Balanced roller piston compressor with central mass reductions for improved compressor stability.

Description

Balanced roller piston compressor with central mass reductions for improved compressor stability. FIELD OF THE INVENTION

[001] The present invention relates generally to electric compressors and, more particularly, to an electric compressor that compresses a refrigerant using a rolling piston. Background of the invention

[002] Compressors have long been used in refrigeration systems. Rotary compressors typically use a rotating drive shaft and a compression device connected to the drive shaft that rotates with the drive shaft to compress the refrigerant. For example, scroll-type compressors, in which an orbital scroll is rotated in a circular motion relative to a fixed scroll to compress a refrigerant, have been used in systems designed to provide refrigeration in specific areas. For example, these scroll-type compressors have long been used in HVAC systems of motor vehicles, such as automobiles, to provide air conditioning. These compressors can also be used, in reverse, in applications requiring a heat pump. Generally, these compressors are driven using rotary motion derived from the automobile engine.Other types of rotary compressors, such as a reciprocating compressor, have also been used.

[003] With the advent of electric or battery-powered and / or hybrid vehicles, in which the vehicle may be powered exclusively by a battery, these compressors need to be driven or powered by the battery instead of a motor. These compressors may be called electric compressors.

[004] In addition to cooling the passenger compartment of the motor vehicle, electric compressors can be used to provide Petition 870250084195, dated 09 / 18 / 2025, page 9 / 166 2 / 43 Heating or cooling other areas or components of the motor vehicle. For example, it may be desirable to heat or cool the electronic systems and the battery or battery compartment when the battery is being charged, especially during fast charging modes, as this generates heat that can damage or degrade the battery and / or other system. It can also be used to cool the battery during periods when it is not being charged or used, as heat can damage or degrade it. Because the electric compressor can be activated at various times, even when the motor vehicle is not in operation, such use requires electrical power from the battery, thus reducing the battery's operating time.

[005] Rotary-driven compression devices must be balanced to reduce noise and vibration and maximize compressor efficiency and service life.

[006] Thus, it is desirable to provide an electric compressor with high efficiency, low noise and maximum service life. The present invention aims to solve one or more of the problems or advantages identified above. BRIEF SUMMARY OF THE INVENTION

[007] In one aspect of the present invention, a compressor has a compression device for compressing a refrigerant. The compressor operates by means of the rotation of the compression device within a compression chamber. The compression device includes a piston device with a cylinder and a rolling piston configured to rotate about the cylinder. The rolling piston is in contact with an inner surface of the compression chamber and, with a vane, forms sub-chamber(s) in which the refrigerant is compressed as the piston device rotates within the compression chamber.

[008] In a first embodiment of the present invention, a compression device is provided located within a chamber of Petition 870250084195, dated 09 / 18 / 2025, p. 10 / 166 3 / 43 Compression of an electric compressor. The electric compressor is configured to compress a refrigerant and includes a housing, a refrigerant inlet port, a refrigerant outlet port, a motor, and a drive shaft. The housing defines an intake volume and a discharge volume and has a central axis. The housing defines the compression chamber. The refrigerant inlet port is coupled to the housing and configured to introduce refrigerant into the intake volume. The refrigerant outlet port is coupled to the housing and configured to allow the compressed refrigerant to exit the electric compressor from the discharge volume. The motor is mounted inside the housing. The drive shaft is coupled to the motor and configured to rotate around the central axis.The compression device is coupled to the drive shaft and configured to receive coolant from the intake volume and compress it as the drive shaft is rotated by the engine. The compression device includes a piston device, comprising a cylinder and a rotating piston. The cylinder is eccentrically coupled to the drive shaft. The cylinder has a circular outer circumference. The rolling piston is tubular and concentric with the cylinder. The rolling piston has an outer surface in contact with an inner surface of the compression chamber. The rolling piston rotates the cylinder as the drive shaft and piston device are rotated by the engine. A vane movably coupled to the housing and having one end adjacent to the compression chamber is inclined so that the end of the vane is in contact with the rolling piston as the piston device is rotated by the drive shaft.The housing, piston device, and vane form variable sub-chambers within the compression chamber as the piston device is rotated within the compression chamber, where the coolant enters one of the sub-chambers of the intake volume. Petition 870250084195, dated 09 / 18 / 2025, page 11 / 166 4 / 43 compressed as the piston device is rotated and exits one of the sub-chambers into the discharge volume.

[009] Optionally, the cylinder has an internal chamber configured to provide the cylinder with a rotational center of mass around the central axis.

[0010] Optionally, the cylinder is fixed to the transmission shaft by means of an interference fit.

[0011] Optionally, the housing includes a vane groove, with the vane positioned slidingly within the vane groove. The vane groove may be connected to the discharge volume, with the vane directed towards the piston device by the refrigerant within the discharge volume. The housing may include a cylinder housing with the vane groove located within the cylinder housing. The cylinder housing may further include a suction port coupled between the compression chamber and the intake volume, and an internal discharge chamber coupled between the compression chamber and the discharge volume. The compression device may further include a vane mechanism coupled to the cylinder housing, configured to control the release of pressurized refrigerant from the compression chamber through the internal discharge chamber.

[0012] In a second embodiment of the present invention, an electric compressor is provided configured to compress a refrigerant. The electric compressor includes a housing, a refrigerant inlet port, a refrigerant outlet, and a compression device. The housing defines an intake volume and a discharge volume and has a central shaft. The housing further defines a compression chamber. The refrigerant inlet port is coupled to the housing and configured to introduce the refrigerant into the intake volume. The refrigerant outlet port is coupled to the housing and Petition 870250084195, dated 09 / 18 / 2025, page 12 / 166 The 5 / 43 configuration allows compressed refrigerant to exit the electric compressor from the discharge volume. The compression device is located within the compression chamber and coupled to a drive shaft. The compression device is configured to receive refrigerant from the intake volume and compress it as the drive shaft rotates. The compression device includes a piston device comprising a cylinder, a bearing piston, and a vane. The cylinder is eccentrically coupled to the drive shaft. The cylinder has a circular outer circumference. The bearing piston is tubular and concentric to the cylinder. The bearing piston has an outer surface in contact with an inner surface of the compression chamber. The bearing piston rotates around the cylinder as the drive shaft and piston device are rotated by the motor.The vane is movably attached to the housing and has one end adjacent to the compression chamber. The vane is angled so that its end comes into contact with the rolling piston as the piston device is rotated by the drive shaft. The housing, the piston device, and the vane form variable sub-chambers within the compression chamber as the piston device is rotated within the compression chamber. The refrigerant enters one of the variable sub-chambers from the intake volume, is compressed as the piston device is rotated, and exits through one of the sub-chambers to the discharge volume.

[0013] In a third embodiment of the present invention, an electric compressor is provided configured to compress a refrigerant. The electric compressor includes a housing, a motor, a drive shaft, a refrigerant inlet port, a refrigerant outlet, and a compression device. The motor is mounted inside the housing. The drive shaft is coupled to the motor and configured to rotate around the central axis. The housing defines a volume Petition 870250084195, dated 09 / 18 / 2025, page 13 / 166 The housing has a 6 / 43 intake and a discharge volume and features a central shaft. The housing also defines a compression chamber. The refrigerant inlet port is coupled to the housing and configured to introduce refrigerant into the intake volume. The refrigerant outlet port is coupled to the housing and configured to allow compressed refrigerant to exit the electric compressor from the discharge volume. The compression device is located within the compression chamber and coupled to the drive shaft. The compression device is configured to receive refrigerant from the intake volume and compress it as the drive shaft is rotated by the motor. The compression device includes a piston device, including a cylinder, a bearing piston, and a vane. The cylinder is eccentrically coupled to the drive shaft. The cylinder has a circular outer circumference. The bearing piston is tubular and concentric with the cylinder.The rolling piston has an outer surface in contact with an inner surface of the compression chamber. The rolling piston rotates around the cylinder as the drive shaft and piston device are rotated by the engine. The vane is movably coupled to the housing and has one end adjacent to the compression chamber. The vane is angled so that the end of the vane is in contact with the rolling piston as the piston device is rotated by the drive shaft. The housing, piston device, and vane form variable sub-chambers within the compression chamber as the piston device is rotated within the compression chamber. The coolant enters one of the variable sub-chambers from the intake volume, is compressed as the piston device is rotated, and exits from one of the sub-chambers into the discharge volume.

[0014] Optionally, the housing includes a cylinder housing and a rear head, with the discharge volume being formed, Petition 870250084195, dated 09 / 18 / 2025, p. 14 / 166 7 / 43 at least partially, by the cylinder housing, the rear head and the refrigerant outlet port. The housing may further include an inverter cover and a central housing. The central housing and the inverter cover may form an inverter cavity, and the electric compressor may further include an inverter module mounted within the inverter cavity and configured to convert direct current electrical energy into alternating current electrical energy. The housing may include a first drive shaft support element and a second drive shaft support element, and the electric compressor may include a first and a second ball bearing located within the first and second drive shaft support elements, configured to receive the respective ends of the drive shaft.

[0015] Optionally, the cylinder has an internal chamber and a rotational center of mass around the central axis.

[0016] Optionally, the cylinder is fixed to the transmission shaft by means of an interference fit.

[0017] Optionally, the housing has a vane groove, with the vane positioned slidingly within the vane groove. The vane groove may be connected to the discharge volume, with the vane directed towards the piston device by the refrigerant within the discharge volume. The housing may include a cylinder housing with the vane groove located within the cylinder housing.

[0018] Optionally, the cylinder housing may include a suction port coupled between the compression chamber and the intake volume, and an internal discharge chamber coupled between the compression chamber and the discharge volume. The compression device may also include a vane mechanism coupled to the cylinder housing, configured to control the release of coolant. Petition 870250084195, dated 09 / 18 / 2025, page 15 / 166 8 / 43 pressurized from the compression chamber through the internal discharge chamber.

[0019] Optionally, the cylinder housing includes a rim to assist in the correct positioning of the rolling piston in relation to the cylinder housing.

[0020] Optionally, the electric compressor may also include an inner cover configured to be positioned within the central housing, adjacent to a flange of the central housing. The inner cover may form a third drive shaft support element with a third sphere located within the third drive shaft support element and configured to receive the drive shaft.

[0021] In a fourth embodiment of the present invention, an electric compressor is provided configured to compress a refrigerant. The electric compressor includes a housing, a refrigerant inlet port, a refrigerant outlet port, a motor, an inverter module, a drive shaft, and a compression device. The housing defines an intake volume and a discharge volume and has a central shaft. The housing includes a central housing, a cylinder housing, a rear head, and an inverter cover. The central housing and the inverter cover form an inverter cavity. The cylinder housing forms a compression chamber and has a vane groove connected to the discharge volume. The refrigerant inlet port is coupled to the housing and configured to introduce the refrigerant into the intake volume.The refrigerant outlet port is coupled to the housing and configured to allow compressed refrigerant to exit the electric compressor from the discharge volume. The discharge volume is formed, at least partially, by the central housing, the rear head, and the refrigerant outlet port. The motor is mounted inside the housing. The inverter module is mounted inside the inverter cavity and configured... Petition 870250084195, dated 09 / 18 / 2025, page 16 / 166 9 / 43 A compressor is designed to convert direct current electrical energy into alternating current electrical energy. The drive shaft is coupled to the motor and configured to rotate around its central axis. The compression device is located inside the compression chamber and coupled to the drive shaft. The compression device is configured to receive coolant from the intake volume and compress the coolant as the drive shaft is rotated by the motor. The compression device includes a piston device and a vane. The piston device includes a cylinder and a rolling piston. The cylinder is eccentrically coupled to the drive shaft. The cylinder has an inner chamber and a rotational center of mass around its central axis. The cylinder has a circular outer circumference. The rolling piston is tubular and concentric with the cylinder.The rolling piston has an outer surface in contact with an inner surface of the compression chamber. The rolling piston rotates around the cylinder as the drive shaft and piston device are rotated by the engine. The vane is located within the vane groove and has one end adjacent to the compression chamber. The vane is directed towards the piston device by the coolant within the discharge volume, so that the end of the vane remains in contact with the rolling piston while the piston device is rotated by the drive shaft. The housing, piston device, and vane form variable sub-chambers within the compression chamber as the piston device is rotated within the compression chamber. Coolant enters one of the variable sub-chambers from the intake volume, is compressed as the piston device is rotated, and exits through one of the sub-chambers into the discharge volume. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] These and other features and advantages of the present Petition 870250084195, dated 09 / 18 / 2025, page 17 / 166 10 / 43 inventions will be more easily appreciated when considered in connection with the following detailed description and accompanying drawings.

[0023] Figure 1A is a cross-sectional view of a compressor according to an embodiment of the present invention.

[0024] Figure 1B is a second cross-sectional view of the electric compressor in Figure 1A.

[0025] Figure 2A is a cross-sectional view of an electrical compression device of Figure 1A, according to an embodiment of the present invention.

[0026] Figure 2B is a perspective view of the compression device in Figure 2A.

[0027] Figure 2C is an enlarged perspective view of a part of the compression device in Figure 2A.

[0028] Figure 2D is a perspective view of the compression device portion of Figure 2C.

[0029] Figure 2E is a partial cross-section of the compression device portion of Figure 2A.

[0030] Figure 2F is a perspective view of a vane and spring of the compression device of Figure 2A, according to an embodiment of the present invention.

[0031] Figures 3A-3G are cross-sectional views of the compression device of Figure 2A during a compression cycle.

[0032] Figure 4 is a graphical representation of a piston device of the compression device of Figure 2A, according to an embodiment of the present invention.

[0033] Figure 5A is a side view of a drive shaft of the electric compressor and piston device of Figure 4, according to an embodiment of the present invention.

[0034] Figure 5B is a cross-sectional view of the transmission shaft and piston device of Figure 5A. Petition 870250084195, dated 09 / 18 / 2025, page 18 / 166 11 / 43

[0035] Figure 6A is a front view of a compression device with integrated discharge chambers, according to an embodiment of the present invention.

[0036] Figure 6B is a side view of the compression device of Figure 6A and a transmission shaft, according to an embodiment of the present invention.

[0037] Figure 6C is a rear view of the compression device of Figure 6A.

[0038] Figure 7A is a perspective view of the compression device in Figure 6A.

[0039] Figure 7B is a first perspective view of a cylinder housing of the compression device of Figure 6A, according to an embodiment of the present invention.

[0040] Figure 7C is a second perspective view of the cylinder housing of Figure 7B.

[0041] Figure 8 is a rear view of a compression device and a magnetic debris filter, according to an embodiment of the present invention.

[0042] Figure 9A is an enlarged view of the compression device and magnetic debris filter of Figure 8.

[0043] Figure 9B is an enlarged view of the magnetic debris filter assembly of Figure 8.

[0044] Figure 10A is a front view of a filter structure of the magnetic debris filter assembly of Figure 8, according to an embodiment of the present invention.

[0045] Figure 10B is a side view of the filter structure of Figure 10A.

[0046] Figure 10C is a cross-sectional view of the filter structure of Figure 10A.

[0047] Figure 11A is a cross-sectional view of a device Petition 870250084195, dated 09 / 18 / 2025, p. 19 / 166 12 / 43 compression device for an electric compressor and an oil separator, according to one embodiment of the present invention.

[0048] Figure 11B is a front view of the oil compression and separator device of Figure 11A.

[0049] Figure 12A is a side view of an oil separator disc of Figure 11A, according to an embodiment of the present invention.

[0050] Figure 12B is a top view of the disk in Figure 11A.

[0051] Figure 12C is a perspective view of the disk in Figure 11A.

[0052] Figure 13A is a side view of a compressor vane with side seals, according to an embodiment of the present invention.

[0053] Figure 13B is a front view of the blade in Figure 13A.

[0054] Figure 13C is an enlarged view of the palette in Figure 13A.

[0055] Figure 13D is a bar chart of test data associated with the palette in Figure 13A. DETAILED DESCRIPTION OF THE INVENTION

[0056] With reference to the Figures, where equal numbers indicate equal or corresponding parts along the various views, a compressor 10 with a housing 12 is shown. The electric compressor 10 is particularly suitable for motor vehicles, such as motor vehicles (not shown). The electric compressor 10 can be used as a cooling device or as a heat pump to heat and / or cool different parts of the vehicle. For example, the electric compressor 10 can be used as part of the heating, ventilation and air conditioning (HVAC) system in electric vehicles (not shown) to cool or heat the passenger compartment.

[0057] In addition, the electric compressor 10 can be used for Petition 870250084195, dated 09 / 18 / 2025, page 20 / 166 13 / 43 to heat or cool the passenger compartment, onboard electronics and / or a battery used to power the vehicle while it is not in operation, for example, during a charging cycle. Compressor 10 can also be used while the vehicle is not in operation and while the battery is not being charged, to maintain or minimize battery life degradation.

[0058] In the illustrated embodiment, the electric compressor 10 is a rotary type compressor that acts to compress a refrigerant quickly and efficiently for use in different systems of a motor vehicle, for example, an electric or hybrid vehicle. In use, a mixture of refrigerant and oil (for lubrication) can be used. In one aspect of the present invention, the oil can be separated from the refrigerant before it exits the compressor 10.

[0059] The electric compressor 10 includes a housing 12 and a compression device 18 located, or contained, within the housing 12. The compressor 10 has a central shaft 78. As explained in more detail below, the compression device 18.

[0060] In the illustrated embodiment, the electric compressor 10 may include an inverter section 14 and a motor section 16. The housing 12 may include a central housing 20, a rear inverter cover 22, a rear head 24 (which may be called a discharge head), and a cylinder housing 26. As shown, the central housing 20 may house the motor section 16 and the compression device 18. In other embodiments, the inverter section 14 and / or the motor section 16 may be external to the housing 12.

[0061] In one embodiment, the inverter rear cover 22, the central housing 20, the cylinder housing 26 and the rear head 24 may be made of machined aluminum. The compressor 10 may be mounted, for example, inside the body of a motor vehicle, by means of a plurality of mounting points (not shown). Petition 870250084195, dated 09 / 18 / 2025, page 21 / 166 14 / 43 General arrangement and operation of the electric compressor 10

[0062] The rear cover of the inverter 22 and one end of the central housing 20 form an inverter cavity 28. The rear cover of the inverter 22 is fixed to the central housing 20 by a plurality of screws 30 (only one of which is shown in Figure 1A). An inverter gasket (not shown) may be positioned between the rear cover of the inverter 22 and the central housing 20, preventing the entry of moisture, dust and other contaminants into the inverter cavity 28. The rear head 24 may be fixed to the central housing 20 by a plurality of screws 82.

[0063] An inverter module 32 mounted inside the inverter cavity 28 formed by the inverter rear cover 22 and the central housing 20. The inverter module 32 may include an inverter circuit 34 mounted on a printed circuit board, which is mounted in the central housing 20. The inverter circuit 34 converts direct current (DC) electrical energy received from outside the electric compressor 10 into three-phase alternating current (AC) energy to supply / power a motor 38 (see below). The inverter circuit may also control the rotational speed of the electric compressor 10. High-voltage DC current is supplied to the inverter circuit via a high-voltage connector (not shown). Low-voltage DC current to drive the inverter circuit, as well as control signals to control the operation of the inverter circuit and the motor section 16, may be supplied via a low-voltage connector (not shown).

[0064] The central housing 20 forms a motor cavity 36. The motor section 16 includes a motor 38 located within the motor cavity 36. In one embodiment, the motor 38 is a three-phase AC motor with a stator 40 and a rotor 42. The stator 40 has a generally hollow cylindrical shape with six individual coils (two for each phase). The stator 42 is contained within and mounted in the central housing 20 and Petition 870250084195, dated 09 / 18 / 2025, page 22 / 166 15 / 43 remains stationary relative to the central housing 20. The rotor 42 is located inside and centered relative to the stator 40.

[0065] A drive shaft 44 is coupled to the rotor 42 and rotates with it. In the illustrated embodiment, the drive shaft 44 is press-fitted into a central opening 42A of the rotor 42. The drive shaft 44 has a first end 44A and a second end 44B. As shown, the central housing 20 includes a first drive shaft support element 20A within the motor cavity 36. A first ball bearing 46 located within an opening formed by the first drive shaft support element 20A supports and allows the first end 44A of the drive shaft 44 to rotate. In the illustrated embodiment, the cylinder housing 26 includes a second drive shaft support element 20B. A second ball bearing 48 located within an opening formed by the second drive shaft support element 20B allows the second end 44B of the drive shaft 44 to rotate.In the illustrated embodiment, the first and second ball bearings 46, 48 are press-fitted into the openings formed by the first transmission shaft support element 20A and the second transmission shaft support element 20B, respectively.

[0066] As mentioned earlier, the electric compressor is a rotary compressor. In one aspect of the present invention, the compression device 18 includes a piston device 50 eccentrically coupled to the second end 44B of the drive shaft 44 and a vane 56. As will be explained in more detail below, the drive shaft 44 is rotated within a compression chamber 58 by the cylinder housing 26 of the housing 12. Furthermore, the vane 56 is inclined inwards.

[0067] Generally, the refrigerant and oil are mixed (in low Petition 870250084195, dated 09 / 18 / 2025, page 23 / 166 16 / 43 pressure) enters the electric compressor 10 through a refrigerant inlet port 60 and exits the electric compressor 10 (at high pressure) through the refrigerant outlet port 62 after being compressed by the compression device 18. The refrigerant follows a refrigerant path through the electric compressor 10. The refrigerant enters the refrigerant inlet port 60 and enters an intake volume 64 formed between the cylinder housing 26 and the rear head 24 (see Figures 1A-1B) adjacent to the refrigerant inlet port 60. The refrigerant is then drawn through the engine section 16 and enters the compression chamber 58 (see below).

[0068] The refrigerant is compressed by the compression device and exits the compression chamber 58 to the discharge volume 66. The discharge volume 66 is in communication with the refrigerant outlet port 62. The pressurized refrigerant exits the compression device 18 through one or more holes 90 (see Figures 7B-7C). The release of the pressurized refrigerant can be controlled by a paddle mechanism 72. Compression device with balanced roller piston

[0069] With particular reference to Figures 1A-1B, 2A-2B, 3A-3G, and 5A-5B, a compression device 18, according to one embodiment of the present invention, includes the cylinder housing 26 and a piston device 50 which includes a cylinder 52 and a rolling piston 54. The compression device 18 is located within the compression chamber 58 and is coupled to the drive shaft 44. Generally, the compression device 18 is configured to receive coolant from the intake volume 64 and compress the coolant as the drive shaft 44 is rotated by the engine 38.

[0070] Cylinder 52 has a circular cross-section and outer circumference and is eccentrically coupled to the transmission shaft 44. The rolling piston 54 is tubular and concentric with cylinder 52. The Petition 870250084195, dated 09 / 18 / 2025, page 24 / 166 17 / 43 bearing piston 54 has an outer surface 54A in contact with an inner surface 58A of the compression chamber 58. The bearing piston 54 rotates around the cylinder 52 while the drive shaft 44 and the piston device 50 are rotated by the motor 38.

[0071] In the illustrated embodiment, the compression device 18 further includes a vane 56. The vane 56 is movably coupled to the housing 12. As shown, one end 56A of the vane 56 is adjacent to the compression chamber 58 and the vane is inclined so that the end 56A of the vane 56 is in contact with the rolling piston 54 as the piston device 50 is rotated by the drive shaft 44. The vane 56 can be inclined inwards by means of a spring 134 (see Figures 2E and 2F) or other suitable mechanism. Housing 12, piston device 50 and vane 56 form variable sub-chambers 58B and 58C within compression chamber 58 as piston device 50 is rotated within compression chamber 58. As explained in more detail below, coolant enters one of the variable sub-chambers from intake volume 64, is compressed when piston device 50 is rotated and exits from one of the sub-chambers 58B, 58C to discharge volume 66.

[0072] With reference to Figures 3A-3G, the position or state of the compression device 18 during a compression cycle of the compressor 10 is shown. At the beginning of a compression cycle (as shown in Figure 3A), the vane 56 is pushed outward by the outer surface 54A of the rolling piston 54, so that the end 56A of the vane 56 is flush with the inner surface 58A of the compression chamber 58. At this point in the compression cycle, the compression chamber 58 has a single sub-chamber 58C.

[0073] As the piston device 50 rotates, the subchamber 58B is formed by the outer surface 54A of the rolling piston 54, the vane 56 and the inner surface 58A of the compression chamber. Petition 870250084195, dated 09 / 18 / 2025, page 25 / 166 18 / 43 (see Figure 3B). As shown in Figures 3A-3F, the cylinder housing 26 of housing 12 includes an internal suction chamber 26A connected to the intake volume 64 and the compression chamber 58 by means of a suction port 26B.

[0074] Returning to Figure 3B, subchamber 58B is opened to suction chamber 26A and refrigerant enters subchamber 58B. As shown in Figures 3C-3D, as piston device 50 is rotated by drive shaft 44, the volume of subchamber 58B increases and refrigerant continues to enter or be pumped into subchamber 58B.

[0075] As shown in Figure 3F, as the piston device 50 continues to rotate, the sub-chamber 58B is cut off from the internal suction chamber 26A and the suction port 26B and therefore from the intake volume 64. As shown in Figures 3A-3G, in the illustrated embodiment, the cylinder housing 26 includes an internal discharge chamber 26C which is connected to the discharge volume 66 and the compression chamber 58 by means of a discharge port 26D.

[0076] As shown in Figure 3F, when subchamber 58B is isolated or cut off from intake volume 64, the subchamber is connected to the internal discharge chamber 26C and the discharge port 26D (see Figures 3F-3G).

[0077] As the piston device 50 continues to rotate, the sub-chamber 58B decreases, thus compressing the refrigerant. The release of the pressurized refrigerant is controlled by a reed mechanism 72 coupled to the rear of the cylinder housing 26 (see Figure 6C). In the illustrated embodiment, a single reed mechanism 72 is used. However, it should be noted that more than one reed mechanism may be used. In one embodiment, the reed mechanism 72 may include a discharge reed (not shown) and a reed retainer 72A. The discharge reed may be made of a Petition 870250084195, dated 09 / 18 / 2025, p. 26 / 166 19 / 43 flexible material, such as steel. Characteristics such as material and strength are selected to control the pressure at which the pressurized refrigerant is released from the compression device 18. The vane retainer 72A is made of a rigid and inflexible material, such as stamped steel. The vane retainer 72A controls or limits the maximum displacement of the discharge vane relative to the cylinder housing 26. In the illustrated embodiment, the reading mechanism 72 is held or fixed to the cylinder housing 26 by means of a fastener 74.

[0078] As shown in Figures 2A-2B and 3A-3G, in the illustrated embodiment, the cylinder housing 26 includes a vane groove 76 configured to slide-receive the vane 56. The vane groove 76 has a first end 76A open to or adjacent to the compression chamber 58 and a second end 76B located adjacent to the outer surface of the cylinder housing 26 (see Figure 2B). In the illustrated embodiment, the second end 76B of the vane groove 76 is coupled to the discharge volume 66. During operation, the pressurized refrigerant from the discharge volume 66 applies a force to the vane 56, displacing it so that the vane end 56A remains in contact with the outer surface of the rolling piston 54A.

[0079] Cylinder 52 and rolling piston 54 may be made of cast iron. As shown in Figures 1A, 1B and Figure 4, in the illustrated embodiment, the drive shaft 44 is centered on the central shaft 78 of the compressor 10. The piston device 50 has a central piston shaft 80 that is offset from the central shaft 78 (see Figures 2B and 4).

[0080] In one aspect of the present invention, the cylinder 52 has a hollow inner chamber 52A. The cylinder 52 and the inner chamber 52A are configured so that the rotational center of mass is aligned with the central axis 78 of the compressor 10 and the transmission shaft 44. Petition 870250084195, dated 09 / 18 / 2025, page 27 / 166 20 / 43 This arrangement eliminates the need for other separate balancing components or mechanisms. As shown in the illustrated embodiment, the inner chamber 52A is located on the compression side of the cylinder housing 26.

[0081] In one embodiment of the present invention, the piston device 50 and the cylinder 52 are keyed to the transmission shaft 44. As shown in Figures 2A, 4 and 5B, in the illustrated embodiment of the present invention, one end of the transmission shaft 44 has a flat surface 44C. The cylinder 52 has an opening 52B with a flat side 52C configured to receive the end of the transmission shaft 44. In one aspect of the present invention, the cylinder 52 and the transmission shaft 44 have an interference fit between them.

[0082] As shown in Figure 6B, cylinder 52 may include a lip 52D to assist in the proper positioning of the rolling piston 54 relative to cylinder 52. The inner diameter of the rolling piston 54 may be slightly larger than the outer diameter of cylinder 52 to allow coolant to pass between them for lubrication purposes.

[0083] Returning to Figure 1A, in the illustrated embodiment, the compression device 18 may further include an inner cover 84. The inner cover 84 is configured to be positioned within the central housing 20, adjacent to a flange 20C of the central housing 20. As shown, when the compressor 10 is mounted, the compression chamber 58 is formed by the inner cover 84 and the cylinder housing 26. The piston device 50 is located within the compression chamber 58. As shown, the inner cover 84 forms a third support element for the drive shaft 84A, configured to receive a third ball bearing 86. The drive shaft 44 is positioned through the third ball bearing 86 and the Petition 870250084195, dated 09 / 18 / 2025, page 28 / 166 21 / 43 third support element of the transmission tie rod 84A, and supported by them. As shown, the rear head 24 is fixed to the central housing 20 by the screws 82.

[0084] With particular reference to Figures 1A-1B, 2A-2B, 3A-3G, and 5A-5B, a compression device 18, according to one embodiment of the present invention, includes the cylinder housing 26 and a piston device 50 which includes a cylinder 52 and a rolling piston 54. The compression device 18 is located within the compression chamber 58 and is coupled to the drive shaft 44. Generally, the compression device 18 is configured to receive coolant from the intake volume 64 and compress the coolant as the drive shaft 44 is rotated by the engine 38.

[0085] Cylinder 52 has a circular cross-section and outer circumference and is eccentrically coupled to the transmission shaft 44. The rolling piston 54 is tubular and concentric with cylinder 52. The rolling piston 54 has an outer surface 54A in contact with an inner surface 58A of the compression chamber 58. The rolling piston 54 rotates around cylinder 52 while the transmission shaft 44 and the piston device 50 are rotated by the motor 38.

[0086] In the illustrated embodiment, the compression device 18 further includes a vane 56. The vane 56 is movably coupled to the housing 12. As shown, one end 56A of the vane 56 is adjacent to the compression chamber 58 and the vane is inclined so that the end 56A of the vane 56 is in contact with the rolling piston 54 as the piston device 50 is rotated by the drive shaft 44. The vane 56 may be inclined inwards by means of a spring 134 or other suitable mechanism. The housing 12, the piston device 50 and the vane 56 form variable sub-chambers 58B, 58C within the compression chamber 58 as the piston device 50 is rotated within the compression chamber 58. As Petition 870250084195, dated 09 / 18 / 2025, p. 29 / 166 22 / 43 explained in more detail below, the coolant enters one of the variable sub-chambers of intake volume 64, is compressed when the piston device 50 is rotated and exits from one of the sub-chambers 58B, 58C to the discharge volume 66.

[0087] With reference to Figures 3A-3G, the position or state of the compression device 18 during a compression cycle of the compressor 10 is shown. At the beginning of a compression cycle (as shown in Figure 3A), the vane 56 is pushed outward by the outer surface 54A of the rolling piston 54, so that the end 56A of the vane 56 is flush with the inner surface 58A of the compression chamber 58. At this point in the compression cycle, the compression chamber 58 has a single sub-chamber 58C.

[0088] As the piston device 50 rotates, the subchamber 58B is formed by the outer surface 54A of the rolling piston 54, the vane 56 and the inner surface 58A of the compression chamber 58 (see Figure 3B). As shown in Figures 3A-3F, the cylinder housing 26 of housing 12 includes an inner suction chamber 26A connected to the intake volume 64 and the compression chamber 58 by means of a suction port 26B.

[0089] Returning to Figure 3B, subchamber 58B is opened to suction chamber 26A and refrigerant enters subchamber 58B. As shown in Figures 3C-3D, as piston device 50 is rotated by drive shaft 44, the volume of subchamber 58B increases and refrigerant continues to enter or be pumped into subchamber 58B.

[0090] As shown in Figure 3F, as the piston device 50 continues to rotate, the sub-chamber 58B is cut off from the inner suction chamber 26A and the suction port 26B and therefore from the intake volume 64. As shown in Figures 3A-3G, in the illustrated embodiment, the cylinder housing 26 includes a chamber of Petition 870250084195, dated 09 / 18 / 2025, p. 30 / 166 23 / 43 internal discharge 26C which is connected to the discharge volume 66 and the compression chamber 58 by means of a discharge port 26D.

[0091] As shown in Figure 3F, when subchamber 58B is isolated or cut off from intake volume 64, the subchamber is connected to the internal discharge chamber 26C and the discharge port 26D (see Figures 3F-3G).

[0092] As the piston device 50 continues to rotate, the sub-chamber 58B decreases, thus compressing the refrigerant. The release of the pressurized refrigerant is controlled by a reed mechanism 72 coupled to the rear of the cylinder housing 26 (see Figure 6C). In the illustrated embodiment, a single reed mechanism 72 is used. However, it should be noted that more than one reed mechanism may be used. In one embodiment, the reed mechanism 72 may include a discharge reed (not shown) and a reed retainer 72A. The discharge reed may be made of a flexible material, such as steel. Characteristics such as material and strength are selected to control the pressure at which the pressurized refrigerant is released from the compression device 18. The reed retainer 72A is made of a rigid and inflexible material, such as stamped steel.The vane retainer 72A controls or limits the maximum displacement of the discharge vane relative to the cylinder housing 26. In the illustrated embodiment, the reading mechanism 72 is held or fixed to the cylinder housing 26 by means of a fastener 74.

[0093] As shown in Figures 2A-2B and 3A-3G, in the illustrated embodiment, the cylinder housing 26 includes a vane groove 76 configured to slide-receive the vane 56. The vane groove 76 has a first end 76A open to or adjacent to the compression chamber 58 and a second end 76B located adjacent to an external surface of the cylinder housing 26 (see Figure 2B). In the illustrated embodiment, the second end 76B Petition 870250084195, dated 09 / 18 / 2025, p. 31 / 166 24 / 43 of the vane groove 76 is coupled to the discharge volume 66. During operation, the pressurized refrigerant from the discharge volume 66 applies a force to the vane 56, displacing it so that the end of the vane 56A remains in contact with the outer surface of the rolling piston 54A.

[0094] Cylinder 52 and rolling piston 54 may be made of cast iron. As shown in Figures 1A, 1B and Figure 4, in the illustrated embodiment, the drive shaft 44 is centered on the central shaft 78 of the compressor 10. The piston device 50 has a central piston shaft 80 that is offset from the central shaft 78 (see Figures 2B and 4).

[0095] In one aspect of the present invention, the cylinder 52 has a hollow inner chamber 52A. The cylinder 52 and the inner chamber 52A are configured so that the rotational center of mass is aligned with the central axis 78 of the compressor 10 and the transmission shaft 44. This arrangement eliminates the need for other separate balancing components or mechanisms. As shown in the illustrated embodiment, the inner chamber 52A is located on the compression side of the cylinder housing 26.

[0096] In one embodiment of the present invention, the piston device 50 and the cylinder 52 are keyed to the transmission shaft 44. As shown in Figures 2A, 4 and 5B, in the illustrated embodiment of the present invention, one end of the transmission shaft 44 has a flat surface 44C. The cylinder 52 has an opening 52B with a flat side 52C configured to receive the end of the transmission shaft 44. In one aspect of the present invention, the cylinder 52 and the transmission shaft 44 have an interference fit between them.

[0097] As shown in Figure 6C, the cylinder housing may include a lip 26E to assist in proper positioning. Petition 870250084195, dated 09 / 18 / 2025, page 32 / 166 25 / 43 of the bearing piston 54 in relation to the cylinder housing 26. The inner diameter of the bearing piston 54 may be slightly larger than the outer diameter of the cylinder 52 to allow coolant to pass between them for lubrication purposes.

[0098] Returning to Figure 1A, in the illustrated embodiment, the compression device 18 may further include an inner cover 84. The inner cover 84 is configured to be positioned within the central housing 20, adjacent to a flange 20C of the central housing 20. As shown, when the compressor 10 is mounted, the compression chamber 58 is formed by the inner cover 84 and the cylinder housing 26. The piston device 50 is located within the compression chamber 58. As shown, the inner cover 84 forms a third support element for the drive shaft 84A, configured to receive a third ball bearing 86. The drive shaft 44 is positioned through the third ball bearing 86 and the third support element of the drive rod 84A, and supported by them. As shown, the rear head 24 is fixed to the central housing 20 by the screws 82. Compression device subassembly with integrated discharge chambers

[0099] With particular reference to Figures 1A-1B, 7A-7C and 8, in one aspect of the present invention, the electric compressor 10 may include a compression device subassembly 88 with one or more integrated discharge chambers or high-pressure cavities 66A, 66B and 66C (see Figures 1A-1B). In the illustrated embodiment, the compression device subassembly 88 includes the cylinder housing 26 and the compression device 18.

[00100] As discussed above, the electric compressor 10 is configured to compress a refrigerant and includes housing 12, a refrigerant inlet port 60, and a refrigerant outlet port 62. Petition 870250084195, dated 09 / 18 / 2025, p. 33 / 166 26 / 43 the motor 38 and the drive shaft 44. Housing 12 defines the intake volume 64 and has a central shaft 78. The refrigerant inlet port 60 is coupled to housing 12 and configured to introduce refrigerant into the intake volume 64. The refrigerant outlet port 62 is coupled to housing 12 and configured to allow compressed refrigerant to exit the electric compressor 10. The motor 38 is mounted inside housing 12. The drive shaft 44 is coupled to the motor 38 and configured to rotate around the central shaft 78.

[00101] In the illustrated embodiment, the compression device subassembly includes the cylinder housing 26 (which may also be part of the housing 12) and the piston device 50. The cylinder housing 26 and the piston device 50 may be referred to as compression device 18.

[00102] With particular reference to Figure 7A, the cylinder housing 26 has a first side 26F and a second side 26G. The cylinder housing 26 forms, at least in part, the compression chamber 58. The compression chamber 58 has an open end 58D adjacent to the first side 26F of the cylinder housing 26. One or more high-pressure cavities 66A, 66B, 66C are formed at least partially within the second side 26G of the cylinder housing 26. One or more high-pressure cavities 66A, 66B, 66C form at least part of a discharge chamber 66. The compressed refrigerant exits the compression chamber 18 into the discharge chamber 66 (or one or more high-pressure cavities 66A, 66B, 66C) through the bore 90. As shown in Figures 7B-7C, in the illustrated embodiment, the bore 90 has a first end 90A located within the compression chamber 18 and a second end 90B located within one of the high-pressure cavities 66A. 66B, 66C.The second end 90B of bore 90 is located adjacent to the vane mechanism 72. In operation, the compressed refrigerant is released from the chamber. Petition 870250084195, dated 09 / 18 / 2025, page 34 / 166 27 / 43 compression 18 during a compression cycle when the refrigerant pressure is above a predetermined limit. The predetermined limit is determined by the vane mechanism 72.

[00103] The compression device subassembly 88 includes the compression device 18. In the illustrated embodiment, the piston device 50 may include the cylinder 52 and the rolling piston 54. As discussed above, the cylinder 52 is eccentrically coupled to the drive shaft 44 and has a circular outer circumference. The rolling piston 54 may be tubular and concentric to the cylinder 52. The rolling piston 54 has an outer surface 54A in contact with the inner surface 58A of the compression chamber 58. In operation, the rolling piston 54 rotates around the cylinder 52 while the drive shaft 44 and the piston device 50 are rotated by the motor 38.

[00104] By integrating, at least in part, the high-side pressure cavities 66A, 66B, 66C and / or the discharge cavity 66 within the cylinder housing 26, the overall size of the compressor package 10 can be reduced.

[00105] In one aspect of the present invention, the rear head 24 may form the end of each of the high-side pressure cavities 66A, 66B, and 66C. In one embodiment, an inner side of the rear head 24 may be substantially (or relatively) flat. In other words, the discharge cavity 66 is composed of or located primarily within the cylinder housing 26, and the rear head 24 represents one side of each of the high-side pressure cavities 66A, 66B, and 66C.

[00106] In another embodiment, one or more high-side pressure cavities 66A, 66B, 66C may be formed by the cylinder housing 26 and the rear head 24. With particular reference to Figures 1A1B, the cylinder housing 26 may include one or more recesses of the cylinder housing 92A, 92B, 92C and the rear head 24 may Petition 870250084195, dated 09 / 18 / 2025, p. 35 / 166 28 / 43 include one or more recesses of the rear cylinder head 94A, 94B, 94C. Each of the high-side pressure cavities 66A, 66B, 66C may be composed of one of the cylinder housing recesses 92A, 92B, 92C and one of the rear cylinder head recesses 94A, 94B, 94C.

[00107] As discussed above, in the illustrated embodiment, the compression device 18 may further include a vane 56 movably coupled to the cylinder housing 26. The vane 56 has an end 56A adjacent to the compression chamber 58. The vane 56 is inclined so that the end 56A of the vane 56 is in contact with the rolling piston 54 while the piston device 50 is rotated by the transmission shaft 44. In the illustrated embodiment, the vane 56 is located within a vane groove 76 of the cylinder housing 26.

[00108] The housing 12 or cylinder housing 26, the piston device 50 and the vane 56 form variable sub-chambers 58B, 58C within the compression chamber 58 as the piston device 50 is rotated within the compression chamber 58. As discussed above, the coolant enters one of the variable sub-chambers 58B, 58C from the intake volume 64, is compressed as the piston device 50 is rotated and exits from one of the sub-chambers 58B, 58C to the discharge volume 66.

[00109] With particular reference to Figures 7A and 7B, the cylinder housing 26 may further include a groove 96 between the high-side pressure cavities 66A, 66B, 66B, allowing pressurized refrigerant to flow between them (as shown by arrows 98). Magnetic Debris Filter

[00110] With particular reference to Figures 8, 9A-9B and 10A-10C, in another aspect of the present invention, the electric compressor 10 may include a magnetic debris filter 100. The magnetic debris filter 100 is configured to capture debris created during the cycle of Petition 870250084195, dated 09 / 18 / 2025, page 36 / 166 29 / 43 Electric compressor compression 10. Generally, as discussed above, the electric compressor 10 is configured to compress a refrigerant and includes a housing 12, a refrigerant inlet port 60, a refrigerant outlet port 62, and a compression device 18. The housing 12 defines an intake volume 64 and a discharge volume 66 and has a central shaft 78. The housing 12 further defines a compression chamber 58. The refrigerant inlet port 60 is coupled to the housing 12 and is configured to introduce the refrigerant into the intake volume 64. The refrigerant outlet port 62 is coupled to the housing 12 and configured to allow the compressed refrigerant to exit the electric compressor 12 from the discharge volume 66. The compression device 18 is located within the compression chamber 58 and coupled to a drive shaft 44.The compression device 18 is configured to receive refrigerant from the intake volume 64 and compress it as the drive shaft 44 rotates. The housing 12, the compression device 18, and the compression chamber 58 define a refrigerant flow path 108 (shown in part in Figures 1A and 1B) between the refrigerant inlet port 60 and the refrigerant outlet port 62. As discussed in more detail below, the housing 12 defines a filter mounting opening 102 located after the compression device 18 in the refrigerant flow path 108.

[00111] In the illustrated embodiment, housing 12 may include a cylinder housing 26. In one embodiment, the filter mounting opening 102 is located within the cylinder housing 26. For example, in the embodiment shown in Figures 7A, the cylinder housing 26 may include a plurality of high-pressure cavities 66A, 66B, 66C that define, at least in part, the discharge volume 66. As discussed above, the compressed refrigerant may exit the compression chamber 58 through the hole 90 (as per control). Petition 870250084195, dated 09 / 18 / 2025, page 37 / 166 30 / 43 side by the vane mechanism 72). The refrigerant flows through the high-pressure cavities 66A, 66B, 66C through the slots 96 in the direction of the arrows 98 (see Figure 7B). In the illustrated embodiment, the filter mounting opening 102 is located above the internal high-pressure cavity 66C. As shown, the external shape of the magnetic debris filter 100 can correspond to the shape of the filter mounting opening 102. In one embodiment, the magnetic debris filter 100 is located between the cylinder housing 26 and the central housing 20 and is held in place when the electric compressor 10 is mounted. In another embodiment, the magnetic debris filter 100 can be press-fitted into the filter mounting opening 102.

[00112] With particular reference to Figures 9A-9B, the magnetic debris filter includes a filter structure 104 and a magnetic element 106.The filter structure 104 fits within the filter mounting opening 102 and includes a magnetic opening 104A configured to receive the magnetic element 106. The filter mounting opening 102 may also include one or more refrigerant openings 104B. In the illustrated embodiment, compressed refrigerant enters the internal high-pressure cavity 66C; debris, for example, iron debris, is captured by the magnetic element 106. The compressed refrigerant can then exit the internal high-pressure cavity 66C through one or more refrigerant openings 104B.

[00113] In one embodiment of the present invention, the filter structure 104 may be composed of aluminum. The magnetic element 106 may be a magnet. Alternatively, the magnetic element 106 may include one or more magnets 106A (shown in dashed lines in Figure 9B) embedded in a substrate 106B.

[00114] As shown in Figure 10C, the magnetic opening 104A can be partially defined by a flange 104C. The magnetic element 106 can be retained within the magnetic opening 104A by Petition 870250084195, dated 09 / 18 / 2025, page 38 / 166 31 / 43 middle of a press fit. Rotary disc oil separator

[00115] With particular reference to Figures 11A-11B and 12A-12B, in another aspect of the present invention, the electric compressor 10 may include an oil separator mechanism 110. The electric compressor 10 is configured to compress a refrigerant. As discussed above, in use, the refrigerant within the electric compressor 10 may be a mixture of refrigerant and oil (for lubrication), which may be referred to as refrigerant or refrigerant mixture for simplicity. Before the compressed refrigerant exits the electric compressor 10 through the outlet port 62, it is desirable to substantially separate or de-oil the refrigerant. The separated oil remains within the housing 12 to provide lubrication to the moving components of the electric compressor 10.

[00116] As discussed above, the electric compressor 10 may include a housing 12, a refrigerant inlet port 60, a refrigerant outlet port 62, a drive shaft 44, and a compression device 18. The housing 12 defines an intake volume 64 and a discharge volume 66 and has a central shaft 78. The housing 12 further defines a compression chamber 58. The refrigerant inlet port 60 is coupled to the housing 12 and is configured to introduce refrigerant into the intake volume 64. The drive shaft 44 is located within the housing 12. The refrigerant outlet port 62 is coupled to the housing 12 and is configured to allow the compressed refrigerant to exit the electric compressor 10 from the discharge volume 66. The compression device 18 is located within the compression chamber 58 and is coupled to the drive shaft 44.Compression device 18 is configured to receive refrigerant from intake volume 64 and compress it as transmission shaft 44 rotates. Housing 12, the device of... Petition 870250084195, dated 09 / 18 / 2025, p. 39 / 166 Compression chamber 18 and compression chamber 58 define a refrigerant flow path 98 between refrigerant inlet port 60 and refrigerant outlet port 62.

[00117] With particular reference to Figures 11A-11B, in one embodiment, housing 12 includes the central housing 20 and the inner cover 84. Housing 12 may also include the rear head 24 (see Figures 1A-1B). The rear head 24, although not shown in Figure 11A, is adjacent to and above the central housing 20.

[00118] In one aspect of the present invention, in operation the electric compressor 10 would be oriented vertically (as shown in Figure 11A) with the rear head 24 located at the top (indicated by arrow 112).

[00119] As shown in the illustrated embodiment, the oil separator mechanism 110 includes a disc-shaped oil separator 114. The disc-shaped oil separator 114 has a center 116 and is coupled to the transmission shaft 44, being configured to rotate with it around the center 116. As shown, the disc-shaped oil separator 114 is located next to the discharge volume 66. In the illustrated embodiment, the disc-shaped oil separator 114 is located inside the high-pressure internal cavity 66C. The oil separator mechanism 110 includes a flange 118 configured to fit over the upper end of the transmission shaft 44. In one embodiment, the flange 118 is press-fitted onto the upper end of the transmission shaft 44. In other embodiments, the oil separator mechanism 110 may be fixed to the upper end of the transmission shaft 44 by any suitable means, for example, a fastener (not shown).

[00120] With specific reference to Figures 12A-12C, the disc-shaped oil separator 114 has a continuous outer edge 120 and a plurality of trough-shaped elements 122. Each Petition 870250084195, dated 09 / 18 / 2025, page 40 / 166 33 / 43 trough-shaped element 122 has a first end 122A and a second end 122B. The first end 122A is located adjacent to the center 116 and extends outward toward the second end 122B. In the illustrated embodiment, the second end 122B of each trough-shaped element 122 is located on the continuous outer edge 120 of the disc-shaped oil separator 114.

[00121] Each trough-shaped element 122 has an associated width, w. In one aspect of the present invention, the width, w, increases as the trough-shaped element 122 extends from the center 116 of the disc-shaped oil separator 114. The disc-shaped oil separator 114 can be made of steel, plastic, aluminum, or other suitable material.

[00122] The oil separator mechanism 110 is configured to separate the oil from the refrigerant before it is discharged. The refrigerant may be in gaseous form and, when mixed with oil, the mixture may be immiscible due to high temperatures. In use, the oil separator 114 rotates with the drive shaft 44. As the compressed refrigerant / oil mixture enters the discharge volume 66 (or the high-pressure inner cavity 66C), the mixture is forced upwards in the direction of the arrows 124. The rotating oil separator 114 and the trough-shaped features 122 interrupt the flow of the mixture. This interaction displaces the oil to the outer walls of the discharge chamber 66 and allows the oil to accumulate at the bottom of the discharge volume 66, then being introduced into the bottom of the compressor 10, i.e., the intake volume 64. Cylinder blade retention sleeve

[00123] With specific reference to Figures 2C, 2D and 2E, in another aspect of the present invention, a cylindrical vane retaining sleeve 128 can be positioned around the cylinder housing 26 and Petition 870250084195, dated 09 / 18 / 2025, p. 41 / 166 34 / 43 configured to retain the vane 56 within the vane groove 76. The cylinder housing 26, the compression device 18, the vane 56 and the cylindrical vane retaining sleeve 128 may be referred to as an assembly 126. Generally, the assembly 126 may be located within the housing 12 of an electric compressor 10.

[00124] As described above, the electric compressor 10 can be configured to compress a refrigerant. In the embodiments illustrated, the electric compressor 10 includes the housing 12, the refrigerant inlet port 60, the refrigerant outlet port 62, and the drive shaft 44. The housing 12 has a central shaft 78 and defines the intake volume 64 and a discharge volume 66. The refrigerant inlet port 60 is coupled to the housing 12 and configured to introduce the refrigerant into the intake volume 63. The refrigerant outlet port 62 is coupled to the housing 12 and configured to allow the compressed refrigerant to exit the electric compressor 10 from the discharge volume 66. The drive shaft 44 is coupled to a motor 36 (which may be internal or external to the housing 12, see above). The drive shaft 44 is configured to rotate about the central shaft 78.

[00125] With specific reference to Figure 2C, the cylinder housing 26 has an inner surface 130 and an outer surface 132. The cylinder housing 26 defines at least partially the compression chamber 58 (see Figures 1B). In the illustrated embodiment, the cylinder housing 26 is positioned within the central housing 20, with the outer surface 132 adjacent to an inner surface of the central housing 20 (see Figure 1A).

[00126] In the illustrated embodiment, the vane groove 76 is formed, or defined, by the cylinder housing 26. Returning to Figures 2C2E, the vane groove 76 has a first open end 76A and a second open end 76B located on the surfaces Petition 870250084195, dated 09 / 18 / 2025, page 42 / 166 35 / 43 internal and external 130, 132 of the cylinder housing 26, respectively.

[00127] As discussed above, the compression device 18 is configured to receive coolant from the intake volume 64. The coolant is compressed as the drive shaft 44 rotates. In the illustrated embodiments, the compression device 18 includes a piston device 50. The piston device 50 includes a cylinder 52 and a rolling piston 54. The cylinder 52 is configured to be eccentrically coupled to the drive shaft 44. The rolling piston 54 is tubular and concentric to the cylinder 52. The rolling piston 54 has an outer surface 54A (see Figures 2A and 4) in contact with the inner surface of the cylinder housing 26. The rolling piston 54 is configured to rotate around the cylinder 52 as the drive shaft 44 and the piston device 50 rotate. The vane 56 is movably positioned within the vane groove 76.

[00128] As shown in Figure 2F, the vane 56 has an upper end 56B adjacent to the outer surface 132 of the cylinder housing 26 and a lower end 56A adjacent to the inner surface 130 of the cylinder housing 26. The vane 56 can be tilted so that the lower end 56A of the vane 56 is in contact with the rolling piston 54 while the piston device 50 is rotated by the drive shaft 44.

[00129] With specific reference to Figures 2C-2E, the cylindrical vane retaining sleeve 128 is positioned around the outer surface 132 of the cylinder housing 26 and configured to retain the vane 56 within the vane groove 76. As discussed above, the vane groove 76 can be connected to the discharge volume 66 and the vane 56 being directed towards the piston device 50 by (compressed) refrigerant within the discharge volume 66. Alternatively, or additionally, a spring 134 can be positioned between the Petition 870250084195, dated 09 / 18 / 2025, p. 43 / 166 36 / 43 cylindrical vane retaining sleeve 128 and vane 56 to direct vane 56 towards piston device 50. Blade with spring-retaining groove

[00130] With specific reference to Figure 2F, in one embodiment, the vane 56 includes a spring groove 140 with an open end 140A located at the upper end 56B of the vane 56. The spring groove 140 extends from the upper end 56B of the vane 56 toward a lower end 140B of the spring groove 140. A spring locating pin 142 may be positioned at the lower end 140B of the spring groove 140 to receive and retain a spring end 134. Blade with side seal

[00131] With specific reference to Figures 13A, 13B and 13C, in another aspect of the present invention, a pair of vane side seals 148 can be coupled to the vane 140. The cylinder housing 26, the compression device 18, the vane 56 and the pair of side seals 146 can be referred to as an assembly 144. Generally, the assembly 126 can be located within the housing 12 of an electric compressor 10.

[00132] As described above, the electric compressor 10 can be configured to compress a refrigerant. In the illustrated embodiments, the electric compressor 10 includes the housing 12, the refrigerant inlet port 60, the refrigerant outlet port 62, and the drive shaft 44. The housing 12 has a central shaft 78 and defines the intake volume 64 and a discharge volume 66. The refrigerant inlet port 60 is coupled to the housing 12 and configured to introduce the refrigerant into the intake volume 63. The refrigerant outlet port 62 is coupled to the housing 12 and configured to allow the compressed refrigerant to exit the electric compressor 10 from the discharge volume 66. The drive shaft 44 is coupled to a Petition 870250084195, dated 09 / 18 / 2025, page 44 / 166 37 / 43 motor 36 (which may be internal or external in relation to housing 12, see above). The drive shaft 44 is configured to rotate around the central axis 78.

[00133] In the illustrated embodiment, the reed groove 76 is formed, or defined, by the cylinder housing 26. Returning to Figures 2C2E, the reed groove 76 has a first open end 76A and a second open end 76B located on the inner and outer surfaces 130 and 132 of the cylinder housing 26, respectively. The reed groove 76 is closed or delimited on the sides to separate the differential between the lower and upper sides of the compressor 10 during a compression cycle. In the illustrated embodiment, one side of the reed groove 76 may be formed by the cylinder housing 26 (see Figure 2C) and the other side of the reed groove 76 may be formed by the inner cover 84 (see Figure 1A). In embodiments or configurations, the sides of the reed groove 76 may be formed by different portions of the compressor 10.In some older technology compressors, the sealing on the sides of a vane depends on the tolerances of the parts and an oil film.

[00134] As discussed above, the compression device 18 is configured to receive coolant from the intake volume 64. The coolant is compressed as the drive shaft 44 rotates. In the illustrated embodiments, the compression device 18 includes a piston device 50. The piston device 50 includes a cylinder 52 and a rolling piston 54. The cylinder 52 is configured to be eccentrically coupled to the drive shaft 44. The rolling piston 54 is tubular and concentric to the cylinder 52. The rolling piston 54 has an outer surface 54A (see Figures 2A and 4) in contact with the inner surface of the cylinder housing 26. The rolling piston 54 is configured to rotate around the cylinder 52 as the drive shaft 44 and the piston device 50 rotate. The vane 56 is Petition 870250084195, dated 09 / 18 / 2025, page 45 / 166 38 / 43 positioned movably within the vane groove 76.

[00135] Returning to Figures 13A-13C, in the illustrated embodiment, the blade 56 includes first and second side edges 56C, 56D between the ends 56A, 56B of the blade 56. As shown, one of the side seals 146 is coupled to one of the first and second side edges 56C, 56D.

[00136] In one embodiment, the first and second seals 146 are made of a material with non-stick and heat-resistant properties, such as a synthetic fluoropolymer. A suitable material is polytetrafluoroethylene (PTFE).

[00137] In the illustrated embodiment, each of the first and second side edges 56C and 56D includes a side groove 56E (only one of which is shown) configured to receive the first and second seals 146, respectively. In one embodiment, the blade 56 may be made of aluminum and the side grooves 56E and 56F are formed in the side edges 56C and 56D by means of a milling process. The first and second seals 146 may be attached to the first and second side edges 56C and 56D by means of a friction fitting and / or adhesive or other suitable means.

[00138] The first and second seals 146 are designed to minimize internal refrigerant (and oil) leaks on the low and high pressure sides of the compressor 10, in order to increase compressor performance. With specific reference to Figure 13D, in a test, compressor performance improved (in terms of volumetric efficiency) by approximately 10% at different compressor speeds.

[00139] The description above describes multiple features of an electronic compressor, including, among others, a compression device with a rolling piston, a sub-assembly with integrated discharge chambers, a magnetic debris filter, an oil separator, a cylindrical vane retaining sleeve and / or a vane with Petition 870250084195, dated 09 / 18 / 2025, page 46 / 166 39 / 43 side seal(s). It should be noted that the features described in the disclosure above may be used independently or together, in any combination.

[00140] The invention described above has been in accordance with the relevant legal standards and is therefore of an illustrative and not limiting nature. Variations and modifications to the disclosed embodiment may become apparent to those skilled in the art and fall within the scope of the invention. List of Reference Numbers for electric compressor (or e-compressor) external housing inverter section motor section compression device central housing 20A first support element of the transmission shaft 20B second support element of the transmission shaft 20C flange, reverse head, rear cover, cylinder housing. 26A internal suction chamber 26B suction port 26C internal discharge chamber 26D discharge door 26E lip 26F first side of the cylinder housing 26G second side of the cylinder housing cavity inverter screws Petition 870250084195, dated 09 / 18 / 2025, page 47 / 166 40 / 43 inverter module inverter circuit motor cavity motor stator rotor center opening transmission shaft first end second end flat surface first ball bearing Second ball bearing piston device cylinder inner chamber opening flat side lip rolling piston outer surface of rolling piston vane one end of the vane (lower end) upper end of the vane first lateral edge of the vane second lateral edge of the vane lateral groove lateral groove compression chamber inner surface of the compression chamber Petition 870250084195, dated 09 / 18 / 2025, page 48 / 166 41 / 43 sub-chamber sub-chamber open end of compression chamber refrigerant inlet port refrigerant outlet port intake volume discharge volume high-pressure cavity high-pressure cavity high-pressure cavity reed mechanism reed retainer fastener reed groove first end of reed groove second end of reed groove hole central shaft central shaft piston screws inner cover third transmission shaft support element third ball bearing compression device sub-assembly hole (in cylinder housing - for discharge chamber) first end of hole second end of hole cylinder head recess cylinder head recess cylinder head recess Petition 870250084195, dated 09 / 18 / 2025, page 49 / 166 42 / 43 94A rear recess of the head 94B rear recess of the head 94C rear recess of the head groove (in the cylinder housing) coolant flow path 100 magnetic debris filter 102 filter mounting opening 104 filter structure 104A magnetic opening 104B soda opening(s) 104C flange 106 magnetic element 106A magnets 106B substrate 108 refrigerant flow path 110 oil separator mechanism 112 arrow 114 disc-shaped oil separator 116 center 118 flange 120 continuous outer edge 122 trough-shaped feature 122A first end 122B second end 124 arrow 126 cylinder housing assembly, compression device, vane and cylindrical vane retaining sleeve)) 128 cylindrical vane retaining sleeve 130 inner surface of the cylinder housing 132 outer surface of the cylinder housing Petition 870250084195, dated 09 / 18 / 2025, page 50 / 166 43 / 43 134 spring 136 location resource 138 pin reception opening 140 spring groove 140A open end of the spring groove 140B lower end of the spring groove 142 spring locating pin 144 cylinder housing assembly, compression device, vane and cylindrical vane retaining sleeve)) 146 side seals

Claims

1. Compression device (18), characterized in that it is located within a compression chamber (58) of an electric compressor (10), the electric compressor (10) configured to compress a refrigerant and including a housing (12), a refrigerant inlet port (60), a refrigerant outlet port (62), a motor (38) and a drive shaft (44), the housing (12) defining an intake volume (64) and a discharge volume (66) and having a central shaft, the housing (12) defining the compression chamber (58), the refrigerant inlet port (60) coupled to the housing (12) and configured to introduce the refrigerant into the intake volume (64), the refrigerant outlet port (62) coupled to the housing (12) and configured to allow the compressed refrigerant to exit the electric compressor (10) from the discharge volume (66), the motor (38) mounted within the housing (12),The transmission shaft (44) coupled to the motor (38) and configured to rotate around the central axis (78), the compression device (18) being coupled to the transmission shaft (44) and configured to receive coolant from the intake volume (64) and compress the coolant as the transmission shaft (44) is rotated by the motor (38), the compression device (18) includes: a piston device (50) including a cylinder (52) and a bearing piston (54), the cylinder (52) being eccentrically coupled to the transmission shaft (44), the cylinder (52) having a circular outer circumference, the bearing piston (54) being tubular and concentric with the cylinder (52), the bearing piston (54) having an outer surface (54A) in contact with an inner surface (58A) of the compression chamber (58), the bearing piston (54) rotating around the cylinder (52) as the transmission shaft (44) and the piston device (50) are rotated by the motor (38); and,a blade (56) movably coupled to the housing Petition 870250084195, dated 18 / 09 / 2025, page. 52 / 166 2 / 9 (12) and having one end (56A) adjacent to the compression chamber (58), the vane (56) being inclined so that the end (56A) of the vane (56) is in contact with the rolling piston (54) as the piston device (50) is rotated by the transmission shaft (44), the housing (12), the piston device (50) and the vane (56) forming variable sub-chambers (58B, 58C) within the compression chamber (58) as the piston device (50) is rotated within the compression chamber (58), wherein the coolant enters one of the variable sub-chambers (58B, 58C) of the intake volume (64), is compressed as the piston device (50) is rotated and exits one of the sub-chambers to the discharge volume (66).

2. Compression device (18), according to claim 1, characterized in that the cylinder (52) has an internal chamber (52A) configured to provide the cylinder (52) with a rotational center of mass around the central axis (78).

3. Compression device (18), according to claim 1, characterized in that the cylinder (52) is fitted to the transmission shaft (44) by means of an interference fit.

4. Compression device (18), according to claim 1, characterized in that the housing (12) includes a vane groove (76), the vane (56) being positioned slidingly within the vane groove (76).

5. Compression device (18), according to claim 4, characterized in that the vane groove (76) is connected to the discharge volume (66), the vane (56) is directed to the piston device (50) by the refrigerant inside the discharge volume (66).

6. Compression device (18), according to claim 4, the housing (12) characterized in that it includes a cylinder housing (26), the vane groove (76) being located Petition 870250084195, dated 09 / 18 / 2025, page 53 / 166 3 / 9 inside the cylinder housing (26).

7. Compression device (18), according to claim 6, the cylinder housing (26) characterized in that it includes a suction port (26B) coupled between the compression chamber (58) and the intake volume (64) and an internal discharge chamber (26C) coupled between the compression chamber (58) and the discharge volume (66), the compression device (18) further including a vane mechanism (72) coupled to the cylinder housing (26) configured to control the release of pressurized refrigerant from the compression chamber (58) through the internal discharge chamber (26C).

8. Electric compressor (10) configured to compress a refrigerant, characterized in that it comprises: a housing (12) defining an intake volume (64) and a discharge volume (66) and having a central shaft (78), the housing (12) further defining a compression chamber (58); a refrigerant inlet port (60) coupled to the housing (12) and configured to introduce the refrigerant into the intake volume (64); a refrigerant outlet port (62) coupled to the housing (12) and configured to allow the compressed refrigerant to exit the electric compressor (10) from the discharge volume (66);and, a compression device (18) located within the compression chamber (58) and being coupled to a transmission shaft (44), the compression device (18) configured to receive the coolant from the intake volume (64) and compress the coolant as the transmission shaft (44) is rotated, the compression device (18) including: a piston device (50) including a cylinder (52) and a rolling piston (54), the cylinder (52) being eccentrically coupled to the transmission shaft (44), the cylinder (52) having a circum Petition 870250084195, dated 09 / 18 / 2025, page. 54 / 166 4 / 9 external circular reference, the rolling piston (54) being tubular and concentric with the cylinder (52), the rolling piston (54) having an external surface (54A) in contact with an internal surface (58A) of the compression chamber (58), the rolling piston (54) rotating around the cylinder (52) as the transmission shaft (44) and the piston device (50) are rotated by the motor (38);and, a vane (56) movably coupled to the housing (12) and having one end (56A) adjacent to the compression chamber (58), the vane (56) being inclined so that the end (56A) of the vane (56) is in contact with the rolling piston (54) as the piston device (50) is rotated by the transmission shaft (44), the housing (12), the piston device (50) and the vane (56) forming variable sub-chambers (58B, 58C) within the compression chamber (58) as the piston device (50) is rotated within the compression chamber (58), wherein the coolant enters one of the variable sub-chambers (58B, 58C) of the intake volume (64), is compressed as the piston device (50) is rotated and exits from one of the sub-chambers to the discharge volume (66).; 9. Electric compressor (10) configured to compress a refrigerant, characterized in that it comprises: a housing (12) defining an intake volume (64) and a discharge volume (66) and having a central shaft (78), the housing (12) further defining a compression chamber (58); a refrigerant inlet port (60) coupled to the housing (12) and configured to introduce the refrigerant into the intake volume (64); a refrigerant outlet port (62) coupled to the housing (12) and configured to allow the compressed refrigerant to exit the electric compressor (10) from the discharge volume (66); a motor (38) mounted inside the housing (12); Petition 870250084195, dated 09 / 18 / 2025, page 55 / 166 5 / 9 a transmission shaft (44) coupled to the motor (38) and configured to rotate around the central shaft (78);and, a compression device (18) located within the compression chamber (58) and being coupled to the transmission shaft (44), the compression device (18) configured to receive coolant from the intake volume (64) and compress the coolant as the transmission shaft (44) is rotated by the engine (38), the compression device (18) including: a piston device (50) including a cylinder (52) and a rolling piston (54), the cylinder (52) being eccentrically coupled to the transmission shaft (44), the cylinder (52) having a circular outer circumference, the rolling piston (54) being tubular and concentric with the cylinder (52), the rolling piston (54) having an outer surface (54A) in contact with an inner surface (58A) of the compression chamber (58), the rolling piston (54) rotating around the cylinder (52) as the transmission shaft (44) and the piston device (50) are rotated by the engine (38);and, a vane (56) movably coupled to the housing (12) and having one end (56A) adjacent to the compression chamber (58), the vane (56) being inclined so that the end (56A) of the vane (56) is in contact with the rolling piston (54) as the piston device (50) is rotated by the transmission shaft (44), the housing (12), the piston device (50) and the vane (56) forming variable sub-chambers (58B, 58C) within the compression chamber (58) as the piston device (50) is rotated within the compression chamber (58), wherein the coolant enters one of the variable sub-chambers (58B, 58C) of the intake volume (64), is compressed as the piston device (50) is rotated and exits from one of the sub-chambers to the discharge volume (66).; 10. Electric compressor (10), according to claim Petition 870250084195, dated 09 / 18 / 2025, page 56 / 166 6 / 9 9, characterized in that the housing (12) includes a cylinder housing (26) and a rear head, the discharge volume (66) being formed, at least partially, by the cylinder housing (26), the rear head and the refrigerant outlet port (62).

11. Electric compressor (10), according to claim 10, characterized in that the housing (12) includes an inverter cover and a central housing, the central housing and the inverter cover forming an inverter cavity, the electric compressor (10) further including an inverter module mounted within the inverter cavity and configured to convert direct current electrical energy into alternating current electrical energy.

12. Electric compressor (10), according to claim 11, the housing (12) characterized in that it includes a first transmission shaft support member (20A) and a second transmission shaft support member (20B).

13. Electric compressor (10), according to claim 12, characterized in that it further includes first and second ball bearings located within the first and second support members of the transmission shaft (20A, 20B) configured to receive respective ends (44A, 44B) of the transmission shaft (44).

14. Electric compressor (10), according to claim 9, characterized in that the cylinder (52) has an internal chamber (52A), the cylinder having a rotational center of mass around the central axis (78).

15. Electric compressor (10), according to claim 9, characterized in that the cylinder (52) is fitted to the transmission shaft (44) by means of an interference fit.

16. Electric compressor (10), according to claim 9, characterized in that the housing (12) includes a vane groove (76), the vane (56) being positioned in a sliding manner Petition 870250084195, dated 09 / 18 / 2025, page 57 / 166 7 / 9 within the vane groove (76).

17. Electric compressor (10), according to claim 16, characterized in that the vane groove (76) is connected to the discharge volume (66), the vane (56) is directed to the piston device (50) by the refrigerant inside the discharge volume (66); 18. Electric compressor (10), according to claim 16, the housing (12) characterized in that it includes a cylinder housing (26), the vane groove (76) being located within the cylinder housing (26).

19. Electric compressor (10), according to claim 18, characterized in that the cylinder housing (26) includes a suction port (26B) coupled between the compression chamber (58) and the intake volume (64) and an internal discharge chamber (26C) coupled between the compression chamber (58) and the discharge volume (66), the compression device (18) further including a vane mechanism (72) coupled to the cylinder housing (26) configured to control the release of pressurized refrigerant from the compression chamber (58) through the internal discharge chamber (26C).

20. Electric compressor (10), according to claim 18, the cylinder housing (26) characterized in that it includes a lip to assist in the proper positioning of the rolling piston (54) in relation to the cylinder housing (26).

21. Electric compressor (10), according to claim 18, characterized in that it further includes an inner cover configured to be positioned within the central housing adjacent to a flange of the central housing.

22. Electric compressor (10) according to claim 21, characterized in that the inner cover forms a third support element for the transmission shaft (84A).

23. Electric compressor (10), according to claim Petition 870250084195, dated 09 / 18 / 2025, page 58 / 166 8 / 9 22, characterized in that it further includes a third ball bearing located within the third transmission shaft support element (84A) configured to receive the transmission shaft (44).

24. Electric compressor (10) configured to compress a refrigerant, characterized in that it comprises: a housing (12) defining an intake volume (64) and a discharge volume (66) and having a central shaft (78), the housing (12) including a central housing, a cylinder housing (26), a rear head and an inverter cover, the central housing and the inverter cover forming an inverter cavity, the cylinder housing (26) forming a compression chamber (58) and having a vane groove (76) connected to the discharge volume (66); a refrigerant inlet port (60) coupled to the housing (12) and configured to introduce the refrigerant into the intake volume (64); a refrigerant outlet port (62) coupled to the housing (12) and configured to allow the compressed refrigerant to exit the electric compressor (10) from the discharge volume (66), the discharge volume (66) being formed, at least partially, by the central housing,the rear head and coolant outlet port (62); a motor (38) mounted inside the housing (12); an inverter module mounted inside the inverter cavity and configured to convert direct current electrical energy into alternating current electrical energy; a transmission shaft (44) coupled to the motor (38) and configured to rotate around the central axis (78); and, a compression device (18) located inside the compression chamber (58) and being coupled to the transmission shaft (44), the compression device (18) configured to receive Petition 870250084195, dated 09 / 18 / 2025, page. 59 / 166 9 / 9 coolant from the intake volume (64) and compress the coolant as the transmission shaft (44) is rotated by the engine (38), the compression device (18) including: a piston device (50) including a cylinder (52) and a rolling piston (54), the cylinder (52) being eccentrically coupled to the transmission shaft (44),the cylinder (52) having an inner chamber (52A), the cylinder (52) having a rotational center of mass around the central axis (78), the cylinder (52) having a circular outer circumference, the rolling piston (54) being tubular and concentric with the cylinder (52), the rolling piston (54) having an outer surface (54A) in contact with an inner surface (58A) of the compression chamber (58), the rolling piston (54) rotating around the cylinder (52) as the transmission shaft (44) and the piston device (50) are rotated by the motor (38); and, a vane (56) within the vane groove (76) and having one end (56A) adjacent to the compression chamber (58), the vane (56) being inclined towards the piston device (50) by the coolant within the discharge volume (66) so that the end (56A) of the vane (56) is in contact with the rolling piston (54) as the piston device (50) is rotated by the drive shaft (44), the housing (12),the piston device (50) and the vane (56) forming variable sub-chambers (58B, 58C) within the compression chamber (58) as the piston device (50) is rotated within the compression chamber (58), where the refrigerant enters one of the variable sub-chambers (58B, 58C) of the intake volume (64), is compressed as the piston device (50) is rotated and exits one of the sub-chambers in the discharge volume (66).

Images