Compression device having integrated discharge chamber(s) and compressor with compression device having integrated discharge chamber(s)

Description

1 / 38 COMPRESSION DEVICE HAVING INTEGRATED DISCHARGE CHAMBER(S) AND COMPRESSOR WITH COMPRESSION DEVICE HAVING INTEGRATED DISCHARGE CHAMBER(S) FIELD OF THE INVENTION

[0001] The 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

[0002] 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.

[0003] 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.

[0004] In addition to cooling the vehicle's passenger compartment Petition 870250084285, dated 09 / 18 / 2025, page 9 / 161 2 / 38 motorized, electric compressors can be used to provide heating or cooling to 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 battery operating time.

[0005] Rotary-driven compression devices must be balanced to reduce noise and vibration and maximize compressor efficiency and lifespan.

[0006] 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

[0007] 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.

[0008] In a first embodiment of the present invention, it is Petition 870250084285, dated 09 / 18 / 2025, page 10 / 1613 / 38 provides a sub-assembly of the compression device 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 has a central axis. The electric compressor includes 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 the compressed refrigerant to exit the electric compressor. 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 sub-assembly includes a cylinder housing and a piston device.The cylinder housing has a first side and a second side and, at least in part, forms the compression chamber. The compression chamber has an open end adjacent to the first side of the cylinder housing. One or more high-pressure cavities are formed, at least partially, within the second side of the cylinder housing. One or more high-pressure cavities form, at least partially, a discharge chamber. The compressed refrigerant exits the compression chamber into one or more high-pressure cavities through a bore. The piston device includes a cylinder and a rolling piston. The cylinder is eccentrically coupled to the drive shaft. The cylinder has a circular outer circumference. The rolling piston is tubular and concentric to 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 while the drive shaft and piston device are rotated by the engine.

[0009] Optionally, the compression device subset Petition 870250084285, dated 09 / 18 / 2025, page 11 / 161 4 / 38 may further comprise a vane movably coupled to the cylinder housing and with one end adjacent to the compression chamber, the vane being inclined so that the vane end contacts the rotating piston as the piston device is rotated by the drive shaft. The housing, piston device, and vane may form variable sub-chambers within the compression chamber as the piston device is rotated within the compression chamber. Coolant may enter one of the variable sub-chambers from the intake volume, be compressed as the piston device is rotated, and exit through one of the sub-chambers to the discharge volume. The cylinder may have an internal chamber configured to provide the cylinder with a rotational center of mass around the central axis.

[0010] Optionally, the cylinder housing includes a vane groove, with the vane positioned slidingly within the 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 cylinder housing may include an internal 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 device coupled to the cylinder housing, configured to control the release of pressurized refrigerant from the compression chamber through the internal discharge chamber.

[0011] In a second embodiment of the present invention, an electric compressor configured to compress a refrigerant is provided. The electric compressor includes a housing, a refrigerant inlet port, a refrigerant outlet port, a motor, a drive shaft, and a compression device. The housing defines Petition 870250084285, dated 09 / 18 / 2025, page 12 / 161 5 / 38 an intake volume and a discharge volume and has a central shaft. The housing further defines a compression chamber. The housing includes a cylinder housing with a first side and a second side. The compression chamber is formed by the cylinder housing and has an open end adjacent to the first side of the cylinder housing. One or more high-pressure cavities are formed, at least partially, within the second side of the cylinder housing. The compressed refrigerant exits the compression chamber to one or more high-pressure cavities through a bore. 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 through the bore. The motor is mounted inside the housing.The drive shaft is coupled to the engine and configured to rotate around the central axis. The compression device is located inside the combustion chamber and is coupled to the drive shaft. The compression device is configured to receive coolant from the intake volume and compress it as the drive shaft is rotated by the engine.

[0012] Optionally, the compression device includes a vane movably coupled to the housing and with one end adjacent to the compression chamber, with the vane angled so that the vane end contacts the rotating piston as the piston device is rotated by the drive shaft. The housing, piston device, and vane may form variable sub-chambers within the compression chamber as the piston device is rotated within the compression chamber. The coolant may enter one of the variable sub-chambers from the intake volume, be compressed as the piston device is rotated, and Petition 870250084285, dated 09 / 18 / 2025, p. 13 / 161 6 / 38 exit through one of the sub-chambers for the discharge volume.

[0013] Optionally, the housing may include a central housing and a rear head. The discharge volume may be formed, at least partially, by the central housing, the rear head, and the refrigerant outlet port. The housing may also include an inverter cover, with the central housing and the inverter cover forming an inverter cavity. The electric compressor may also 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. The first and second ball bearings may be located within the first and second drive shaft support elements and configured to receive the respective ends of the drive shaft.The cylinder may have an internal chamber and a rotational center of mass around the central axis.

[0014] Optionally, the cylinder can be fitted to the drive shaft by means of an interference fit.

[0015] Optionally, the housing may include a vane slot, with the vane positioned slidingly within the slot. The vane slot may be connected to the discharge volume, with the vane directed towards the piston device by the refrigerant within the discharge volume.

[0016] Optionally, the housing may include a cylinder housing and the vane groove may be located within the cylinder housing.

[0017] The cylinder housing may optionally include an internal suction port coupled between the compression chamber and the intake volume, and an internal discharge chamber coupled between Petition 870250084285, dated 09 / 18 / 2025, p. 14 / 161 7 / 38 the compression chamber and the discharge volume. The compression device may also include a vane mechanism coupled to the cylinder housing.

[0018] Optionally, the cylinder housing includes a rim to assist in the correct positioning of the rolling piston in relation to the cylinder housing.

[0019] The electric compressor may also include an inner cover positioned within the central housing, adjacent to a central housing flange. The inner cover may form a third drive shaft support element. A third ball bearing may be located within the third drive shaft support element, configured to receive the drive shaft.

[0020] In a third embodiment of the present invention, an electric compressor configured to compress a refrigerant is provided. The electric compressor includes a housing, 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 has a first side, a second side, and a vane groove connected to the discharge volume, forming a compression chamber. The compression chamber has an open end adjacent to the first side of the cylinder housing. One or more high-pressure cavities are formed, at least partially, within the second side of the cylinder housing.The compressed refrigerant exits the compression chamber into one or more high-pressure cavities through a hole. The refrigerant inlet port is coupled to the housing and configured to introduce the refrigerant to a volume of... Petition 870250084285, dated 09 / 18 / 2025, page 15 / 161 8 / 38 intake. 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 header, and the refrigerant outlet port. The motor is mounted inside the housing. The inverter module is mounted inside the inverter cavity and configured to convert direct current electrical energy into alternating current electrical energy. The drive shaft is coupled to the motor and configured to rotate around the central axis. The compression device is located inside the compression chamber and is 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 comprising a cylinder, a rolling piston, and a vane. The cylinder is eccentrically coupled to the drive shaft. The cylinder has an inner chamber, a circular outer circumference, and a rotational center of mass around the central axis. 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 motor. The vane is located within the vane groove and has one end adjacent to the compression chamber. The vane is inclined toward the piston device by the coolant within the discharge volume, so that the end of the vane comes into 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. Petition 870250084285, dated 09 / 18 / 2025, page 16 / 161 9 / 38 refrigerant enters one of the variable sub-chambers of the intake volume, is compressed as the piston device is rotated, and exits one of the sub-chambers into the discharge volume. BRIEF DESCRIPTION OF THE VARIOUS VIEWS OF THE DRAWINGS

[0021] These and other features and advantages of the present invention will be more easily appreciated when considered in connection with the following detailed description and accompanying drawings.

[0022] Figure 1A is a cross-sectional view of a compressor according to an embodiment of the present invention.

[0023] Figure 1B is a second cross-sectional view of the electric compressor in Figure 1A.

[0024] Figure 2A is a cross-sectional view of an electrical compression device of Figure 1A, according to an embodiment of the present invention.

[0025] Figure 2B is a perspective view of the compression device in Figure 2A.

[0026] Figure 2C is an enlarged perspective view of a part of the compression device in Figure 2A.

[0027] Figure 2D is a perspective view of the compression device portion of Figure 2C.

[0028] Figure 2E is a partial cross-section of the compression device portion of Figure 2A.

[0029] 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.

[0030] Figures 3A-3G are cross-sectional views of the compression device of Figure 2A during a compression cycle.

[0031] 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. Petition 870250084285, dated 09 / 18 / 2025, page 17 / 161 10 / 38

[0032] 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.

[0033] Figure 5B is a cross-sectional view of the transmission shaft and piston device of Figure 5A.

[0034] Figure 6A is a front view of a compression device with integrated discharge chambers, according to an embodiment of the present invention.

[0035] 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.

[0036] Figure 6C is a rear view of the compression device of Figure 6A.

[0037] Figure 7A is a perspective view of the compression device in Figure 6A.

[0038] 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.

[0039] Figure 7C is a second perspective view of the cylinder housing of Figure 7B.

[0040] Figure 8 is a rear view of a compression device and a magnetic debris filter, according to an embodiment of the present invention.

[0041] Figure 9A is an enlarged view of the compression device and magnetic debris filter of Figure 8.

[0042] Figure 9B is an enlarged view of the magnetic debris filter assembly of Figure 8.

[0043] 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. Petition 870250084285, dated 09 / 18 / 2025, page 18 / 161 11 / 38

[0044] Figure 10B is a side view of the filter structure of Figure 10A.

[0045] Figure 10C is a cross-sectional view of the filter structure of Figure 10A.

[0046] Figure 11A is a cross-sectional view of a compression device for an electric compressor and an oil separator, according to an embodiment of the present invention.

[0047] Figure 11B is a front view of the oil compression and separator device of Figure 11A.

[0048] Figure 12A is a side view of an oil separator disc of Figure 11A, according to an embodiment of the present invention.

[0049] Figure 12B is a top view of the disk in Figure 11A.

[0050] Figure 12C is a perspective view of the disk in Figure 11A.

[0051] Figure 13A is a side view of a compressor vane with side seals, according to an embodiment of the present invention.

[0052] Figure 13B is a front view of the blade in Figure 13A.

[0053] Figure 13C is an enlarged view of the palette in Figure 13A.

[0054] Figure 13D is a bar graph of test data associated with the palette in Figure 13A. DETAILED DESCRIPTION OF THE INVENTION

[0055] With reference to the Figures, where equal numbers indicate equal or corresponding parts along the various views, a compressor 10 is shown with a housing 12. 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 refrigeration device or as a heat pump to heat and / or cool different parts of the vehicle. By Petition 870250084285, dated 09 / 18 / 2025, p. 19 / 161 12 / 38 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.

[0056] In addition, the electric compressor 10 can be used to heat or cool the passenger compartment, the on-board electronics and / or a battery used to power the vehicle while it is not in operation, for example, during a charging cycle. The 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 the degradation of the battery's service life.

[0057] 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.

[0058] 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.

[0059] 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. Petition 870250084285, dated 09 / 18 / 2025, page 20 / 161 13 / 38

[0060] 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). General Arrangement and Operation of the Electric Compressor 10

[0061] 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.

[0062] 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).

[0063] The central housing 20 forms a cavity for the motor 36. A Petition 870250084285, dated 09 / 18 / 2025, page 21 / 161 Section 14 / 38 of motor 16 includes a motor 38 located within the motor cavity 36. In one embodiment, 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 remains stationary relative to the central housing 20. The rotor 42 is located within and centered relative to the stator 40.

[0064] 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.

[0065] 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 shaft. Petition 870250084285, dated 09 / 18 / 2025, page 22 / 161 15 / 38 transmission 44 and a vane 56. As will be explained in more detail below, the transmission shaft 44 is rotated within a compression chamber 58 by the cylinder housing 26 of the housing 12. In addition, the vane 56 is inclined inwards.

[0066] Generally, the refrigerant and oil mixture (at low pressure) enter the electric compressor 10 through a refrigerant inlet port 60 and exit 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).

[0067] 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 Rolling Piston

[0068] With particular reference to Figures 1A-1B, 2A-2B, 3A-3G, and 5A-5B, a compression device 18, according to an embodiment of the present invention, includes a 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 the Petition 870250084285, dated 09 / 18 / 2025, page 23 / 161 16 / 38 coolant intake volume 64 and compress the coolant as the drive shaft 44 is rotated by the engine 38.

[0069] 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.

[0070] 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 (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.

[0071] 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 chamber. Petition 870250084285, dated 09 / 18 / 2025, page 24 / 161 17 / 38 compression 58. At this point in the compression cycle, the compression chamber 58 has a single sub-chamber 58C.

[0072] 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.

[0073] 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.

[0074] 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.

[0075] As shown in Figure 3F, when the subchamber 58B is isolated or cut off from the intake volume 64, the subchamber is connected to the internal discharge chamber 26C and the discharge port 26D (see Figures 3F-3G).

[0076] 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 Petition 870250084285, dated 09 / 18 / 2025, p. 25 / 161 18 / 38 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 reed retainer 72A controls or limits the maximum displacement of the discharge reed 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.

[0077] 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.

[0078] Cylinder 52 and rolling piston 54 can 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). Petition 870250084285, dated 09 / 18 / 2025, page 26 / 161 19 / 38 and 4).

[0079] 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.

[0080] 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.

[0081] As shown in Figure 6B, cylinder 52 may include a rim 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.

[0082] Returning to Figure 1A, in the illustrated embodiment, the compression device 18 may also 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 housing of the Petition 870250084285, dated 09 / 18 / 2025, page 27 / 161 20 / 38 cylinder 26. The piston device 50 is located inside 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 tie rod 84A, and supported by them. As shown, the rear head 24 is fixed to the central housing 20 by the screws 82.

[0083] 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.

[0084] 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.

[0085] 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 shaft of Petition 870250084285, dated 09 / 18 / 2025, page 28 / 161 21 / 38 actuation 44. The vane 56 can be tilted 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 explained in more detail below, the refrigerant enters one of the variable sub-chambers of the 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.

[0086] 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.

[0087] 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.

[0088] 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. Petition 870250084285, dated 09 / 18 / 2025, p. 29 / 161 22 / 38

[0089] 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.

[0090] As shown in Figure 3F, when the subchamber 58B is isolated or cut off from the intake volume 64, the subchamber is connected to the internal discharge chamber 26C and the discharge port 26D (see Figures 3F-3G).

[0091] 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.

[0092] As shown in Figures 2A-2B and 3A-3G, in the illustrated embodiment, the cylinder housing 26 includes a vane groove Petition 870250084285, dated 09 / 18 / 2025, p. 30 / 161 23 / 38 configured to receive the vane 56 in a sliding manner. 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 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, tilting it so that the vane end 56A remains in contact with the external surface of the rolling piston 54A.

[0093] 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).

[0094] 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.

[0095] 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 shaft. Petition 870250084285, dated 09 / 18 / 2025, page 31 / 161 24 / 38 transmission 44. In one aspect of the present invention, cylinder 52 and transmission shaft 44 have an interference fit between them.

[0096] As shown in Figure 6C, the cylinder housing may include a flange 26E to assist in the proper positioning of the bearing piston 54 relative 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.

[0097] 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.

[0098] 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 subassembly of Petition 870250084285, dated 09 / 18 / 2025, p. 32 / 161 25 / 38 compression device 88 includes cylinder housing 26 and compression device 18.

[00100] As discussed above, the electric compressor 10 is configured to compress a refrigerant and includes the housing 12, a refrigerant inlet port 60, a refrigerant outlet port 62, the motor 38, and the drive shaft 44. The housing 12 defines the intake volume 64 and has a central shaft 78. The refrigerant inlet port 60 is coupled to the housing 12 and 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 10. The motor 38 is mounted inside the 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 partially 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 embodiment Petition 870250084285, dated 09 / 18 / 2025, p. 33 / 161 Figure 26 / 38 illustrates that bore 90 has a first end 90A located inside the compression chamber 18 and a second end 90B located inside 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 compression chamber 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 transmission 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-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-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-pressure cavities 66A, Petition 870250084285, dated 09 / 18 / 2025, p. 34 / 161 27 / 38 66B and 66C.

[00106] In another embodiment, one or more high-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 include one or more recesses of the rear head 94A, 94B, 94C. Each of the high-pressure cavities 66A, 66B, 66C may be composed of one of the recesses of the cylinder housing 92A, 92B, 92C and one of the recesses of the rear head 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-pressure cavities 66A, 66B, 66B, allowing the refrigerant under pressure to pass through. Petition 870250084285, dated 09 / 18 / 2025, page 35 / 161 28 / 38 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 compression cycle of the electric compressor 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.Refrigerant outlet port 62 is coupled to housing 12 and configured to allow compressed refrigerant to exit the electric compressor 12 from discharge volume 66. Compression device 18 is located within compression chamber 58 and coupled to a drive shaft 44. Compression device 18 is configured to receive refrigerant from intake volume 64 and compress it as drive shaft 44 rotates. Housing 12, compression device 18, and compression chamber 58 define a refrigerant flow path 108 (shown in part in Figures 1A and 1B) between refrigerant inlet port 60 and refrigerant outlet port 62. As discussed in more detail below, housing 12 defines a filter mounting opening 102 located after 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 opening of Petition 870250084285, dated 09 / 18 / 2025, p. 36 / 161 The 29 / 38 filter assembly 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 can exit the compression chamber 58 through the hole 90 (as controlled by the vane mechanism 72). The refrigerant flows through the high-pressure cavities 66A, 66B, 66C through the grooves 96 in the direction of the arrows 98 (see Figure 7B). In the illustrated embodiment, the filter assembly 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 assembly 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 Petition 870250084285, dated 09 / 18 / 2025, page 37 / 161 30 / 38 may be a magnet. Alternatively, the magnetic element 106 may include one or more magnets 106A (shown as 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 means 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 Petition 870250084285, dated 09 / 18 / 2025, page 38 / 161 31 / 38 allow the compressed refrigerant to exit the electric compressor 10 from the discharge volume 66. The compression device 18 is located inside the compression chamber 58 and is coupled to the 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 98 between the refrigerant inlet port 60 and the 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 flange 118 is press-fitted onto the upper end of the transmission shaft 44. Petition 870250084285, dated 09 / 18 / 2025, page 39 / 161 In 32 / 38 modes, the oil separator mechanism 110 can 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 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 Petition 870250084285, dated 09 / 18 / 2025, page 40 / 161 33 / 38 discharge volume 66, then introduced into the lower part of the compressor 10, that is, the intake volume 64. Cylindrical 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 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 can be referred to as an assembly 126. Generally, the assembly 126 can 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. Petition 870250084285, dated 09 / 18 / 2025, page 41 / 161 34 / 38 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 inner and outer surfaces 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 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 transmission 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 Petition 870250084285, dated 09 / 18 / 2025, p. 42 / 161 35 / 38 vane 56 inside 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 refrigerant (compressed) inside the discharge volume 66. Alternatively, or additionally, a spring 134 can be positioned between the cylindrical vane retaining sleeve 128 and the vane 56 to direct the vane 56 towards the piston device 50. Wiper blade with spring retention 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 one end of the spring 134. Wiper blade with side seal(s)

[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 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 inlet port Petition 870250084285, dated 09 / 18 / 2025, page 43 / 161 Refrigerant 60 (36 / 38) is coupled to housing 12 and configured to introduce refrigerant into intake volume 63. Refrigerant outlet port 62 is coupled to housing 12 and configured to allow compressed refrigerant to exit the electric compressor 10 from discharge volume 66. Drive shaft 44 is coupled to a motor 36 (which may be internal or external to housing 12, see above). Drive shaft 44 is configured to rotate about central axis 78.

[00133] 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 inner and outer surfaces 130 and 132 of the cylinder housing 26, respectively. The vane 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 vane groove 76 may be formed by the cylinder housing 26 (see Figure 2C) and the other side of the vane groove 76 may be formed by the inner cover 84 (see Figure 1A). In embodiments or configurations, the sides of the vane 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 piston of Petition 870250084285, dated 09 / 18 / 2025, page 44 / 161 37 / 38 bearing 54 is tubular and concentric to cylinder 52. The bearing piston 54 has an outer surface 54A (see Figures 2A and 4) in contact with the inner surface of the cylinder housing 26. The bearing piston 54 is configured to rotate around cylinder 52 as the drive shaft 44 and piston device 50 rotate. The vane 56 is movably positioned within the vane groove 76.

[00135] Returning to Figures 13A-13C, in the illustrated embodiment, the vane 56 includes first and second side edges 56C, 56D between the ends 56A, 56B of the vane 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. Petition 870250084285, dated 09 / 18 / 2025, page 45 / 161 38 / 38

[00139] The above description 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 side seal(s). It should be noted that the features described in the above disclosure may be used independently or in combination, 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. Petition 870250084285, dated 09 / 18 / 2025, page 46 / 161

Claims

1 / 10 CLAIMS 1. Subassembly of a compression device (88) 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 having a central shaft (78), the electric compressor (10) includes a 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), the motor (38) mounted inside the housing (12), the drive shaft (44), coupled to the motor (38) and configured to rotate around the central shaft (78),the subassembly of the compression device (88) characterized in that it includes: a cylinder housing (26) having a first side (26F) and a second side (26G) and at least in part forming the compression chamber (58), the compression chamber (58) having an open end (58D) adjacent to the first side (26F) of the cylinder housing (26), one or more high-pressure cavities (66A, 66B, 66C) formed at least partially within the second side (26G) of the cylinder housing (26), one or more high-pressure cavities (66A, 66B, 66C) forming at least partially a discharge chamber (66), wherein the compressed refrigerant exits the compression chamber (58) to one or more high-pressure cavities (66A, 66B, 66C) through a hole (90); and, 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 Petition 870250084285,from 09 / 18 / 2025, page. 47 / 161 2 / 10 outer circumference circular, 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) being rotated by the motor (38), the housing (12) including a rear head (24), the rear head (24) positioned adjacent to the second side (26F) of the cylinder housing (26), one or more high-pressure cavities (66A, 66B, 66C) being formed by the cylinder housing (26) and the rear head (24), wherein the cylinder housing (26) includes one or more recesses of the cylinder housing (92A, 92B, 92C) and the rear head. (24) includes one or more recesses of the rear head (94A, 94B, 94C), each of the high-pressure cavities (66A, 66B,66C) consisting of one of the recesses in the cylinder housing (92A, 92B, 92C) and one of the recesses in the rear cylinder head (94A, 94B, 94C).

2. Subassembly of the compression device (88), according to claim 1, characterized in that it further comprises a vane (56) movably coupled to the cylinder housing (26) 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 (58B, 58C) in the discharge volume (66). Petition 870250084285, dated 18 / 09 / 2025, p. 48 / 161 3 / 10 3. Subassembly of the compression device (88), according to claim 4, 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).

4. Subassembly of the compression device (88), according to claim 2, characterized in that the cylinder housing (26) includes a vane groove (76), the vane (56) being positioned slidingly within the vane groove (76).

5. Subassembly of the compression device (88), according to claim 4, characterized in that the vane groove (76) is connected to the discharge volume (66), the vane (56) being inclined to the piston device (50) by the refrigerant within the discharge volume (66).

6. Subassembly of the compression device (88), according to claim 5, the cylinder housing (26) characterized in that it includes an internal suction port coupled between the compression chamber (58) and the intake volume (64) and an internal discharge chamber (66) coupled between the compression chamber (58) and the discharge volume (66), the compression device further including a vane device coupled to the cylinder housing (26) configured to control the release of pressurized refrigerant from the compression chamber (58) through the internal discharge chamber (66).

7. 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), the housing (12) including a cylinder housing (26) having a first side (26F) and a second side (26G), the compression chamber being formed by the cylinder housing (26) and having an open end (58D) Petition 870250084285, dated 09 / 18 / 2025, page. 49 / 161 4 / 10 adjacent to the first side (26F) of the cylinder housing (26), one or more high-pressure cavities formed at least partially within the second side (26G) of the cylinder housing (26), where the compressed refrigerant exits the compression chamber (58) to one or more high-pressure cavities (66A, 66B, 66C) through a hole (90), the housing (12) including a rear head,the rear head positioned adjacent to the second side of the cylinder housing, to one or more high-pressure cavities formed by the cylinder housing and the rear head; a refrigerant inlet port (60) coupled to the housing (12) and configured to introduce refrigerant into the intake volume (64); a refrigerant outlet port (62) coupled to the housing (12) and configured to allow compressed refrigerant to exit the electric compressor (10) from the discharge volume (66) through the hole (90); a motor (38) mounted inside the housing (12); a drive 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 drive 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 by the engine (38), the compression device (18) including a piston device (50) including a cylinder (52) and a rolling piston (54), the cylinder (52B) 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 a surface Petition 870250084285, dated 09 / 18 / 2025, page. 50 / 161 5 / 10 internal (58A) of the compression chamber (58), the rolling piston (54) rotating around the cylinder (52) as the drive shaft (44) and the piston device (50) are rotated by the motor (38), the housing (12) including a rear head (24),the rear cylinder head (24) positioned adjacent to the second side (26F) of the cylinder housing (26), the one or more high-pressure cavities (66A, 66B, 66C) being formed by the cylinder housing (26) and the rear cylinder head (24), wherein the cylinder housing (26) includes one or more recesses of the cylinder housing (92A, 92B, 92C) and the rear cylinder head (24) includes one or more recesses of the rear cylinder head (94A, 94B, 94C), each of the high-pressure cavities (66A, 66B, 66C) being composed of one of the recesses of the cylinder housing (92A, 92B, 92C) and one of the recesses of the rear cylinder head (94A, 94B, 94C).

8. Electric compressor (10), according to claim 7, the compression device (18) characterized in that it includes: 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 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 (58B, 58C) into the discharge volume (66).

9. Electric compressor (10), according to claim 7, characterized in that the housing (12) includes a central housing (20) and a rear head (24), the discharge volume Petition 870250084285, dated 09 / 18 / 2025, page 51 / 161 6 / 10 (66) being formed, at least partially, by the central housing (20), the rear head (24) and the refrigerant outlet port (62).

10. Electric compressor (10), according to claim 9, characterized in that the housing (12) includes an inverter cover (22), the central housing (20) and the inverter cover (20) forming an inverter cavity (28), the electric compressor (10) further including an inverter module (32) mounted within the inverter cavity (28) and configured to convert direct current electrical energy into alternating current electrical energy.

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

12. Electric compressor (10), according to claim 11, characterized in that it further includes first and second ball bearings (46, 48) located within the first and second transmission shaft support members (20A, 20B) configured to receive respective transmission shaft ends (44).

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

14. Electric compressor (10), according to claim 7, characterized in that the cylinder (52) is fitted to the transmission shaft by means of an interference fit.

15. Electric compressor (10), according to claim 7, characterized in that the housing (12) includes a vane groove (76), the vane (56) being positioned in a sliding manner within the vane groove (76).

16. Electric compressor (10), according to claim Petition 870250084285, dated 09 / 18 / 2025, page 52 / 161 7 / 10 15, characterized in that the vane groove (76) is connected to the discharge volume (66), the vane (56) being inclined towards the piston device (50) by the refrigerant inside the discharge volume (66).

17. Electric compressor (10), according to claim 15, the housing (12) characterized in that it includes a cylinder housing (26), the vane groove (76) being located within the cylinder housing (26).

18. Electric compressor (10), according to claim 17, the cylinder housing (26) characterized in that it includes an internal suction port coupled between the compression chamber (58) and the intake volume (64) and an internal discharge chamber (66) 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.

19. Electric compressor (10), according to claim 17, characterized in that the cylinder housing (26) includes a rim (26E) to assist in the proper positioning of the rolling piston (54) in relation to the cylinder housing (26).

20. Electric compressor (10), according to claim 17, characterized in that it further includes an inner cover (84) configured to be positioned within the central housing (20) adjacent to a flange (104C) of the central housing (20).

21. Electric compressor (10), according to claim 20, characterized in that the inner cover (84) forms a third support element for the transmission shaft (84A).

22. Electric compressor (10), according to claim 21, characterized in that it further includes a third ball bearing (86) located within the third support element of the transmission shaft (84A) configured to receive the transmission shaft (44).

23. 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 (20), a cylinder housing (26), a rear head (24) and an inverter cover (20), the central housing (20) and the inverter cover (20) forming an inverter cavity (28), the cylinder housing (26) having a first side (26F), a second side (26G) and a vane groove (76) connected to the discharge volume (66), the compression chamber (58) being formed by the cylinder housing (26) and having an open end (58D) adjacent to the first side (26F) of the cylinder housing (26), one or more high-pressure cavities (66A, 66B, 66C) formed at least partially within the second side (26G) of cylinder housing (26),wherein the compressed refrigerant exits the compression chamber (58) to one or more high-pressure cavities (66A, 66B, 66C) through a hole (90); 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 (20), the rear head (24) and the refrigerant outlet port (62); a motor (38) mounted inside the housing (12); an inverter module (32) mounted inside the cavity of Petition 870250084285, dated 18 / 09 / 2025,pg. 54 / 161 9 / 10 inverter (28) 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, the compression device (18) configured to receive the coolant from the intake volume (64) and compress the coolant as the transmission shaft is rotated by the motor (38), the compression device (18) including: a piston device (50) including a cylinder (52) and a rolling piston (54), the cylinder being eccentrically coupled to the transmission shaft, the cylinder having an inner chamber (52A), the cylinder having a rotational center of mass around the central axis (78), the cylinder having a circular outer circumference, the rolling piston (54) being tubular and concentric with the cylinder,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 as the transmission shaft and 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 refrigerant 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, 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 refrigerant enters one of the Petition 870250084285,from 09 / 18 / 2025, page. 55 / 161 10 / 10 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 (58B, 58C) into the discharge volume (66), the housing (12) including a rear head (44), the rear head (44) positioned adjacent to the second side (26G) of the cylinder housing (26), the one or more high-pressure cavities (66A, 66B, 66C) being formed by the cylinder housing (26) and the rear head (44), wherein the cylinder housing (26) includes one or more recesses of the cylinder housing (92A, 92B, 92C) and the rear head (44) includes one or more recesses of the rear head (94A, 94B, 94C), each of the high-pressure cavities pressure (66A, 66B, 66C) being composed of one of the recesses of the cylinder housing (92A, 92B, 92C) and one of the recesses of the rear head (94A, 94B, 94C). Petition 870250084285, dated 09 / 18 / 2025, p. 56 / 161,

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