Fluid control module for waste heat recovery systems

Abstract

A fluid control module ( 200, 400 ) for a waste heat recovery system ( 100 ) with a working fluid is provided. The fluid control module comprises a module body ( 250, 430 ) at least partially enclosing a pump ( 220 ) and at least one valve ( 210, 230, 240, 410, 420 ), the module body having no dynamic seals to atmosphere.

We claim: 
     
         1 . A fluid control module for a waste heat recovery system with a working fluid, comprising:
 a module body at least partially enclosing a pump and at least one valve, the module body having no dynamic seals to atmosphere.   
     
     
         2 . Fluid control module according to  claim 1 , wherein the pump and the at least one valve are adapted to be substantially immersed in the working fluid. 
     
     
         3 . Fluid control module according to  claim 1 , wherein the pump is adapted to be driven electrically. 
     
     
         4 . Fluid control module according to  claim 1 , wherein the pump comprises a moving element, in particular a rotor, that is adapted to be immersed in the working fluid. 
     
     
         5 . Fluid control module according to  claim 1 , wherein the pump comprises one or more bearings adapted to be immersed in the working fluid. 
     
     
         6 . Fluid control module according to  claim 1 , wherein the pump comprises a stator at least partially enclosed by the module body. 
     
     
         7 . Fluid control module according to  claim 1 , wherein the at least one valve comprises an electromagnetic actuator comprising a core, the core being adapted to be immersed in the working fluid. 
     
     
         8 . Fluid control module according to  claim 1 , wherein the at least one valve comprises a return spring adapted to place the at least one valve in a zero position state when the at least one valve is not actuated. 
     
     
         9 . Fluid control module according to  claim 8 , wherein the return spring is adapted to be immersed in the working fluid. 
     
     
         10 . Fluid control module according to  claim 1 , wherein the at least one valve includes a solenoid at least partially enclosed by the module body. 
     
     
         11 . Fluid control module according to  claim 1 , and comprising a first liquid control valve configured to selectively provide a fluid communication path between a fluid supply and a first evaporator port and a second liquid control valve adapted to selectively provide a fluid communication path between the fluid supply and a second evaporator port. 
     
     
         12 . Fluid control module according to  claim 1 , and comprising a proportional flow control valve that includes a proportional stem that is adapted to proportionally regulate a flow of the working fluid between a first evaporator port and a second evaporator port. 
     
     
         13 . Fluid control module according to  claim 12 , and comprising a return spring assembly adapted to return the proportional flow control valve to a zero position state. 
     
     
         14 . Fluid control module according to  claim 1 , wherein the at least one valve includes a stem adapted to regulate the working fluid flow to a pilot valve actuator on a bypass valve includes a stem adapted to regulate a flow of the working fluid to a bypass circuit to de-superheat the working fluid. 
     
     
         15 . Fluid control module according to  claim 1 , wherein the at least one valve includes a stem adapted to regulate the working fluid flow to a pilot valve actuator on a bypass valve and to a bypass circuit to de-superheat the working fluid. 
     
     
         16 . Fluid control module according to  claim 1 , and further comprising a power line that is coupled to the pump or the at least one valve wherein the power line is at least partially enclosed by the module body. 
     
     
         17 . Fluid control module according to  claim 1 , and further comprising a pump return that returns fluid from the at least one valve to the pump. 
     
     
         18 . A method of forming a fluid control module for a waste heat recovery system with a working fluid, comprising:
 forming and at least partially enclosing a pump and at least one valve with a module body without forming a dynamic seal to atmosphere.   
     
     
         19 . The method of forming the fluid control module of  claim 18 , further comprising the step of substantially immersing the pump and the at least one valve in the working fluid. 
     
     
         20 . The method of  claim 18 , further comprising forming and immersing a rotor in the working fluid. 
     
     
         21 . The method of  claim 18 , further comprising forming and immersing one or more bearings in the working fluid. 
     
     
         22 . The method of  claim 18 , further comprising forming and at least partially enclosing a stator in the module body. 
     
     
         23 . The method of  claim 18 , further comprising forming and immersing a core in the working fluid. 
     
     
         24 . The method of  claim 18 , further comprising forming and adapting a return spring to place the at least one valve in a zero position state when the at least one valve loses power. 
     
     
         25 . The method of  claim 24  further comprising immersing the return spring in the working fluid. 
     
     
         26 . The method of  claim 24  comprising at least partially enclosing a solenoid with the module body. 
     
     
         27 . The method of  claim 18  comprises forming a proportional flow control valve. 
     
     
         28 . The method of  claim 27  comprises forming and adapting a proportional stem to proportionally regulate a working fluid flow between a first evaporator port and a second evaporator port. 
     
     
         29 . The method of  claim 27  further comprises forming and adapting a return spring assembly to return the proportional control valve to a zero position state. 
     
     
         30 . The method of  claim 18  includes forming a stem adapted to regulate the working fluid flow to a pilot valve actuator on a bypass valve. 
     
     
         31 . The method of  claim 18  includes forming a stem to regulate the working fluid flow to a bypass circuit to de-superheat the working fluid. 
     
     
         32 . The method of  claim 18  includes forming a stem to regulate the working fluid flow to a pilot valve actuator on a bypass valve and to a vapor control module to de-superheat the working fluid. 
     
     
         33 . The method of forming the fluid control module of  claim 18 , further comprising forming and coupling a power line to the pump or the at least one valve and at least partially enclosing the power line with the module body. 
     
     
         34 . The method of forming the fluid control module of  claim 18 , further comprising forming a pump return that returns fluid from the one or more valves to the pump. 
     
     
         35 . Method of operating a fluid control module, comprising:
 receiving a working fluid at an inlet of the fluid control module; and   providing the working fluid to one or more evaporators and to a pilot valve actuator on a bypass valve without containing the working fluid with an atmospheric dynamic seal.   
     
     
         36 . The method of operating a fluid control module of  claim 35 , further comprising providing the working fluid to a bypass circuit without containing the working fluid with the atmospheric dynamic seal. 
     
     
         37 . The method of  claim 35 , further comprising providing the working fluid to a venturi that forms a portion of the bypass circuit.