Rolling piston rotary compressor

Abstract

An apparatus includes a semi-enclosed compressor housing, an electrically driven dual cylinder rolling piston rotary compressor assembly housed in the housing, motor driven electronics, and an auxiliary housing. The auxiliary housing defines a semi-closed refrigerant inlet compartment having a wall. The auxiliary housing also defines an electronics compartment that shares a wall with the inlet compartment but is semi-enclosed separate from the inlet compartment. The compressor housing is semi-closed coupled with and in fluid communication with the inlet compartment. The electronics compartment accommodates electronics.

Description

[0001] Cross - Reference to Related Applications

[0002] This application claims the benefit of priority of U.S. Provisional Patent Application No. 63 / 438,769, filed on Jan. 12, 2023, and U.S. Provisional Patent Application No. 63 / 355,611, filed on Jun. 26, 2022, both of which are incorporated herein by reference. Technical Field

[0003] Various embodiments herein relate to a positive displacement compressor, and more particularly, to a semi-hermetic, electric-driven, rolling piston rotary compressor for compressing refrigerant in air conditioning, refrigeration, heat pump, and / or other cooling and / or heating systems for electric vehicles, internal combustion engine vehicles, aircraft, watercraft, buildings, manufacturing systems, and / or other suitable applications. Background Art

[0004] Mitigating climate change will require rethinking historical paradigms. While rotary scroll refrigerant compressors can generally outperform similarly sized rolling piston rotary compressors within a narrow range of fairly constant load conditions, an increasing number of cooling and heating applications will present relatively wide ranges and dynamic load conditions that may benefit from a more suitable rolling piston rotary compressor. For example, internal combustion engine (“ICE”) vehicles typically use scroll compressors in their driver / passenger cabin heating, ventilation, and air conditioning (“HVAC”) systems. However, conventional ICE vehicles typically have ample power to operate the HVAC system (which presents a fairly narrow and constant compressor load). Additionally, ICE vehicles typically do not have significant additional refrigeration demands. On the other hand, electric vehicles are increasingly demanding battery cooling, brake cooling, and additional thermal management of various powertrain-related air and / or liquid heat exchange systems in addition to the conventional driver / passenger cabin HVAC. This additional load can be significantly more dynamic than a conventional HVAC system.

[0005] There is a need for suitable rolling piston rotary compressors to reduce overall HVAC power consumption and meet various battery cooling, brake cooling, and / or other electric vehicle cooling demands, and accordingly produce more efficient (longer range) electric vehicles. Additionally, in addition to supporting cooling systems, rolling piston compressors can generally operate as heat pumps that can provide heat more efficiently than conventional resistive heaters. As electric vehicle technology continues to develop and the number of electric vehicles on the road increases, the demand for (and potential benefits of) efficient rolling piston rotary compressors will continue to grow. Summary of the Invention

[0006] In some embodiments, a device includes a semi-hermetic compressor housing, an electric drive dual-cylinder rolling piston rotary compressor assembly received within the housing, motor drive electronics, and an auxiliary housing. The auxiliary housing defines a semi-hermetic refrigerant inlet compartment having a wall. The auxiliary housing also defines an electronics compartment that shares a wall with the inlet compartment but is semi-hermetically separated from the inlet compartment. The compressor housing is semi-hermetically coupled to and in fluid communication with the inlet compartment. The electronics compartment houses the electronics.

[0007] In some embodiments, a device includes a first rolling piston rotary compressor roller, a second rolling piston rotary compressor roller, a substantially hollow camshaft configured to cooperate with the first and second rollers, an Archimedes screw, and a flexible coupling mechanically coupled to the camshaft therewith. The flexible coupling has a first end portion extending from the camshaft in a first direction, a second end portion extending in a second direction and engaging the Archimedes screw, and an intermediate portion extending between the first and second end portions and bending from the first direction to the second direction.

[0008] In some embodiments, a device includes a first rolling piston rotary compressor roller, a second rolling piston rotary compressor roller, a camshaft configured to cooperate with the first and second rollers, and a motor including a rotor. The rotor is mechanically coupled to the camshaft and includes a first end and a second end. The rotor is generally cylindrical between the first and second ends. A first generally disk-shaped weight is attached to the first end of the rotor. The first weight has a first generally C-shaped portion extending therefrom. A second generally disk-shaped weight is attached to the second end of the rotor. The second weight has a second generally C-shaped portion extending therefrom. The second generally C-shaped portion is positioned on the second end of the rotor at a rotational displacement of approximately 180 degrees relative to the first generally C-shaped portion. A first generally disk-shaped cap is attached to the first weight. The first cap has a third generally C-shaped portion extending therefrom. The third generally C-shaped portion faces the first weight at a rotational displacement of approximately 180 degrees relative to the first generally C-shaped portion. A second generally disk-shaped cap is attached to the second weight. The second cap has a fourth generally C-shaped portion extending therefrom. The fourth generally C-shaped portion faces the second weight at a rotational displacement of approximately 180 degrees relative to the second generally C-shaped portion.

[0009] In some embodiments, a device includes a semi-enclosed compressor housing and a pair of rolling piston rotary compressor cylinders housed in the housing, the pair of rolling piston rotary compressor cylinders including a first rolling piston rotary compressor cylinder and including a second rolling piston rotary compressor cylinder. A pair of compressor cylinder discharge valves include a first valve mechanically coupled to the first cylinder and include a second valve mechanically coupled to the second cylinder. A pair of plates are inserted between the first cylinder and the second cylinder. The pair of plates includes a first plate. The first plate defines a first groove. The pair of plates includes a second plate. The second plate faces the first plate and defines a second groove. The first groove and the second groove jointly define a first acoustic muffler chamber. The pair of valves are configured to control the flow of refrigerant from the first cylinder and the second cylinder to the first chamber.

[0010] In some embodiments, a device includes a semi-enclosed compressor housing and a pair of rolling piston rotary compressor cylinders contained in the housing, the pair of rolling piston rotary compressor cylinders including a first rolling piston rotary compressor cylinder and a second rolling piston rotary compressor cylinder. A pair of compressor cylinder discharge valves include a first valve mechanically coupled to the first cylinder and a second valve mechanically coupled to the second cylinder. A camshaft extends through the cylinder. The camshaft has an inner portion and an outer portion. An inner bearing supports the inner portion of the camshaft. A first inner plate is positioned inside the bearing and defines a first acoustic muffler chamber having a pair of refrigerant flow holes therein. The pair of holes includes a first hole extending around a first corresponding axis and includes a second hole extending around a second corresponding axis. The second inner plate is positioned inside the first plate and defines a second acoustic muffler chamber having a first refrigerant discharge port therein. The first discharge port extends around a third corresponding axis. The valve is configured to control the refrigerant flow from the first cylinder and the second cylinder to the first chamber. The second chamber is fluidly connected to the first chamber, but neither the first axis nor the second axis is aligned with the third axis.

[0011] It should be understood that the various embodiments described in this summary and elsewhere in this application can be expressed in a large number of different combinations and sub-combinations. All such useful, novel and creative combinations and sub-combinations are contemplated herein, while recognizing that explicit expression of each of these combinations is not necessary. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Some of the figures shown herein may include dimensions. Additionally, the figures shown herein may be created from scaled drawings, scaled models, or scalable photographs. It should be understood that these dimensions, or the relative scaling within the figures, are shown by way of example and are not to be construed as limiting, unless so stated in the claims. One of ordinary skill in the art will also recognize that computer-aided design (“CAD”) renderings may include lines related to changes in surface geometry and not necessarily to component features.

[0013] Figure 40 A top front left perspective view of a semi-hermetic compressor in accordance with various aspects of the present invention is shown.

[0014] Figure A Shown is Figure 40 a top front left perspective partial exploded view of the semi-hermetic compressor of

[0015] Figure B Shown is Figure A a top front left perspective partial exploded view of an electric drive two-cylinder rolling piston rotary compressor assembly of

[0016] Figure C Shown is Figure B a top front left perspective exploded view of a two-cylinder rolling piston rotary compressor assembly of

[0017] Figure D Shown is Figure C a top rear right perspective exploded view of a two-cylinder rolling piston rotary compressor assembly of

[0018] Figure 59 Shown is Figure 40 a vertical cross-sectional view of the semi-hermetic compressor of Figure 40 in the direction of line 59-59 of

[0019] Figure 61 Shown is Figure 40 a vertical cross-sectional view of the semi-hermetic compressor of Figure 40 in the direction of line 61-61 of

[0020] Figure 62 Shown is an enlarged isolated vertical cross-sectional view of a semi-hermetic coupling of a semi-hermetic compressor housing and an auxiliary housing taken from Figure 61 of

[0021] Figure 63 Shown is Figure 62 a perspective view of a chamfered gasket of a semi-hermetic coupling of

[0022] Figure F Shown is an alternative semi-hermetic compressor in accordance with various aspects of the present disclosure similar to Figure 40Vertical cross-sectional view in the direction of line 61-61.

[0023] Figure 48 Shows Figure A Top front right isometric view of the outer part of an electric-driven double-cylinder rolling piston rotary compressor assembly.

[0024] Figure 47 Shows Figure 40 A semi-hermetic compressor in Figure 40 Vertical cross-sectional view in the direction of line 47-47.

[0025] Figure 57 Shows an enlarged vertical cross-sectional isolated view of the helical oil pump assembly taken from Figure 47 of Figure 40 a semi-hermetic compressor.

[0026] Figure 56 Shows Figure 40 exploded isometric view of the helical oil pump assembly of a semi-hermetic compressor.

[0027] Figure 54 Shows an enlarged vertical cross-sectional isolated view of the refrigerant discharge pipe taken from Figure 47 of Figure 40 a semi-hermetic compressor.

[0028] Figure 53 Shows Figure 40 isometric view of the refrigerant discharge pipe of a semi-hermetic compressor.

[0029] Figure 51 Shows an enlarged vertical cross-sectional isolated view of the tail oil pipe joint installed at the rear end of the camshaft taken from Figure 47 of Figure 40 a semi-hermetic compressor.

[0030] Figure 50 Shows an enlarged vertical cross-sectional isolated view of the tail oil pipe joint taken from Figure 51 of Figure 40 a semi-hermetic compressor.

[0031] Figure 49 Shows Figure 40 isometric view of the tail oil pipe joint of a semi-hermetic compressor.

[0032] Figure 45 Shows Figure B Top front left isometric view of the counterweight motor rotor assembly of an electric-driven double-cylinder rolling piston rotary compressor.

[0033] Figure 44 Shows a top front left isometric partial exploded view of the counterweight motor rotor assembly.

[0034] Figure 68 shows Figure B of the acoustic muffler system of the power-driven twin-cylinder rolling piston rotary compressor assembly in Figure 40 the direction of line 68-68.

[0035] Figure 65 shows Figure 40 a complementary exploded perspective view of the intermediate acoustic muffler plate of the semi-hermetic compressor.

[0036] Figure 69 shows an isolation cross-sectional view of the inner end of an alternative acoustic muffler system of an alternative semi-hermetic compressor according to aspects of the present invention in a direction similar to Figure 68 that. DETAILED DESCRIPTION

[0037] To facilitate an understanding of the principles of the present invention, reference will now be made to the embodiments shown in the drawings and specific language will be used to describe these embodiments. However, it should be understood that no limitation of the scope of the present invention is intended, such changes and further modifications in the devices shown, and such further applications of the principles of the present invention as are contemplated, would normally occur to a person skilled in the art to which the present invention pertains. At least one embodiment of the present invention will be described and illustrated, and the present application may show and / or describe other embodiments of the present invention and further permit reasonable and logical inferences of other embodiments to be understood by a person of ordinary skill in the art. Unless specifically limited to one or more particular materials herein, any component of the present invention may be made of any one or more suitable metals, plastics, woods, fabrics, fibers, and / or combinations thereof (and / or any other suitable materials or combinations thereof) that would be understood by a person of ordinary skill in the art.

[0038] It should be understood that any reference to "the present invention" refers to an embodiment among a series of inventions, and unless otherwise stated, no single embodiment includes devices, methods, or constitutions that should be included in all embodiments. Additionally, although some embodiments of the present invention may provide a discussion of "advantages", it should be understood that other embodiments may not include those same advantages or may include different advantages. Any advantages described herein should not be construed as limiting any claims. For example, the use of words such as "various embodiments" or "preferably" indicates features and aspects that exist in at least one embodiment but are optional for some embodiments, and thus it should be understood that the use of the word "preferred" means the term "optional".

[0039] Throughout the specification and drawings, like reference numerals refer to like components. Additionally, the use of the N-series prefix for element numbers (NXX.XX) refers to elements that are the same as the unprefixed elements (XX.XX) except for those features that are different as shown and described. For example, element 1020.1 would be the same as element 20.1 except for those features that are different from those of element 1020.1 as shown and described. Additionally, common features of common elements and related elements may be drawn in the same manner in different drawings, and / or the same symbols may be used in different drawings. Therefore, it is not necessary to describe the same features of 1020.1 and 20.1, as these common features are obvious to a person of ordinary skill in the relevant art. Additionally, it should be understood that some features of 1020.1 and 20.1 may be backward compatible such that features (NXX.XX) of embodiments discussed later may include features (MXX.XX) that are compatible with various other embodiments discussed earlier, as would be understood by a person of ordinary skill in the art. This description convention also applies to element numbers with an apostrophe (‘), double apostrophe (“), triple apostrophe (“’), and asterisk or star (*) suffix. Therefore, it is not necessary to describe the same features of 20.1, 20.1’, 20.1”, 20.1”’, 20*, as these common features are obvious to a person of ordinary skill in the relevant art.

[0040] The following are paragraphs expressing specific embodiments of the present invention. In the paragraphs that follow, some element numbers are prefixed with “X” to indicate that these terms are related to any like features shown in the drawings or described in the text. However, a person of ordinary skill in the art will recognize that the discussion applies to various other unprefixed element numbers for features applicable to other embodiments.

[0041] Different words may be used herein to describe the same element number, or to refer to element numbers (NXX.XX) within a particular series of features. It should be understood that these multiple different words are not intended to provide a redefinition of any language herein. It should be understood that these words indicate that a particular feature may be considered in various different linguistic ways, which are not necessarily additive or exclusive.

[0042] Figure 40 A top front left perspective view of a semi-hermetic compressor 100 in accordance with various aspects of the present invention is shown. Compressor 100 includes a semi-hermetic compressor housing 120. Compressor housing 120 is configured to semi-hermetically house an electric drive two-cylinder rolling piston rotary compressor assembly 140 ( Figure 40 not visible in Figure AAs shown, and is mainly made of aluminum castings properly sealed with gaskets and bolted. The compressor housing 120 includes a total refrigerant discharge port 160, and the total refrigerant discharge port 160 is configured to be semi-closedly coupled to a hose, pipe or the like (not shown) appropriately for supplying compressed refrigerant gas thereto. The compressor 100 also includes an auxiliary housing 180 bolted to the compressor housing 120. The auxiliary housing 180 is also mainly made of aluminum castings properly sealed with gaskets and bolted, and includes a total refrigerant inlet port 200, and the total refrigerant inlet port 200 is configured to be semi-closedly coupled to a hose, pipe or the like (not shown) appropriately for receiving relatively low-pressure refrigerant gas therefrom. The auxiliary housing 180 further includes a power receiving part or socket 220, and the power receiving part or socket 220 is appropriately configured to be electrically coupled to a mating plug (not shown) for receiving power (for powering the compressor assembly 140) from an electric vehicle power system or other suitable external power source (not shown). The auxiliary housing 180 includes an electrical signal port 240, and the electrical signal port 240 is appropriately configured to be electrically coupled to a mating port (not shown) for receiving an electrical signal (for controlling the operation of the compressor assembly 140) from an electric vehicle power management system or other suitable external control system (not shown).

[0043] Figure A A top front left perspective partial exploded view of the semi-hermetic compressor assembly 100 is shown. The semi-hermetic compressor housing 120 includes a chamber body 260 and a rear / rear cover plate 280. The electric-driven double-cylinder rolling piston rotary compressor assembly 140 is installed in the chamber body 260. Bolts 300 extend through the cover plate 280 and into the chamber body 260. Under the push of the bolts 300, the cover plate 280 is semi-hermetically sealed to the compressor assembly 140 and the chamber body 260. In addition, the chamber body 260 defines a mating groove 320 and an intermediate refrigerant receiving port 340. The auxiliary housing 180 includes a protrusion 360 installed in the mating groove 320, and includes an intermediate refrigerant delivery port 380 semi-hermetically coupled to the receiving port 340 through a suction pipe assembly 500 ( Figure A not shown in, but Figure B visible in). Bolts 400 fix the auxiliary housing 180 to the chamber body 260. The compressor assembly 100 also includes a total refrigerant discharge pipe 404 extending upward through the discharge port 160.

[0044] Figure BShows a top front left perspective partially exploded view of an electric drive twin cylinder rolling piston rotary compressor assembly 140. The compressor assembly 140 includes a core compressor assembly 420, a helical oil pump assembly 440, a gas flow diverter or baffle 460, bolts 480, a suction pipe assembly 500, an electric motor 540, and a hollow camshaft 560. The camshaft 560 extends along axis 580 through the compressor assembly 420 and includes a front end portion 600 and a rear end portion 620. The front end portion 600 projects forward from the assembly 420. The rear end portion 620 projects rearward from the assembly 420. The oil pump assembly 440 includes a cup-shaped fitting 640. As further discussed in relation to Figure 57 and Figure 56 , the fitting 640 couples the assembly 440 to the front end portion 600 of the camshaft 560. The baffle 460 arches over the oil pump assembly 440 and is positioned between the discharge pipe 404 ( Figure B not shown, but Figure A visible) and the oil pump assembly 440 (generally above the oil pump assembly 440 and below the discharge pipe 404). The bolts 480 secure the baffle 460 to the compressor assembly 42. The baffle 460 is designed to suppress refrigerant turbulence near the oil pump assembly 440 (and in turn suppress oil agitation), which the inventors believe can improve oil pump inlet conditions, and which the inventors believe can correspondingly improve the efficiency / performance of the oil pump assembly 440. The suction pipe assembly 500 is semi-closedly coupled to the compressor assembly 420 and generally extends laterally and downwardly therefrom. The electric motor 520 can be any suitable direct current (“DC”) motor (brush or brushless) or alternating current (“AC”) motor. The electric motor 520 includes a counterweight motor rotor assembly 660 mechanically coupled to the rear end portion 620 of the camshaft 560. It should be understood that the electric motor 520 is operable to rotate the counterweight motor rotor assembly 660. It should also be understood that the core compressor assembly 420 is operable to draw refrigerant into it through the suction pipe assembly 500 and compress the refrigerant in response to rotation of the camshaft 560.

[0045] Figure C and Figure DRespectively shown are a top front left perspective exploded view and a top rear right perspective exploded view of an electric drive two-cylinder rolling piston rotary compressor assembly 140. The compressor assembly 140 includes a front end cap 680, a vane or reed valve 700, a first or front cylinder cover plate 720, a vane 740, a first or front compression cylinder 760, a suction tube assembly 500, a hollow camshaft 560, an axial flow impeller 780 fastened to the camshaft 560, a tail oil pipe joint 800 substantially inserted into the rear portion 620 of the camshaft 560 but still protruding from the camshaft 560, a first or front compression roller 820, a first or front intermediate cylinder cover plate 840, a second or rear intermediate cylinder cover plate 860, a second or rear compression roller 880, a second or rear compression cylinder 900, a plug or stopper 920, a second or rear cylinder cover plate 940, a first or intermediate inner end cap 960, and a second or rear or rear inner end cap 980.

[0046] Figure 59 Shows a vertical cross-sectional view of a semi-hermetic compressor 100 in the direction of line 59-59 of Figure 40 The auxiliary housing 180 defines a semi-hermetic refrigerant inlet compartment 1000 having a wall 1020. The auxiliary housing 180 also includes a filter screen 1040 diagonally crossing the inlet compartment 1000. In addition, the auxiliary housing 180 defines an electronic device compartment 1060. The electronic device compartment 1060 shares the wall 1020 with the inlet compartment 1000. However, when the auxiliary housing 180 is fully assembled, the electronic device compartment 1060 has no fluid communication with the inlet compartment 1000. When the auxiliary housing 180 is fully assembled, the electronic device compartment 1060 is semi-hermetically separated (or semi-hermetically divided) from the inlet compartment 1000. At the same time, through the suction tube assembly 500, the semi-hermetic compressor housing 120 is semi-hermetically coupled to the inlet compartment 1000 and is in fluid communication with the inlet compartment 1000.

[0047] The compressor 100 includes motor-driven electronic devices 1080 housed in the electronic device compartment 1060. The motor-driven electronic devices 1080 can be one or more capacitors, inductance coils, transformers, resistors, transistors or other semiconductor devices, integrated circuits, inverter circuits, and combinations thereof, or other electrical or electronic devices or circuits for appropriately delivering power and / or control signals to the motor 520. During operation of the semi-hermetic compressor assembly 100, the compressor assembly 140 sucks refrigerant (not shown) through the refrigerant inlet port 200 and into the inlet compartment 1000. As the refrigerant flows (typically downward) through the inlet compartment 1000, the refrigerant can effectively cool the motor-driven electronic devices 1080 (by absorbing the heat generated by the electronic devices 1080 and transferred through the wall 1020), which can desirably extend the life of the electronic devices 1080 and can to some extent evaporate any unwanted liquid from the refrigerant. Additionally, the filter screen 1040 can filter out unwanted impurities from the refrigerant. Although in other embodiments the filter screen 1040 can generally be oriented perpendicular to the wall 1020, it should be understood that the inclined orientation of the filter screen 1040 provides an increased surface area compared to a vertically oriented filter screen.

[0048] Figure 61 A vertical cross-sectional view of the semi-hermetic compressor 100 is shown in the direction of line 61-61 of Figure 40 The semi-hermetic compressor housing 120 includes a first outer wall portion 1100 having a generally convex cross-section. The auxiliary housing 180 includes a second outer wall portion 1120 having a generally concave cross-section. The second outer wall portion 1120 faces the first outer wall portion 1100 and is radially spaced apart from the first outer wall portion 1100. The generally concave cross-section is generally arcuately mirror-image to the generally convex cross-section, and the second outer wall portion 1120 is radially spaced apart from the first outer wall portion 100 by at least 10 mm. In other embodiments, the second outer wall portion 1120 is radially spaced apart from the first outer wall portion 1100 by approximately 0.1 mm to 15 mm.

[0049] Figure 62 A view taken from Figure 61An enlarged vertical cross-sectional isolation view of the semi-closed coupling (provided by the suction pipe assembly 500) from the semi-closed compressor housing 120 to the auxiliary housing 180. The suction pipe assembly 500 includes a straight pipe 1140 having a radial flange 1160. It should be understood that the flange 1160 facilitates inserting and sealing the pipe 1140 into the receiving port 340 of the chamber body 260 of the compressor housing 120. The suction pipe assembly 500 further includes a chamfered gasket 1180. The gasket 1180 distributes the pressure exerted by the suction volume over the entire area of the suction pipe flange 1160. The suction pipe assembly 500 further includes a pair of radial seal O-rings 1200, a first axial seal O-ring 1220, and a second axial seal O-ring 1240. Figure 63 A perspective view of the gasket 1180 is shown.

[0050] Figure F A vertical cross-sectional view of an alternative semi-closed compressor 1260 according to various aspects of the present invention is shown in a direction similar to Figure 40 line 61-61. Comparing Figure F with Figure 62 it should be understood that, relative to the compressor 100, the compressor 1260 has replaced the straight pipe 1140 with a J-shaped pipe suction accumulator tube 1280. It should be understood that the suction accumulator tube 1280 has a hole 1300 therein and has a generally J-shaped cross-section.

[0051] Figure 48 A top front right perspective view of the outer portion of the electric drive double-cylinder rolling piston rotary compressor assembly 140 is shown.

[0052] Figure 47 A vertical cross-sectional view of the semi-closed compressor 100 is shown in the direction of Figure 40 line 47-47. Referring to Figure 47 it should be understood that the axial flow impeller 780 (which is fixedly coupled to the hollow camshaft 560 therein) is arranged such that during the operation of the semi-closed compressor 100, when the camshaft 560, the impeller 780, and the joint 800 rotate together, it promotes the oil flow from the helical oil pump assembly 440 through the camshaft 560 to the joint 800 and out of the joint 800. It can also be seen that the camshaft 560 also has an intermediate side hole 1320 positioned in front of the joint 800. It should be understood that the side hole also distributes oil.

[0053] Figure 57 Shown is taken from Figure 47An enlarged vertical cross-sectional isolated view of the helical oil pump assembly 440 of the semi-hermetic compressor 100. The oil pump assembly 440 is an Archimedes screw pump, which includes a coil spring 1340, a screw 1360 made of plastic or any other suitable material, an outer sleeve or tube 1380, and a cup-shaped fitting 640 made of metal or any other suitable material. The tube 1380 is mechanically coupled to the cup-shaped fitting 640. The screw extends along axis 1420. The line 1420 is preferably angled (non-coaxial or non-parallel) with respect to the axis 580 (of the extended portion of the camshaft 560). The spring 1340 is fixedly coupled at one end to the camshaft 560 and transfers / redirects the rotational movement of the camshaft 560 to the screw 1360. Accordingly, the opposite portion or end 1440 of the spring 1340 extends into and is fixedly coupled to the screw 1360. The screw 1360 rotates within the tube 1380 to pump out fluid (oil in this example) in a manner of the Archimedes screw principle. The tube 1380 (which does not rotate) is fixedly coupled to the bearing 1460 through the fitting 640. In the fitting 640, the bearing 1460 abuts the camshaft 560 at the camshaft lubrication hole or inlet 1480. The oil pumped out by the screw 1360 flows into the spring 1340 (near the camshaft 560) through the gap between the coils of the spring 1340 (it should be understood that this gap is exaggerated where the spring 1340 bends from the axis 1420 (of the screw 1360) towards the camshaft lubrication inlet 1480), and then flows into the camshaft lubrication inlet 1480 from inside the spring 1320. The distal end 1500 of the spring (i.e., the end relatively further away from the crankshaft lubrication inlet 1480) is closed by a metal plug 1520, and the metal plug 1520 can also fixedly couple the spring 1340 to the screw 1360. Figure 56 An exploded perspective view of the helical oil pump assembly 440 is shown. In an alternative embodiment, the coil spring 1340 can be replaced by a suitable flexible rod.

[0054] Figure 54 An enlarged vertical cross-sectional isolated view taken from Figure 47 the discharge pipe 404, Figure 53A perspective view of the discharge pipe 404 is shown. The discharge pipe 404 is designed to inhibit lubricating oil (circulating in the compressor housing 120 during operation of the compressor 100) from being carried away by the refrigerant flow through the discharge port 160. The discharge pipe 404 includes a side wall 1540. The side wall 1540 defines an inlet hole 1560 therethrough. The inlet hole 1560 receives refrigerant and / or oil-containing refrigerant entering the discharge pipe 404. The discharge pipe 404 further includes a bottom end 1580 that defines a drip hole 1600. It should be understood that the drip hole 1620 allows oil droplets to drip or fall back into the compressor housing 120 for recirculation through the cooperation of the oil pump assembly 440, the impeller 780, and the camshaft 560. The discharge pipe 404 also has a top, upward outlet opening or hole 1580 that is coupled to the discharge port 160. It should be understood that the outlet opening 1580 allows compressed refrigerant and / or relatively less oil-containing compressed refrigerant to be supplied from the compressor housing 120 through the discharge port 160.

[0055] Figure 51 An enlarged vertical cross-sectional isolated view of the tail oil pipe joint 800 taken from Figure 47 is shown. Figure 50 An enlarged vertical cross-sectional isolated view of the tail oil pipe joint 800 taken from Figure 51 is shown. Figure 49 A perspective view of the tail oil pipe joint 800 is shown. As Figure 51 shown (as discussed above), the oil joint 800 is inserted into and protrudes from the rear portion 620 of the camshaft 560. Further, as can be seen from Figure 51 and more easily seen in Figure 50 and Figure 49 , the joint 800 is generally cup-shaped and tapered to facilitate insertion into the camshaft 560 and has a side wall 1640. The side wall 1640 defines an oil release hole or opening 1660 thereon. It should be understood that although the joint 800 is substantially inserted into the camshaft 560, the joint 800 does protrude from the camshaft 560 enough such that the camshaft 560 does not block or seal the hole 1660, thereby allowing the joint 800 to release oil through the hole 1160 when the camshaft 560 rotates during operation of the compressor 100.

[0056] Figure 45 A top front left perspective view of the counterweight motor rotor assembly 660 is shown. Figure 44Shows a top front left perspective partially exploded view of a counterweight motor rotor assembly 660. The rotor assembly 660 is generally cylindrical and has a first end 1680, a second end 1700, and a generally cylindrical core 1720 that extends axially between the first end 1680 and the second end 1700. The core 1720 is suitably constructed to have conventional wire / windings, magnetic material, and / or other conventional motor rotor materials and features that enable the rotor assembly 660 to operate to rotate properly in response to a magnetic field / electromagnetic field. The rotor assembly 660 includes a first generally disc-shaped counterweight plate 1740 attached to the first end 1680 of the core 1720 and generally axially aligned with the core 1720, and the rotor assembly 660 includes a second generally disc-shaped counterweight plate 1760 attached to the second end 1700 of the core 1720 and generally axially aligned with the core 1720. The first plate 1740 has a first generally C-shaped portion 1780 extending therefrom. The second plate 1760 has a second generally C-shaped portion 1800 extending therefrom. The second portion 1800 is positioned with a rotational displacement of approximately 180 degrees relative to the first portion 1780.

[0057] The assembly 660 also includes a first generally disc-shaped cap 1820 attached to the first plate 1740. The first cap 1820 has a third generally C-shaped portion 1840 extending therefrom. The third portion 1840 is oriented toward the first plate 1740 with a rotational displacement of approximately 180 degrees relative to the first portion 1780. The assembly 660 also includes a second generally disc-shaped cap 1860 attached to the second plate 1760. The second cap 1860 has a fourth generally C-shaped portion 1880 extending therefrom.

[0058] The fourth portion 1880 is oriented toward the second plate 1760 with a rotational displacement of approximately 180 degrees relative to the second portion 1800.

[0059] The rotor caps 1820 and 1860 can be made of plastic (or any other suitable material) to reduce their weight (and thus reduce their impact on the size of the counterweights used for balancing). In some embodiments, the mass of the third portion 1840 is at least five times less than the mass of the first portion 1780, and the mass of the fourth portion 1880 is at least five times less than the mass of the second portion 1800.

[0060] Figure 68 Shows a truncated oblique cross-sectional view of an acoustic muffler system 1900 of an electric drive two-cylinder rolling piston rotary compressor assembly 140.

[0061] As Figure 68 shown, the muffler system 1900 includes:

[0062] 1.) An outer or front camshaft bearing 1920;

[0063] 2.) A front end cap 680 (see alsoFigure C );

[0064] 3.) The first intermediate plate 840 (see also Figure C );

[0065] 4.) The second intermediate plate 860 (see also Figure C );

[0066] 5.) The inner or opposed rear camshaft bearing 1940;

[0067] 6.) The first inner end cap 960 (see also Figure C ); and

[0068] 7.) The second inner end cap 980 (see also Figure C ).

[0069] The outer bearing 1920 and the front end cap 680 together form a first acoustic muffler chamber or volume 1960. The first intermediate plate 840 and the second intermediate plate 860 together form a second acoustic muffler chamber or volume 1980. The inner bearing 1940 and the first inner end cap 960 form a third acoustic muffler chamber or volume 2000. The first inner end cap 960 and the second inner end cap 980 form a fourth acoustic muffler chamber or volume 2020. The first acoustic muffler chamber 1960, the second acoustic muffler chamber 1980, the third acoustic muffler chamber 2000, and the fourth acoustic muffler chamber 2020 are kept in uninterrupted fluid communication with each other through a hole 2040 extending through the outer bearing 1920, a hole 2060 extending through the first intermediate plate 840, a corresponding passage 2080 extending between the hole 2040 and the hole 2060, a hole 2100 extending through the second intermediate plate 860, a hole 2120 extending through the inner bearing 1940, a corresponding passage 2140 extending between the hole 2100 and the hole 2120, and a hole 2160 in the first inner end cap 960.

[0070] The outer bearing 1920 and the front end cap 680 are semi - enclosed and joined together. The second inner end cap 980 includes an inner ring portion 2180. The ring portion 2180 surrounds a corresponding inner portion 2200 of the inner bearing 1940 but is radially spaced therefrom such that the ring portion 2180 and the inner portion 2200 together provide an annular refrigerant discharge hole 2220.

[0071] During operation of the compressor assembly 140, the compressed refrigerant is alternately released from the first cylinder 760 and the second cylinder 900 into the muffler system 1900. The refrigerant is acoustically attenuated by the acoustic muffler system 1900 and circulates and flows through the acoustic muffler system 1900 and is discharged into the semi - enclosed compressor housing 120 through the annular hole 2220.

[0072] Figure 65 Shows complementary exploded perspective views of a first intermediate acoustic muffler plate 840 and a second intermediate acoustic muffler plate 860. The intermediate plates 840, 860 are undercut to form an acoustic cavity 2240 that reduces the emission of unwanted sound / noise. It should be understood that in some embodiments, the exact shape of the cavity 2240 may differ from that shown herein as long as the overall geometry produces suitable acoustic attenuation.

[0073] Figure 69 Shows an isolated cross-sectional view of the inner end of an alternative acoustic muffler system 2260 of an alternative semi-hermetic compressor according to various aspects of the present invention in a direction similar to Figure 68 The muffler system 2260 includes an outer cap 2280 having two side-by-side holes 2300 for discharging refrigerant (only one of which is Figure 69 visible in the figure), the holes are not aligned with the holes 2320 of the smaller inner cap 2340, and are located in the lower part of the alternative compressor to assist in flushing its lubricating oil.

[0074] It should be understood that various aspects of the present invention can be incorporated into air and / or liquid heat exchange air conditioners, refrigeration, heat pumps, and / or other cooling and / or heating systems for electric vehicles, internal combustion engine vehicles, aircraft, watercraft, buildings, manufacturing systems, and / or other suitable applications.

[0075] Although the invention has been illustrated and described in detail in the drawings and the foregoing description, the drawings and the foregoing description are to be considered illustrative rather than restrictive, it should be understood that only certain embodiments have been shown and described, and all changes and modifications consistent with the spirit of the present invention are desired to be protected.

Claims

1. A device, comprising: a semi - enclosed compressor housing; a power - driven twin - cylinder rolling piston rotary compressor assembly, accommodated in said housing; motor - driven electronics; and an auxiliary housing, said auxiliary housing defining a semi - enclosed refrigerant inlet compartment having a wall and defining an electronics compartment that shares a wall with said inlet compartment but is semi - enclosed and separated from said inlet compartment; wherein said compressor housing is semi - enclosed and fluidly connected to said inlet compartment, and said electronics compartment houses said electronics.

2. The device according to claim 1, wherein said compressor housing includes a first outer wall portion having a first convex cross - section, said auxiliary housing includes a second outer wall portion having a generally concave cross - section, said second outer wall portion faces said first outer wall portion, said second outer wall portion is radially spaced from said first outer wall portion, and said generally concave cross - section is generally arcuately mirror - imaged with said generally convex cross - section.

3. The device according to claim 1, wherein said second outer wall portion is radially spaced from said first outer wall portion by about 0.1 mm to 15 mm.

4. The device according to claim 3, wherein said second outer wall portion is radially spaced from said first outer wall portion by at least 10 mm.

5. The device according to claim 4, comprising: a suction accumulator, extending into said inlet compartment, wherein said compressor housing is semi - enclosed and connected to said inlet compartment through said suction accumulator.

6. The device according to claim 5, wherein said suction accumulator includes a tube having a generally J - shaped cross - section.

7. The device according to claim 3, wherein said compressor housing is substantially made of aluminum.

8. The device according to claim 5, wherein said compressor housing is substantially made of aluminum.

9. A device, comprising: a first rolling piston rotary compressor roller; a second rolling piston rotary compressor roller; a substantially hollow camshaft, arranged to cooperate with said first roller and said second roller; an Archimedes screw; and a flexible coupling, mechanically coupled to said camshaft therein, having a first end portion extending from said camshaft in a first direction, having a second end portion extending in a second direction and engaging said Archimedes screw, and having an intermediate portion extending between said first end portion and said second end portion and bending from said first direction to said second direction.

10. The device according to claim 9, wherein said flexible coupling includes a flexible rod.

11. The device according to claim 9, wherein said flexible coupling includes a flexible coil.

12. The device according to claim 11, including an oil flow tube covering said intermediate portion of said coil.

13. The device according to claim 12, wherein said first direction is generally vertical and said second direction is generally downward.

14. The device according to claim 13, comprising: an axial - flow impeller, fixed to said camshaft therein, wherein said first end portion of said coil is fixed to said axial - flow impeller.

15. The device according to claim 13, comprising: a semi - enclosed compressor housing; A baffle, positioned generally above the oil flow tube, the baffle including a bottom surface and a top surface; A refrigerant discharge tube, positioned generally above the top surface of the baffle, opening inside the compressor housing, extending through the compressor housing, and opening outside the compressor housing, wherein the oil flow tube and the baffle are received within the compressor housing, and the bottom surface of the baffle is in fluid communication with the top surface of the baffle within the compressor housing.

16. The apparatus according to claim 15, wherein the baffle arches generally above the oil flow tube.

17. The apparatus according to claim 16, wherein the compressor housing includes a first portion having an inner diameter, the baffle being positioned generally within the first portion of the compressor housing, and the baffle laterally spanning a majority of the inner diameter.

18. The apparatus according to claim 17, wherein the baffle includes a notched left portion and a notched right portion.

19. The apparatus according to claim 18, wherein the baffle is substantially laterally symmetric.

20. The apparatus according to claim 16, wherein the refrigerant discharge tube includes a bottom portion defining a refrigerant drip hole, a top portion defining a refrigerant discharge port, and a generally longitudinal portion extending between the bottom portion and the top portion and defining a refrigerant receiving hole, wherein the drip hole is smaller than the discharge port, and the drip hole is smaller than the receiving hole.

21. An apparatus, comprising: A first rolling piston rotary compressor roll; A second rolling piston rotary compressor roll; A camshaft, arranged to cooperate with the first roll and the second roll, An electric motor, including a rotor, the rotor being mechanically coupled to the camshaft, the rotor including a first end, including a second end, and being generally cylindrical between the first end and the second end; A first generally disc-shaped counterweight, attached to the first end of the rotor, the first counterweight having a first generally C-shaped portion extending therefrom; A second generally disc-shaped counterweight, attached to the second end of the rotor, the second counterweight having a second generally C-shaped portion extending therefrom, the second generally C-shaped portion being positioned on the second end of the rotor at a rotational displacement of approximately 180 degrees relative to the first generally C-shaped portion; A first generally disc-shaped cap, attached to the first counterweight, the first cap having a third generally C-shaped portion extending therefrom, the third generally C-shaped portion facing the first counterweight at a rotational displacement of approximately 180 degrees relative to the first generally C-shaped portion; and A second generally disc-shaped cap, attached to the second counterweight, the second cap having a fourth generally C-shaped portion extending therefrom, the fourth generally C-shaped portion facing the second counterweight at a rotational displacement of approximately 180 degrees relative to the second generally C-shaped portion.

22. The apparatus according to claim 21, wherein the first substantially C-shaped portion has a first mass, the second substantially C-shaped portion has a second mass, the third substantially C-shaped portion has a third mass, the fourth substantially C-shaped portion has a fourth mass, and the first mass is at least five times the third mass.

23. An apparatus comprising: a semi-hermetic compressor housing; a pair of rolling piston rotary compressor cylinders received in the housing, including a first rolling piston rotary compressor cylinder and including a second rolling piston rotary compressor cylinder; a pair of compressor cylinder discharge valves, including a first valve mechanically coupled to the first cylinder and including a second valve mechanically coupled to the second cylinder; and a pair of plates inserted between the first cylinder and the second cylinder, the plates including a first plate defining a first groove, the plates including a second plate facing the first plate and defining a second groove, the first groove and the second groove together defining a first acoustic muffler chamber, wherein the valves are arranged to control the refrigerant flow from the first cylinder and the second cylinder to the first chamber.

24. The apparatus according to claim 23, wherein the second groove is substantially mirror-image to the first groove.

25. The apparatus according to claim 24, wherein each of the plates is disc-shaped.

26. The apparatus according to claim 25, wherein the valves are arranged to alternately direct the refrigerant flow from the first cylinder and the second cylinder to the first chamber.

27. The apparatus according to claim 26, comprising: a camshaft extending through the cylinders, the camshaft having an inner portion and an outer portion; an outer bearing supporting the outer portion of the camshaft; and an outer plate positioned outside the bearing and defining a second acoustic muffler chamber, wherein the second chamber is in fluid communication with the first chamber.

28. An apparatus comprising: a semi-hermetic compressor housing; a pair of rolling piston rotary compressor cylinders received in the housing, including a first rolling piston rotary compressor cylinder and including a second rolling piston rotary compressor cylinder; a pair of compressor cylinder discharge valves, including a first valve mechanically coupled to the first cylinder and including a second valve mechanically coupled to the second cylinder; a camshaft extending through the cylinders, the camshaft having an inner portion and an outer portion; an inner bearing supporting the inner portion of the camshaft; a first inner plate positioned inside the bearing and defining a first acoustic muffler chamber having a pair of refrigerant flow holes, the pair of holes including a first hole extending around a first respective axis, the pair of holes including a second hole extending around a second respective axis; and a second inner plate positioned inside the first plate and defining a second acoustic muffler chamber having a first refrigerant discharge port, the first discharge port extending around a third respective axis, The valve is configured to control the refrigerant flow from the first cylinder and the second cylinder to the first chamber, and the second chamber is in fluid communication with the first chamber, but neither the first axis nor the second axis is aligned with the third axis.

29. The apparatus according to claim 28, wherein the camshaft extends longitudinally about a fourth axis and the third axis is aligned with the fourth axis.

30. The apparatus according to claim 29, wherein the first discharge port has an inner diameter, the inner bearing includes a bearing portion having an outer diameter and extending into the first discharge port, and the outer diameter of the bearing portion is less than the inner diameter of the first discharge port.

31. The apparatus according to claim 30, wherein the second inner plate defines a second discharge port in the second chamber, the first discharge port is positioned relatively lower than the camshaft, and the second discharge port is positioned relatively lower than the camshaft.

32. The apparatus according to claim 28, comprising: a pair of intermediate plates inserted between the first cylinder and the second cylinder, the intermediate plates including a first intermediate plate defining a first groove, the pair of intermediate plates including a second intermediate plate facing the first intermediate plate and defining a second groove, the first groove and the second groove together defining a third acoustic muffler chamber, wherein the valve is configured to control the refrigerant flow from the first cylinder and the second cylinder to the third chamber, and the third chamber is in fluid communication with the first chamber.

33. The apparatus according to claim 32, comprising: an outer bearing supporting the outer portion of the camshaft; and an outer plate positioned outside the bearing and defining a fourth acoustic muffler chamber, wherein the fourth acoustic muffler chamber is in fluid communication with the third chamber.

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