Compressor with cooling air and liquid coolant passages in axial heat exchanger arrangement

Abstract

A compressor device includes a motor cooling system that provides a first flow of a first fluid through a housing for cooling the motor. The motor cooling system includes a first fluid flow section at a first axial position. The first fluid flow section extends radially downstream relative to a rotation axis. Furthermore, the device includes a bearing cooling system that provides a second flow of a second fluid through a housing for cooling the bearing. The bearing cooling system includes a second flow section at a second axial position axially spaced from the first axial position. The second flow section extends radially downstream relative to a rotation axis. The first and second flow sections are disposed in a heat exchanger device configured to transfer heat between the second and first fluids.

Description

Technical Field

[0001] This disclosure generally relates to compressors, and more specifically, to compressors having cooling air passages and liquid coolant passages arranged in an axial heat exchanger assembly. Background Technology

[0002] Various systems include compressors for supplying compressed fluids. For example, fuel cell systems typically include a fuel cell compressor for compressing air before it is supplied to the fuel cell stack. This can improve the operating efficiency of the fuel cell system.

[0003] However, conventional compressors can suffer from various drawbacks. For example, some compressors may include fluid-cooled bearings. Cooling one or more bearings can prove challenging, leading to inefficient operation and / or premature wear. Additionally, the cooling systems within conventional compressors can be bulky. Furthermore, these compressors can be expensive and inefficient to manufacture.

[0004] Therefore, it is desirable to provide a compressor with a bearing cooling system that provides improved cooling performance. It is also desirable that the bearing cooling system be highly compact and manufacturable. Other desirable features and characteristics of this disclosure will become apparent from the following detailed description and appended claims, taken in conjunction with the accompanying drawings and this discussion of the background art. Summary of the Invention

[0005] In one embodiment, a compressor assembly is disclosed, comprising a housing, a rotating assembly having a compressor impeller, and a bearing supporting the rotating assembly to rotate about a rotational axis within the housing. The compressor assembly also includes a motor for driving the rotating assembly to rotate about the rotational axis. Furthermore, the compressor assembly includes a motor cooling system that provides a first flow of a first fluid through the housing for cooling the motor. The motor cooling system includes a first fluid flow section at a first axial position. The first fluid flow section extends radially downstream relative to the rotational axis. Additionally, the compressor assembly includes a bearing cooling system that provides a second flow of a second fluid through the housing for cooling the bearing. The bearing cooling system includes a second flow section at a second axial position, axially spaced from the first axial position. The second flow section extends radially downstream relative to the rotational axis. Furthermore, the first and second flow sections are disposed in a heat exchanger assembly configured to transfer heat between the second and first fluids.

[0006] In another embodiment, a method of manufacturing a compressor assembly is disclosed. The method includes housing a rotating assembly of the compressor assembly within a housing of the compressor assembly, wherein the rotating assembly includes a compressor impeller. The method also includes housing a motor of the compressor assembly within the housing, wherein the motor is configured to drive the rotating assembly to rotate about a rotation axis. Furthermore, the method includes using bearings of the compressor assembly to support the rotation of the rotating assembly about the rotation axis within the housing. Additionally, the method includes providing a motor cooling system that provides a first flow of a first fluid through the housing for cooling the motor. The motor cooling system includes a first fluid flow section at a first axial position. The first fluid flow section extends radially downstream relative to the rotation axis. The method also includes providing a bearing cooling system that provides a second flow of a second fluid through the housing for cooling the bearing. The bearing cooling system includes a second flow section at a second axial position, axially spaced from the first axial position. The second flow section extends radially downstream relative to the rotation axis. The method further includes arranging the first and second flow sections in a heat exchanger assembly configured to transfer heat between the second and first fluids.

[0007] In another embodiment, a compressor device includes a housing comprising a compressor housing, a motor housing, and internal components. The compressor housing has an inlet, a diffuser region, and a volute passage. The internal components have a thrust bearing portion and a diffuser portion adjacent to the diffuser region. The compressor device also includes a rotating assembly having a compressor impeller and a bearing supporting the rotating assembly for rotation about a rotational axis within the housing. The compressor device also includes a motor that drives the rotating assembly to rotate about the rotational axis, such that the compressor impeller compresses air flowing from the inlet through the diffuser region and into the volute passage. Furthermore, the compressor device includes a motor cooling system that provides a first liquid coolant flow through the motor housing for cooling the motor and partially through the internal components of the housing. The motor cooling system includes a first fluid flow section at a first axial position. The first fluid flow section extends radially downstream relative to the rotational axis. Additionally, the compressor device includes a bearing cooling system that receives a quantity of air from the volute passage and provides a second airflow through the housing for cooling the bearing. The bearing cooling system includes a second flow section at a second axial position, axially spaced from the first axial position. The second flow section extends radially downstream relative to the axis of rotation. The first and second flow sections are disposed in a heat exchanger device configured to transfer heat from air to a liquid coolant. Attached Figure Description

[0008] The present disclosure will now be described in conjunction with the following accompanying drawings, wherein like reference numerals denote like elements, and wherein:

[0009] Figure 1 This is a schematic diagram of a compressor device according to an exemplary embodiment of the present disclosure, the compressor device being shown as being integrated within a fuel cell system;

[0010] Figure 2 yes Figure 1 A first longitudinal cross-sectional view of the compressor unit;

[0011] Figure 3 yes Figure 1 A second longitudinal section view of the compressor unit;

[0012] Figure 4 It is along Figure 1 Axial cross-sectional view of the compressor unit taken from line 4-4;

[0013] Figure 5 This is an axial cross-sectional view of a compressor assembly according to another exemplary embodiment;

[0014] Figure 6 This is an axial cross-sectional view of a compressor assembly according to another exemplary embodiment; and

[0015] Figure 7 This is an axial cross-sectional view of a compressor device according to another exemplary embodiment of the present disclosure. Detailed Implementation

[0016] The following specific embodiments are merely exemplary in nature and are not intended to limit this disclosure or its application and use. Furthermore, they are not intended to be construed as being limited by the foregoing background information or any theories presented in the following specific embodiments.

[0017] Broadly speaking, the exemplary embodiments disclosed herein include compressor units, such as electric chargers or electric compressors, having a bearing cooling system that provides improved bearing cooling and thus provides improved operational and wear protection for the bearings of the compressor unit. The compressor units are also compact and highly manufacturable.

[0018] The compressor unit may include a housing and a rotating assembly that rotates about a rotational axis within the housing. The compressor unit may include bearings, such as air bearings, that support the rotation of the rotating assembly within the housing. The compressor unit may also include a motor, such as an electric motor, that drives the rotating assembly to rotate about the rotational axis. Furthermore, the compressor unit may include a motor cooling system through which a first coolant fluid flows to cool the motor. The compressor unit may additionally include a bearing cooling system through which a second coolant fluid flows to cool the bearing. The motor cooling system and the bearing cooling system may include corresponding portions disposed together in a heat exchanger assembly within the housing for transferring heat between the first fluid and the second fluid. In some embodiments, one or more flow sections of the motor cooling system may be disposed together with one or more flow sections of the bearing cooling system in the heat exchanger assembly, wherein the flow sections are spaced apart along the axis of the compressor unit. In another embodiment, the flow sections may be disposed relative to the rotational axis between the first flow section and the second flow section of the motor cooling system. The motor cooling system and the bearing cooling system may be configured such that heat is transferred from the second coolant fluid (of the bearing cooling system) to the first coolant fluid (of the motor cooling system) to cool the second coolant fluid. Ultimately, this can improve operational efficiency and provide wear protection for the compressor unit.

[0019] Furthermore, in some embodiments, one or more components may define multiple regions of the compressor assembly. For example, a single component may define at least a portion of the compressor flow passage (e.g., a diffuser region and / or a portion of the volute flow passage), and may also define a portion of the bearings supporting the compressor assembly. Additionally, in some embodiments, the component may define a portion of the bearing cooling system and / or a portion of the motor cooling system. These features may improve manufacturability, reduce the number of components, and / or provide additional advantages.

[0020] First reference Figure 1 A compressor unit 102 is illustrated according to an exemplary embodiment. The compressor unit 102 may be an electric charger or an electric compressor unit. Similarly, as shown, the compressor unit 102 may be incorporated within the fuel cell system 100; however, it will be understood that the compressor unit 102 may be incorporated into another system without departing from the scope of this disclosure.

[0021] In some embodiments, the fuel cell system 100 may be included in a vehicle, such as an automobile, truck, SUV, van, motorcycle, etc. However, it will be understood that the fuel cell system 100 may be configured for different uses without departing from the scope of this disclosure.

[0022] The fuel cell system 100 may include a fuel cell stack 104 comprising multiple fuel cells. Hydrogen may be supplied to the fuel cell stack 104 from a tank 106, and oxygen may be supplied to the fuel cell stack 104 to generate electricity through a known chemical reaction. The fuel cell stack 104 may generate electricity for an electrical device such as an electric motor 105. As described, the fuel cell system 100 may be included in a vehicle; thus, in some embodiments, the electric motor 105 may convert electrical power into mechanical power to drive and rotate the axles of the vehicle (and thus drive and rotate one or more wheels). Oxygen may be supplied to the fuel cell stack 104, at least in part, by a compressor unit 102.

[0023] like Figures 1-3 As shown, the compressor assembly 102 typically includes a rotating assembly 118 and a housing 119 that houses and encloses the rotating assembly 118. The rotating assembly 118 is supported by one or more bearings 121 to rotate about a rotation axis 120 within the housing 119.

[0024] The rotating assembly 118 typically includes an elongated cylindrical shaft 140 having a first end 142 and a second end 144. The rotating assembly 118 may also include a compressor impeller 130 fixed to the first end 142 of the shaft 140. The compressor impeller 130 may include a front side 146 having a plurality of blades 147 and an opposing rear side 148 facing the second end 144. In some embodiments, one or more bearings 121 may be configured as a sliding bearing, an air bearing, and / or an oil-free bearing.

[0025] Compressor assembly 102 may define motor section 112. Motor section 112 may include an electric motor 134 housed within a motor housing 150 of housing 119. Motor 134 may typically include a rotor 136 and a stator 138 of known type. Rotor 136 may be mounted on shaft 140, and stator 138 may surround rotor 136. Rotor 136 and stator 138 may be housed and encapsulated within a thin-walled motor housing 139. Motor housing 139 of motor 134 may be fixed and supported within motor housing 150 with one or more gaps therebetween. First end 142 and second end 144 of shaft 140 may extend out of corresponding sides of motor housing 139 and may be supported within motor housing 150 by bearing 121. Thus, motor 134 is operatively attached to rotating assembly 118 to drive rotating assembly 118 to rotate about axis 120 within housing 119.

[0026] The compressor assembly 102 may further include a compressor section 110. The compressor section 110 may include a compressor impeller 130 housed within a compressor housing 152 of a housing 119. The compressor housing 152 may define a compressor flow path 151 having a tubular inlet 153 centered on an axis 120. The inlet 153 may have various shapes and profiles without departing from the scope of this disclosure. The flow path 151 of the compressor housing 152 may also define at least a portion of a volute passage 154 extending about the axis 120. In some embodiments, the compressor housing 152 may be an integral (single-piece) component manufactured by casting, additive manufacturing, or otherwise. The compressor housing 152 may be fixedly attached to an axial surface 156 of a motor housing 150 and may cover the front side 146 of the compressor impeller 130. The compressor impeller 130 may be driven by a motor 134 to rotate about the axis 120 within the compressor housing 152 of the compressor section 110.

[0027] In some embodiments, the compressor assembly 102 may include an intermediate housing member 158. In some embodiments, the intermediate housing member 158 may define a portion of the housing 119 and a portion of the bearing 121. Therefore, the intermediate housing member 158 may be referred to as a "thrust cover," and will be referred to as such hereinafter. In some embodiments, the thrust cover 158 may be an integral, one-piece, disc-shaped component. The thrust cover 158 may include a first axial surface 160 and a second axial surface 162. The thrust cover 158 may be disposed at and / or between the compressor section 110 and the motor section 112. The first axial surface 160 may face the rear side 148 of the compressor housing 152 and the compressor impeller 130. A first outer radial edge portion 163 may be opposite, engaged, and / or fixedly attached to the compressor housing 152, and a second outer radial edge portion 164 may be opposite, engaged, and / or fixedly attached to the motor housing 150. The second axial surface 162 may be opposite, engaged, and / or fixedly attached to the axial surface 156 of the motor housing 150. Thus, the diffuser portion 170 of the thrust cover 158 cooperates with the compressor housing 152 to define a diffuser region 172 of the compressor unit 102, which is radially outward from the outer radial edge of the compressor impeller 130. Further outward, a first axial surface 160 of the thrust cover 158 cooperatively defines an inlet into the volute passage 154. Similarly, the second axial surface 162 and other portions of the thrust cover 158 define one or more fluid passages, sections, chambers, etc., as will be described in detail below. Furthermore, the thrust cover 158 may include a thrust bearing portion 174 on its inner radial portion for defining and / or supporting the bearing 121. As shown, the thrust bearing portion 174 may be axially received between the annular compressor collar 176 and the thrust disc 178 of the bearing 121.

[0028] During the operation of the compressor unit 102, the inlet airflow (by...) Figure 1 (Indicated by arrow 122) The airflow 122 can flow into inlet 153, and the inlet airflow 122 can be compressed as it flows downstream between compressor impeller 130 and compressor housing 152, through diffuser region 172, and into volute passage 154. The compressed airflow (indicated by arrow 124) can exit volute passage 154 and can be directed to intercooler 128, and then to fuel cell stack 104 to improve the operating efficiency of fuel cell system 100.

[0029] In addition, exhaust streams from fuel cell stack 104 (indicated by arrow 132) can be discharged into the atmosphere, such as... Figure 1 As shown in the diagram. In other words, the exhaust flow 132 can be directed away from the compressor unit 102. Therefore, the rotating assembly 118 can be driven to rotate without a turbine. In other words, in some embodiments, the rotating assembly 118 can be turbine-less and can be driven solely by the electric motor 134. In other embodiments, the exhaust flow 132 can be directed back to the compressor unit 102, for example, to drive the rotation of the turbine impeller included in the rotating assembly 118. This, in turn, can drive the rotation of the compressor impeller 130, for example, to assist the electric motor 134.

[0030] Additionally, the compressor unit 102 may include a motor cooling system 180. Typically, the motor cooling system 180 provides a first flow of a first fluid (e.g., a liquid coolant) through the housing 119 for cooling the motor 134. The motor cooling system 180 may also be directed through the housing 119 for cooling the bearing 121 and surrounding structures, as will be discussed. The motor cooling system 180 may include an inlet 181 and an outlet 182 (both located at...). Figure 1 (Schematally shown in the diagram) and multiple channels, chambers, etc., which form one or more continuous fluid paths connecting inlet 181 and outlet 182.

[0031] like Figure 1 As shown, the motor cooling system 180 may include a coolant jacket 184 defined by the gap between the motor housing 139 and the motor casing 150. The coolant jacket 184 may be subdivided into a portion 186 that commonly surrounds the outer diameter of the motor 134, a first axial end portion 188, and a second axial end portion 189. Figure 3As shown, the motor cooling system 180 may further include a first axial channel 190 that extends generally axially through the motor housing 150 from the outer diameter portion 186 toward the compressor section 110. The first axial channel 190 may be straight and may have a circular (round) cross-section (perpendicular to the flow direction). Moreover, the first axial channel 190 may extend axially at an angle 191 relative to the axis 120 to the axial face 156 of the motor housing 150. The first axial channel 190 may open at the axial face 156, where it fluidly connects to and intersects with the radial flow section 192 of the motor cooling system 180.

[0032] The radial flow section 192 may be at least partially defined by an annular groove 194 in the thrust cap 158. The groove 194 may be defined between the first and second outer radial edge portions 163, 164 of the thrust cap 158. Thus, the groove 194 may extend radially inward from the outer diameter edge of the thrust cap 158. Furthermore, the radial flow section 192 may extend circumferentially about axis 120. The radial flow section 192 may connect with the second axial passage 196 of the motor cooling system 180. Figure 3 Fluid connection. A second axial channel 196 may extend from the axial face 156 and into the motor housing 150, generally axially away from the compressor section 110, to fluidly connect back to the outer diameter portion 186 of the cooling jacket 184. Figure 3 As shown, the second axial channel 196 may be disposed on the side of the axis 120 opposite to the first axial channel 190 (e.g., spaced 180 degrees around the axis 120). Moreover, the second axial channel 196 may be disposed at an angle (e.g., an inverse of the angle 191 of the first axial channel 190).

[0033] Therefore, the motor cooling system 180 may define one or more fluid flow paths for the first coolant (e.g., a liquid coolant) to flow downstream from inlet 181 to outlet 182. During operation, the first fluid may flow from inlet 181 to coolant jacket 184. From there, the first fluid may flow through a first axial channel 190 and into radial flow section 192. There, the fluid may flow circumferentially and radially inward toward axis 120 through thrust cap 158. Moving further downstream, the fluid may flow to a second axial channel 196, return to coolant jacket 184, and then flow to outlet 182.

[0034] Additionally, the compressor unit 102 may include a bearing cooling system 200. Typically, the bearing cooling system 200 provides a second flow of a second fluid (e.g., air or other gaseous coolant) through the housing 119 for cooling the bearing 121. The bearing cooling system 200 may also be directed through the housing 119 to be arranged in a heat exchanger unit together with the motor cooling system 180, as will be discussed.

[0035] The bearing cooling system 200 may include an inlet 202 and an outlet 204. In some embodiments, the inlet 202 and / or outlet 204 may be in fluid communication with the compressor flow path 151. For example, as Figure 1 As shown, inlet 202 may be fluidly connected to compressor flow path 151 (e.g., at volute passage 154) to receive airflow therefrom, and outlet 204 may be fluidly connected to return flow to compressor flow path 151 (e.g., at inlet 153). Furthermore, bearing cooling system 200 may include multiple passages, chambers, etc., forming one or more continuous fluid paths connecting inlet 202 and outlet 204.

[0036] like Figure 2 As shown, inlet 202 may include a pitot tube (“reverse” pitot tube) disposed within and fluidly connected to the volute channel 154. Furthermore, bearing cooling system 200 includes one or more orifices 206 forming a channel extending from axial face 156 and radially inward through motor housing 150.

[0037] The bearing cooling system 200 may also include a flow section 210. In some embodiments, the flow section 210 may be cooperatively defined by a second axial surface 162 of the thrust cap 158 and an axial surface 156 of the motor housing 150. For example, the second axial surface 162 and / or the axial surface 156 may include one or more recesses 212 defined between one or more walls 214. In the illustrated embodiment, for example, both axial surfaces 156 and 162 include corresponding recesses 212 and walls 214 that are axially (i.e., along axis 120) aligned to define various sections of the flow section 210 through the bearing cooling system 200. In other words, as Figure 2 As shown, axial surface 156 may include a first recess 220 axially aligned with a second recess 222 of axial surface 162 to cooperatively define a segment 224 of flow section 210. As shown, multiple segments 224 of flow section 210 may exist defining the flow section 210 between axial surfaces 156 and 162.

[0038] like Figures 4-7 As shown, segments 224 of flow section 210 can be arranged together to form a continuous flow path. As shown, segment 224 can have various arrangement structures without departing from the scope of this disclosure. Figures 4-7 In each embodiment, the flow path through the flow section 210 and the downstream direction of the flow path are indicated by arrow 226. As shown, the flow path 226 may extend radially downstream relative to the rotation axis 120. More specifically, in some embodiments, the flow path 226 may extend radially inward relative to the rotation axis 120 in the downstream direction. Moreover, the flow path 226 of the flow section 210 may extend from one side of the rotation axis 120 to the opposite side of the rotation axis 120, such as... Figures 4-7 As shown in the figure. In some embodiments, the flow path 226 may extend radially and circumferentially about the axis of rotation 120. The flow path 226 may extend arcuately and / or linearly and straightly as it extends in the downstream direction.

[0039] In particular, Figure 4 In one embodiment, the flow path 226 through the flow section 210 includes a plurality of arcuate segments, each including a first arcuate segment 232, a second arcuate segment 234, and a third arcuate segment 236 extending arcuately about the axis 120. The arcuate segments 232, 234, and 236 may each have different radii, and the radius of each arcuate segment may remain substantially constant relative to the axis of rotation 120. The arcuate segments 232, 234, and 236 may be concentric and centered on the axis 120, with the second arcuate segment 234 radially disposed between the first arcuate segment 232 and the third arcuate segment 236. Furthermore, a first circumferential gap 238 may be present in one of the walls 214, and the gap 238 may fluidly connect the first arcuate segment 232 and the second arcuate segment 234. Similarly, a second circumferential gap 240 may exist in another wall 214, and the gap 240 may fluidly connect the second arcuate section 234 and the third arcuate section 236. The flow path 226 may have an input region 228 defined within the first (outer) arcuate section 232, and the flow path 226 may extend downstream along a tortuous path, circumferentially passing through the first arcuate section 232 in the opposite direction, then radially inward through the gap 238 into the second arcuate section 234, then circumferentially passing through the second arcuate section 234 in the opposite direction, then radially inward through the gap 240 into the third arcuate section 236, and finally reaching the output region 230 of the flow section 210.

[0040] exist Figure 5 In another embodiment shown, the flow section 210 may include an arcuate section 242 extending circumferentially and radially inward, spiraling from its input region 228 to its output region 230 toward axis 120. Figure 6In other embodiments shown, the flow section 210 may include a plurality of longitudinal straight sections 244 connected end-to-end to extend from one side of axis 120 to the other, from its input region 228 to its output region 230. Figure 6 As shown, when the flow path 226 extends about the axis 120, the flow path 226 can gradually extend radially inward relative to the axis 120 (i.e., gradually approach the axis 120). Furthermore, in Figure 7 In the illustrated embodiment, the flow section 210 may include a plurality of longitudinally straight segments 246 connected end-to-end to extend from one side of axis 120 to the other and back. As shown, the input region 228 may be on one side and radially positioned on the outer side. The flow path 226 may split from the input region 228 in the opposite direction, turn vertically and extend to the opposite side of axis 120, turn vertically again and extend back to the original side of axis 120. As shown, the flow path 226 may extend radially inward relative to axis 120 (i.e., gradually approach axis 120).

[0041] like Figure 3 As shown, the bearing cooling system 200 may further include a first bearing injection path 250 that fluidly connects the output region 230 to the thrust and / or journal members of the bearing 121. For example, the first bearing injection path 250 may be a channel extending radially inward through an inner diameter portion of the thrust cap 158 to fluidly connect the output region 230 of the flow section 210 to a gap on an axial side of the thrust disc 178. Thus, fluid (air) from the compressor flow path 151 can be supplied through the bearing cooling system 200 to cool the bearing 121. Furthermore, the bearing cooling system 200 may also include a second bearing injection path 251 that fluidly connects the output region 230 to the thrust and / or journal members of the bearing 121. For example, the second bearing injection path 251 may include an orifice extending axially toward the motor 134 to fluidly connect the output region 230 of the flow section 210 to the gap between the motor housing 139 and the motor casing 150. (An annular sealing member 255 may be present, which seals and separates the liquid coolant in the first axial end portion 188 from the air supplied by the second bearing injection path 251.) An axial path 253 may also be present, defined between the shaft 140 and the inner radial lip 254 of the motor housing 150, which supplies air from the second bearing injection path 251 to the other axial side of the thrust disc 178. Air in this region may also flow to the journal element of the bearing 121. Furthermore, the bearing cooling system 200 may include features defining a further downstream flow path.

[0042] Therefore, during operation, the inlet 202 of the bearing cooling system 200 can receive air from the compressor flow path 151. This air can flow downstream through the orifice 206 ( Figure 2 The air then flows into the input region 228 of the flow section 210. The flow can continue radially inward along the flow path 226 of the flow section 210 and can flow to the bearing 121 through the first bearing injection path 250 and the second bearing injection path 251. The air can eventually flow to the outlet 204.

[0043] Export 204 Figure 1 and 2 The diagram is schematically shown. As shown, outlet 204 can be an elongated channel defined through one or more portions of housing 119 and extending back to inlet 153 for fluid connection to compressor flow path 151. In some embodiments, outlet 204 may extend from a region adjacent to a second end 144 of shaft 140, through motor housing 150 and / or compressor housing 152 for fluid connection to inlet 153. A first end outlet branch 260 may also be present. Figure 2 Branch 260 may be a radially extending orifice. Branch 260 may extend through the motor housing 150 at an axial position between the motor 134 and the axial face 156. Branch 260 may intersect a portion of the outlet 204 extending from the second end 144. In this way, the flow from branch 260 may return to the inlet 153. Furthermore, in some embodiments, at least a portion of the outlet 204 may extend along the exterior of the housing 119. Thus, the outlet 204 may allow the second fluid of the bearing cooling system 200 to return to the inlet 153 of the compressor flow path 151, upstream of the compressor impeller 130.

[0044] The bearing cooling system 200 and the motor cooling system 180 may be arranged together in a heat exchanger assembly to facilitate heat transfer between them. For example, the flow section 210 of the bearing cooling system 200 and the axial end portion 188 of the motor cooling system 180 may be positioned at different axial locations along axis 120, and heat may be exchanged between fluids passing axially (i.e., generally along axis 120) through the intermediate portion 270 of the motor housing 150. The flow section 210 and the radial flow section 192 of the motor cooling system 180 may also be positioned at different axial locations along axis 120, and heat may be exchanged between fluids passing axially through the intermediate portion 272 of the thrust cap 158. For example, in some embodiments and / or under some operating conditions, the air in the flow section 210 of the bearing cooling system 200 operates hotter than the liquid coolant in the radial flow section 192 and the axial end portion 188 of the motor cooling system 180. Therefore, the liquid coolant may be a radiator and may receive heat from the air in the flow section 210 during such operation.

[0045] Therefore, the heat exchanger devices of the bearing and motor cooling systems 180, 200 can provide effective cooling for the bearing 121. This ultimately improves the operating efficiency of the compressor unit 102. These features also make the compressor unit 102 robust during its long operating life. Furthermore, due to the above features, the compressor unit 102 can be compact and lightweight. In addition, the compressor unit 102 of this disclosure is highly manufacturable, with a relatively low number of parts and a convenient assembly process.

[0046] While at least one exemplary embodiment has been presented in the foregoing detailed embodiments, it should be understood that numerous variations exist. It should also be understood that one or more exemplary embodiments are merely examples and are not intended to limit the scope, applicability, or construction of this disclosure in any way. Rather, the foregoing detailed embodiments will provide those skilled in the art with a convenient roadmap for implementing exemplary embodiments of this disclosure. It should be understood that various changes can be made to the function and arrangement of the elements described in the exemplary embodiments without departing from the scope of this disclosure as set forth in the appended claims.

Claims

1. A compressor device, comprising: case; A rotating assembly with a compressor impeller; A bearing that supports the rotation of the rotating assembly within the housing about a rotation axis; A motor drives the rotating assembly to rotate about the rotation axis; A motor cooling system that provides a first flow of a first fluid through the housing for cooling the motor, the motor cooling system including a first fluid flow section at a first axial position, the first fluid flow section extending radially in a downstream direction relative to the axis of rotation; A bearing cooling system provides a second flow of a second fluid through the housing for cooling the bearing, the bearing cooling system including a second fluid flow section at a second axial position axially spaced from a first axial position, the second fluid flow section extending radially in a downstream direction relative to the axis of rotation; as well as The first fluid flow section and the second fluid flow section are disposed in a heat exchanger device configured to transfer heat between the second fluid and the first fluid.

2. The compressor device according to claim 1, wherein, The second fluid flow section includes at least one arcuate segment that extends arcuately around the axis of rotation.

3. The compressor device according to claim 2, wherein, The at least one arcuate segment extends radially and circumferentially relative to the axis of rotation.

4. The compressor device according to claim 2, wherein, The at least one arcuate segment extends with a constant radius relative to the axis of rotation.

5. The compressor device according to claim 1, wherein, The second fluid flow section includes a plurality of longitudinal straight sections connected end-to-end to extend from one side of the rotation axis to the opposite side of the rotation axis.

6. The compressor device according to claim 1, wherein, The second fluid flow section extends from one side of the rotation axis to the opposite side of the rotation axis.

7. The compressor device according to claim 1, wherein, The housing includes a compressor housing having a volute channel, and the compressor impeller is configured to compress the flow of the second fluid when the second fluid flows into the volute channel; as well as The bearing cooling system includes an inlet communicating with the volute channel, and the second fluid flow section is located downstream of the inlet.

8. The compressor device according to claim 7, wherein, The compressor housing includes a compressor inlet, wherein the compressor impeller receives the second fluid through the compressor inlet; as well as The bearing cooling system includes an outlet that returns the second fluid to the compressor inlet upstream of the compressor impeller.

9. The compressor assembly of claim 1, further comprising an integral housing member having a thrust bearing portion and a diffuser portion for compressing the second fluid; in, The first fluid flow section is confined within the integral shell member.

10. The compressor device according to claim 9, wherein, The housing includes a motor housing that houses the motor, the motor housing having a first axial surface; The integral shell component includes a second axial surface opposite to the first axial surface; and The first axial surface and the second axial surface cooperate to define at least a portion of the second fluid flow section.

11. The compressor device according to claim 10, wherein, The first axial surface includes at least one first recess, and the second axial surface includes at least one second recess; and The at least one first recess and the at least one second recess cooperate to define at least a portion of the second fluid flow section.

12. The compressor device according to claim 11, wherein, The motor cooling system has a third fluid flow section at a third axial position, which is axially spaced from the first axial position and the second axial position. as well as The second fluid flow section is axially disposed between the first fluid flow section and the third fluid flow section.

13. The compressor device according to claim 1, wherein, The second fluid flow section extends radially inward relative to the axis of rotation along the downstream direction.

14. The compressor device according to claim 1, wherein, The bearing is an air bearing.

15. A compressor device, comprising: The housing includes a compressor housing, a motor housing, and internal components, wherein the compressor housing has an inlet, a diffuser region, and a volute channel, and wherein the internal components have a thrust bearing portion and a diffuser portion adjacent to the diffuser region; A rotating assembly with a compressor impeller; A bearing that supports the rotation of the rotating assembly within the housing about a rotation axis; A motor drives the rotating assembly to rotate about the rotation axis, causing the compressor impeller to compress the air flowing from the inlet through the diffuser region and into the volute passage; A motor cooling system that provides a first liquid coolant flow through the motor housing for cooling the motor and partially through the internal components of the housing, the motor cooling system including a first fluid flow section at a first axial position, the first fluid flow section extending radially in a downstream direction relative to the axis of rotation; A bearing cooling system receives a certain amount of air from the volute channel and provides a second airflow through the housing for cooling the bearing. The bearing cooling system includes a second fluid flow section at a second axial position, which is axially spaced from the first axial position, and the second fluid flow section extends radially in a downstream direction relative to the axis of rotation. as well as The first fluid flow section and the second fluid flow section are disposed in a heat exchanger device configured to transfer heat from the air to the liquid coolant.

16. The compressor device according to claim 15, wherein, The first fluid flow section extends through the internal components of the housing, and the second fluid flow section is defined by the surface of the internal components of the housing.

17. The compressor device according to claim 16, wherein, The motor cooling system has a third fluid flow section at a third axial position within the motor housing, the third axial position being axially spaced from the first axial position and the second axial position; as well as The second fluid flow section is axially disposed between the first fluid flow section and the third fluid flow section.

18. The compressor device according to claim 15, wherein, The second fluid flow section extends radially inward relative to the axis of rotation along the downstream direction.

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