Electric compressor having compression device with fixed scroll and orbiting scroll comprising improved scroll base plate

Abstract

An electric compressor includes a housing, a refrigerant inlet port, a refrigerant outlet port, an inverter portion, a motor portion, a compression device, and a front cover. The shell defines an air inlet volume area and an exhaust volume area. The refrigerant inlet port is coupled to the housing and configured to introduce refrigerant into an intake volume region. The compression device is a scroll compression device configured to compress a refrigerant. The refrigerant outlet port is coupled to the housing and is configured to allow compressed refrigerant to exit the scroll electric compressor from an exhaust volume region.

Description

Technical Field

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

[0002] Compressors have long been used in cooling systems. In particular, scroll compressors have been used in systems designed to provide cooling in a specific area, in which an orbiting scroll rotates in a circular motion relative to a fixed scroll to compress a refrigerant.

[0003] For example, such scroll compressors have long been used in HVAC systems of motor vehicles (e.g., automobiles) to provide air conditioning. Such compressors can also be used in applications requiring heat pumps. Typically, these compressors are driven by the rotational motion from the automobile engine.

[0004] With the advent of battery powered or electric vehicles and / or hybrid vehicles, where the vehicle may at times be powered only 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.

[0005] 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, when the battery is being charged, especially in a fast charging mode, it may be necessary to heat or cool the electronic systems and the battery or battery compartment, as this generates heat that may damage or degrade the performance of the battery and / or other systems. It may also be used to cool the battery when the battery is not being charged or used, as heat may damage or degrade the performance of the battery. Since the electric compressor may be operated at various times, even when the motor vehicle is not in operation, such use obviously requires electrical energy from the battery, thereby shortening the operating time of the battery.

[0006] Additionally, electric compressors may run at very high speeds, for example, 2,000 RPM (or higher). Such high speeds may generate undesirable noise.

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

[0008] In a first embodiment of the present invention, a scroll electric compressor configured to compress refrigerant is provided. The scroll electric compressor includes a housing, a refrigerant inlet port, a refrigerant outlet port, an inverter module, a motor, a drive shaft, and a compression device. The housing defines an intake volume area and an exhaust volume area. The refrigerant inlet port is coupled to the housing and configured to introduce refrigerant into the intake volume area. The refrigerant outlet port is coupled to the housing and configured to allow compressed refrigerant to leave the scroll electric compressor from the exhaust volume area. The inverter module is mounted inside the housing and is suitable for converting direct current into alternating current. The motor is mounted in the housing and the drive shaft is coupled to the motor.

[0009] The compression device receives refrigerant from the intake volume and compresses the refrigerant when the drive shaft is rotated by the motor. The compression device includes a fixed scroll and an orbiting scroll.

[0010] The fixed scroll has a first side and a second side of the fixed scroll, is located in the housing and fixed relative to the housing, the orbiting scroll has a first side and a second side of the orbiting scroll, the fixed scroll includes a fixed scroll base located on the first side of the fixed scroll, and a fixed scroll wrap extending from the fixed scroll base to the second side of the fixed scroll. The orbiting scroll includes an orbiting scroll base located on the first side of the orbiting scroll, and an orbiting scroll wrap extending from the orbiting scroll base to the second side of the orbiting scroll.

[0011] The rotating scroll is connected to the drive shaft. The rotating scroll and the fixed scroll form a compression chamber for receiving refrigerant from the intake volume and compressing the refrigerant when the drive shaft rotates about the central axis. One of the fixed scroll base and the rotating scroll base has a first portion and a second portion, wherein the depth of the first portion is greater than the depth of the second portion.

[0012] In a second embodiment of the present invention, a scroll electric compressor having a central axis and configured to compress a refrigerant is provided. The scroll compressor includes a housing, a refrigerant inlet port, a refrigerant outlet port, an inverter portion, a motor portion, and a compression portion. The housing defines an intake volume and an exhaust volume. The refrigerant inlet port is coupled to the housing and configured to introduce refrigerant into the intake volume. The refrigerant outlet port is coupled to the housing and configured to allow compressed refrigerant to leave the scroll electric compressor from the exhaust volume.

[0013] The inverter part includes an inverter housing, an inverter back cover and an inverter module. The inverter back cover is connected to the inverter housing and forms an inverter cavity. The inverter module is installed in the inverter cavity and is suitable for converting direct current into alternating current.

[0014] The motor portion includes a drive shaft located in the housing, the drive shaft having a first end and a second end and defining a central axis. The motor is located in the housing to controllably rotate the drive shaft about the central axis.

[0015] The compression device receives refrigerant from the intake volume and compresses the refrigerant when the drive shaft is rotated by the motor. The compression device includes a fixed scroll and an orbiting scroll.

[0016] The fixed scroll has a first side and a second side of the fixed scroll and is located in the housing and fixed relative to the housing. The orbiting scroll has a first side and a second side of the orbiting scroll. The fixed scroll includes a fixed scroll base located on the first side of the fixed scroll and a fixed scroll wrap extending from the fixed scroll base to the second side of the fixed scroll. The orbiting scroll includes an orbiting scroll base located on the first side of the orbiting scroll and an orbiting scroll wrap extending from the orbiting scroll base to the second side of the orbiting scroll.

[0017] The orbiting scroll is coupled to the drive shaft. The orbiting scroll and the fixed scroll form a compression chamber for receiving refrigerant from the intake volume and compressing the refrigerant when the drive shaft rotates about the central axis. One of the fixed scroll base and the orbiting scroll base has a first portion and a second portion, wherein the depth of the first portion is greater than the depth of the second portion.

[0018] In a third embodiment of the present invention, a compression device for use with a scroll electric compressor configured to compress refrigerant is provided. The scroll electric compressor includes a housing, a refrigerant inlet port, a refrigerant outlet port, an inverter module, a motor, and a drive shaft. The housing defines an intake volume and an exhaust volume. The refrigerant inlet port is coupled to the housing and configured to introduce refrigerant into the intake volume. The refrigerant outlet port is coupled to the housing and configured to allow compressed refrigerant to leave the scroll electric compressor from the exhaust volume. The inverter module is mounted in the housing and is suitable for converting direct current to alternating current. The motor is mounted in the housing. The drive shaft is coupled to the motor. The compression device receives refrigerant from the intake volume and compresses the refrigerant when the drive shaft is rotated by the motor.

[0019] The compression device includes a fixed scroll having a first side and a second side and being located in a housing and fixed relative to the housing. The fixed scroll includes a fixed scroll base located on the first side of the fixed scroll, and a fixed scroll wrap extending from the fixed scroll base to the second side of the fixed scroll. The rotating scroll has a first side and a second side of the rotating scroll, and includes a rotating scroll base located on the first side of the rotating scroll, and a rotating scroll wrap extending from the rotating scroll base to the second side of the rotating scroll. The rotating scroll is coupled to a drive shaft. The rotating scroll and the fixed scroll form a compression chamber for receiving refrigerant from an intake volume and compressing the refrigerant when the drive shaft rotates about a central axis. One of the fixed scroll base and the rotating scroll base has a first portion and a second portion, wherein the depth of the first portion is greater than the depth of the second portion. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] BRIEF DESCRIPTION OF THE DRAWINGS

[0021] These and other features and advantages of the present invention will become more readily understood with reference to the following detailed description and accompanying drawings.

[0022] Figure 1A is a first perspective view of an electric compressor according to an embodiment of the present invention.

[0023] Figure 1B yes Figure 1A A partial view of an electric compressor with the center housing removed.

[0024] Figure 2 yes Figure 1A A second perspective view of an electric compressor.

[0025] Figure 3 yes Figure 1A A first side view of an electric compressor.

[0026] Figure 4 yes Figure 1A A second side view of the electric compressor.

[0027] Figure 5 yes Figure 1A Front view of the electric compressor.

[0028] Figure 6 yes Figure 1A Rear view of the electric compressor.

[0029] Figure 7 yes Figure 1A A top view of an electric compressor.

[0030] Figure 8 yes Figure 1A Bottom view of the electric compressor.

[0031] Fig. 9 yes Figure 1A A first cross-sectional view of an electric compressor.

[0032] Fig.10 yes Figure 1A A second cross-sectional view of an electric compressor.

[0033] Fig.11 yes Figure 1A Exploded view of the inverter of an electric compressor.

[0034] Fig.12 is a partial exploded view of the electric compressor of FIG. 1 , including a motor and a drive shaft.

[0035] Fig.13 yes Figure 1A Exploded view of the compression device of an electric compressor.

[0036] Fig.14A yes Fig.12 A first perspective view of the drive shaft.

[0037] Fig. 14B yes Fig.14A A second perspective view of the drive shaft.

[0038] Fig.15A yes Fig.12 A first perspective view of the rotor and counterweight of an electric motor.

[0039] Fig. 15B yes Fig.15A A second perspective view of the rotor and counterweight.

[0040] Fig.16A is a partial first perspective view of the electric compressor of FIG. 1 , including an orbiting scroll, a drive pin and a rocker mechanism.

[0041] Fig. 16B yes Fig.16A A second perspective view of a portion of an electric compressor.

[0042] Fig. 16C yes Fig.13 A perspective view of the compression device insert.

[0043] Fig.16D yes Fig. 16C A second perspective view of the plugin.

[0044] Fig.16E yes Fig. 16C A cross-sectional view of the plug-in.

[0045] Fig.16F yes Fig.11 A perspective view of an inverter housing of an inverter.

[0046] Figure 16G yes Fig.13 A partial expanded view of the compression device.

[0047] Figures 17A-17J FIG. 1 is a diagram of a fixed scroll and an orbiting scroll of a compression device of the electric compressor of FIG. 1 according to an embodiment of the present invention.

[0048] Fig.18A yes Fig.13 A partial first perspective view of a compression device including a fixed scroll and an orbiting scroll.

[0049] Fig.18B yes Fig.18A A partial second perspective view of the compression device.

[0050] Fig.18C yes Fig.13 A first perspective view of a fixed scroll of a compression device.

[0051] Fig.18D yes Fig.13 A second perspective view of the fixed scroll of the compression device.

[0052] Fig.18E yes Fig.13 A third perspective view of the fixed scroll of the compression device.

[0053] Fig.18F is with Fig.13 A perspective view of the reed mechanism associated with the compression device.

[0054] Figure 18G yes Fig.13 A cross-sectional view of a fixed scroll of a compression device.

[0055] Fig.19A is a first perspective view of a front cover of an electric compressor forming an oil separator according to an embodiment of the present invention.

[0056] Fig.19B yes Fig.19A A second perspective view of the front cover of FIG.

[0057] Fig.19C yes Fig.19A A cross-sectional view of the front cover.

[0058] Fig. 20A is a partial view of an electric compressor according to an embodiment of the present invention, showing a cross-sectional view of the housing and the isolation and restraint system.

[0059] 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.

[0060] Fig. 20C is a first perspective view of a thrust body according to an embodiment of the present invention.

[0061] Fig.20D yes Fig. 20C Second perspective view of the thrust body. DETAILED DESCRIPTION

[0062] See also Figure 1A-20D , wherein the same numerals in the multiple views represent the same or corresponding parts, an electric compressor 10 having a housing 12 is provided. The electric compressor 10 is particularly suitable for use in motor vehicles, such as automobiles (not shown). The electric compressor 10 can be used as a cooling device or a heat pump (reverse) 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. Additionally, 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 running (e.g., during a charging cycle). The electric compressor 10 can also be used when the vehicle is not running and the battery is not charged to maintain or minimize the decay of battery life. In the illustrated embodiment, the capacity of the electric compressor 10 is 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 electric compressor 10 disclosed herein is not limited to any such volume and can be sized or scaled to meet the specifications of specific requirements.

[0063] In the illustrated embodiment, the electric compressor 10 is a scroll compressor for quickly and efficiently compressing refrigerant for use in different systems of a motor vehicle, such as an electric or hybrid vehicle. The electric compressor includes an inverter portion 14, a motor portion 16, and a compression device (or compression assembly) 18 contained within a housing 12. The housing 12 includes an inverter rear 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 portion 16 and the compression device 28.

[0064] In a first aspect of the electric compressor 10 of the present disclosure, an electric compressor 10 having a compression device with a fixed scroll having an improved scroll base is provided. In a second aspect of the electric compressor 10 of the present disclosure, an electric compressor 10 with an isolation and restraint system is provided. In a third aspect of the electric compressor 10 of the present disclosure, an electric compressor 10 having a head design structure with a reed mechanism with three reeds is provided.

[0065] In one embodiment, the inverter back cover 20, the inverter housing 22, the center housing 24, and the front cover 28 are made of machined aluminum. The inverter 10 may be mounted via a plurality of mounting points 120 within the body of, for example, a motor vehicle.

[0066] General Arrangement and Operation of Electric Compressor 10

[0067] 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 center housing 24 by a plurality of bolts 34, which extend through ports 36 in the inverter back cover 20 and ports 38 in the inverter housing 22 and thread into threaded ports 40 in the center housing 24. An inverter gasket 42 is located between the inverter back cover 20 and the inverter housing 22 to prevent moisture, dust and other contaminants from entering the interior cavity 30. A motor gasket 54A is located between the inverter housing 22 and the center housing 24 to provide and maintain a refrigerant seal with the environment.

[0068] See also 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 circuit 46 mounted on a printed circuit board 48, and the printed circuit board is mounted on 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 power / supply the motor 54 (see below). The inverter circuit 46 also controls the speed of the electric compressor 10. High-voltage direct current is supplied to the inverter circuit 46 via the high-voltage connector 50. The low-voltage direct current that drives the inverter circuit 46 and the control signal that controls the operation of the inverter circuit 46 and the motor part 16 are provided via the low-voltage connector 52.

[0069] The center housing 24 forms a motor cavity 56. The motor portion 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 inner surface 24A of the center housing 22. Fig.12 The motor 54 is a three-phase AC motor having a stator 56. The stator 56 has a generally hollow cylindrical shape and six individual windings (two per phase). The stator 56 is contained within and mounted to the motor housing 22 and remains stationary relative to the motor housing 22.

[0070] 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 56. The rotor 60 has a plurality of balancing weights 60A, 60B fixed thereto. When the motor 54 drives the compression device 18, the balancing weights balance the motor 54 and can be machined from brass.

[0071] Electrical power is supplied to the motor 54 via a set of terminals 54A which are sealed to the motor cavity 56 by O-rings 54B.

[0072] The drive shaft 90 is coupled to the rotor 60 and rotates therewith. In the illustrated embodiment, the drive shaft 90 is press-fitted into the center 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 opening formed by the first drive shaft support 22 supports the first end of the drive shaft 90 and allows the drive shaft to rotate. The center housing 24 includes a second drive shaft support 24A. The second ball bearing 64 located in the opening 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 openings formed by the first drive shaft support 22 of the inverter housing 22 and the second drive shaft support 24A of the center housing 24, respectively.

[0073] 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 60B. The rotor 60 rotates with the drive shaft 90 to drive the orbiting scroll 66 to move and rotate under the control of the inverter module 44.

[0074] See also Fig.14A , 14B , 16A and 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 on an eccentric trajectory, i.e., a circular motion, about the central axis 90C, while the orientation of the orbiting scroll 66 remains unchanged relative to the fixed scroll 26. The center of the orbiting scroll 66 is located along an offset axis 90D of the drive shaft 90, which passes through an orbiting scroll port (or drive pin location) 90E located at the second end 90D of the drive shaft 90 (see Fig.14A When the drive shaft 90 is rotated by the motor 54, as the drive shaft 90 rotates about the central axis 90C, the orbiting scroll 66 follows the movement of the orbiting scroll port 90E via the drive pin 126, the drive hub of the rocker mechanism 124 and the bearing 108.

[0075] 1, 2 and 9, the mixed refrigerant and oil (low pressure) enters the electric compressor 10 via the refrigerant inlet port 68 and leaves the electric compressor 10 (high pressure) via the refrigerant outlet 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 inlet port 68 and enters the intake volume 74 formed between the motor side 22A of the inverter housing 22 and the center housing 24 adjacent to the refrigerant inlet port 68. The refrigerant is then drawn through the motor portion 16 and enters the compression intake volume 76 ( Fig.14A as indicated by arrow 92).

[0076] The fixed scroll 26 is mounted in the center 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 to 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 wraps 26A, 66A have trailing ends 26C, 66C adjacent the outer edge of the respective scroll 26A, 66B and spiral inwardly toward the respective central ends 26D, 66D.

[0077] The corresponding top seal structures 94 are located in grooves 26E, 66E located at the top surfaces of the fixed scroll 26 and the orbiting scroll 66, respectively. The top seal structures 94 are composed of a flexible material, such as polyphenylene sulfide (PPS) plastic. When assembled, the top seal structures 94 are pressed against the opposing bases 26A, 66A to provide a seal therebetween. In one embodiment, the grooves 26E, 66E are longer than the length of the top seal structures 94, thereby providing space for adjustment / movement along the length of the top seal structures 94.

[0078] See also Figures 17A-17I , the refrigerant enters the compression device 12 from the compressed air intake volume 76. Figures 17A-17I , a cross-sectional view of the top of the fixed scroll 26 and the orbiting scroll 66 is shown.

[0079] As discussed in detail below, the fixed scroll base 26A and the orbiting scroll base 66A form a compression chamber 80 into which low-pressure or non-pressurized (saturated pressure) refrigerant enters from the compression device 12. As the orbiting scroll 66 moves to close the compression chamber 80, the volume of the compression chamber 80 decreases to pressurize the refrigerant. At any time during the cycle, one or more compression chambers 80 are in different stages of the compression cycle. The following description only relates to a set of compression chambers 80 during a complete cycle of the electric compressor 10.

[0080] Refrigerant enters compression chambers 80 formed between the orbiting scroll 66A and the fixed scroll 26A. Refrigerant is transported toward the center of these chambers during the cycle of the compressor 10. During the illustrated cycle of the electric compressor 10, the orbiting scroll 66 rotates in a circular motion as indicated by arrow 78, which is caused by the relative position of the orbiting scroll 66 with respect to the fixed scroll 26.

[0081] 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 trailing end 26C, 66C is spaced apart from the other scroll wrap 66B, 26B. At this point, the compression chamber 80 is open to the compression intake volume 76 to allow low pressure refrigerant to fill the compression chamber 80 from the compression intake volume 76. As the orbiting scroll 66 moves along the path 78, the space between the trailing end 26C, 66C and the other scroll wrap 66B, 26B decreases until the compression chamber 80 is closed to the compression intake volume 76 ( Figures 17B-17E As the orbiting scroll 66 continues to move along the path 78, the volume of the compression chamber 80 is further reduced, thereby pressurizing the refrigerant in the two compression chambers 80 ( Fig.17F -H). Figures 17I-17J As shown, as the orbiting scroll 66 continues to rotate, the two compression chambers 80 merge into a single volume. This volume is further reduced until the pressurized refrigerant is discharged from the compression device 18 (see below).

[0082] As will be described below, refrigerant enters cavities formed between the walls of the orbiting scroll 66 and the fixed scroll 26. Refrigerant is delivered toward the center of these cavities during a cycle of the compressor 10. During one cycle of the illustrated electric compressor 10, the orbiting scroll 66 rotates or moves in a circular motion as indicated by arrows 78, which is created by the relative position of the orbiting scroll 66 relative to the fixed scroll 26.

[0083] 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 hole 84A and two side holes 84B in the fixed scroll 26 (see FIG. Fig.18C and 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 hole 84A and the two side holes 84B (see below).

[0084] like Fig.18D and 18EAs shown, in the illustrated embodiment, the reed mechanism 86 includes a discharge reed 86A and a reed retainer 86B. The discharge reed 86A is made of a flexible material, such as steel. The material and strength and other properties are selected to control the pressure when the pressurized refrigerant is released from the compression device 18. The reed retainer 86B is made of a rigid, non-flexible material, such as stamped steel. The reed retainer 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 portion 16 to provide lubrication and cooling for the rotating parts of the electric compressor 10, such as the rotor 60, the drive shaft 90 and all bearings 62, 64, 108. The oil is sucked upward toward the top of the motor 54 by the rotation of the rotor 60. From there, the oil enters the interior of the motor 54 to lubricate the second ball bearing 64, and through the rotational force within the motor portion 16, the oil can impact the motor side 22A of the inverter housing 22. The oil is further directed into the ball bearing 62 through the motor side 22A, which is further discussed below.

[0085] In the illustrated embodiment, the reed mechanism 86 is held or secured in place via a separate fastener 89. Fig.18E and 18F As shown, the reed mechanism 86 includes a plurality of ports 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 surrounding the aperture 84, which helps regulate the pressure of the refrigerant exiting the compression device 18. Additionally, a debris collection groove 83C collects debris near the apertures 84A, 84B to prevent interference with the reed mechanism 86.

[0086] like Fig. 9 As shown, the path of the refrigerant through the electric compressor is indicated by dashed arrow 72 .

[0087] 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 scroll 66 and the fixed scroll 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 separates from the compressed refrigerant within the front cover 28 and returns to the compression device 18.

[0088] The oil separator 96 helps to separate 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 tank 98 that collects oil from the oil separator 96 before the oil is recirculated by the motor 54, the motor cavity 56 and the compression device 18. In use, the electric compressor 10 is generally as follows Figure 3-5 The orientation shown is such that gravity acts as indicated by arrow 106 and oil collects within oil tank 98 .

[0089] See also Fig. 9 , arrow 88 shows the general path of oil flowing from the bottom of the electric compressor 10, through the compression device 18, out of the hole 84 to the discharge volume 82 of the front cover 28 and back to the compression device 18.

[0090] In the illustrated embodiment, the front cover 28 is mounted to the center housing 24 by a plurality of bolts 122 that are inserted into and threaded into corresponding ports in the center housing 24. A fixed end gasket 110 and a rear end gasket 112 are located between the center housing 24 and the fixed scroll 26 to provide a seal.

[0091] The oil separator 96 helps to separate the mixed oil and refrigerant. Typically, the oil separator 96 removes only some of the oil in the mixed oil and refrigerant. The separator oil is stored in the oil tank and circulated back by the compression device 18, where the oil is mixed with the refrigerant.

[0092] In the illustrated embodiment, the oil separator 96 is integrated into the front cover 28. The front cover 28 also defines an oil tank 98 that collects oil from the oil separator 96 before the oil is recirculated by the motor 54, the motor cavity 56 and the compression device 18. In use, the electric compressor 10 is generally oriented as follows: Figure 3-5 As shown, gravity acts as shown by arrow 106 and the oil collects in the oil tank 98. Fig. 9 , arrow 88 shows the general path of oil from the bottom of the electric compressor 10, through the compression device 18, out of the hole 84 to the discharge volume 82 of the front cover 2 and back to the compression device 18. As shown, the oil is drawn into the compression device 18 where it is remixed into or with the refrigerant.

[0093] As described above, the refrigerant is actually a mixture of refrigerant and oil, which enters the electric compressor 10 through the refrigerant inlet port 70. The mixture of oil and refrigerant is sucked into the motor portion 16, thereby providing lubrication and cooling for the rotating parts 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 the oil can impact the motor side 22A of the inverter housing 22 through the rotational force within the motor portion 16. The refrigerant and oil are further guided into the ball bearing 62 through the motor side 22A, which will be discussed further below.

[0094] Concentric protrusions of the rocker mechanism and the drive shaft

[0095] See Figure 13-18BIn 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 126. In one embodiment, the concentric protrusion 126 is formed integrally with the drive shaft 90. As described below, the rocker mechanism 124 is used to rotate the orbiting scroll 66 around the drive shaft 90 in an eccentric trajectory.

[0096] 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 rocker mechanism 124, which moves the rotating scroll 66 along its eccentric trajectory. 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 rotating scroll 66 when the rotating scroll 66 travels along the eccentric trajectory. 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 subjected to considerable pressure. Therefore, both pins are made of hardened material, such as SAE52100 bearing steel. Additionally, 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 trajectory of the rotating scroll 66. In addition, the eccentric pin of the prior art requires additional processing on the surface of the drive shaft 90, including precise holes for the drive pin and the eccentric pin.

[0097] As discussed in more detail below, the eccentric pin of the prior art is replaced with a concentric protrusion 90F.

[0098] In the illustrated embodiment, the scroll electric compressor 10 includes a housing 12, a refrigerant inlet port 68, a refrigerant outlet 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 intake volume 74 and an exhaust volume 82. The refrigerant inlet port 68 is coupled to the housing 12 and is configured to introduce refrigerant into the intake volume 74. The refrigerant outlet port 70 is coupled to the housing 12 and is configured to allow compressed refrigerant to leave the scroll electric compressor 10 from the exhaust volume 82. The drive shaft 90 is located within the housing 12 and has a first end 90A and a second end 90B. The drive shaft 90 defines a central axis 90C and is centered on the central axis.

[0099] The concentric projection 90F is located at the second end 90B of the drive shaft 90 and is centered on the central axis 90C. The concentric projection 90F extends away from the drive shaft 90 along the central axis 90C. The concentric projection 90F includes a drive pin opening 90E. The motor 54 is located within the housing 12 and is coupled to the drive shaft 90 to controllably rotate the drive shaft 90 about the central axis 90C. The drive pin 126 is located within the drive pin opening 90E and extends away from the drive shaft 90. The drive pin 126 is parallel to the concentric projection 90F.

[0100] The concentric pin 90F may also include an undercut 90G, and the outer surface may be case hardened or coated or bearing surface treated. The concentric pin 90F may also be further processed simultaneously with the drive shaft 90 .

[0101] 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 intake 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.

[0102] The rocker mechanism 124 is coupled to the drive shaft 90 and has first and second ports 124A, 124B for receiving the concentric protrusion 90F and the drive pin 126. The rocker mechanism 124 also includes an outer peripheral surface 124C.

[0103] The ball bearing 108 is located between the inner peripheral surface 66E of the orbiting scroll 66 and the outer peripheral surface 124C of the rocker mechanism 124, and is adjacent to the inner peripheral surface of the orbiting scroll and the outer peripheral surface of the rocker mechanism, respectively. The drive shaft 90, the drive pin 126, the orbiting scroll 66, and the rocker mechanism 124 are arranged to rotate the orbiting scroll 66 in an eccentric trajectory about the central axis 90C.

[0104] 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 is formed simultaneously with the drive shaft 90 and in the same machining process, further improving manufacturing efficiency.

[0105] Figure 16G The partially expanded view of the compression device 18 shown in the further shows the concentric protrusion 90F. The concentric protrusion 90F interacts with and guides the rocker mechanism 124. The size and machining controlled tolerances of the concentric protrusion 90F match the first port 124A to form a controllable gap to limit the radial movement of the eccentric trajectory of the orbiting scroll 66. Unlike the prior art, the concentric protrusion 90F does not require a second pin or any additional machining. The concentric protrusion 90F also cooperates with the guide pin 128 and the groove 66G on the lower surface 66F of the orbiting scroll 66, which will be further discussed below.

[0106] The scroll electric compressor 10 includes an inverter portion 14, a motor portion 16, and a compression device 18. The motor portion 16 includes a motor housing 54 that defines a motor cavity 56. The compression portion 18 includes a fixed scroll 26. The housing 12 is at least partially formed by the fixed scroll 26 and the center housing 24.

[0107] See Fig.13 , 16B 18A-18F, the orbiting scroll 66 has a lower surface 66F. The lower surface 66F has a plurality of annular grooves 66G. The center housing 24 includes a plurality of hinge guide pin openings 128. The guide pins 128 are located in the guide pin openings 66G and extend toward the compression device 18 to enter the annular grooves 66G. The guide pins 128 are configured to limit the articulation of the orbiting scroll 66 when the orbiting scroll 66 rotates about the central axis 90C. In one embodiment, each annular groove 66G includes a collar 118. The thrust plate 130 is located between the fixed scroll 26 and the thrust body 150 (see below) and provides a wear surface between them.

[0108] Discharge head design with three-reed mechanism and oil separator

[0109] In the illustrated embodiment, the electric compressor 10 includes a multi-chamber pulsation muffler system 160 and an oil separator 96, which can be located in the discharge volume 82 and is 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 required to separate the mixed oil and refrigerant before the refrigerant leaves the electric compressor 10.

[0110] Typically, during each cycle, i.e., rotation (or wrap) 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 hole 84A and two side holes 84B in the fixed scroll 26. The release of refrigerant through the holes 84A, 84B is controlled by a central spring 87A and two side springs 87B, respectively. The multi-chamber pulsation muffler system 160 and the oil separator 96 will be described in more detail below.

[0111] Vortex bearing oil hole

[0112] The electric compressor 10 may include a rolling bearing oiling hole. As described 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, the oil delivered to the ball bearing 108 may be limited, resulting in reduced durability. Fig. 9As shown, oil holes 138 allow oil (and refrigerant) to flow from discharge chamber 82 to ball bearing 108 along path 73 (which may be referred to as a “nose bleed” path).

[0113] The scroll electric compressor 10 may include a housing 12, a refrigerant inlet port 68, a refrigerant outlet port 70, an inverter module 144, a motor 54, a drive shaft 90, and a compression device 18. The housing 12 defines an intake volume 74 and an exhaust volume 82. The refrigerant inlet port 68 is coupled to the housing 12 and is configured to introduce refrigerant into the intake volume 74. The refrigerant outlet port 70 is coupled to the housing 12 and is configured to allow compressed refrigerant to leave the scroll electric compressor 10 from the exhaust volume 82. The inverter module 144 is mounted in the housing 12 and is suitable for converting direct current into alternating current. The motor 54 is mounted in the housing 12. The drive shaft 90 is coupled to the motor 54. The compression device 18 receives refrigerant from the intake 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 pin 136 .

[0114] 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 intake volume 72 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 port 140 that passes through the orbiting scroll 66 from the first side 66F to the second side 66G.

[0115] The rocker mechanism 124 is coupled to the drive shaft 90. The ball bearing 108 is located between and adjacent the orbiting scroll 66 and the rocker mechanism 124. The drive shaft 90, the orbiting scroll 66, and the rocker mechanism 124 are arranged to cause the orbiting scroll 66 to rotate about the central axis 90C in an eccentric trajectory.

[0116] like Figures 16B-16E As shown, the tip of the orbiting scroll 66 includes an insert 136 and has an oil hole 138. The insert 136 may be press fit within an oil hole 140 of the orbiting scroll 66. The oil hole 138 is configured to allow oil or compressed refrigerant to flow through the orbiting scroll 66 to the ball bearing 108 at a controlled flow rate.

[0117] The size of the oil hole 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 hole 138 can be selected so that only oil is allowed to pass through and the pressure equalization between the first side and the second side of the orbiting scroll 66 is limited. By using a separate insert 136 instead of machining the oil hole 138 directly in the orbiting scroll 66, efficient manufacturing can be achieved. And the insert 136 can have an oil hole 138 that is specially designed and adjusted to allow the oil flow and the refrigerant flow to increase or decrease according to the diameter and geometry of the oil hole 138.

[0118] like Figures 16D-16E As shown, in one embodiment, the oil hole 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 larger diameter than the first hole 138A and is only used to shorten the length of the first hole 138A. The oil and coolant flow is intended to provide heat and lubrication to the ball bearing 108 to withstand the radial force generated by the eccentric trajectory of the rotating scroll 66.

[0119] In addition, as described 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.

[0120] like Fig. 9 As shown, oil holes 138 allow oil (and refrigerant) to flow from discharge chamber 82 to ball bearing 108 along path 73 (which may be referred to as a “nose bleed” path).

[0121] Bearing oil connecting hole

[0122] The electric compressor 10 may include one or more bearing oil communication holes. As described 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 center housing 24. The first and second ball bearings 62, 64 are located in the first and second drive shaft supports 22B, 24A.

[0123] The position of the first drive shaft support 22B is not a circulation area of ​​the refrigerant (and oil), which may lead to poor lubrication and affect the durability of the electric compressor 10.

[0124] As shown in FIG. 16F , the first drive shaft support 22B may include one or more holes 22C to allow oil to enter the first drive shaft support 22B and lubricate the first ball bearing 62 .

[0125] 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 inlet port 68 , a refrigerant outlet port 70 , an inverter module 44 , a motor 54 , a drive shaft 90 , and a compression device 18 .

[0126] The housing 12 defines an intake volume 74 and an exhaust volume 82, and includes first and second drive shaft supports 22B, 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.

[0127] The second ball bearing 64 is located in the second drive shaft support 24A. The refrigerant inlet port 68 is coupled to the housing 12 and configured to introduce refrigerant into the intake volume 74. The refrigerant outlet port 70 is coupled to the housing 12 and configured to allow compressed refrigerant to leave the scroll electric compressor 10 from the discharge volume 82. The inverter module 144 is mounted in the housing 12 and is suitable for converting direct current into alternating current. The motor 54 is mounted 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 located in the first bearing 62, and the second end 90B of the drive shaft 90 is located in the second bearing 64. The compression device 18 receives refrigerant from the intake volume 74 and compresses the refrigerant when the drive shaft 90 is rotated by the motor 54. As described above, in the illustrated embodiment, the first drive shaft support 22 can be formed on the motor side 22A of the inverter housing 22.

[0128] The rotational motion within the motor portion 16 of the compression device 18 creates a flow path and motion for the oil from the oil tank 98, such as Fig. 9 As shown by arrow 88 in the figure, oil flows from the oil tank 98 to the motor portion 16 and continues to flow to the stator 58 and rotor 60. The rotational motion of the rotating 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 to 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.16FAs shown. The ribs 22D provide the rigidity required to support the first drive shaft support 22 and allow the ridged backing and the pockets to secure the first bearing 62. The inverter housing 22 may also define an oil cavity (not shown) in which oil collected between the ribs 22D is directed downwardly by gravity and into the oil. 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 oil flow into the oil cavity 22E and the first bearing 62. Fig.16F Two communication holes 22C are shown, but it is 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 hole diameter is 3.5 mm, and the motor side 22A includes an inclined wall between the ribs 22D. Additionally, the motor side 22A may include an external oil collection area 22.

[0129] Dome inverter cover

[0130] The scroll electric compressor 10 of the present invention may include a dome-type inverter cover 20. The scroll electric compressor 10 includes a housing 12, a refrigerant inlet port 68, a refrigerant outlet 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 intake volume 70 and an exhaust volume 82. The housing 12 has a generally cylindrical shape and a central axis 90C. The refrigerant inlet port 68 is coupled to the housing 12 and is configured to introduce refrigerant into the intake volume 70. The refrigerant outlet port 82 is coupled to the housing 12 and is configured to allow compressed refrigerant to leave the scroll electric compressor 10 from the discharge volume 82.

[0131] The inverter module 44 is mounted within the housing 12 and is adapted to convert direct current into alternating current. The motor 54 is mounted within 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 intake volume and compress the refrigerant when the drive shaft 90 is rotated by the motor 54.

[0132] As described above, the compression device 18 may rotate at high speeds (>2,000 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 focus vibrations from the compression device 18 .

[0133] In order to disperse vibrations rather than focus vibrations from the compression device 18 , the inverter rear cover 20 of the scroll type electric compressor 10 of the fifth aspect of the present disclosure is provided with a generally curved or domed profile.

[0134] As shown in the figure, particularly as shown in Figures 1, 3 and 6, 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 generally perpendicular to the central axis 90C, and has a vertex 20C and a periphery 20D. The first part 20A has a shape relative to the dome, so that the inverter cover 20 has a curved profile from the vertex 20C to the periphery 20D. The size and position of the curvature may be determined or limited by other considerations, such as packaging constraints, i.e., the space in which the electric scroll compressor 10 must be installed, and the constraints (i.e., position and size) imposed by internal components. The first part 20A must also be combined with other features, such as a mouth for receiving fastening bolts. The second part 20B may include a non-dome portion of the inverter cover 20, i.e., a relatively flat portion located at the periphery of the inverter cover.

[0135] Fixed scroll with improved scroll base

[0136] In a first aspect of the present invention, a scroll electric compressor 10 with an improved fixed scroll bottom plate is configured for compressing refrigerant. The scroll electric compressor 10 includes a housing 12, a refrigerant inlet port 68, a refrigerant outlet port 70, an inverter module 44, a motor 54, a drive shaft 90, and a compression device 18. The housing 12 defines an intake volume area 74 and an exhaust volume area 82.

[0137] The refrigerant inlet port 68 is coupled to the housing 12 and is configured to introduce refrigerant into the intake 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 exhaust volume 82. The inverter module 144 is mounted within the housing 12 and is adapted to convert direct current to alternating current. The motor 54 is mounted within the housing 12 and the drive shaft 90 is coupled to the motor 54.

[0138] Generally, as described above, compression device 18 receives refrigerant from intake volume 74 and compresses the refrigerant when drive shaft 90 is rotated by motor 54 .

[0139] The compression device 18 includes the fixed scroll 26 and the orbiting scroll 66. The compression device 18 defines a front chamber volume 134. The front chamber volume 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 wraps 26B, 66B are in contact), the pressure within antechamber volume 134 drops due to suction, which can affect the efficiency of 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 compression device 18). This increases the "volume" of compression device 18 and smoothes the compression cycle.

[0140] 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 134 .

[0141] In the illustrated embodiment, the cutout 136 is located in the bottom plate or base 26A of the fixed scroll 26 .

[0142] 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 to the second side 26G of the fixed scroll 26. Fig.18C and 18G As shown, the cutout 136 in the bottom of the fixed scroll base 26 defines a first portion having a depth d1 that is greater than a depth d2 of the second portion 138 .

[0143] The size of the first portion or cutout 136 may be limited by several constraints. First, the depth d1 must leave enough material to maintain the structural integrity of the fixed scroll 26. Additionally, to ensure that the cavity 80 is sealed, the geometry of the cutout must remain outside of the scroll wrap 66B to allow the cavity 80 to close and seal, as shown in FIG. Fig.17D As shown. The cutout 136 may provide additional volume within the antechamber 134 to allow the volume within the cavity 80 in 17D to be completely filled. The cutout 136 is limited by the path of the orbiting scroll 66B and the required bottom and wall thickness of the fixed scroll 26. Additionally, machining and access to the bottom plate of the fixed scroll may provide additional limitations on the size and area outside the sealing area of ​​the orbiting scroll 66B.

[0144] Isolation / restraint systems

[0145] In a second aspect of the present invention, an isolation and restraint system 148 may be used to isolate the casing 12 from oscillations and pulsations induced by the orbiting scroll 66 .

[0146] In a typical scroll electric compressor, the motor and fixed scroll are directly coupled to the housing. As described above, the guide pins directly coupled to the housing can cooperate with the annular grooves on the orbiting scroll to limit the articulation of the orbiting scroll as it rotates about the drive shaft. With this arrangement, vibrations and pumping pulsations from the orbiting scroll can be transmitted to the housing and, through the brackets, to, for example, the vehicle structure.

[0147] The scroll electric compressor 10 is configured to compress refrigerant. The scroll electric compressor includes a housing 12, a refrigerant inlet port 68, a refrigerant outlet port 70, an inverter module 144, a motor 54, a drive shaft 90 and a compression device 18. The housing 12 defines an intake volume area 74 and an exhaust volume area 82, and has a generally cylindrical shape. The refrigerant inlet port 68 is coupled to the housing 12 and is configured to introduce refrigerant into the intake volume area 74. The refrigerant outlet port 70 is coupled to the housing 12 and is configured to allow compressed refrigerant to leave the scroll electric compressor 12 from the exhaust volume area 82. The inverter module 144 is mounted inside the housing 12 and is suitable for converting direct current into alternating current. 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 for receiving refrigerant from the intake volume area 74 and compressing the refrigerant when the drive shaft 90 is rotated by the motor 54.

[0148] As described above, the compression device 16 includes the fixed scroll 26 and the 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 for receiving refrigerant from the intake volume 74 and compressing the refrigerant when the drive shaft 90 rotates about the central axis 90C.

[0149] The orbiting scroll 66 has a lower surface having a plurality of annular grooves 66G (see above).

[0150] See Fig. 20A The scroll electric compressor 10 further includes a thrust body 150, a plurality of articulated guide pins 24B, a plurality of mounting pins 152, and a plurality of spacer sleeves 154. The thrust body 150 has a plurality of guide pin openings 152A. A plurality of articulated guide pins 24B extend from the guide pin openings 152 and extend toward the compression portion 18 and enter the annular groove 66B. The guide pins 24B are configured to limit the articulation of the orbiting scroll 66 when the orbiting scroll 66 rotates around the central axis 90.

[0151] Each mounting pin 152 has a housing end 152A and a thrust body end 152B. The housing end 152 is press-fitted into a corresponding receiving hole in the housing 12. The thrust body end 152B is cylindrical with an outer surface. A plurality of isolation sleeves 154 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 152 of each mounting pin 152 is sealed in a corresponding sleeve 154 and received in a corresponding groove 150A in the thrust body 150. In this way, the thrust body 150 and the housing 12 are connected only by the mounting pin 152, which is isolated or insulated by the sleeve 154 to prevent or minimize the transmission of vibration from the rotating scroll 66 to the housing 12.

[0152] like Fig. 20A As shown, in one embodiment, the spacer sleeve 152 is integrally formed with a circular spacer or ring 156 .

[0153] like Fig. 20B As shown, in another embodiment, the thrust body end 152B of each mounting pin 152 is completely sealed by a flexible material using, for example, an overmolding process. The outer surface of the isolation sleeve 154 may be friction treated to facilitate isolation.

[0154] Electric compressor head design structure

[0155] In a third aspect of the disclosed electric compressor 10, the front cover 28 design includes an oil separator 96 and a three-reed mechanism 86. As described below, the design of the front cover 28, fixed scroll 26, and reed mechanism 86 defines a multi-chamber pulsation muffler system.

[0156] In prior art electric compressors, refrigerant is released from the compression device once per rotation (or orbit) 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 of the pulsations generated in the refrigerant may excite its components (inside or outside the electric compressor), which may generate undesirable noise, vibration and harshness (NVH) and low durability conditions.

[0157] See also Figures 18C-18F and Figures 19A-19B , the multi-chamber pulsation muffler system 160 compresses refrigerant and releases it twice from the compression device 18 during the compression cycle. As discussed in more detail below, the compression device 18 includes two smaller secondary discharges, which are placed (adjacent) in two secondary discharge chambers, which are located downstream (in the discharge head) of the central discharge port pressure drop. As further described below, the front cover 28 defines a parallel discharge path for the refrigerant flowing out of the compression device 18 to the refrigerant outlet port 70.

[0158] In the illustrated embodiment, the compressor 10 includes a housing 12, an inverter module 44, an electric motor 54, and a compression device 18. The housing 12 defines an intake volume 74 and an exhaust volume 82. The housing 12 has a generally cylindrical shape and a central axis 90C. The inverter module 44 is mounted inside the housing 12 and is adapted to convert direct current to alternating current. The electric motor 54 is mounted within the housing.

[0159] The compression device 18 is coupled to the motor 54 for receiving the refrigerant from the intake volume 74 and compressing the refrigerant when the motor 54 rotates.

[0160] The compression device 18 has a central compression device outlet orifice 84A and first and second side compression device outlet orifices 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 outlet orifices 84B earlier in the compression cycle than releasing refrigerant via the central discharge orifice 84A.

[0161] Additionally, the oil separator 96 utilizes two parallel paths between the compression device 18 and the refrigerant outlet port 70 to reduce the net pressure drop while maintaining this pulsation reduction.

[0162] 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 described above, oil is used to provide lubrication between the moving components of the electric compressor 10. During operation, the oil and the refrigerant mix. Before the refrigerant leaves the electric compressor 10, the oil separator 96 must separate the mixed oil and refrigerant.

[0163] Typically, refrigerant is released from the compression device 18 during each cycle, i.e., rotation (or orbit) of the orbiting scroll 66. In the illustrated embodiment, refrigerant leaves the compression device 18 through a central hole 84A and two side holes 84B in the fixed scroll 26. Refrigerant release from the holes 84A, 84B is controlled by a central spring 87A and two side springs 87B, respectively (see below).

[0164] In the illustrated embodiment, the oil separator 96 connects the discharge chamber (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. Additionally, the oil separator 96 utilizes two parallel paths between the compression device 18 and the refrigerant outlet port 70 to reduce the net pressure drop while maintaining this pulsation reduction.

[0165] The oil separator 96 may include a series of baffles 98A extending from the inner surface of the front cover 28. As shown, the wall 98A divides the discharge volume 82 into a central discharge chamber 82A, two side discharge chambers 82B, an upper discharge chamber 82C, and an oil tank 98. The central discharge chamber 82A is adjacent to the central reed 87A and receives the mixed pressurized refrigerant and oil from the compression device 18 through the reed 87A by the central hole 84. The side discharge chambers 82B are adjacent to the corresponding side reeds 87B and receive the mixed pressurized refrigerant and oil from the compression device 18 through the side holes 84B via the corresponding reeds 87B. Typically, the refrigerant pressure in the chambers is: central discharge chamber 82A>side discharge chamber 82B>upper discharge chamber 82C.

[0166] The central discharge chamber 82A is in fluid communication with the two side discharge chambers 82B via respective side passages 100, which are in fluid communication with the upper discharge chamber 82C and the oil tank 98 via upper and lower discharge passages 102, 104, respectively. In one embodiment, the side passages 100 extend at an acute angle to the side discharge chambers 82B. The angle of the passages 100 further directs the impact of the discharged refrigerant and oil mixture to further improve separation and increase the oil separated by the oil separator 96. For example, in Fig.19C , the side channel 100 extends through and down into the side discharge chamber 82B at an angle of about 45 degrees relative to the inner wall of the central discharge chamber 82A. However, the angle can vary depending on the application or the surface contour of the side discharge chamber 82C, and can be increased to about 60 degrees in some variations. The angle can vary, but is designed to direct the flow to create turbulence and direct the impact of the flow to create a tortuous path within the side discharge chamber 82C to increase separation of the oil entering the lower discharge channel 104.

[0167] 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 chevron shaped (inverted "v") and is located between the central chamber 82 and the oil tank 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 drawn 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 separate. The oil drips into the oil tank 98.

[0168] 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 82B and be discharged via the refrigerant outlet port 70.

[0169] An oil tank 98 is located below the pair of side chambers and is connected thereto via respective lower discharge passages 104. The oil tank 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 tank 98 through the lower discharge passages 104 located in the side discharge chamber 82B.

[0170] As described above, the reed mechanism 86 includes a discharge reed 86A and a reed retainer 86B, which define reeds 87A, 87B. The discharge reed 86A is used to adjust the pressure of the refrigerant leaving the compression device 18 through the central hole 84A and the two side holes 84B respectively.

[0171] The foregoing invention has been described in accordance with relevant legal standards, and therefore the description is exemplary rather than restrictive. Those skilled in the art may make various variations and modifications to the disclosed embodiments, and these variations and modifications all fall within the scope of the present invention.

Claims

1. A scroll electric compressor configured to compress a refrigerant, the scroll electric compressor comprising: a housing defining an intake volume and an exhaust volume; a refrigerant inlet port coupled to the housing and configured to introduce refrigerant into the intake volume; a refrigerant outlet port coupled to the housing and configured to allow compressed refrigerant to exit the scroll electric compressor from a discharge volume; an inverter module mounted in the housing and adapted to convert direct current into alternating current; a motor mounted in the housing; a drive shaft coupled to the motor; and, a compression device for receiving refrigerant from the intake volume and compressing the refrigerant when the drive shaft is rotated by the motor, the compression device comprising a fixed scroll having a first side and a second side of the fixed scroll and being fixed relative to the housing within the housing, and an orbiting scroll having a first side and a second side of the orbiting scroll, the fixed scroll comprising: a fixed scroll base located on a first side of the fixed scroll, and a fixed scroll wrap extending from the fixed scroll base toward a second side of the fixed scroll, the orbiting scroll comprising: an orbiting scroll base located on a first side of the orbiting scroll, and an orbiting scroll wrap extending from the orbiting scroll base toward a second side of the orbiting scroll, the orbiting scroll being coupled to the drive shaft, the orbiting scroll and the fixed scroll forming a compression chamber for receiving refrigerant from the intake volume and compressing the refrigerant when the drive shaft rotates about a central axis, wherein one of the fixed scroll base and the orbiting scroll base has a first portion and a second portion, wherein a depth of the first portion is greater than a depth of the second portion.

2. The scroll electric compressor according to claim 1, wherein: One of the fixed scroll base and the orbiting scroll base is a fixed scroll base.

3. The scroll type electric compressor according to claim 2, wherein: Each of the fixed scroll wrap and the orbiting scroll wrap has a trailing end and a center end.

4. The scroll electric compressor according to claim 3, comprising a top sealing structure located at the top surface of each of the fixed scroll wrap and the rotating scroll wrap, each top sealing structure being pressed against an opposite one of the rotating scroll base and the fixed scroll base to provide a seal therebetween.

5. The scroll type electric compressor according to claim 4, wherein: The first portion is located within a space on the fixed scroll base, the space being defined when the trailing end of the orbiting scroll base contacts the fixed scroll wrap during a compression cycle such that the compression chamber is closed.

6. The scroll electric compressor according to claim 1, further comprising: a rocker mechanism coupled to the drive shaft; as well as, a ball bearing located between the orbiting scroll and the rocker mechanism and adjacent to the orbiting scroll and the rocker mechanism, respectively, the drive shaft, the orbiting scroll and the rocker mechanism being arranged to cause the orbiting scroll to rotate about a central axis in an eccentric trajectory, and, A pin has an oil hole and is press-fitted into the oil port of the orbiting scroll, wherein the oil hole is configured to allow oil to pass through the orbiting scroll to the ball bearing.

7. The scroll electric compressor according to claim 1, wherein: The housing includes a motor portion, the housing defining a cavity for accommodating the motor and a compression portion.

8. The scroll type electric compressor according to claim 7, wherein: The fixed scroll is mounted to the motor housing, the rotating scroll having a lower surface with a plurality of annular grooves, the motor housing including a plurality of hinge guide pin openings, and a plurality of guide pins located in the guide pin openings and extending into the annular grooves at the compression portion, the guide pins being configured to limit the articulation of the rotating scroll when the rotating scroll rotates about a central axis.

9. The scroll-type electric compressor of claim 8, comprising a plurality of annular inserts located within the annular groove.

10. The scroll type electric compressor according to claim 1, wherein: The housing includes a first drive shaft support and a second drive shaft support, and further includes: a first ball bearing positioned within the first drive shaft support and configured to receive a first end of the drive shaft; and A second ball bearing is positioned within the second drive shaft support and is configured to receive a second end of the drive shaft.

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