Electric compressor with integrated sensor

Abstract

An electric compressor includes a housing, a refrigerant input port, a refrigerant output port, an inverter section, a motor section, a compression device, and a front cover. The housing defines an inlet volume region and an outlet volume region. The refrigerant input port is coupled to the housing and is configured to introduce the refrigerant to the inlet volume region. The compression device is a scroll compression device configured to be capable of compressing the refrigerant. The refrigerant output port is coupled to the housing and is configured to allow compressed refrigerant to exit the scroll electric compressor from the discharge volume region. The electric compressor includes an integrated pressure and / or temperature sensor.

Description

Technical Field

[0001] The present invention generally relates to an electric compressor, and more particularly to an electric compressor that compresses refrigerant using a scroll compression device. Background Art

[0002] Compressors have long been used in cooling systems. In particular, scroll compressors, in which an orbiting scroll rotates in a circular motion relative to a fixed scroll to compress a refrigerant, have been used in systems designed to provide cooling in a particular area. For example, such scroll compressors have long been used in HVAC systems of motor vehicles such as automobiles to provide air conditioning. Such compressors may also be used in turn in applications requiring heat pumps. Typically, these compressors are driven using the rotational motion from the automobile engine.

[0003] With the advent of battery-driven or electric vehicles and / or hybrid vehicles, where the vehicle may sometimes be powered solely by the battery, such compressors must be driven or powered by the battery rather than the engine. Such compressors may be referred to as electric compressors.

[0004] In addition to cooling the passenger compartment of a motor vehicle, an electric compressor may also 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 while the battery is being charged, particularly during a rapid charge mode, as this would generate heat that could damage or degrade the battery and / or other systems. It may also be used to cool the battery during times when the battery is not being charged or in use, as heat could damage or degrade the battery. Since the electric compressor can operate at various times, including possibly even when the motor vehicle is not in operation, such use obviously requires electrical energy from the battery, thereby reducing the operating time of the battery.

[0005] In use, it may be necessary or advantageous to control the electric compressor using the pressure and / or temperature of the refrigerant at the inlet and / or discharge side of the compressor. In existing designs, the pressure and temperature of the inlet and discharge sides are typically measured by sensors external to the electric compressor, such as located in the refrigerant lines to and from the electric compressor. There may be several disadvantages to using external sensors, such as the use of obsolete sensor technology, additional costs for raw materials and labor, and the need for additional wires or wire harnesses to connect the sensors to the engine control unit (ECU).

[0006] Therefore, it may be advantageous to integrate pressure and / or temperature sensors within the electric compressor. Such integration can be used to decouple pressure and temperature disturbances occurring between the line and the compressor for more direct measurements. It also enables the compressor to use these measurement data for optimization decisions (protection mode, speed changes, etc.). Summary of the invention

[0007] Therefore, it is desirable to provide an electric compressor with high efficiency, low noise and maximum operating life.The present invention is directed to one or more of the above problems or advantages.

[0008] In a first aspect of the present invention, a scroll electric compressor configured to compress refrigerant is provided. The scroll electric compressor includes a housing, an inverter module, a motor, a compression device, an internal housing partition and a pressure sensor. The housing defines an entry volume, a discharge volume and an inverter cavity. The housing has a generally cylindrical shape and a central axis. The inverter module is mounted in the inverter cavity of the housing and is adapted to convert DC power into AC power. The motor is mounted in the housing. The compression device is coupled to the motor, receives the refrigerant from the entry volume, and compresses the refrigerant when the motor rotates. The internal housing partition separates the entry volume from the inverter cavity and includes a passage therethrough for receiving refrigerant from the entry volume. The passage has an entry volume end and an inverter cavity end. The pressure sensor is positioned in the inverter cavity adjacent to the inverter cavity end of the passage for sensing the pressure associated with the refrigerant in the passage.

[0009] In a second aspect of the present invention, a scroll electric compressor configured to compress refrigerant is provided. The scroll electric compressor includes a housing, an inverter module, a motor, a compression device, an internal housing partition, a retainer, a pressure sensor, and a temperature sensor. The housing defines an entry volume, a discharge volume, and an inverter cavity, and has a generally cylindrical shape and a central axis. The housing includes an inverter housing and an inverter back cover. The inverter housing and the inverter back cover define the inverter cavity. The inverter housing includes a retainer hole. The inverter module is mounted in the inverter cavity of the housing and is suitable for converting DC power into AC power. The inverter module includes a printed circuit board. The motor is mounted in the housing. The compression device is coupled to the motor, receives the refrigerant from the entry volume, and compresses the refrigerant when the motor rotates. The internal housing partition separates the entry volume from the inverter cavity and includes a passage therethrough for receiving refrigerant from the entry volume. The passage has an entry volume end and an inverter cavity end. The retainer is located within the retainer aperture and defines at least a portion of the internal housing divider. The passage is located within the retainer. The pressure sensor is mounted to the printed circuit board and positioned within the inverter cavity adjacent to the inverter cavity end of the passage for sensing a pressure associated with the refrigerant within the passage. The temperature sensor is positioned within the entry volume and coupled to the printed circuit board via a plurality of wires.

[0010] In a third aspect of the present invention, a scroll electric compressor configured to compress refrigerant is provided. The scroll electric compressor includes a housing, an inverter module, a motor, a compression device, an internal housing partition, a pressure sensor housing partition, and a pressure sensor. The housing defines an entry volume, an exit volume, and an inverter cavity, and has a generally cylindrical shape and a central axis. The housing includes an inverter housing and an inverter back cover. The inverter housing and the inverter back cover define the inverter cavity. The inverter housing includes a pressure sensor module hole. The inverter module includes a printed circuit board. The inverter module is mounted in the inverter cavity of the housing and is suitable for converting DC power into AC power. The motor is mounted in the housing. The compression device is coupled to the motor for receiving the refrigerant from the entry volume and for compressing the refrigerant when the motor rotates. The internal housing partition separates the entry volume from the inverter cavity and includes a passage therethrough for receiving refrigerant from the entry volume. The passage has an entry volume end and an inverter cavity end. The pressure sensor module housing has a pressure sensor cavity and an entry volume sidewall and is located within the pressure sensor module aperture. The entry volume sidewall defines at least a portion of the internal housing partition. The passage is located within the entry volume sidewall. The pressure sensor module includes a pressure sensor module printed circuit board electrically coupled to the printed circuit board. The pressure sensor is positioned within the pressure sensor cavity and adjacent to the inverter cavity end of the passage for sensing a pressure associated with the refrigerant in the passage. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] These and other features and advantages of the present invention will become more readily understood when considered in conjunction with the following detailed description and accompanying drawings.

[0012] Figure 1A is a first perspective view of a motor-driven compressor according to an embodiment of the present invention.

[0013] Figure 1B yes Figure 1A A partial view of the electric compressor with the central housing removed.

[0014] Figure 2 yes Figure 1A A second perspective view of the electric compressor.

[0015] Figure 3 yes Figure 1A A first side view of an electric compressor.

[0016] Figure 4 yes Figure 1A A second side view of the electric compressor.

[0017] Figure 5 yes Figure 1A Front view of an electric compressor.

[0018] Figure 6 yes Figure 1A Rear view of the electric compressor.

[0019] Figure 7 yes Figure 1A A top view of an electric compressor.

[0020] Figure 8 yes Figure 1A Bottom view of the electric compressor.

[0021] Fig. 9 yes Figure 1A A first cross-sectional view of an electric compressor.

[0022] Fig.10 yes Figure 1A A second cross-sectional view of an electric compressor.

[0023] Fig.11 yes Figure 1A Exploded view of the inverter of the electric compressor.

[0024] Fig.12 is an exploded view of a portion of the electric compressor of FIG. 1 including a motor and a drive shaft.

[0025] Fig.13 yes Figure 1A Exploded view of the compression device of an electric compressor.

[0026] Fig.14A yes Fig.12 A first perspective view of the drive shaft.

[0027] Fig. 14B yes Fig.14A A second perspective view of the drive shaft.

[0028] Fig.15A yes Fig.12 A first perspective view of the rotor and counterweight of an electric motor.

[0029] Fig. 15B yes Fig.15A A second perspective view of the rotor and counterweight.

[0030] Fig.16A 1 is a first perspective view of a portion of the electric compressor of FIG. 1 including an orbiting scroll, a drive pin, and a rocker mechanism.

[0031] Fig. 16B yes Fig.16A A second perspective view of a portion of an electric compressor.

[0032] Fig. 16C yes Fig.13 A perspective view of the plug of a compression device.

[0033] Fig.16D yes Fig. 16C A second perspective view of the stopper.

[0034] Fig.16E yes Fig. 16C A cross-sectional view of the plug.

[0035] Fig.16F yes Fig.11 A perspective view of an inverter housing of an inverter.

[0036] Figure 16G yes Fig.13 A partial enlarged view of the compression device.

[0037] Figures 17A-17J is a diagram of a fixed scroll and an orbiting scroll of a compression device of the electric compressor of FIG. 1 according to one embodiment of the present invention.

[0038] Fig.18A yes Fig.13 A first perspective view of a portion of a compression device including a fixed scroll and an orbiting scroll.

[0039] Fig.18B yes Fig.18A A second perspective view of a portion of a compression device.

[0040] Fig. 18C yes Fig.13 A first perspective view of a fixed scroll of a compression device.

[0041] Fig.18D yes Fig.13 A second perspective view of the fixed scroll of the compression device.

[0042] Fig.18E yes Fig.13 A third perspective view of the fixed scroll of the compression device.

[0043] Fig.18F is with Fig.13 A perspective view of the reed mechanism associated with the compression device.

[0044] Figure 18G yes Fig.13 A cross-sectional view of a fixed scroll of a compression device.

[0045] Fig.19A is a first perspective view of a front cover of an electric compressor forming an oil separator according to one embodiment of the present invention.

[0046] Fig.19B yes Fig.19A A second perspective view of the front cover of FIG.

[0047] Fig.19C yes Fig.19A A cross-sectional view of the front cover.

[0048] Fig. 20A is a partial view of an electric compressor with a cut-away view of a housing and an isolation and restraint system according to one embodiment of the present invention.

[0049] Fig. 20B is a partial view of an isolation and restraint system for use with an electric compressor according to another embodiment of the present invention.

[0050] Fig. 20C is a first perspective view of a thrust body according to an embodiment of the present invention.

[0051] Fig.20D yes Fig. 20C Second perspective view of the thrust body.

[0052] Fig.21 is a functional block diagram of an electric compressor with integrated pressure and temperature sensors according to one embodiment of the present invention.

[0053] Fig.22A is a cross-sectional view of an electric compressor with an integrated pressure and temperature sensor according to a first embodiment of the present invention.

[0054] Fig. 22B yes Fig.22A A cutaway perspective view of an electric compressor.

[0055] Fig. 22C yes Fig.22A A partially exploded view of an electric compressor.

[0056] Fig.22D yes Fig.22A A second cut-away perspective view of the electric compressor.

[0057] Fig.22E yes Fig.22A A perspective view of the inverter housing of an electric compressor.

[0058] Fig.22F yes Fig.22A A first perspective view of a holder of an electric compressor.

[0059] Figure 22G yes Fig.22F A second perspective view of the retainer.

[0060] Fig.22H yes Fig.22F A third perspective view of the retainer.

[0061] Fig.22I yes Fig.22F A cross-sectional view of a retainer.

[0062] Fig.23A is a cross-sectional view of an electric compressor with an integrated pressure sensor according to a second embodiment of the present invention.

[0063] Fig. 23B yes Fig.23A A cutaway perspective view of an electric compressor.

[0064] Fig.23C yes Fig.23A A second cut-away perspective view of the electric compressor.

[0065] Fig.23D yes Fig.23A A third cross-sectional perspective view of an electric compressor.

[0066] Fig.23E yes Fig.23A A partial perspective view of an electric compressor including an inverter housing.

[0067] Fig.23F yes Fig.23E A first perspective view of an inverter housing.

[0068] Figure 23G yes Fig.23E A second perspective view of the inverter housing.

[0069] Fig.24A is a cross-sectional view of an electric compressor with an integrated pressure sensor and an integrated temperature sensor according to a third embodiment of the present invention.

[0070] Fig. 24B yes Fig.24A A cutaway perspective view of an electric compressor.

[0071] Fig.24C yes Fig.24A A partial perspective view of an electric compressor.

[0072] Fig.24D yes Fig.24A A partially exploded view of an electric compressor.

[0073] Fig.24E yes Fig.24A A first perspective view of an inverter housing of an electric compressor.

[0074] Fig.24F yes Fig.24E A second perspective view of the inverter housing.

[0075] Figure 24G yes Fig.24A A first perspective view of a pressure sensor module housing of an electric compressor.

[0076] Fig.24H yes Figure 24G FIG. 1 is a second perspective view of a pressure sensor module housing.

[0077] Fig.25A is a cross-sectional view of an electric compressor with an integrated pressure sensor according to a fourth embodiment of the present invention.

[0078] Fig.25B yes Fig.25A A cutaway perspective view of an electric compressor.

[0079] Fig.25C yes Fig.25A A partial perspective view of an electric compressor.

[0080] Fig.25D yes Fig.25A A first perspective view of an inverter housing of an electric compressor.

[0081] Fig.25E yes Fig.25D A second perspective view of the inverter housing.

[0082] Fig.26A is a perspective view of an electric compressor with an integrated pressure sensor and a passage from a discharge chamber to the pressure sensor according to one embodiment of the present invention.

[0083] Fig.26B yes Fig.26A A cross-sectional view of an electric compressor. DETAILED DESCRIPTION

[0084] refer to Figure 1A-26B, wherein the same reference numerals represent the same or corresponding parts in all the multiple views, an electric compressor 10 having an outer housing 12 is provided. The electric compressor 10 is particularly suitable for use in motor vehicles, such as automotive vehicles (not shown). The electric compressor 10 can be used as a cooling device or as a heat pump (conversely) to heat and / or cool different aspects of the vehicle. For example, the electric compressor 10 can be used as part of a heating, ventilation and air conditioning (HVAC) system in an electric vehicle (not shown) to cool or heat the passenger compartment. In addition, the electric compressor 10 can be used to heat or cool the passenger compartment, onboard electronic equipment and / or a battery for powering the vehicle when the vehicle is not in operation, such as during a charging cycle. The electric compressor 10 can also be used when the vehicle is not in operation and when the battery is not charging to maintain battery life or minimize degradation of battery life. In the illustrated embodiment, the electric compressor 10 has a capacity of 36 cubic centimeters (cc). Capacity refers to the initial volume captured in the compression device when the scroll disk of the compression device is initially closed or contacted (see below). It should be noted that the motor-compressor 10 disclosed herein is not limited to any such capacity, and may be sized or proportioned to meet particular desired specifications.

[0085] In the illustrated embodiment, the electric compressor 10 is a scroll compressor that is used to quickly and efficiently compress refrigerant for use in different systems of motor vehicles, such as electric or hybrid vehicles. The electric compressor 10 includes an inverter section 14, a motor section 16, and a compression device (or compression assembly) 18 housed in an outer housing 12. The outer housing 12 includes an inverter back cover 20, an inverter housing 22, a center housing 24, and a front cover 28 (which may be referred to as a discharge head). The center housing 24 houses the motor section 16 and the compression device 18.

[0086] In a first aspect of the electric compressor 10 of the present disclosure, there is provided an electric compressor 10 having a compression device having a fixed scroll having an improved scroll bottom plate. In a second aspect of the electric compressor 10 of the present disclosure, there is provided an electric compressor 10 having an isolation and restraint system. In a third aspect of the electric compressor 10 of the present disclosure, there is provided an electric compressor 10 having a head design having a reed mechanism with three reeds.

[0087] In one embodiment, the inverter back cover 20, inverter housing 22, center housing 24, and front cover 28 are constructed of machined aluminum. The inverter 10 may be mounted via a plurality of mounting points 120, for example, within the body of a motor vehicle.

[0088] General Arrangement and Operation of the Electric Compressor 10

[0089] The inverter back cover 20 and the inverter housing 22 form an inverter cavity 30. The inverter back cover 20 is mounted to the inverter housing 22 by a plurality of bolts 32. The inverter back cover 20 and the inverter housing 22 are mounted to the central housing 24 by a plurality of bolts 34, which extend through holes 36 in the inverter back cover 20 and holes 38 in the inverter housing 22 and are threaded into threaded holes 40 in the central housing 24. An inverter gasket 42 positioned between the inverter back cover 20 and the inverter housing 22 prevents moisture, dust, and other contaminants from entering the interior cavity 30. A motor gasket 54C is positioned between the inverter housing 22 and the central housing 24 to provide and maintain a refrigerant seal relative to the ambient environment.

[0090] refer to Fig.11 , the inverter module 44 is mounted in the inverter cavity 30 formed by the inverter back cover 20 and the inverter housing 22. The inverter module 44 includes an inverter or controller circuit 46 mounted on a printed circuit board 48, and the printed circuit board 48 is mounted to the inverter housing 22. The inverter circuit 46 converts the direct current (DC) power received from the outside of the electric compressor 10 into three-phase alternating current (AC) power to supply / drive the motor 54 (see below). The inverter circuit 46 also controls the speed of the electric compressor 10. High voltage DC current is supplied to the inverter circuit 46 via the high voltage connector 50. The low voltage DC current for driving the inverter circuit 46 and the control signal for controlling the operation of the inverter circuit 46 and the motor section 16 are supplied via the low voltage connector 52.

[0091] The central housing 24 forms a motor cavity 56. The motor section 16 includes a motor 54 located within the motor cavity 56. The motor cavity 56 is formed by the motor side 22A of the inverter housing 22 and the interior surface 24C of the central housing 22. Fig.12 The motor 54 is a three-phase AC motor having a stator 56. The stator 58 has a generally hollow cylindrical shape with six individual coils (two per phase). The stator 58 is housed within and mounted to the motor housing 24 and remains stationary relative to the motor housing 24.

[0092] The motor 54 includes a rotor 60 located within and centered relative to the stator 58. The rotor 60 has a generally hollow cylindrical shape and is located within the stator 58. The rotor 60 has a plurality of balancing weights 60A, 60B fixed thereto. The balancing weights balance the motor 54 when the motor 54 drives the compression device 18, and the balancing weights may be machined from brass.

[0093] Power is supplied to the motor 54 via a set of terminals 54A which are sealed relative to the motor cavity 56 by O-rings 54B.

[0094] The drive shaft 90 is coupled to the rotor 60 and rotates therewith. In the illustrated embodiment, the drive shaft 90 is press-fitted in the central hole 60C of the rotor 60. The drive shaft 90 has a first end 90A and a second end 90B. The inverter housing 22 includes a first drive shaft support 22B located on the motor side of the inverter housing 22. The first ball bearing 62 located in the hole formed by the first drive shaft support 22B supports the first end of the drive shaft 90 and allows the first end of the drive shaft 90 to rotate. The central housing 24 includes a second drive shaft support 24A. The second ball bearing 64 located in the hole formed by the second drive shaft support 24A allows the second end 90B of the drive shaft 90 to rotate. In the illustrated embodiment, the first and second ball bearings 62, 64 are press-fitted with the holes formed by the first drive shaft support 22B of the inverter housing 22 and the second drive shaft support 24A of the central housing 24.

[0095] As described above, the electric compressor 10 is a scroll compressor. The compression device 18 includes a fixed scroll 26 and an orbiting scroll 66. The orbiting scroll 66 is fixed to the second end of the rotor 60. Rotating under the control of the inverter module 44, the rotor 60 rotates with the drive shaft 90 to drive the orbiting scroll 66 to move.

[0096] refer to Fig.14A , Fig. 14B , Fig.16A and Fig. 16B , the drive shaft 90 has a central axis 90C about which the rotor 60 and the drive shaft 90 rotate. The orbiting scroll 66 moves in an eccentric orbit about the central axis 90C, i.e., moves in a circular motion, while the orientation of the orbiting scroll 66 relative to the fixed scroll 26 remains unchanged. The center of the orbiting scroll 66 is along the orbiting scroll hole (or drive pin location) 90E (see FIG. 1 ) located at the second end 90B of the drive shaft 90. Fig.14A When the drive shaft 90 is rotated by the motor 54, the orbiting scroll 66 follows the movement of the orbiting scroll hole 90E through the drive pin 126 and the drive hub of the rocker mechanism 124 and the bearing 108 as the drive shaft 90 rotates about the central axis 90C.

[0097] Please refer to Figure 1 for details. Figure 2 and Fig. 9 , the mixed refrigerant and oil (at low pressure) enters the electric compressor 10 via the refrigerant input port 68, and leaves the electric compressor 10 (at high pressure) via the refrigerant output port 70 after being compressed by the compression device 18. Fig. 9As shown in the cross-sectional view of FIG. 1 , the refrigerant passes through the electric compressor 10 along a refrigerant path 72. As shown, the refrigerant enters the refrigerant input port 68 and enters an inlet volume 74 formed between the motor side 22A of the inverter housing 22 and the center housing 24 adjacent to the refrigerant input port 68. The refrigerant is then drawn through the motor section 16 and into the compression inlet volume 76 formed between the inner wall of the fixed scroll 26 and the orbiting scroll 66 (defined by the Fig.14A 92 in FIG.

[0098] The fixed scroll 26 is mounted in the central housing 24. Fig. 9 and Fig.13 As shown, the fixed scroll 26 has a fixed scroll base 26A and a fixed scroll wrap 26B extending away from the fixed scroll base 26A toward the orbiting scroll 66. Figures 16A-16B As shown, the orbiting scroll 66 has an orbiting scroll base 66A and an orbiting scroll wrap 66B extending from the orbiting scroll base 66A toward the fixed scroll 26. The wrap 26B, 66B has a trailing end 26C, 66C adjacent the outer edge of the respective scroll 26, 66, and wraps inwardly toward the respective central end 26D, 66D.

[0099] The corresponding tip seals 94 are disposed in grooves (not shown) located at the top surfaces of the fixed scroll 26 and the orbiting scroll 66, respectively. The tip seals 94 are constructed of a flexible material such as polyphenylene sulfide (PPS) plastic. When assembled, the tip seals 94 are pressed against the opposing bases 26A, 66A to provide a seal therebetween. In one embodiment, the grooves are longer than the length of the tip seals 94 to provide room for adjustment / movement along the length of the tip seals 94.

[0100] refer to Figures 17A-17I , the refrigerant enters the compression device 12 from the compression entry volume 76. Now referring to Figures 17A-17I , a cross-sectional view of the top of the fixed scroll 26 and the orbiting scroll 66 is shown.

[0101] As discussed in detail below, the fixed scroll plate 26B and the orbiting scroll plate 66B form compression chambers 80 into which low-pressure or unpressurized (saturated pressure) refrigerant enters from the compression device 12. As the orbiting scroll 66 moves to allow the compression chambers 80 to close and the volume of the compression chambers 80 to decrease to pressurize the refrigerant. At any one time during the cycle, one or more compression chambers 80 are at different stages in the compression cycle. The following description only relates to a set of compression chambers 80 during a complete cycle of the electric compressor 10.

[0102] Refrigerant enters compression chambers 80 formed between orbiting scroll wrap 66B and fixed scroll wrap 26B. Refrigerant is transported toward the center of these chambers during a cycle of compressor 10. During one cycle of motor compressor 10, orbiting scroll 66 is shown orbiting in a circular motion indicated by arrow 78 resulting from the relative position of orbiting scroll 66 with respect to fixed scroll 26.

[0103] exist Fig.17A , the position of the orbiting scroll 66 at the beginning of the cycle is shown. As shown, in this initial position, the tail end 26C, 66C is spaced apart from the other scroll circle 66B, 26B. At this time, the compression chamber 80 is open to the compression entry volume area 76, thereby allowing refrigerant to fill the compression chamber 80 from the compression entry volume area 76 at a low pressure. As the orbiting scroll 66 moves along the path 78, the space between the tail end 26C, 66C and the other scroll 66, 16 is reduced until the compression chamber 80 is relatively close to the compression entry volume area 76 ( Figures 17B-17E As the orbiting scroll 66 continues to move along 78, the volume of the compression chamber 80 is further reduced, thereby Fig.17F -H) in the refrigerant pressurization. Figures 17I-18G As shown, as the orbiting scroll 66 continues to orbit, the two compression chambers 80 combine into a single volume area. The volume area is further reduced until the pressurized refrigerant is discharged from the compression device 18 (see below).

[0104] As discussed below, refrigerant enters chambers formed between the orbiting plate scroll 66 and the walls of the fixed plate scroll 26. During a cycle of the compressor 10, the refrigerant is transported toward the center of these chambers. During one cycle of the electric compressor 10, the orbiting plate scroll 66 is shown orbiting or moving in a circular motion indicated by arrow 78 formed by the relative position of the orbiting plate scroll 66 with respect to the fixed plate scroll 26.

[0105] Returning to FIG. 1 , the front cover 28 forms a discharge volume 82. The discharge volume 82 communicates with the refrigerant outlet port 70. As discussed in more detail below, the pressurized refrigerant leaves the compression device 18 through the central aperture 84A and two side apertures 84B in the fixed scroll 26 (see FIG. 1 ). Fig. 18C and Fig.18E The release of the pressurized refrigerant is controlled by a reed mechanism 86. In the illustrated embodiment, the reed mechanism 86 includes three reeds: a central reed 87A and two side reeds 87B corresponding to the central aperture 84A and the two side apertures 84B (see below).

[0106] like Fig.18D and Fig.18EAs shown, in the illustrated embodiment, the reed mechanism 86 includes a discharge reed 86A and a reed stopper 86B. The discharge reed 86A is made of a flexible material such as steel. Properties 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 stopper 86B is made of a rigid, non-flexible material such as stamped steel. The reed stopper 86B controls or limits the maximum displacement of the discharge reed 86A relative to the fixed scroll 26. Typically, oil is directed backward through the motor section 16 to provide lubrication and cooling for the rotating parts of the electric compressor 10 (e.g., the rotor 60, the drive shaft 90, and all bearings 62, 64, 108). By the rotation of the rotor 60, the oil is pumped upward toward the top of the motor 54. From there, the oil enters the interior of the motor 54 to lubricate the second ball bearing 64, and by the rotational force in the motor section 16, the oil can impact the motor side 22A of the inverter housing 22. The oil is further directed by the motor side 22A into the ball bearings 62 , as discussed further below.

[0107] In the illustrated embodiment, the reed mechanism 86 is held or secured in place via a separate fastener 89. Fig.18E and Fig.18F As shown, the reed mechanism 86 includes a plurality of holes 86C configured to receive associated posts 83A on the fixed scroll 26. Fig.18E As shown, the back side of the fixed scroll 26 includes a baffle 83B around the apertures 84A, 84B that helps regulate the pressure of the refrigerant exiting the compression device 18. In addition, a debris collection groove 83C collects debris near the apertures 84A, 84B to prevent interference with the reed mechanism 86.

[0108] like Fig. 9 As shown, the path of the refrigerant through the electric compressor is indicated by dashed arrow 72 .

[0109] The electric compressor 10 utilizes oil (not shown) to provide lubrication between components of the compression device 18 and the motor 54, such as between the orbiting and fixed scrolls 66, 26, and within the ball bearings 62, 64. The oil mixes with the refrigerant within the compression device 18 and the motor 54 and exits the compression device 18 via the orifice 84. As discussed in more detail below, the oil is separated from the compressed refrigerant within the front cover 28 and returned to the compression device 18.

[0110] The oil separator 96 assists in the separation of the mixed oil and refrigerant. In the illustrated embodiment, the oil separator 96 is integrated into the front cover 28. The front cover 28 also defines an oil reservoir 98 that collects oil from the oil separator 96 before the oil is recirculated through the motor 54 and the motor cavity 56 and the compression device 18. In use, the electric compressor 10 is generally operated as follows. Figure 3-5The orientation shown is such that gravity acts as indicated by arrow 106 and oil collects within oil reservoir 98 .

[0111] refer to Fig. 9 , arrow 88 shows the general path that the oil travels from the bottom of the electric compressor 10 , through the compression device 18 , out of the orifice 84 to the discharge volume 82 of the front cover 28 and back to the compression device 18 .

[0112] In the illustrated embodiment, the front cover 28 is mounted to the center housing 24 by a plurality of bolts 122 that are inserted through corresponding holes therein and threaded into holes in the center housing 24. A fixed head gasket 110 and a rear head gasket 112 are located between the center housing 24 and the fixed scroll 26 to provide a seal.

[0113] The oil separator 96 helps to separate the mixed oil and refrigerant. Typically, the oil separator 96 removes only a portion of the oil in the mixed oil and refrigerant. The separator oil is stored in the oil reservoir and circulated back through the compression device 18, where it is mixed with the refrigerant again.

[0114] In the illustrated embodiment, the oil separator 96 is integrated into the front cover 28. The front cover 28 also defines an oil reservoir 98 that collects oil from the oil separator 96 before the oil is recirculated through the motor 54 and the motor cavity 56 and the compression device 18. In use, the electric compressor 10 is generally Figure 3-5 The orientation shown is such that gravity acts as indicated by arrow 106 and the oil collects in the oil reservoir 98. Fig. 9 , arrow 88 shows the general path of the oil traveling from the bottom of the motor compressor 10, through the compression device 18, out of the orifice 84 to the discharge volume 82 of the front cover 28 and back to the compression device 18. As shown, the oil is drawn upwardly back into the compression device 18 where it is mixed back into or with the refrigerant.

[0115] As described above, refrigerant, actually a mixture of refrigerant and oil, enters the electric compressor 10 via the refrigerant input port 68. The mixture of oil and refrigerant is sucked into the motor section 16, thereby providing lubrication and cooling for the rotating components of the electric compressor 10, such as the rotor 60 and the drive shaft 90. The oil and refrigerant enter the interior of the motor 54 to lubricate the second ball bearing 64, and through the rotational force within the motor section 16, the oil can impact the motor side 22A of the inverter housing 22. The refrigerant and oil are further guided by the motor side 22A into the ball bearing 62, which will be discussed further below.

[0116] Concentric protrusion of rocker mechanism and drive shaft

[0117] Specific reference Figure 13-18B In a first aspect of the electric compressor 10 of the present disclosure, the electric compressor 10 includes a rocker mechanism 124, and the drive shaft 90 has a concentric protrusion 90F. In one embodiment, the concentric protrusion 90F is formed integrally with the drive shaft 90. As discussed below, the rocker mechanism 124 is used to rotate the orbiting scroll 66 around the drive shaft 90 in an eccentric orbit.

[0118] In the prior art, the drive shaft is coupled to the rocker mechanism by a drive pin and a separate eccentric pin, both of which are pressed into the drive shaft. The drive pin is used to rotate the swing link mechanism 124, which moves the orbiting scroll 66 along its eccentric orbit. The drive pin and the eccentric pin are inserted into corresponding holes at the end of the drive shaft. The eccentric pin is used to limit the articulation of the orbiting scroll 66 when the orbiting scroll 66 moves along its eccentric orbit. Neither the drive pin nor the eccentric pin is positioned along the central axis of the drive shaft. When the drive shaft rotates, the drive pin and the eccentric pin are under considerable stress. Therefore, both pins are made of hardened material (such as SAE 52100 bearing steel). In addition, the eccentric pin may require an aluminum bushing or other sliding bearing to prevent damage to the eccentric pin because the eccentric pin is used to limit the radial movement of the eccentric orbit of the orbiting scroll 66. Furthermore, the prior art eccentric pins require additional machining on the surface of the drive shaft 90, including precise holes for the drive pin and the eccentric pin.

[0119] As discussed in more detail below, the eccentric pin of the prior art is replaced with a concentric protrusion 90F.

[0120] In the illustrated embodiment, the scroll electric compressor 10 includes a housing 12, a refrigerant input port 68, a refrigerant output port 70, a drive shaft 90, a concentric protrusion 90F, a motor 54, a compression device 18, a rocker mechanism 124, a drive pin 126, and a ball bearing 108. The housing 12 defines an entry volume 74 and a discharge volume 82. The refrigerant input port 68 is coupled to the housing 12 and is configured to be able to introduce refrigerant into the entry volume 74. The refrigerant output port 70 is coupled to the housing 12 and is configured to be able to allow compressed refrigerant to leave the scroll electric compressor 10 from the discharge volume 82. The drive shaft 90 is located in the housing 12 and has a first and a second end 90A, 90B. The drive shaft 90 defines a central axis 90C and is centered on the central axis 90C.

[0121] The concentric protrusion 90F is located at the second end 90B of the drive shaft 90 and is centered on the central axis 90C. The concentric protrusion 90F extends away from the drive shaft 90 along the central axis 90C. The concentric protrusion 90F includes a drive pin hole 90E. The motor 54 is located within the housing 12 and is coupled to the drive shaft 90 so that the drive shaft 90 can be controlled to rotate around the central axis 90C. The drive pin 126 is located in the drive pin hole 90E and extends away from the drive shaft 90. The drive pin 126 is parallel to the concentric protrusion 90F.

[0122] The concentric pin 90F may also include an undercut structure 90G, and the outer surface may be case hardened or after a coating or bearing surface treatment. The concentric pin 90F may further be machined simultaneously with the drive shaft 90 .

[0123] As described above, the compression device 18 includes a fixed scroll 26 and an orbiting scroll 66. The fixed scroll 26 is located within the housing 12 and is fixed relative to the housing 12. The orbiting scroll 66 is coupled to the drive shaft 90. The orbiting scroll 66 and the fixed scroll 26 form a compression chamber 80 (see above) for receiving refrigerant from the inlet volume 74 and for compressing the refrigerant when the drive shaft 90 rotates about the central axis 90C. The orbiting scroll 66 has an inner circumferential surface 66E.

[0124] The rocker mechanism 124 is coupled to the drive shaft 90 and has first and second holes 124A, 124B for receiving the concentric protrusion 90F and the drive pin 126. The rocker mechanism 124 also includes an outer circumferential surface 124C.

[0125] The ball bearing 108 is positioned between and abuts each of the inner circumferential surface 66E of the orbiting scroll 66 and the outer circumferential surface 124C of the rocker mechanism 124. The drive shaft 90, the drive pin 126, the orbiting scroll 66 and the rocker mechanism 124 are arranged so that the orbiting scroll 66 rotates in an eccentric orbit about the central axis 90C.

[0126] In one embodiment, the concentric protrusion 90F is integrally formed with the drive shaft 90. The drive shaft 90, the concentric protrusion 90F and the rocker mechanism 124 can be machined from steel. The concentric protrusion 90F formed simultaneously with the drive shaft 90 and in the same machining operation further improves manufacturing efficiency.

[0127] Figure 16GThe enlarged view of a portion of the compression device 18 shown in FIG further shows the concentric protrusion 90F. The concentric protrusion 90F interacts with and guides the rocker mechanism 124. The size design and machining of the concentric protrusion 90F have controlled tolerances with the first hole 124A to produce a controlled clearance that limits the radial movement of the eccentric track of the orbiting scroll 66. Unlike the prior art, the concentric protrusion 90F does not require a second pin or any additional machining operations. The concentric protrusion 90F also cooperates with the guide pin 24B and the groove 66I located on the lower surface 66F of the orbiting scroll 66, which will be discussed further below.

[0128] The scroll motor compressor 10 includes an inverter section 14, a motor section 16, and a compression device 18. The motor section 16 includes a motor housing 24 defining a motor cavity 56. The compression section 18 includes a fixed scroll 26. The housing 12 at least partially forms the fixed scroll 26 and the center housing 24.

[0129] Specific reference Fig.13 , Fig. 16B and Figures 18A-18F In the illustrated embodiment, the orbiting scroll 66 has a lower surface 66F. The lower surface 66F has a plurality of annular grooves 66I. The center housing 24 includes a plurality of articulation guide pin holes 155. The guide pins 24B are located within the guide pin holes 155 and extend toward the compression device 18 and into the annular grooves 66I. The guide pins 24B are configured to limit the articulation of the orbiting scroll 66 when the orbiting scroll 66 orbits around the central axis 90C. In one embodiment, each of the annular grooves 66I includes an annular sleeve 118. The thrust plate 142 is located between the fixed scroll 26 and the thrust body 144 (see below) and provides a wear surface therebetween.

[0130] Discharge head design with three-leaf reed mechanism and oil separator

[0131] In the illustrated embodiment, the electric compressor 10 includes a multi-chamber pulsation muffler system 159 and an oil separator 96, which may be located in the discharge volume 82 and integrally formed with the discharge head or front cover 28. As described above, oil is used to provide lubrication between the moving parts of the electric compressor 10. During operation, the oil and the refrigerant mix. The oil separator 96 is necessary to separate the mixed oil and refrigerant before the refrigerant leaves the electric compressor 10.

[0132] Typically, during each cycle, i.e., during the orbiting rotation (or orbiting) of the orbiting scroll 66, refrigerant is released from the compression device 18. In the illustrated embodiment, the refrigerant leaves the compression device 18 through a central aperture 84A and two side apertures 84B in the fixed scroll 26. The release of refrigerant through the apertures 84A, 84B is controlled by a central spring 87A and two side springs 87B, respectively. The multi-chamber pulsation muffler system 159 and the oil separator 96 are described in more detail below.

[0133] Scroll bearing oil port

[0134] The electric compressor 10 may include a scroll bearing oil injection port 138 (see Fig. 16C and Fig.16E As discussed above, the compression device 18 of the present disclosure includes a ball bearing 108. In the illustrated embodiment, the ball bearing 108 is located between the rocker mechanism 124 and the orbiting scroll 66. However, due to the location of the ball bearing 108 within the compression device 18, there may be limited oil delivery to the ball bearing 108, thereby reducing durability. Fig. 9 As shown, oil orifice 138 allows oil (and refrigerant) to travel from discharge chamber 82 to ball bearing 108 along path 73 (which may be referred to as a “nose bleed” path).

[0135] The scroll electric compressor 10 may include a housing 12, a refrigerant input port 68, a refrigerant output port 70, an inverter module 44, a motor 54, a drive shaft 90, and a compression device 18. The housing 12 defines an entry volume 74 and a discharge volume 82. The refrigerant input port 68 is coupled to the housing 12 and is configured to be able to introduce refrigerant into the entry volume 74. The refrigerant output port 70 is coupled to the housing 12 and is configured to be able to allow compressed refrigerant to leave the scroll electric compressor 10 from the discharge volume 82. The inverter module 44 is mounted in the housing 12 and is suitable for converting DC power into AC power. The motor 54 is mounted in the housing 12. The drive shaft 90 is coupled to the motor 54. The compression device 18 receives the refrigerant from the entry volume 74 and compresses the refrigerant when the drive shaft 90 is rotated by the motor 54. The compression device 18 includes the fixed scroll 26 , the orbiting scroll 66 , a rocker mechanism 124 , a ball bearing 108 , and a plug 136 .

[0136] The fixed scroll 26 is located within the housing 12 and is fixed relative to the housing 12. The orbiting scroll 66 is coupled to the drive shaft 90. The orbiting scroll 66 and the fixed scroll 26 form a compression chamber 80 for receiving refrigerant from the inlet volume 74 and compressing the refrigerant when the drive shaft 90 rotates about the central axis 90C. The orbiting scroll 66 has a first side (or lower surface) 66F and a second side (or upper surface) 66G. The orbiting scroll 66 has an oil hole 140 that passes through the orbiting scroll 66 from the first side 66F to the second side 66G.

[0137] The rocker mechanism 124 is coupled to the drive shaft 90. A ball bearing 108 is positioned between and adjacent each of the orbiting scroll 66 and the rocker mechanism 124. The drive shaft 90, the orbiting scroll 66, and the rocker mechanism 124 are arranged so that the orbiting scroll 66 orbits about the central axis 90C in an eccentric orbit.

[0138] like Figures 16B-16E As shown, the end of the orbiting scroll 66 includes a plug 136 and has an oil orifice 138. The plug 136 may be press-fit into an oil hole 140 of the orbiting scroll 66. The oil orifice 138 is configured to allow a controlled flow rate of oil or compressed refrigerant to pass through the orbiting scroll 66 to the ball bearing 108.

[0139] The size of the oil orifice 138 can be adjusted according to the specifications of the electric compressor 10. For example, given the specifications of the electric compressor 10, the diameter of the oil orifice 138 can be selected so as to only allow oil to pass through and limit the pressure equalization between the first side and the second side of the orbiting scroll 66. By using a separate plug 136, rather than machining the oil orifice 138 directly in the orbiting scroll 66, manufacturing efficiencies can be achieved. And the plug 136 can have an oil orifice 138 that is specifically designed and adjusted to allow oil flow and refrigerant flow to increase or decrease according to the diameter and geometry of the oil orifice 138.

[0140] like Figures 16D-16E As shown, in one embodiment, the oil orifice 138 may have a first hole 138A and a second hole 138B, wherein the diameter of the first hole 138A is smaller than the diameter of the second hole 138B. For example, in one application of this embodiment, the first hole 138A has a diameter of about 0.3 mm. The second hole 138B has a diameter greater than the diameter of the first hole 138A and is only used to shorten the length of the first hole 138A. The flow of oil and coolant is designed to provide heat and lubricant to the ball bearing 108, which supports the radial force generated by the eccentric track of the orbiting scroll 66.

[0141] In addition, as discussed above, the orbiting scroll 66 has an orbiting scroll base 66A and an orbiting scroll wrap 66B. The orbiting scroll wrap 66B may have an orbiting scroll tail end 66C and an orbiting scroll center end 66D. As shown, the oil hole 140 is located in the orbiting scroll center end 66D. The plug 136 may be fixed to the oil hole 140 by press fitting or any other method of fixing the plug 136.

[0142] like Fig. 9 As shown, oil orifice 138 allows oil (and refrigerant) to travel from discharge chamber 82 to ball bearing 108 along path 73 (which may be referred to as a “sniffle” path).

[0143] Bearing oil connecting hole

[0144] The electric compressor 10 may include one or more bearing oil communication holes. As discussed above, in the illustrated embodiment, the drive shaft 90 is rotated by the motor 54 to controllably actuate the compression device 18. The drive shaft 90 has a first end 90A and a second end 90B. The housing 10 of the electric compressor 10 forms a first drive shaft support 22B and a second drive shaft support 24A. In the illustrated embodiment, the first drive shaft support 22B is formed in the motor side 22 of the inverter housing 22A, and the second drive shaft support 24A is formed in the central housing 24. The first and second ball bearings 62, 64 are located in the first and second drive shaft supports 22B, 24A.

[0145] The position of the first drive shaft support 22B is not a circulation area of ​​the refrigerant (and oil), which may cause a low lubrication condition and affect the durability of the electric compressor 10.

[0146] like Fig.16F As shown, the first drive support 22B may include one or more holes 22C to allow oil to enter the first drive support 22B and lubricate the first ball bearing 62 .

[0147] In the illustrated embodiment, the scroll electric compressor 10 includes a housing 12 , a first ball bearing 62 , a second ball bearing 64 , a refrigerant input port 68 , a refrigerant output port 70 , an inverter module 44 , a motor 54 , a drive shaft 90 , and a compression device 18 .

[0148] The housing 12 defines an inlet volume 74 and an outlet volume 82, and includes a first drive shaft support 22B and a second drive shaft support 24A. The first ball bearing 62 is located in the first drive shaft support 22B. The first drive shaft support 22B of the housing 12 includes one or more oil communication holes 22C for allowing oil to enter the first ball bearing 62.

[0149] The second ball bearing 64 is located in the second drive shaft support 24A. The refrigerant input port 68 is coupled to the housing 12 and is configured to be able to introduce refrigerant into the entry volume area 74. The refrigerant output port 70 is coupled to the housing 12 and is configured to be able to allow compressed refrigerant to leave the scroll electric compressor 10 from the discharge volume area 82. The inverter module 44 is installed in the housing 12 and is suitable for converting DC power into AC power. The motor 54 is installed in the housing 12. The drive shaft 90 is coupled to the motor 54. The drive shaft 90 has a first end 90A and a second end 90B. The first end 90A of the drive shaft 90 is positioned in the first bearing 62, and the second end 90B of the drive shaft 90 is positioned in the second bearing 64. The compression device 18 receives the refrigerant from the entry volume area 74 and compresses the refrigerant when the drive shaft 90 is rotated by the motor 54. As discussed above, in the illustrated embodiment, the first drive shaft support 22B can be formed on the motor side 22A of the inverter housing 22.

[0150] The rotational motion within the motor section 16 of the compression device 18 creates a flow path and motion for the oil from the oil reservoir 98, such as Fig. 9 As shown by arrows 88 in FIG. 1 , oil flows from the oil reservoir 98 to the motor section 16 and continues to the stator 58 and rotor 60. The rotational motion of the orbiting scroll, rotor and drive shaft pulls the oil upward to mix with the inlet flow of the refrigerant path 72. The rotational motion of the rotor 60 and drive shaft 90 will further push the oil onto the motor side 22A of the inverter housing 22. The surface of the motor side 22A also includes a series of ribs 22D, such as Fig.16F As shown. The ribs 22D provide the rigidity required for supporting the first drive shaft support 22B and allow for ridged backing and pockets to secure the first bearing 62. The inverter housing 22 may also define an oil chamber 22E, where oil collected between the ribs 22D is directed downwardly by gravity and into the oil chamber 22E. The ribs 22D and the inclined surfaces of the motor side 22A cooperate to capture and direct oil splashed or pushed onto the motor side 22A by the rotor 60 or the drive shaft 90 to help increase the oil flowing into the oil chamber 22E and the first bearing 62. Fig.16F Two communication holes 22C are shown, but it should be understood that additional or less than two oil communication holes 22C may be included above and between the ribs 22D on the motor side 22A of the inverter housing 22. For example, in the illustrated embodiment, the diameter of the holes is 3.5 mm, and the motor side 22A includes inclined walls between the ribs 22D. In addition, the motor side 22A may include an outer oil collection area.

[0151] Dome-shaped inverter cover

[0152] The scroll electric compressor 10 of the present invention may include a dome-shaped inverter cover 20. The scroll electric compressor 10 includes a housing 12, a refrigerant input port 68, a refrigerant output port 70, an inverter module 44, a motor 54, a drive shaft 90, a compression device 18 and an inverter cover 20. The housing 12 defines an L entry volume area 74 and a discharge volume area 82. The housing 12 has a generally cylindrical shape and a central axis 90C. The refrigerant input port 68 is coupled to the housing 12 and is configured to be able to introduce refrigerant into the entry volume area 70. The refrigerant output port 70 is coupled to the housing 12 and is configured to be able to allow compressed refrigerant to leave the scroll electric compressor 10 from the discharge volume area 82.

[0153] The inverter module 44 is mounted in the housing 12 and is adapted to convert DC power into AC power. The motor 54 is mounted in the housing 12. The drive shaft 90 is coupled to the motor 54. The compression device 18 is coupled to the drive shaft 90 and is configured to receive refrigerant from the inlet volume and compress the refrigerant when the drive shaft 90 is rotated by the motor 54.

[0154] As discussed above, the compression device 18 may rotate at high speeds (>2000 RPM), which may create undesirable noise, vibration and harshness (NVH) and low durability conditions. In the prior art, the inverter cover 20 is typically flat and tends to amplify and / or concentrate vibrations from the compression device 18 .

[0155] In order to disperse vibrations rather than concentrate vibrations from the compression device 18 , the inverter back cover 20 of the electric scroll compressor 10 of the fifth aspect of the present disclosure is provided with a substantially curved or dome-shaped profile.

[0156] As shown in the figure, specifically in Figure 1, Figure 3 and Figure 6 As shown, the inverter cover 20 is located at one end of the scroll electric compressor 10, and includes a first part 20A and a second part 20B. The first part 20A includes a vertex or vertex part 20C, and is substantially perpendicular to the central axis 90C, and has a vertex 20C and a periphery 20D. The first part 20A has a relatively dome shape, so that the inverter cover 20 has a curved profile from the vertex 20C toward the periphery 20D. The amount and position of the bend can be determined or limited by other considerations, such as outsourcing constraints, that is, the space in which the electric scroll compressor 10 must be installed, and the restrictions imposed by internal components, that is, position and size. The first part 20A may also have to be combined with other features, such as holes for receiving fastening bolts. The second part 20B may include a non-dome-shaped portion of the inverter cover 20, that is, a relatively flat portion located around the periphery of the inverter cover.

[0157] Fixed scroll with improved scroll base

[0158] In a first aspect of the present invention, a scroll electric compressor 10 having an improved fixed scroll bottom plate is configured to compress refrigerant. The scroll electric compressor 10 includes a housing 12, a refrigerant input port 68, a refrigerant output port 70, an inverter module 44, a motor 54, a drive shaft 90, and a compression device 18. The housing 12 defines an inlet volume area 74 and a discharge volume area 82.

[0159] The refrigerant input port 68 is coupled to the housing 12 and is configured to introduce refrigerant into the inlet volume 74. The refrigerant outlet port 70 is coupled to the housing 12 and is configured to allow compressed refrigerant to exit the scroll electric compressor 12 from the discharge volume 82. The inverter module 44 is mounted within the housing 12 and is adapted to convert DC power into AC power. The motor 54 is mounted within the housing 12 and the drive shaft 90 is coupled to the motor 54.

[0160] Generally, as discussed above, the compression device 18 receives refrigerant from the inlet volume 74 and compresses the refrigerant when the drive shaft 90 is rotated by the motor 54 .

[0161] The compression device 18 includes the fixed scroll 26 and the orbiting scroll 66. The compression device 18 defines a front chamber volume area 134. The front chamber volume area 134 (see Fig. 18C and 18G ) supplies refrigerant to chamber 80 at the beginning of the compression cycle. During the compression cycle, when chamber 80 is closed (when rings 26B, 66B are in contact), the pressure in the antechamber volume area 134 drops due to suction, which affects the efficiency of the electric compressor 10. In one aspect of the present invention, it is desirable to increase the volume of the antechamber (to make additional refrigerant available to the compression device 18). This increases the "capacity" of the compression device 18 and smoothes the compression cycle.

[0162] In the illustrated embodiment, the base 26A, 66A of one of the fixed scroll 26 and the orbiting scroll 66 has a cutout 136 to increase the antechamber volume area 134 .

[0163] In the illustrated embodiment, the cutout 136 is located in the floor or base 26A of the fixed scroll 26 .

[0164] As shown, the fixed scroll 26 has a first side 26F defined by the fixed scroll base 26A and a second side 26G defined by the top surface of the fixed scroll wrap 26B. The fixed scroll wrap 26B extends from the fixed scroll base 26A toward the second side 26G of the fixed scroll 26. Fig. 18C and Figure 18GAs shown, the cutout 136 in the bottom plate of the fixed scroll base 26A defines a first portion having a depth d l Greater than the depth d of the second portion 138 2 .

[0165] The size of the first portion or cutout 136 may be limited by a pair of constraints. First, the depth d 1 Sufficient material must be left to maintain the structural integrity of the fixed scroll 26. In addition, to ensure that the chamber 80 is sealed, the geometry of the cutout must be maintained outside the orbital ring 66B to allow the chamber 80 to be as Fig.17D The cutout 136 can provide additional volume within the antechamber 134 to allow the volume of the chamber 80 in 17D to be completely filled. The cutout 136 is limited by the path of the orbiting scroll 66 and by the required bottom plate and wall thickness of the fixed scroll 26. In addition, machining tools and access to the bottom plate of the fixed scroll can provide additional limitations on the size and area outside the sealing area of ​​the orbiting scroll 66.

[0166] Isolation / restraint systems

[0167] In a second aspect of the present invention, an isolation and restraint system 145 may be used to isolate the casing 12 from oscillations and pulsations caused by the orbiting plate scroll 66 .

[0168] In a typical scroll electric compressor, the motor and fixed scroll are directly coupled to the housing. As discussed above, a guide pin directly coupled to the housing can cooperate with an annular groove on the orbiting scroll to limit the articulation of the orbiting scroll as it rotates about the drive shaft. With this type of arrangement, oscillations and pumping pulsations from the orbiting scroll can be transmitted to the housing and, through the mounting, to, for example, the vehicle structure.

[0169] The scroll electric compressor 10 is configured to be able to compress refrigerant. The scroll electric compressor includes a housing 12, a refrigerant input port 68, a refrigerant output port 70, an inverter module 44, a motor 54, a drive shaft 90 and a compression device 18. The housing 12 defines an entry volume area 74 and a discharge volume area 82, and has a generally cylindrical shape. The refrigerant input port 68 is coupled to the housing 12 and is configured to be able to introduce refrigerant into the entry volume area 74. The refrigerant output port 70 is coupled to the housing 12 and is configured to be able to allow compressed refrigerant to leave the scroll electric compressor 12 from the discharge volume area 82. The inverter module 44 is installed in the housing 12 and is suitable for converting DC power into AC power. The motor 54 is installed in the housing 12. The drive shaft 90 is coupled to the motor 54. The compression device 18 is coupled to the drive shaft 90 for receiving refrigerant from the entry volume area 74 and compressing the refrigerant when the drive shaft 90 is rotated by the motor 54.

[0170] As discussed above, the compression device 16 includes a fixed scroll 26 and an orbiting scroll 66. The fixed scroll 26 is located within and fixed relative to the housing 12. The orbiting scroll 66 is coupled to the drive shaft 90. The orbiting scroll 66 and the fixed scroll 26 form a compression chamber 80 for receiving refrigerant from the inlet volume 74 and for compressing the refrigerant when the drive shaft 90 rotates about the central axis 90C.

[0171] The orbiting plate scroll 66 has a lower surface with a plurality of annular grooves 66I (see above).

[0172] Specific reference Fig. 20A The scroll electric compressor 10 further includes a thrust body 144, a plurality of articulation guide pins 24B, a plurality of mounting pins 148, and a plurality of spacer sleeves 146. The thrust body 144 has a plurality of guide pin holes 155. The plurality of mounting pins 148 extend from the guide pin holes 155. The guide pins 24B are configured to limit the articulation of the orbiting scroll 66 when the orbiting scroll 66 orbits around the central axis 90.

[0173] Each mounting pin 148 has a shell end 148A and a thrust body end 148B. The shell end 148A is press-fitted into a corresponding receiving hole in the shell 12. The thrust body end 148B is cylindrical with an outer surface. The multiple isolation sleeves 146 are made of a flexible material, such as a chemically resistant synthetic rubber. One such material is ethylene propylene diene monomer (EPDM). The thrust body end 148B of each mounting pin 148 is enclosed in a corresponding sleeve 146 and received in a corresponding groove 153 located in the thrust body 144. In this way, the only connection between the thrust body 144 and the shell 12 is through the mounting pin 148, which is isolated or insulated by the sleeve 146 to prevent or minimize the transmission of vibrations from the orbiting scroll 66 to the shell 12.

[0174] like Fig. 20A As shown, in one embodiment, the spacer sleeve 146 is integrally formed with a circular washer or ring 147 .

[0175] like Fig. 20B As shown, in another embodiment, the thrust body end 148B of each mounting pin 148 is completely encapsulated by a flexible material using, for example, an overmolding process. The outer surface of the isolation sleeve 146 may be ribbed to aid isolation.

[0176] Electric compressor head design

[0177] In a third aspect of the disclosed motor-driven compressor 10, the front cover 28 design includes an oil separator 96 and a three-leaf reed mechanism 86. As discussed below, the design of the front cover 28, fixed scroll 26, and reed mechanism 86 defines a multi-chamber pulsation muffler system 159.

[0178] In the electric compressor of the prior art, refrigerant is released from the compression device once for each orbiting (or orbiting) of the orbiting scroll. This generates first-order pulsations in the compressed refrigerant released by the electric compressor. The relatively high amplitude and low frequency pulsations generated in the refrigerant may excite other components (internal or external to the electric compressor), which may generate undesirable noise, vibration and harshness (NVH) and low durability conditions.

[0179] refer to Figures 18C-18F and Figures 19A-19B, the refrigerant compressed by the multi-chamber pulsation muffler system 159 is released twice from the compression device 18 during the compression cycle. As discussed in more detail below, the compression device 18 includes two smaller secondary discharge ports, which are arranged into two (adjacent) secondary discharge chambers. The secondary discharge chambers are downstream (in the discharge head) of the pressure drop from the central discharge port. As further described below, the front cover 28 defines a parallel discharge path for refrigerant to leave the compression device 18 to the refrigerant output port 70.

[0180] In the illustrated embodiment, the compressor 10 includes a housing 12, an inverter module 44, a motor 54, and a compression device 18. The housing 12 defines an inlet volume 74 and a discharge volume 82. The housing 12 has a generally cylindrical shape and a central axis 90C. The inverter module 44 is mounted within the housing 12 and is adapted to convert DC power into AC power. The motor 54 is mounted within the housing.

[0181] The compression device 18 is coupled to the motor 54 for receiving the refrigerant from the inlet volume 74 and compressing the refrigerant when the motor 54 rotates.

[0182] The compression device 18 has a central compression device output orifice 84A and first and second side compression device output orifices 84B, 84B, for controllably releasing compressed refrigerant into the discharge volume 82 during a compression cycle. The compression device 18 is configured to release compressed refrigerant into the discharge volume 82 via the first and second side compression device output orifices 84B, 84B, earlier in the compression cycle, before releasing refrigerant via the central discharge orifice 84A.

[0183] Furthermore, the oil separator 96 utilizes two parallel paths between the compression device 18 and the refrigerant output port 70 to reduce the net pressure drop while maintaining the reduction in pulsation.

[0184] In the illustrated embodiment, the oil separator 96 may be located in the discharge volume 82 and integrally formed with the discharge head or front cover 28. As discussed above, oil is used to provide lubrication between the moving parts of the motor compressor 10. During operation, the oil and refrigerant mix. The oil separator 96 is necessary to separate the mixed oil and refrigerant before the refrigerant leaves the motor compressor 10.

[0185] Typically, during each cycle, i.e., during the orbiting rotation (or orbiting) of the orbiting scroll 66, refrigerant is released from the compression device 18. In the illustrated embodiment, the refrigerant leaves the compression device 18 through a central aperture 84A and two side apertures 84B in the fixed scroll 26. The release of the refrigerant through the apertures 84A, 84B is controlled by a central reed 87A and two side reeds 87B, respectively (see below).

[0186] In the illustrated embodiment, the oil separator 96 connects the discharge chambers (see below) through a relatively small passage to create a pressure drop between the chambers. This serves to smooth the flow of compressed refrigerant out of the electric compressor 10. In addition, the oil separator 96 utilizes two parallel paths between the compression device 18 and the refrigerant output port 70 to reduce the net pressure drop while maintaining the reduction in pulsation.

[0187] The oil separator 96 may include a series of walls 98A extending from the inner surface of the front cover 28. As shown, the wall 98A separates the discharge volume 82 into a central discharge chamber 82A, two side discharge chambers 82B, an upper discharge chamber 82C, and an oil reservoir 98. The central discharge chamber 82A is adjacent to the central reed 87A and receives mixed pressurized refrigerant and oil from the compression device 18 through the central orifice 84A via the reed 87A. The side discharge chambers 82B are adjacent to the corresponding side reeds 87B and receive mixed pressurized refrigerant and oil from the compression device 18 through the side orifices 84B via the corresponding reeds 87B. Typically, the pressure of the refrigerant in the chambers is: central discharge chamber 82A>side discharge chamber 82B>upper discharge chamber 82C.

[0188] The central discharge chamber 82A is in fluid communication with two side discharge chambers 82B via respective side passages 100, which are in fluid communication with the upper discharge chamber 82C and the oil reservoir 98 via upper and lower discharge passages 102, 104, respectively. In one embodiment, the side passages 100 extend through the side discharge chambers 82B at an acute angle. The angle of the passages 100 further directs the impact of the discharged refrigerant and oil mixture to further improve separation and increase the amount of oil separated by the oil separator 96. For example, in Fig.19C , the side channel 100 extends through and downwardly into the side discharge chamber 82B at an angle of approximately 45 degrees relative to the inner wall of the central discharge chamber 82A. However, this angle may vary depending on the application or surface contour of the side discharge chamber 82B, and may be increased to approximately 60 degrees in some variations. This angle may vary, but is designed to direct the flow to create turbulence and to direct the flow impingement to create a tortuous path within the side discharge chamber 82B, thereby increasing the separation of the oil into the lower discharge channel 104.

[0189] As shown, the oil separator 96 includes a central discharge chamber 82A and a lower baffle 132. In the illustrated embodiment, the lower baffle 132 is herringbone-shaped (inverted "V" shape) and is located between the central chamber 82 and the oil reservoir 98. The shape of the lower baffle 132 creates a low pressure area directly below. The mixed oil and refrigerant enter the central discharge chamber 82A and are sucked downward by the low pressure area. When the mixed oil and refrigerant contact the upper surface of the lower baffle 132, the oil and refrigerant are separated. The oil falls into the oil reservoir 98.

[0190] The refrigerant may enter the side discharge chamber 82B via the side passage 100 and / or the lower discharge passage 104. The refrigerant may then enter the upper discharge chamber 82C and then exit via the refrigerant output port 70.

[0191] The oil reservoir 98 is located below the pair of side chambers and is connected to the pair of side chambers via corresponding lower discharge passages 104. The oil reservoir is configured to receive oil separated from the compressed refrigerant in the side chambers. Gravity acting on the oil assists in the separation, and the oil falls into the oil reservoir 98 through the lower discharge passage 104 located in the side discharge chamber 82B.

[0192] As discussed above, the reed mechanism 86 includes a discharge reed 86A and a reed retainer 86B defining reeds 87A, 87B. The discharge reed 86A is used to adjust the pressure at which refrigerant is allowed to exit the compression device 18 through the central aperture 84A and the two side apertures 84B, respectively.

[0193] Electric compressor with integrated sensor

[0194] refer to Fig.21 and Figures 22A-26B In one aspect of the present invention, the electric vortex sensor 10 may include one or more integrated sensors 150. Fig.21 , a functional block diagram of an electric compressor 10 with an integrated sensor 150 is shown. In one embodiment, the integrated sensor 150 includes an integrated first pressure sensor 150A. In another embodiment, the integrated sensor 150 may also include an integrated first temperature sensor 150B. As shown, the integrated first pressure sensor 150A and the integrated first temperature sensor 150B are connected to a first filter circuit 152, which is used to adjust and filter the raw sensor data from the integrated sensors 150A, 150B. The filter circuit 152 is coupled to the off-board vehicle electronic control unit 230 and provides the filtered / adjusted sensor signal to the off-board vehicle electronic control unit 230. The first temperature sensor 150B can be connected to the printed circuit board 48 by a pair of wires (see below) passing through the internal housing partition 168.

[0195] In one embodiment, the integrated first pressure sensor 150A and the filter circuit 152 are integrated into a single integrated circuit 156, such as a micro-electromechanical system (MEMS). In the illustrated embodiment, the first integrated pressure sensor 150A and the first integrated temperature sensor 150B are configured to be able to measure or establish the pressure and temperature associated with the entry volume 74, respectively.

[0196] The electric compressor 10 may also include an integrated second pressure sensor 150C and an integrated second temperature sensor 150D. The integrated second pressure and temperature sensors 150C, 150D are connected to a second filter circuit 158. As shown, the integrated second pressure sensor 150C and the second filter circuit 158 ​​may be integrated into a second integrated circuit 160, such as a second MEMS.

[0197] As discussed in more depth below, the first pressure sensor 150A and the first temperature sensor 150B may be configured to sense or establish pressure and temperature, respectively, associated with the inlet volume 74. The second pressure sensor 150C and the second temperature sensor 150D may be configured to sense or establish pressure and temperature, respectively, associated with the outlet volume 82.

[0198] refer to Figures 22A-26B , several embodiments will be discussed below.

[0199] exist Figures 22A-22I In the first embodiment shown, the electric scroll compressor 10 includes an integrated first pressure sensor 150A and an integrated first temperature sensor 150B. As described above, the inverter or controller circuit 46 is mounted to the printed circuit board 48. In an embodiment, as shown in FIG. Figures 22A-22I As shown, the first pressure sensor 150 is mounted directly to the printed circuit board 48 .

[0200] In the second embodiment, if Figures 23A-23G As shown, the electric scroll compressor 10 includes only the first pressure sensor 150A mounted to the printed circuit board 48 .

[0201] As discussed in more detail below, in the third and fourth embodiments, the electric compressor 10 includes a pressure sensor module 162. The pressure sensor module 162 includes a pressure sensor module housing 162A. The pressure sensor module housing 162A defines a pressure sensor cavity 162C. A pressure sensor module (or second) printed circuit board 162B is positioned within the pressure sensor cavity 162C and is electrically coupled to the printed circuit board 48 via an electrical connector 166 for communication between the sensors 150A, 150B. The pressure sensor 150A is mounted directly to the pressure sensor module printed circuit board 162B.

[0202] The first temperature sensor 150B may be connected or wired to the second printed circuit board 162B. The removable pressure sensor module including the first pressure sensor 150A and the first temperature sensor 150B may be preassembled and installed in the electric compressor 10 as a preassembled unit.

[0203] As discussed above, the electric compressor 10 has an outer housing or casing 12. The casing 12 includes an inverter housing 22 and an inverter back cover 20. The inverter housing and the inverter back cover 20 define an inverter cavity 30. An inverter module 44 is located / positioned within the inverter cavity 30. The inverter module 44 includes an inverter or controller circuit 46 at least partially mounted on a printed circuit board 48. As discussed in more detail below, in Figures 22A-22I , Figures 23A-23G , Figures 24A-24H and Figures 25A-25E In each of the embodiments shown in , the electric compressor 10 includes an internal housing partition 168 that separates the entry volume 74 and the inverter chamber 30. The internal housing partition 168 includes a passage 170 therethrough for receiving refrigerant from the entry volume 74. The passage 170 has an entry volume end 170A and an inverter chamber end 170B. The entry volume end 170A is open to the entry volume 74. As discussed in more detail below, the first pressure sensor 150A is positioned within the inverter chamber 30 adjacent to the inverter chamber end 170B of the passage 170 for sensing the pressure associated with the refrigerant within the passage (and therefore with the entry volume 74).

[0204] refer to Figures 26A-26B As shown, the electric scroll compressor 10 includes an integrated second pressure sensor 150C and a second temperature sensor 150D. Figures 26A-26B The embodiment shown in can be used with or adapted for use by any of the first, second, third and fourth embodiments.

[0205] First embodiment of an electric scroll compressor with integrated sensor

[0206] refer to Figures 22A-22I , shows a scroll type electric compressor 10 with an integrated first pressure sensor 150A and an integrated first temperature sensor 150B according to a first embodiment. Fig.22A , Fig. 22B , Fig. 22C and Figures 22F-22I In the first embodiment, the scroll type electric compressor includes a retainer 180. Fig.22EAs best shown, the inverter housing 22 includes a retainer hole 182 for receiving a retainer 180. In the illustrated embodiment, the retainer 180 includes an outer edge 180A located on an outer surface of the retainer 180 and extending away from the retainer 180. The outer edge 180A is positioned between the surface 22A of the inverter housing 22 and the retainer 184, and is held in place by the surface 22A of the inverter housing 22 and the retainer 184. Alternatively or additionally, the retainer 180 can be held in place relative to the inverter housing 22 by an interference fit. The retainer 180 can be made of a non-metallic material, such as plastic. As shown, the retainer 180 defines at least a portion of the internal housing divider 168.

[0207] In the illustrated embodiment, the channel 170 is positioned or located within the retainer 180. The retainer 180 can be cylindrical with a generally circular outer circumference. The retainer 180 can include an upper cavity 180B defined by an upper ridge 180C. As shown, in the illustrated embodiment, the upper ridge 180C surrounds the outer edge of the top of the retainer 180.

[0208] As shown, the pressure sensor 150A and the filter circuit 152 may be implemented in a MEMS integrated circuit or package 156 mounted directly on the printed circuit board 48. The MEMS package 156 includes a pressure sensitive plate 156A located near the inverter cavity end 170B of the channel 170. The pressure sensitive plate 156A measures or senses the pressure associated with the refrigerant entering the volume 74 and the channel 170. As discussed above, the filter circuit 152 conditions the signal from the pressure sensor 150A, which is communicated to the controller circuit 46, which communicates the filtered or conditioned pressure signal to the vehicle electronic control unit 230.

[0209] An adhesive 186 may be used to seal the MEMS package 156 relative to the bottom surface of the upper cavity 180B of the retainer 180. An O-ring 188 located between the outer surface of the retainer 180 and the inner surface of the inverter housing 22 may be provided to seal the upper cavity 180B and the inverter cavity 30 from the access volume 74 adjacent to the bottom surface of the retainer 180 (opposite the upper cavity 180B).

[0210] In the illustrated first embodiment, the electric compressor 10 includes the first temperature sensor 150B. However, it should be noted that the first temperature sensor 150B is optional.

[0211] As shown, the first temperature sensor 150B is positioned so that the entry volume 74 is close to or adjacent to the bottom surface of the holder 180. The first temperature sensor 150B may be a thermistor and may be connected or electrically coupled to the printed circuit board 48 via a pair of wires 150B-1. Figure 22G , Fig.22H and Fig.22I , the pair of wires 150B-1 can pass through the corresponding holes 180D. Each hole 180D includes a first end 180D-1 in the bottom surface of the holder 180 and a second end 180D-2 in the upper cavity 180B.

[0212] The printed circuit board 48 may include one or more daughter boards. For example, the printed circuit board 48 may include a daughter board 48A. The MEMS package 156 may be mounted directly to the daughter board 48A, which is assembled in a complementary recess in the main board 48B of the printed circuit board when the electric compressor 10 is assembled. Suitable electrical contacts on the daughter board 48A and the main board 48B connect the MEMS package 156 to the inverter circuit 46 mounted to the main board 48B. It should also be noted that the stopper 184 may include two or more than two stopper portions 184A, 184B.

[0213] As mentioned above, the first temperature sensor 150B is optional. If the first temperature sensor 150B is not used, the holder 180 does not include the hole 180D.

[0214] Second embodiment of an electric scroll compressor with integrated sensor

[0215] Specific reference Figures 23A-23G , shows an electric compressor 10 according to a second embodiment. In the second embodiment, the inner housing partition 168 is constituted by the inverter housing 22 or is a part of the inverter housing 22. In other words, the electric compressor 10 does not include a separate retainer 180 (of the first embodiment). As with the first embodiment, the MEMS package 156 is directly mounted to the printed circuit board 48. Specific reference Figures 23A-23D , the inverter housing 22 includes a raised housing feature 200 that is lifted from the inverter housing 22 to mate with the MEMS package 156. The raised housing feature 200 is part of the inverter housing 22 and is formed integrally with the inverter housing 22. A channel 220 is located in the raised housing feature 200 extending from the lower surface of the inverter housing 22 toward the inverter cavity 30. The channel 170 includes an entry volume end 170A and an inverter cavity end 170B. The raised housing feature 200 includes an upper surface 200A adjacent to the MEMS package 156 and in contact with the MEMS package 156. The joint between the MEMS package 156 and the upper surface 200A of the raised housing feature 200 can be sealed with an O-ring 202 and / or an adhesive (in the cavity 204).

[0216] In the illustrated embodiment, the passage 170 includes a lower portion 170-1, an intermediate portion 170-2, and an upper portion 170-3. The lower portion 170-1 extends from the lower surface of the inverter housing 22 and forms an entry volume end 170A of the passage. The intermediate portion 170-2 is located at the opposite end of the lower portion 170-1. The upper portion 170-3 is positioned above the intermediate portion 170-2 and forms an inverter cavity end 170B of the passage 170. The lower portion 170-1 has a diameter greater than the diameter of the upper portion 170-3. The intermediate portion 170-2 has a diameter equal to the diameter of the lower portion 170-1 at one end, and has a diameter equal to the diameter of the upper portion 170-3 at the opposite end.

[0217] As shown, the pressure sensor 150A and the filter circuit 152 may be implemented in a MEMS integrated circuit or package 156 mounted directly on the printed circuit board 48. The MEMS package 156 includes a pressure sensitive plate 156A located near the inverter cavity end 170B of the channel 170. The pressure sensitive plate 156A measures or senses the pressure associated with the refrigerant entering the volume 74 and the channel 170. As described above, the filter circuit 152 conditions the signal from the pressure sensor 150A, which is communicated to the controller circuit 46, which communicates the filtered or conditioned pressure signal to the vehicle electronic control unit 230.

[0218] Third embodiment of an electric scroll compressor with integrated sensor

[0219] refer to Figures 24A-24H , shows an electric compressor 10 according to a third embodiment. In the third embodiment, the electric compressor 10 includes a pressure sensor module 162. In one aspect of the present invention, the pressure sensor module 162 may be preassembled and removable from the electric compressor 10.

[0220] In the illustrated embodiment, the pressure sensor module 162 of the third embodiment includes a first pressure sensor 150A and a first temperature sensor 150B. However, it should be noted that the first temperature sensor 150B is optional. In other words, the pressure sensor module 162 of the third embodiment may be provided with only the first pressure sensor 150A. As discussed above, the pressure sensor module 162 includes a pressure sensing housing 162A defining a pressure sensor cavity 162C. The pressure sensing housing 162A may also include an entry volume sidewall 162D. The channel 170 may be formed within the entry volume sidewall 162D.

[0221] As shown, in the illustrated embodiment, the pressure sensor module housing 162A may include a first portion 162A-1 and a second portion 162A-2. The first portion 162A-1 and the second portion 162A-2 may be formed of a non-metallic material such as plastic. An entry volume sidewall 162D may be formed in the first portion 162A-1 of the pressure sensor module housing 162A.

[0222] As shown, the inverter housing 22 may include a groove 22F positioned around the periphery of the pressure sensor module hole 22G for receiving a stopper 164 configured to fix the pressure sensor module 162 within the pressure sensor module hole 22G. The stopper 164 may be, for example, Fig.24D The C-clamp form shown.

[0223] As shown, the pressure sensor module 162 may also include a first temperature sensor 150B. The first temperature sensor 150B may be coupled to the pressure sensor module printed circuit board via a plurality of wires 210. When the scroll electric compressor 10 is assembled, the temperature sensor 150B is located within the entry volume 74. As shown, the pressure sensor module 162 may include one or more holes 212 for receiving the plurality of wires 210.

[0224] Fourth embodiment of an electric scroll compressor with integrated sensor

[0225] refer to Figures 25A-25E , shows an electric compressor 10 according to a fourth embodiment. In the fourth embodiment, the electric compressor 10 includes a pressure sensor module 162. In one aspect of the present invention, the pressure sensor module 162 may be preassembled and removable from the electric compressor 10.

[0226] In the illustrated embodiment, the pressure sensor module 162 of the fourth embodiment includes a first pressure sensor 150A. As discussed above, the pressure sensor module 162 includes a pressure sensing housing 162A defining a pressure sensor cavity 162C. The pressure sensor module circuit board 162B is positioned in the pressure sensor cavity 162C, and the first pressure sensor 150A is mounted thereon. As shown, in the fourth embodiment, the pressure sensor module housing 162A is open at one end (adjacent to the inverter housing 22), and the internal housing partition 168 is formed by the inverter housing 22. The channel 170 is fixed by the internal housing partition 168 in the inverter housing 22. In the illustrated embodiment, the channel 170 includes a lower portion 170-1, a middle portion 170-2, and an upper portion 170-3. The lower portion 170-1 extends from the lower surface of the inverter housing 22 and forms an entry volume end 170A of the channel. The middle portion 170-2 is located at the opposite end of the lower portion 170-1. The upper portion 170-3 is located above the middle portion 170-2 and forms the inverter cavity end 170B of the channel 170. The lower portion 170-1 has a diameter greater than the diameter of the upper portion 170-3. The middle portion 170-2 has a diameter at one end equal to the diameter of the lower portion 170-1 and a diameter at the opposite end equal to the diameter of the upper portion 170-3.

[0227] As discussed above, the channel 170 includes an entry volume end 170A and an inverter cavity end 170B. The upper surface of the inverter housing 22 is adjacent to and in contact with the MEMS package 156. The joint between the MEMS package 156 and the upper surface of the inverter housing 22 can be sealed with an O-ring 202 and / or an adhesive (in the cavity 204).

[0228] Electric scroll compressor with integrated sensor on the discharge side

[0229] In the first, second, third, and fourth embodiments discussed above, the electric compressor 10 may include a first pressure sensor 150A and / or a first temperature sensor 150B for measuring a pressure and / or temperature associated with the inlet volume 74. In certain applications, it may be desirable to establish a pressure and / or temperature associated with the discharge side of the compressor 10, i.e., the discharge volume 82.

[0230] Specific reference Figures 26A-26B, the housing 12 of the electric compressor 10 can define a second channel 220. The second channel 220 has a discharge chamber end 220A and an inverter chamber end 220B. The discharge chamber end 220A is positioned together with the discharge chamber 82. The inverter chamber end 220B is located at / inside or adjacent to the inverter housing 22. Pressurized refrigerant from the discharge volume area 82. The second pressure sensor 150C can be located in the inverter cavity 30 and is configured to be able to establish a pressure associated with the pressurized refrigerant from the discharge volume area 82 in the second channel 220. As Fig.26A As shown, the second passage 220 may be implemented in a rib 222 located along the outer surface of the housing 12. The second temperature sensor 150D, if used / provided, may be located within the exhaust volume 82 and coupled to the printed circuit board 48 via a plurality of wires passing through the second passage 220.

[0231] The foregoing invention has been described in accordance with relevant legal standards, and thus the description is illustrative rather than limiting in nature. Variations and modifications to the disclosed embodiments will be apparent to those skilled in the art and fall within the scope of the invention.

Claims

1. A scroll type electric compressor configured to compress a refrigerant, in, The scroll electric compressor comprises: a housing defining an inlet volume, an exhaust volume, and an inverter cavity, the housing having a generally cylindrical shape and having a central axis; an inverter module mounted in the inverter cavity of the housing and adapted to convert DC power into AC power; a motor mounted in the housing; a compression device coupled to the motor for receiving refrigerant from the inlet volume and compressing the refrigerant when the motor rotates; an internal housing partition separating the entry volume from the inverter cavity, the internal housing partition including a passage through the internal housing partition for receiving refrigerant from the entry volume, the passage having an entry volume end and an inverter cavity end; and, A pressure sensor is positioned within the inverter cavity adjacent an inverter cavity end of the passage for sensing a pressure associated with the refrigerant within the passage.

2. The scroll electric compressor according to claim 1, in, The housing includes an inverter housing and an inverter back cover, the inverter housing and the inverter back cover define the inverter cavity, the inverter module includes a printed circuit board, wherein the pressure sensor is mounted to the printed circuit board.

3. The scroll electric compressor according to claim 2, in, An inner housing partition is formed by the inverter housing.

4. The scroll type electric compressor according to claim 2, in, The scroll electric compressor further includes a retainer, wherein the inverter housing includes a retainer hole for receiving the retainer, wherein the retainer defines at least a portion of the inner housing partition, and the passage is located within the retainer.

5. The scroll type electric compressor according to claim 4, in, The scroll-type electric compressor also includes a temperature sensor positioned within the intake volume and coupled to the printed circuit board via a plurality of wires.

6. The scroll type electric compressor according to claim 5, in, The holder includes at least one aperture for receiving the plurality of wires.

7. The scroll type electric compressor according to claim 1, in, The scroll electric compressor also includes a temperature sensor positioned within the intake volume and coupled to the printed circuit board via a plurality of wires.

8. The scroll type electric compressor according to claim 7, in, The inner housing divider includes at least one aperture for receiving the plurality of wires.

9. The scroll type electric compressor according to claim 1, in, The housing defines a second passage through the housing for receiving pressurized refrigerant from the discharge volume area, the second passage having a discharge volume area end and an inverter cavity end, and the scroll electric compressor also includes a second pressure sensor, which is positioned in the inverter cavity adjacent to the inverter cavity end of the second passage for sensing the pressure associated with the refrigerant in the second passage.

10. The scroll type electric compressor according to claim 9, in, The second channel is located within a rib located along an outer surface of the housing.

11. The scroll type electric compressor according to claim 10, in, The scroll-type electric compressor also includes a temperature sensor positioned within the discharge volume and coupled to the printed circuit board via a plurality of wires.

12. The scroll type electric compressor according to claim 11, in, The plurality of wires pass through the second channel.

13. The scroll type electric compressor according to claim 1, in, The scroll electric compressor further includes a pressure sensor module, which includes: a pressure sensor module housing having a pressure sensor cavity, the pressure sensor module including a pressure sensor module printed circuit board electrically coupled to the printed circuit board and positioned within the pressure sensor cavity; and, A pressure sensor is mounted to the pressure sensor module printed circuit board and is positioned within the pressure sensor cavity adjacent the inverter cavity end of the channel for sensing pressure associated with the refrigerant within the channel.

14. The scroll type electric compressor according to claim 13, in, The housing includes an inverter housing including a pressure sensor module aperture, a pressure sensor module positioned within the pressure sensor module aperture and including an entry volume sidewall defining at least a portion of the inner housing divider, the passageway being located within the entry volume sidewall.

15. The scroll type electric compressor according to claim 14, in, The inverter housing includes a groove positioned around a periphery of the pressure sensor module hole for receiving a stopper configured to stop the pressure sensor module within the pressure sensor module hole.

16. The scroll type electric compressor according to claim 15, in, The pressure sensor module includes a temperature sensor coupled to the pressure sensor module printed circuit board via a plurality of wires, the temperature sensor being located within the intake volume when the scroll electric compressor is assembled.

17. The scroll type electric compressor according to claim 13, in, The pressure sensor module includes at least one aperture for receiving the plurality of wires.

18. The scroll type electric compressor according to claim 14, in, The inner housing partition is formed by the inverter housing.

19. The scroll type electric compressor according to claim 13, in, The housing includes an inverter housing and an inverter back cover, the inverter housing and the inverter back cover define the inverter cavity, the inverter module includes a printed circuit board, wherein the pressure sensor module printed circuit board is electrically coupled to the printed circuit board.

20. The scroll type electric compressor according to claim 19, in, The inverter housing includes a pressure sensor module hole for receiving the pressure sensor module, wherein the inverter housing includes a groove positioned around the periphery of the pressure sensor module hole for receiving a stopper configured to limit the pressure sensor module within the pressure sensor module hole.

21. The scroll type electric compressor according to claim 19, in, The pressure sensor module includes a temperature sensor coupled to the pressure sensor module printed circuit board via a plurality of wires, the temperature sensor being located within the intake volume when the scroll electric compressor is assembled.

22. The scroll type electric compressor according to claim 21, in, The pressure sensor module includes at least one aperture for receiving the plurality of wires.

23. A scroll type electric compressor configured to compress a refrigerant, in, The scroll electric compressor comprises: a housing defining an inlet volume, an outlet volume, and an inverter cavity, the housing having a generally cylindrical shape and having a central axis, the housing including an inverter housing and an inverter back cover, the inverter housing and the inverter back cover defining the inverter cavity, the inverter housing including a retainer hole; an inverter module mounted in the inverter cavity of the housing and adapted to convert DC power into AC power, the inverter module comprising a printed circuit board; a motor mounted in the housing; a compression device coupled to the motor for receiving refrigerant from the inlet volume and compressing the refrigerant when the motor rotates; an inner housing partition separating the entry volume from the inverter cavity, the inner housing partition including a passage through the inner housing partition for receiving refrigerant from the entry volume, the passage having an entry volume end and an inverter cavity end; a retainer positioned within the retainer bore and defining at least a portion of the inner housing divider, the passageway being positioned within the retainer; a pressure sensor mounted to the printed circuit board and positioned within the inverter cavity adjacent to the inverter cavity end of the channel for sensing pressure associated with the refrigerant within the channel; and, A temperature sensor is positioned within the entry volume and coupled to the printed circuit board via a plurality of wires.

24. The scroll type electric compressor according to claim 23, in, The holder includes at least one aperture for receiving the plurality of wires.

25. The scroll type electric compressor according to claim 24, in, The housing defines a second passage through the housing for receiving pressurized refrigerant from the discharge volume area, the second passage having a discharge volume area end and an inverter cavity end, and the scroll electric compressor also includes a second pressure sensor, which is positioned in the inverter cavity adjacent to the inverter cavity end of the second passage for sensing the pressure associated with the refrigerant in the second passage.

26. The scroll type electric compressor according to claim 25, in, The second channel is located within a rib located along an outer surface of the housing.

27. The scroll type electric compressor according to claim 26, in, The scroll-type electric compressor also includes a temperature sensor positioned within the discharge volume and coupled to the printed circuit board via a plurality of wires.

28. The scroll type electric compressor according to claim 27, in, The plurality of wires pass through the second channel.

29. A scroll type electric compressor configured to compress a refrigerant, in, The scroll electric compressor comprises: a housing defining an inlet volume, an outlet volume, and an inverter cavity, the housing having a generally cylindrical shape and having a central axis, the housing including an inverter housing and an inverter back cover, the inverter housing and the inverter back cover defining the inverter cavity; an inverter module including a printed circuit board and mounted in an inverter cavity of the housing, the inverter module being adapted to convert DC power into AC power; a motor mounted in the housing; a compression device coupled to the motor for receiving refrigerant from the inlet volume and compressing the refrigerant when the motor rotates; an inner housing partition separating the entry volume from the inverter cavity, the inner housing partition including a passage through the inner housing partition for receiving refrigerant from the entry volume, the passage having an entry volume end and an inverter cavity end; a pressure sensor module housing having a pressure sensor cavity, the pressure sensor module including a pressure sensor module printed circuit board electrically coupled to the printed circuit board and positioned within the pressure sensor cavity; A pressure sensor is mounted to the pressure sensor module printed circuit board and is positioned within the pressure sensor cavity adjacent the inverter cavity end of the channel for sensing pressure associated with the refrigerant within the channel.

30. The scroll type electric compressor according to claim 29, in, The inverter housing includes a pressure sensor module aperture within which the pressure sensor module is positioned and includes an entry volume sidewall defining at least a portion of the inner housing divider, the passageway being located within the entry volume sidewall.

31. The scroll type electric compressor according to claim 30, in, The inverter housing includes a groove positioned around a periphery of the pressure sensor module hole for receiving a stopper configured to stop the pressure sensor module within the pressure sensor module hole.

32. The scroll type electric compressor according to claim 31, in, The pressure sensor module includes a temperature sensor coupled to the pressure sensor module printed circuit board via a plurality of wires, the temperature sensor being located within the intake volume when the scroll electric compressor is assembled.

33. The scroll type electric compressor according to claim 32, in, The pressure sensor module includes at least one aperture for receiving the plurality of wires.

34. The scroll type electric compressor according to claim 29, in, The inner housing partition is formed by the inverter housing.

35. The scroll type electric compressor according to claim 29, in, The housing defines a second passage through the housing for receiving pressurized refrigerant from the discharge volume area, the second passage having a discharge volume area end and an inverter cavity end, and the scroll electric compressor also includes a second pressure sensor, which is positioned in the inverter cavity adjacent to the inverter cavity end of the second passage for sensing the pressure associated with the refrigerant in the second passage.

36. The scroll type electric compressor according to claim 35, in, The second channel is located within a rib located along an outer surface of the housing.

37. The scroll type electric compressor according to claim 36, in, The scroll-type electric compressor also includes a temperature sensor positioned within the discharge volume and coupled to the printed circuit board via a plurality of wires.

38. The scroll type electric compressor according to claim 37, in, The plurality of wires pass through the second channel.

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