of refrigerant inlet pipe 614 internal cross section. This contributes to minimize refrigerant
pressure drop. Furthermore, the rotating flap 602a oriented at 90 degrees keep flow area for
the refrigerant equivalent as compared to the inlet pipe 614 and outlet pipe 616 by increasing
inner diameter of the valve body 612. Then this first EXV 108 integrated 2-way FCV 110
20 axially integrated within on the rotating flap 602a to reduce protruding volume occupied by
surface of the rotating flap 602a, and the reduction in protruding volume reduces refrigerant
pressure drop. The first FCV 110 achieves compactness, lightweight, low cost and low pressure
drop features compared to separated solution of first EXV 108 and the first FCV 110, with
associated bypass passage pipes if first EXV 108 does not have bypass function.
25
Fig. 2 illustrates an EVTMS – (Hot Gas Pre-Heating) HGPH Option. In a second embodiment
of the disclosed invention, the EVTMS HGBH option is described in Fig. 2 and Fig. 4. Here
two scenarios are there, the 1st is in Fig. 2 in which integrated first EXV 108 - FCV 110 is
positioned after the air-cooled condenser 106 and the 2nd is in Fig. 4 in which integrated first
30 EXV 108 - FCV 110 is positioned before air-cooled condenser 106. EVTMS 100 uses the basic
principles of vapour compression refrigerant cycle and single-phase coolant cycle. The first
closed cycle includes electric compressor 102, water-cooled condenser 104, air-cooled
condenser 106, the first FCV 110, first EXV 108, evaporator 112 and first connecting pipes
12
with or without internal heat exchanger (IHX) 404, as shown in Fig 4. The electric compressor
102, which is powered by a battery unit 114, compresses the refrigerant vapour thereby
increasing temperature and pressure of refrigerant. The two condensers, for example, the watercooled condenser 104 and the air-cooled condenser 106, are condensing high pressure and high
5 temperature refrigerant using coolant and air respectively, which are coming from the second
closed cycle, and ambient air respectively.
The first EXV 108 controls refrigerant pressure, temperature, and refrigerant flow before
compressor under EVTMS 100 controlling logic. Pressure and temperature sensors, for
10 example, low pressure temperature sensor (LPTS) and high-pressure temperature sensor
(HPTS) respectively as shown in Fig. 2, before and after the electric compressor 102 are used
as the controller input data. In Fig. 2, the first FCV 110 positioned in between the first EXV
108 and the evaporator 112, or the electric compressor 102 is switching refrigerant flow to
evaporator 112 for cooling mode or to electric compressor 102 for HGPH mode. The first EXV
15 108 positioned in between the first FCV 110 and air-cooled condenser 106 is used for its
expansion valve function when the refrigerant cycle is both in cooling mode and in HGPH
mode, differently controlled under EVTMS 100 control logic. In Fig. 4, the first EXV 108
integrated FCV 110 is positioned in between water-cooled condenser 104 and air-cooled
condenser 106, which switches the refrigerant flow to air-cooled condenser 106 for cooling
20 mode or to electric compressor 102 for HGBH heating mode. Integrated first EXV 108 in
between the first FCV 110 and electric compressor 102 is used to maintain required inlet SH
to the electric compressor 102. The EVTMS 100 which is described later is designed to define
this first EXV 108 integrated FCV 110 function.
25 In Fig. 2, concerning HGBH function, the evaporator 112 is bypassed and electric compressor
102 suctions high temp and low-pressure gas phase refrigerant that is controlled by adjusted
coolant flow rate flowing through water-cooled condenser 104, by using EVTMS 100 control
logic. In Fig. 4, concerning HGBH function, it is required that air-cooled condenser 106 is
bypassed and electric compressor 102 is suctioning high temperature and low-pressure gas
30 phase refrigerant that is controlled by integrated REF_EXV/FCV 118 and coolant flow rate
flowing through water-cooled condenser 104, by using EVTMS HGBH control logic. If
applicable region does not require such powerful heating frequently, this simpler system is cost
effective in minimizing refrigerant pressure drop for better cooling mode COP.
13
The first EXV 108 integrated 3-way FCV 110 example is described in Figs. 8A-8B, 9, 10, and
13 for cooling mode in Figs. 8A-8B and for HPGH mode in Fig. 9. Basic structure is butterfly
type motor drive FCV 110, rotating flap 602a, and fixed flap 602b around 90 degrees to change
5 the mode between cooling mode and heating mode. Fig. 13A illustrates a 3-way ball valve
REF-EXV/FCV 118 for EVTMS HGBH (Heating Mode), where basic structure of the REFEXV/FCV 118 comprise ball valve type motor drive third FCV 118 integrated with variable
orifice 120 at a second outlet pipe 122. There are three passages for the refrigerant, namely
refrigerant inlet pipe 126, the first outlet pipe 128, and the second outlet pipe 122. The HGBH
10 is operated that time ball valve, or third FCV 118, allows the refrigerant from second outlet
port 122 either 100% or lesser based on heating and cooling requirement of the cabin and
battery unit 114. If 100% cooling is required that time, the second outlet pipe 122 with the
orifice 120 is closed completely and ball valve 124 rotates by 90 degrees to change the mode
between the heating mode and the cooling mode. The third EXV 402 is integrated at the third
15 FCV 118 inlet pipe 126 or outlet pipe 122 in Fig. 13, which controls refrigerant super heat for
both cooling and heating modes. This control is done with valve stem movement, changing
orifice 120 area cross section for refrigerant flow, which has different axis from rotation axis
of the butterfly valve flap. Then the third EXV 402 integrated 3-way FCV 118 achieves
compactness, lightweight, low cost and low pressure drop features compared to the separated
20 solution of first EXV 108 and the first FCV 110 as disclosed before.
In a third embodiment of the disclosed invention, it is used in HP ACS that is described in Fig.
3. Regardless of whether the battery thermal management system integrated or not, this
example is effective. It can be used in EVTMS HP Heating option that is described in Fig. 1.
25 also. HP ACS uses the basic principles of vapour compression refrigerant cycle. The refrigerant
closed cycle includes electric compressor 102, air-cooled condenser 106, the first FCV 110,
first EXV 108, evaporator 112, HVAC heater 116, accumulator 302, and connecting pipes. The
electric compressor 102, which is powered by a battery unit 114, compresses the refrigerant
vapour thereby increasing temperature and pressure of refrigerant. The air-cooled condenser
30 106 at cooling mode condenses high pressure and high temperature refrigerant using ambient
air. The first EXV 108 controls refrigerant pressure, temperature, and refrigerant flow before
electric compressor 102 under HP ACS controlling logic. Pressure and temperature sensors
before and after the electric compressor 102 are used as the controller input data. Second FCV
14
210 positioned between the air-cooled condenser 106 and the first EXV 108 and/or accumulator
302 switches refrigerant flow to the first EXV 108 for cooling mode or to accumulator 302 for
heating mode. The first EXV 108 in between second FCV 210 and evaporator 112 is used for
its expansion valve function when the refrigerant cycle is in cooling mode under HP ACS
5 control logic. The EVTMS 100 which is described later is designed to define the first EXV 108
integrated FCV 210 function. Concerning heating function that is required, the first EXV 108
and the evaporator 112 are bypassed and refrigerant after air-cooled condenser 106 at
evaporator 112 (heating) mode needs to go to accumulator 302 directly.
10 The EXV integrated 3-way FCV example was described in Figs. 8A-8B, 11, 12, and 13A, for
heating mode in Fig. 11 and for cooling mode in Fig. 10. According to Figs. 8A-8B, the
integrated flow control valve (FCV) 110 comprises a valve body 612, a rotating flow control
unit 602a or a rotating flap, a motor 604 and a solenoid 606, and a valve stem 610. The rotating
flow control unit 602a and a fixed flap 602b are disposed within the valve body 612. The motor
15 604 and the solenoid 606 are positioned at opposing ends 612a and 612b of the valve body
612, where the motor 604 rotates the rotating flow control unit 602a from bottom 612a of the
valve body 612 and the solenoid 606 actuates the fixed flap 602b from top 612b of the valve
body 612. Refrigerant super heat control is performed by movement of the valve stem 610 and
changing area of cross section of an orifice 608 present on the fixed flap 602b, which is
20 separately allocated from the rotating flow control unit 602a, for refrigerant flow between an
inlet pipe 614 and an outlet pipe 616. In other words, for example, the integrated flow control
valve (FCV) 110 shown here is a built in EXV 108 structure at an inlet pipe 614 of 3 or 4
passages in 3- or 4-ways flow control valve. Basic structure is butterfly type motor drive FCV
110, rotating flap 602a around 90 degrees to change the mode between cooling mode and
25 heating mode. The first EXV 108 is integrated at the first FCV 110 outlet side in heating mode
controls refrigerant super heat for both cooling and heating modes. This control is performed
with valve stem 610 movement, changing area cross section of orifice 608 for refrigerant flow,
which has different axis from rotation axis of the fixed flap 602b. In cooling mode, the first
EXV 108 is bypassed. Then this first EXV 108 integrated 3-way FCV 110 achieves
30 compactness, lightweight, low cost and low pressure drop features compared to separated
solution of the first EXV 108 and the first FCV 110.
15
In a fourth embodiment of the disclosed invention, it is used in HP ACS that is described in
Fig. 3. Regardless of whether Battery thermal management system is integrated or not, this
example is effective. HP ACS uses the basic principles of vapour compression refrigerant
cycle. The refrigerant closed cycle includes electric compressor 102, air-cooled condenser 106,
5 the first FCV 110, first EXV 108, evaporator 112, HVAC heater 116, accumulator 302, and
connecting pipes. The electric compressor 102, which is powered by a battery unit 114,
compresses the refrigerant vapour, thereby increasing temperature and pressure of refrigerant.
The air-cooled condenser 106 at cooling mode condenses high pressure and high temperature
refrigerant using ambient air. The first EXV 108 controls refrigerant pressure, temperature, and
10 refrigerant flow before compressor under HP ACS controlling logic. Pressure and temperature
sensors before and after the electric compressor 102 are used as the controller input data. The
first FCV 110 in between the electric compressor 102 outlet and air-cooled condenser 106 or
heater, switches refrigerant flow to air-cooled condenser 106 at condenser function for cooling
mode or to HVAC heater 116 for HP heating mode. The fourth EXV 304 in between HVAC
15 heater 116 and air-cooled condenser 106 at evaporator function is used for its expansion valve
function when the refrigerant cycle is in heating mode under HP ACS control logic. Concerning
requirement for heating function, the refrigerant is going to HVAC heater 116 and returns to
integrated first EXV 108. Concerning requirement for cooling function, refrigerant bypasses
the HVAC heater 116 and EXV 304.
20
The first EXV 108 integrated 4-way FCV 110 example was described in Figs. 8A-8B, 14, and
15 for heating mode in Fig. 14 and for cooling mode in Fig. 15. Basic structure is butterfly type
motor drive FCV 110, fixed flap 602b around 90 degrees to change the mode between cooling
mode and heating mode. The first EXV 108 is integrated at the first FCV 110 inlet side from
25 HVAC heater 116 in heating mode controlling refrigerant super heat for heating mode. This
control is done with valve stem 610 movement, changing area cross section of the orifice 608
for refrigerant flow, which has different axis from rotation axis of the rotating flap 602a or
butterfly valve flap. In cooling mode, the HVAC heater 116 and the EXV 304 are bypassed.
Then this first EXV 108 integrated 4-way FCV 110 achieves compactness, lightweight, low
30 cost and low pressure drop features compared to separated solution of the first EXV 108 and
the first FCV 110.
16
In a fifth embodiment of the proposed invention, it is used in EVTMS HGBH (Using 4-way
ball valve) option that is described in Fig. 5. The EVTMS HGBH uses the basic principles of
vapour compression refrigerant cycle and single-phase coolant cycle. The first closed cycle
includes electric compressor 102, water-cooled condenser 104, air-cooled condenser 106,
5 REF_EXV/FCV 118, first EXV 108, evaporator 112 and connecting pipes with or without IHX
404. The electric compressor 102, which is powered by a battery unit 114, compresses the
refrigerant vapour, thereby increasing temperature and pressure of refrigerant. The two
condensers 104 and 106 condense high pressure and high temperature refrigerant using coolant
and air respectively, which come from the second closed cycle, and ambient air respectively.
10 The REF_EXV/FCV 118 controls the refrigerant pressure, temperature, and refrigerant flow
before the electric compressor 102 under EVTMS HGBH controls logic. Pressure and
temperature sensors before and after the electric compressor 102 are used as the controller input
data. In Fig. 5, the REF_EXV/FCV 118 is allocated in between water-cooled condenser 104
and air-cooled condenser 106 to switch the refrigerant direction to flow in the electric
15 compressor 102 with REF-EXV/FCV 118 function through water-cooled condenser 104 bypassing the air-cooled condenser 106 and the rest of components before the electric compressor
102 if heating is required, and by-pass the water-cooled condenser 104 to the air-cooled
condenser 106 if cooling mode required, to avoid pressure drop of the water-cooled condenser
106, differently controlled under EVTMS HGBH control logic.
20
Concerning HGPH function is required, the air-cooled condenser 106 is bypassed and the
electric compressor 102 suctions high temp and low-pressure gas phase refrigerant that is
controlled by integrated REF_EXV/FCV 118 and coolant flow rate flowing through the watercooled condenser 104, by using EVTMS HGBH control logic. If applicable region does not
25 require so powerful heating frequently, this simpler system is cost effective minimizing
refrigerant pressure drop for better cooling mode COP. The REF_EXV/FCV 118 integrated 4-
way ball valve FLV 118 is described in Figs. 16A and 16B for heating mode in Fig. 16B and
for cooling mode in Fig. 16A. Basic structure is ball valve type motor drive FCV 118, with a
rotating ball valve 124 around 90 degrees to change the mode between cooling mode and
30 heating mode. The third EXV 402 is integrated at FCV 118 outlet side from heater in heating
mode to control refrigerant super heat before compressor for heating mode. This control is done
with valve stem 610 movement, changing orifice 608 area cross section for refrigerant flow,
which has different axis from ball valve rotation axis. In cooling mode, the water-cooled
17
condenser 104 and the first EXV 108 are bypassed. Then this integrated REF_EXV/FCV 118
achieves compactness, lightweight, low cost and low pressure drop features compared to
separated solution of the first EXV 108 and the first FCV 110.
5 Although the invention has been described with reference to specific embodiments, this
description is not meant to be construed in a limiting sense. Various modifications of the
disclosed embodiments, as well as alternate embodiments of the invention, will become
apparent to persons skilled in the art upon reference to the description of the invention. It is
therefore, contemplated that such modifications can be made without departing from the spirit
10 or scope of the present invention as defined

We claim:
1. An integrated flow control valve comprising:
a valve body;
a rotating flap disposed within the valve body;
a motor and a solenoid positioned at opposing ends of the valve body to rotate the
rotating flap;
a valve stem, wherein refrigerant super heat control is performed with movement
of the valve stem and changing area of cross section of an orifice present on the
rotating flap for refrigerant flow between an inlet pipe and an outlet pipe; and
one or more bypassable expansion valves axially integrated within the rotating
flap, wherein the expansion valve reduces protruding volume occupied by surface of
the rotating flap, and wherein the reduction in protruding volume reduces refrigerant
pressure drop.
2. The integrated flow control valve as claimed in claim 1, wherein the rotating flap is
disposed within the valve body to change a mode between operational mode of the
expansion valve and bypassed mode of the expansion valve.
3. The integrated flow control valve as claimed in claim 2, wherein the rotating flap is
oriented in a as bypassed mode to sustain flow area for the refrigerant equivalent as
compared to the inlet pipe and the outlet pipe by increasing inner diameter of the
valve body.
4. An integrated flow control valve comprising:
a valve body;
a rotating flow control unit and a fixed flap disposed within the valve body;
a motor and a solenoid positioned at opposing ends of the valve body, wherein
the motor rotates the rotating flow control unit from bottom of the valve body and the
solenoid actuates the fixed flap from top of the valve body; and
a valve stem, wherein refrigerant super heat control is performed with movement
of the valve stem and changing area of cross section of an orifice present on the fixed
flap, separately allocated from the rotating flow control unit, for refrigerant flow
between an inlet pipe and an outlet pipe.
19
5. The integrated flow control valve as claimed in claim 4, wherein a first expansion
valve defined by the orifice present on the fixed flap and an evaporator are bypassed
for a heating mode in a Heating, Ventilation, and Air Conditioning (HVAC) heater.
6. The integrated flow control valve as claimed in claim 5, wherein the first expansion
valve that is positioned between a first flow control valve defined by the rotating flow
control unit and an air-cooled condenser, is used as an expansion valve when a
refrigerant cycle is both in a cooling mode and in Hot Gas Pre-Heating (HGPH)
mode, which are differently controlled under the Electric Vehicle Thermal
Management System (EVTMS) control logic.
7. The integrated flow control valve as claimed in claim 6, wherein the first expansion
valve that is integrated in the first flow control valve is positioned between a watercooled condenser and the air-cooled condenser, which switches one of the refrigerant
flow to the air-cooled condenser for the cooling mode and to a compressor for the
heating mode, and wherein the integrated first flow control valve and the compressor
are used to maintain required inlet superheat to the compressor.
8. The integrated flow control valve as claimed in claim 4, is a third flow control valve
comprising an inlet pipe, a first outlet pipe, a second outlet pipe, and a ball valve,
wherein the fixed flap is modified with an orifice, wherein the second outlet pipe and
the orifice that are defined as a variable expansion device is completely closed, and
the ball valve rotates to one of change between the cooling mode and the heating
mode, and set an intermediate position to balance both the cooling mode and the
heating mode.
9. The integrated flow control valve as claimed in claim 8, wherein a third expansion
valve is integrated at the outlet pipe of the flow control valve, to control the
refrigerant superheat for both the cooling mode and the heating mode.
10. The integrated flow control valve as claimed in claim 8, wherein the third flow
control valve that is positioned between the water-cooled condenser and the aircooled condenser switches direction of the refrigerant flow towards the compressor
20
through the water-cooled condenser, and by-passing the air-cooled condenser before
the compressor if heating is required, and by-passing the water-cooled condenser
towards the air-cooled condenser if the cooling mode is required, to avoid pressure
drop in the water-cooled condenser.