Integrated intercooler two-stage compression cylinder and pure electric vehicle air compressor

Abstract

This invention discloses a two-stage compression cylinder block with an integrated intercooler and an air compressor for pure electric vehicles, belonging to the field of air compressor technology. It includes a primary cylinder and a secondary cylinder; an intercooling mechanism disposed between the primary and secondary cylinders. The intercooling mechanism cools the airflow delivered to the secondary cylinder through a cooling shell, cooling cylinder, several first heat exchange fins, several second heat exchange fins, a heat exchange block, and a heat exchange base plate. This invention employs an intercooling mechanism disposed between the primary and secondary cylinders, directly cooling the high-temperature, high-pressure airflow discharged from the primary cylinder through the cooling shell, cooling cylinder, first heat exchange fins, second heat exchange fins, heat exchange block, and heat exchange base plate. Compared to traditional external intercoolers, integrating the cooling components between the two cylinders eliminates a large number of external pipeline joints, effectively reducing the overall size of the air compressor, simplifying assembly procedures, and reducing the risk of pipeline leakage.

Description

Technical Field

[0001] This invention relates to the field of air compressor technology, and in particular to a two-stage compression cylinder block with an integrated intercooler and an air compressor for pure electric vehicles. Background Technology

[0002] As a core air source component of the vehicle's braking system, the air compressor in a pure electric vehicle provides high-pressure compressed air for the vehicle's braking, air suspension, and other systems. Two-stage air compressors can achieve higher output air pressure by pre-compressing with a first-stage cylinder and boosting with a second-stage cylinder. However, the compressed gas discharged from the first-stage cylinder is at a high temperature. If this high-temperature gas directly enters the second-stage cylinder for further compression, it will further increase the overall temperature of the air compressor, exacerbating the thermal load on components such as pistons and cylinders. This can easily lead to aging and failure of seals, a decrease in compression efficiency, and in severe cases, overheating protection shutdown of the air compressor, affecting the driving safety of the entire vehicle. Existing two-stage air compressors mostly use external independent coolers for intercooling, which involves many pipe joints, a large overall size, and complicated assembly procedures. Some built-in intercooling structures rely solely on a single heat exchange fin for passive heat dissipation, resulting in limited heat exchange capacity and making them unsuitable for the high-load continuous operation conditions of electric vehicles. At the same time, the disassembly and maintenance of cooling and heat exchange components are inconvenient. Summary of the Invention

[0003] The technical problem to be solved by this invention is to overcome the shortcomings of the prior art and provide a two-stage compression cylinder block and an air compressor for pure electric vehicles with an integrated intercooler. It aims to solve the problems of the fact that the intercooling of two-stage air compressors mostly adopts an external independent cooler, which has many pipe joints, large overall size, and complicated assembly process; some built-in intercooling structures rely on a single heat exchange fin for passive heat dissipation, which has limited heat exchange capacity and cannot be adapted to the high-load continuous working conditions of electric vehicles; at the same time, the cooling heat exchange components are inconvenient to disassemble and maintain.

[0004] To achieve the above-mentioned objectives, the first aspect of the present invention provides a two-stage compression cylinder block with an integrated intercooler, comprising a first-stage cylinder and a second-stage cylinder; An intermediate cooling mechanism is provided between the first-stage cylinder and the second-stage cylinder. The intermediate cooling mechanism cools the high-pressure airflow during the process of conveying from the first-stage cylinder to the second-stage cylinder through a cooling shell, a cooling cylinder, a plurality of first heat exchange plates, a plurality of second heat exchange plates, a heat exchange block, and a heat exchange base plate. A heat exchange system is provided on the cooling shell. The heat exchange system exchanges heat with the heat exchange block and the heat exchange base plate through a first oil cooling plate and two second oil cooling plates therein. The first oil cooling plate and the second oil cooling plate are convenient to be connected to the intermediate cooling mechanism. The heat exchange system also includes: A connecting structure is installed on the two second oil cooling plates for quick assembly and disassembly of the second oil cooling plates; An auxiliary heat exchange structure is installed on the cooling shell and is used for air-cooled auxiliary heat dissipation of the first heat exchange plate.

[0005] Optionally, the intermediate cooling mechanism includes a cooling shell, a cooling cylinder, several supports, several first heat exchange plates, several second heat exchange plates, a heat exchange block, and a heat exchange base plate. The two ends of the cooling shell are respectively connected to the first-stage cylinder and the second-stage cylinder. The cooling cylinder is fixedly installed inside the cooling shell. Several supports are fixedly installed on the outer wall of the cooling cylinder. Several first heat exchange plates are fixedly installed on the inner wall of the cooling cylinder. Several second heat exchange plates are fixedly installed on the first heat exchange plates. The bottom of the first heat exchange plates extends to the bottom of the cooling cylinder. The heat exchange block is fixedly installed on the bottom of the first heat exchange plate. The heat exchange base plate is fixedly installed on the bottom of the heat exchange block. The top of the first heat exchange plate is arc-shaped, and part of the edge of the first heat exchange plate inside the cooling cylinder is in contact with the inner wall of the cooling cylinder. An installation opening is provided on the top of one side of the first heat exchange plate, and the second heat exchange plate is longitudinally distributed inside the installation opening. The edge of the second heat exchange plate is in contact with the inner wall of the cooling cylinder.

[0006] Optionally, the heat exchange system includes a first oil cooling plate, a first oil cooling channel, two second oil cooling plates, and a second oil cooling channel. The first oil cooling channel is fixedly installed on the bottom of the inner wall of the cooling shell. The first oil cooling channel is opened inside the first oil cooling plate, and the inlet and outlet of the first oil cooling channel are both located on the same side of the first oil cooling plate. The two second oil cooling plates are respectively arranged on both sides of the heat exchange block. The second oil cooling channels are opened inside the second oil cooling plates, and the inlet and outlet of the second oil cooling channels are both located on the same side of the second oil cooling plate.

[0007] Optionally, the connection structure includes fixing bolts and a plurality of fixing holes, the plurality of fixing holes being respectively opened on one side of the two second oil cooling plates, the fixing holes on the two second oil cooling plates being in one-to-one correspondence, and the fixing bolts being installed inside the corresponding fixing holes.

[0008] Optionally, a groove is provided on the top of the first oil cooling plate, and the bottom of the heat exchange base plate engages with the groove. Heat exchange silicone grease is provided between the second oil cooling plate and the side wall of the heat exchange block, and between the bottom of the heat exchange base plate and the groove wall.

[0009] Optionally, a first compression cylinder is fixedly installed on the inner wall of the first-stage cylinder, a low-pressure piston is slidably installed on the inner wall of the first compression cylinder, an air inlet is fixedly installed on the outer wall of the first-stage cylinder, a second compression cylinder is fixedly installed on the inner wall of the second-stage cylinder, a high-pressure piston is slidably installed on the inner wall of the second compression cylinder, and an air outlet is fixedly installed on the outer wall of the second-stage cylinder.

[0010] Optionally, a first connecting shell and a first connecting port are fixedly installed on the outer wall of the first-stage cylinder, with the first connecting port located inside the first connecting shell. A second connecting shell and a second connecting port are fixedly installed on the outer wall of the second-stage cylinder, with the second connecting port located inside the second connecting shell. The cooling shell is fixedly connected to the first and second connecting shells on both sides, respectively. Valves are fixedly installed on the bottom of the inner walls of the first and second connecting shells, respectively. The inlet end of the valve on the first connecting shell is connected to the first connecting port, and the outlet end of the valve on the first connecting shell is connected to the inlet end on one side of the cooling cylinder. The inlet end of the valve on the second connecting shell is connected to the outlet end on the other side of the cooling cylinder, and the outlet end of the valve on the second connecting shell is connected to the second connecting port.

[0011] Optionally, a side cover is fixedly installed on one side of the cooling shell, and a first oil inlet, a first oil outlet, a plurality of second oil inlets and a plurality of second oil outlets are fixedly installed on one side of the side cover. A connecting pipe is fixedly installed at one end of the inlet and outlet of the first oil cooling plate and the second oil cooling plate, and the connecting pipe is respectively connected to the corresponding first oil inlet, first oil outlet, second oil inlet and second oil outlet.

[0012] Optionally, an air inlet is provided on one side of the side cover, and a dustproof mesh is fixedly installed on the inner wall of the air inlet. An installation frame is fixedly installed on the other side of the side cover, and the position of the installation frame corresponds to the position of the air inlet. A cooling fan is fixedly installed on the inner wall of the installation frame, and an air outlet is provided on the other side of the cooling shell.

[0013] The second aspect of this invention provides an air compressor for a pure electric vehicle, comprising a two-stage compression cylinder body with an integrated intercooler, and a housing. Two mounting components are fixedly installed on the top of the housing. The first-stage cylinder and the second-stage cylinder are respectively fixedly connected to the top of the corresponding mounting components. The bottom of the cooling shell is fixedly connected to the top of the housing. An eccentric wheel is rotatably installed on one side of the inner wall of the housing. A first rocker arm and a second rocker arm are rotatably installed on one end of the eccentric wheel. Bearings are provided at the connection points between the first rocker arm and the second rocker arm and the eccentric wheel. The other end of the first rocker arm is rotatably connected to the inner wall of the low-pressure piston, and the other end of the second rocker arm is rotatably connected to the inner wall of the high-pressure piston. The low-pressure piston has a larger diameter than the high-pressure piston.

[0014] The beneficial effects of this invention are: 1. The present invention relates to a two-stage compression cylinder block with an integrated intercooler and an air compressor for pure electric vehicles. The intercooling mechanism is set between the first-stage cylinder and the second-stage cylinder. The high-temperature and high-pressure airflow discharged from the first-stage cylinder is directly cooled by heat exchange through a cooling shell, cooling cylinder, first heat exchange fins, second heat exchange fins, heat exchange block, and heat exchange base plate. Compared with the traditional external intercooler, the cooling components are integrated between the two-stage cylinders, eliminating a large number of external pipeline joints, effectively reducing the overall size of the air compressor, simplifying the assembly process, and reducing the risk of pipeline leakage.

[0015] 2. The present invention provides a two-stage compression cylinder block and an air compressor for pure electric vehicles with an integrated intercooler. By using a first oil cooling plate to exchange heat at the bottom of the heat exchange base plate and two second oil cooling plates to exchange heat on both sides of the heat exchange block, a multi-faceted synergistic oil cooling heat exchange system is formed, which greatly improves the heat removal efficiency and ensures that the intercooling mechanism can maintain a good cooling effect under continuous high load operation.

[0016] 3. The present invention relates to a two-stage compression cylinder block with an integrated intercooler and an air compressor for pure electric vehicles. The first and second oil cooling plates of the heat exchange system are used in conjunction with the intercooling mechanism to achieve oil-cooled heat exchange, while an auxiliary heat exchange structure is used to achieve air-cooled auxiliary heat dissipation. The composite heat dissipation mode of oil cooling and air cooling can quickly remove the heat conducted by the heat exchange block and the heat exchange base plate, effectively reduce the intake temperature of the air entering the second stage cylinder, reduce the heat generated in the second stage compression process, reduce the thermal load of the cylinder and piston, and improve the reliability of the air compressor for continuous operation.

[0017] 4. The present invention provides a two-stage compression cylinder block with an integrated intercooler and an air compressor for pure electric vehicles, which adopts a connection structure mounted on the second oil cooling plate. The two second oil cooling plates can be clamped and fixed by the fixing bolts and corresponding fixing holes. During disassembly and assembly, only the fixing bolts need to be removed and installed to achieve quick disassembly of the second oil cooling plate, which facilitates later inspection, cleaning and replacement of heat exchange components, and reduces the difficulty of equipment maintenance. Attached Figure Description

[0018] Figure 1 This is a structural schematic diagram of a two-stage compression cylinder block with an integrated intercooler and an air compressor for pure electric vehicles according to the present invention. Figure 2 This is an overall view of a two-stage compression cylinder block with an integrated intercooler and an air compressor for pure electric vehicles according to the present invention. Figure 3 This is a diagram of a two-stage compression cylinder block with an integrated intercooler and an intercooling mechanism for an air compressor in a pure electric vehicle, according to the present invention. Figure 4 This is a cross-sectional view of a two-stage compression cylinder block with an integrated intercooler and a cooling cylinder for an air compressor in a pure electric vehicle, according to the present invention. Figure 5This is a diagram of an auxiliary heat exchange structure for a two-stage compression cylinder block with an integrated intercooler and an air compressor for a pure electric vehicle, according to the present invention. Figure 6 This is a cross-sectional view of the cooling channels on the first and second oil cooling plates of a two-stage compression cylinder block with an integrated intercooler and an air compressor for pure electric vehicles according to the present invention.

[0019] Explanation of reference numerals in the attached figures: 1. First-stage cylinder; 2. Second-stage cylinder; 3. Inlet; 4. Outlet; 5. First compression cylinder; 6. Low-pressure piston; 7. Second compression cylinder; 8. High-pressure piston; 9. First connecting shell; 10. Second connecting shell; 11. First connecting port; 12. Second connecting port; 13. Valve; 14. Cooling shell; 15. Cooling cylinder; 16. First heat exchanger plate; 17. Second heat exchanger plate; 18. Heat exchanger block; 19. Heat exchanger base plate; 20. First oil cooling plate ; 21. First oil cooling channel; 22. Bracket; 23. Second oil cooling plate; 24. Second oil cooling channel; 25. Side cover; 26. First oil inlet; 27. First oil outlet; 28. Second oil inlet; 29. ​​Second oil outlet; 30. Fixing bolt; 31. Dustproof mesh plate; 32. Mounting frame; 33. Cooling fan; 34. Outer shell; 35. Eccentric wheel; 36. First rocker arm; 37. Second rocker arm; 38. Mounting component; 39. Connecting pipe.

[0020] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0021] It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0022] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection, a direct connection, or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0023] Example 1 Reference Figures 1-6An embodiment of the present invention provides an embodiment of a two-stage compression cylinder block with an integrated intercooler, including a primary cylinder 1 and a secondary cylinder 2; an intercooling mechanism disposed between the primary cylinder 1 and the secondary cylinder 2, the intercooling mechanism cooling the high-pressure airflow during the transport process from the primary cylinder 1 to the secondary cylinder 2 through a cooling shell 14, a cooling cylinder 15, a plurality of first heat exchange plates 16, a plurality of second heat exchange plates 17, a heat exchange block 18, and a heat exchange base plate 19; a heat exchange system disposed on the cooling shell 14, the heat exchange system exchanging heat with the heat exchange block 18 and the heat exchange base plate 19 through a first oil cooling plate 20 and two second oil cooling plates 23, and the first oil cooling plate 20 and the second oil cooling plate 23 being easily connected to the intercooling mechanism; the heat exchange system also includes a connecting structure installed on the two second oil cooling plates 23 for quick assembly and disassembly of the second oil cooling plates 23; and an auxiliary heat exchange structure installed on the cooling shell 14 for air-cooled auxiliary heat dissipation of the first heat exchange plates 16.

[0024] Understandably, the first-stage cylinder 1 is used to perform the first-stage compression of the intake gas, forming medium-pressure, high-temperature gas; the second-stage cylinder 2 is used to perform the second-stage compression of the medium-pressure gas after it has been cooled by the intermediate cooling mechanism, forming high-pressure gas output; the intermediate cooling mechanism is integrated between the first-stage cylinder 1 and the second-stage cylinder 2, eliminating the need for additional connecting pipelines, effectively reducing the overall size of the equipment and lowering the pressure loss during gas flow; the cooling shell 14 serves as the external load-bearing structure of the intermediate cooling mechanism, providing installation space for the internal heat exchange components and sealingly connecting with the cylinders on both sides; the cooling cylinder 15 serves as the core channel for gas flow, guiding the high-temperature gas to flow inside and fully contact the heat exchange components; the first heat exchange plate 16 and the second heat exchange plate 17 significantly increase the contact area between the gas and the heat exchange wall, enhancing convective heat transfer. The heat exchange block 18 and the heat exchange base plate 19 concentrate the heat absorbed by the first heat exchange plate 16 to the heat exchange system, achieving efficient heat removal. The first oil cooling plate 20 and the second oil cooling plate 23 perform forced heat exchange on the heat exchange block 18 and the heat exchange base plate 19 through internally circulating cooling oil. The oil cooling method has the advantages of high heat exchange efficiency and good temperature uniformity, and can quickly remove the accumulated heat. The connection structure enables quick disassembly and assembly of the second oil cooling plate 23, which facilitates the maintenance and replacement of the heat exchange system and reduces maintenance costs. The auxiliary heat exchange structure provides auxiliary heat dissipation for the first heat exchange plate 16 through air cooling, forming a composite heat exchange mode with the oil cooling system, further improving the overall cooling capacity and ensuring that the gas temperature can be reduced to the ideal range under high load conditions.

[0025] In some embodiments, such as Figure 2 , Figure 3 , Figure 4As shown, the intermediate cooling mechanism includes a cooling shell 14, a cooling cylinder 15, several supports 22, several first heat exchange fins 16, several second heat exchange fins 17, a heat exchange block 18, and a heat exchange base plate 19. The cooling shell 14 is connected at both ends to a primary cylinder 1 and a secondary cylinder 2, respectively. The cooling cylinder 15 is fixedly installed inside the cooling shell 14. Several supports 22 are fixedly installed on the outer wall of the cooling cylinder 15. Several first heat exchange fins 16 are fixedly installed on the inner wall of the cooling cylinder 15, and several second heat exchange fins 17 are fixedly installed on the first... On the heat exchange plate 16, the bottom of the first heat exchange plate 16 extends to the bottom of the cooling cylinder 15, the heat exchange block 18 is fixedly installed on the bottom of the first heat exchange plate 16, and the heat exchange base plate 19 is fixedly installed on the bottom of the heat exchange block 18; the top of the first heat exchange plate 16 is arc-shaped, and the edge of the first heat exchange plate 16 located inside the cooling cylinder 15 is in contact with the inner wall of the cooling cylinder 15; an installation opening is provided on the top of one side of the first heat exchange plate 16, and the second heat exchange plate 17 is longitudinally distributed inside the installation opening, and the edge of the second heat exchange plate 17 is in contact with the inner wall of the cooling cylinder 15.

[0026] Understandably, the cooling shell 14 integrates the intermediate cooling mechanism with the cylinder block, ensuring both the sealing of the gas flow channel and improving structural integration. The cooling cylinder 15 provides an independent flow channel for high-temperature gas, allowing the gas to flow in a concentrated manner within the cooling cylinder 15 and fully contact the heat exchange components, preventing disordered diffusion of gas within the cooling shell 14 and reducing heat exchange efficiency. The bracket 22 firmly supports the cooling cylinder 15 inside the cooling shell 14, ensuring the relative positional stability between the cooling cylinder 15 and the cooling shell 14. Several first heat exchange plates 16 increase the heat exchange area of ​​the gas flow channel, enabling the high-temperature gas to fully contact the first heat exchange plates 16 as it flows through the cooling cylinder 15. The first heat exchanger 16 is touched to transfer heat to the first heat exchanger 16; the second heat exchanger 17 further increases the heat exchange area per unit space, and at the same time, it disturbs the gas flow, destroys the gas boundary layer, and enhances the convective heat transfer effect; the bottom of the first heat exchanger 16 extends to the bottom of the cooling cylinder 15 and is connected to the heat exchange block 18, so that the heat absorbed by the first heat exchanger 16 can be transferred to the heat exchange block 18 by heat conduction; the heat exchange block 18, as an intermediate component for concentrated heat conduction, gathers the heat transferred by multiple first heat exchangers 16 and conducts it to the heat exchange base plate 19; the heat exchange base plate 19 contacts the first oil cooling plate 20, so that the heat can be transferred to the oil cooling system and improve the overall heat exchange efficiency.

[0027] In some embodiments, such as Figure 2 , Figure 6As shown, the heat exchange system includes a first oil cooling plate 20, a first oil cooling channel 21, two second oil cooling plates 23, and a second oil cooling channel 24. The first oil cooling channel 21 is fixedly installed on the bottom of the inner wall of the cooling shell 14. The first oil cooling channel 21 is opened inside the first oil cooling plate 20, and the inlet and outlet of the first oil cooling channel 21 are located on the same side of the first oil cooling plate 20. The two second oil cooling plates 23 are respectively arranged on both sides of the heat exchange block 18. The second oil cooling channel 24 is opened inside the second oil cooling plate 23, and the inlet and outlet of the second oil cooling channel 24 are located on the same side of the second oil cooling plate 23.

[0028] Understandably, the first oil cooling plate 20 absorbs the heat transferred by the heat exchange base plate 19 through heat conduction; the first oil cooling channel 21 allows cooling oil to flow through it, and the cooling oil absorbs the heat from the first oil cooling plate 20 during its flow and carries it away, thus achieving forced cooling of the heat exchange base plate 19; the inlet and outlet of the first oil cooling channel 21 are both located on the same side of the first oil cooling plate 20, which facilitates the centralized arrangement and connection of cooling oil pipelines, reduces the space occupied by pipelines, and also facilitates disassembly and maintenance from the same side of the equipment; the two second oil cooling plates 23 absorb heat from both sides of the heat exchange block 18 simultaneously, forming a double-sided symmetrical heat exchange... The heat exchanger 18 is heated to make the temperature distribution more uniform and avoid local overheating. The second oil cooling channel 24 provides cooling oil flow and carries away the heat absorbed by the second oil cooling plate 23. The inlet and outlet of the second oil cooling channel 24 are located on the same side of the second oil cooling plate 23, which also facilitates the centralized connection and maintenance of the pipeline. Through the heat exchange of the bottom of the heat exchange base plate 19 by the first oil cooling plate 20 and the heat exchange of the two sides of the heat exchange block 18 by the two second oil cooling plates 23, a multi-faceted synergistic oil cooling heat exchange system is formed, which greatly improves the heat removal efficiency and ensures that the intermediate cooling mechanism can still maintain a good cooling effect under continuous high load operation.

[0029] In one example, the connection structure includes fixing bolts 30 and several fixing holes. The fixing holes are respectively opened on one side of the two second oil cooling plates 23. The fixing holes on the two second oil cooling plates 23 are in one-to-one correspondence. The fixing bolts 30 are installed in the corresponding fixing holes. The top of the first oil cooling plate 20 is provided with a groove. The bottom of the heat exchange base plate 19 is engaged with the groove. Heat exchange silicone grease is provided between the side walls of the corresponding second oil cooling plates 23 and heat exchange blocks 18, and between the bottom of the heat exchange base plate 19 and the groove wall.

[0030] Understandably, the fixing holes provide installation positioning for the fixing bolts 30; the fixing bolts 30 pass through the corresponding fixing holes on the two second oil cooling plates 23 and are tightened, so that the two second oil cooling plates 23 clamp the heat exchange block 18 from both sides, ensuring a tight fit between the second oil cooling plates 23 and the side walls of the heat exchange block 18, reducing contact thermal resistance and improving heat exchange efficiency; at the same time, the connection method using fixing bolts 30 is simple in structure and easy to disassemble and assemble. When maintenance or replacement of the second oil cooling plates 23 is required, the fixing bolts 30 can be unscrewed to remove the second oil cooling plates 23 from both sides of the heat exchange block 18 without disassembling other parts, which greatly reduces the difficulty and cost of maintenance; the groove on the top of the first oil cooling plate 20 engages with the bottom of the heat exchange base plate 19, realizing quick positioning between the first oil cooling plate 20 and the heat exchange base plate 19, ensuring the installation position of the two; the heat exchange silicone grease filled between the contact surfaces can fill the tiny gaps, expel air, and significantly reduce contact thermal resistance.

[0031] like Figure 2 As shown, a first compression cylinder 5 is fixedly installed on the inner wall of the first-stage cylinder 1, a low-pressure piston 6 is slidably installed on the inner wall of the first compression cylinder 5, an air inlet 3 is fixedly installed on the outer wall of the first-stage cylinder 1, a second compression cylinder 7 is fixedly installed on the inner wall of the second-stage cylinder 2, a high-pressure piston 8 is slidably installed on the inner wall of the second compression cylinder 7, and an air outlet 4 is fixedly installed on the outer wall of the second-stage cylinder 2.

[0032] Understandably, the first compression cylinder 5 provides a precise sliding guide surface for the low-pressure piston 6 and simultaneously forms the wall of the first-stage compression chamber, ensuring the sealing of the compression process. Under the action of the drive mechanism, the low-pressure piston 6 reciprocates axially along the first compression cylinder 5, changing the volume of the first compression chamber to achieve the first-stage compression of the gas, compressing the intake atmospheric pressure gas into medium-pressure, high-temperature gas. The air inlet 3 serves as the channel for external gas to enter the first-stage cylinder 1, and its opening and closing are controlled by a solenoid valve, allowing external gas to smoothly enter the first compression chamber during the intake stroke of the low-pressure piston 6. The second compression cylinder 7 provides a precise sliding guide surface for the high-pressure piston 8 and forms the wall of the second-stage compression chamber. The high-pressure piston 8, under the action of the drive mechanism, reciprocates axially along the first compression cylinder 5, changing the volume of the first compression chamber to achieve the first-stage compression of the gas, compressing the intake atmospheric pressure gas into medium-pressure, high-temperature gas. Under the action of the mechanism, it reciprocates along the axis of the second compression cylinder 7, and by changing the volume of the second compression chamber, it performs a second-stage compression of the medium-pressure gas after it has been cooled by the intermediate cooling mechanism, compressing it into high-pressure gas that meets the requirements of use; the outlet 4 serves as the output channel for the compressed high-pressure gas, and its opening and closing are controlled by a solenoid valve, so as to transport the high-pressure gas compressed in the second-stage cylinder 2 to the gas storage or gas consumption equipment. Through the cooperation of the first compression cylinder 5 and the low-pressure piston 6, and the second compression cylinder 7 and the high-pressure piston 8, the two-stage progressive compression of the gas is realized, which can obtain a higher compression ratio and output pressure than single-stage compression. At the same time, the compression ratio of each stage is relatively small, which is beneficial to reduce the temperature rise and power consumption during the compression process.

[0033] like Figure 2As shown, a first connecting shell 9 and a first connecting port 11 are fixedly installed on the outer wall of the first-stage cylinder 1. The first connecting port 11 is located inside the first connecting shell 9. A second connecting shell 10 and a second connecting port 12 are fixedly installed on the outer wall of the second-stage cylinder 2. The second connecting port 12 is located inside the second connecting shell 10. The cooling shell 14 is fixedly connected to the first connecting shell 9 and the second connecting shell 10 on both sides respectively. Valves 13 are fixedly installed on the bottom of the inner walls of the first connecting shell 9 and the second connecting shell 10 respectively. The inlet end of the valve 13 on the first connecting shell 9 is connected to the first connecting port 11, and the outlet end of the valve 13 on the first connecting shell 9 is connected to the inlet end on one side of the cooling cylinder 15. The inlet end of the valve 13 on the second connecting shell 10 is connected to the outlet end on the other side of the cooling cylinder 15, and the outlet end of the valve 13 on the second connecting shell 10 is connected to the second connecting port 12.

[0034] Understandably, the first connecting shell 9 serves as a transitional connection structure between the first-stage cylinder 1 and the cooling shell 14, providing installation space for the first connecting port 11 and the valve 13, while simultaneously achieving a sealed connection between the first-stage cylinder 1 and the intermediate cooling mechanism. The first connecting port 11 is connected to the compression chamber of the first-stage cylinder 1, used to export the medium-pressure, high-temperature gas compressed by the first-stage cylinder 1 to the intermediate cooling mechanism. The second connecting shell 10 serves as a transitional connection structure between the second-stage cylinder 2 and the cooling shell 14, providing installation space for the second connecting port 12 and the valve 13, achieving a sealed connection between the second-stage cylinder 2 and the intermediate cooling mechanism. The second connecting port 12 is connected to the compression chamber of the second-stage cylinder 2, used to introduce the medium-pressure gas cooled by the intermediate cooling mechanism into the second-stage cylinder 2 for recompression. The housing 14 integrates the first-stage cylinder 1, the intermediate cooling mechanism, and the second-stage cylinder 2 into a single cylinder body structure, resulting in a compact structure and high integration. The valve 13 controls the unidirectional flow of gas between the intermediate cooling mechanism and the cylinder, preventing backflow. The valve 13 on the first connecting housing 9 ensures that the medium-pressure, high-temperature gas discharged from the first-stage cylinder 1 can only flow unidirectionally into the cooling cylinder 15 for cooling, preventing the cooled gas from flowing back into the first-stage cylinder 1. The valve 13 on the second connecting housing 10 ensures that the gas cooled by the cooling cylinder 15 can only flow unidirectionally into the second-stage cylinder 2 for recompression, preventing the gas from flowing back into the cooling cylinder 15 during compression in the second-stage cylinder 2. Through the cooperation of the two valves 13, the unidirectional orderly flow of gas during the two-stage compression and intermediate cooling process is ensured, improving compression efficiency and operational reliability.

[0035] In this embodiment, valve 13 can be a solenoid valve.

[0036] like Figure 5As shown, a side cover 25 is fixedly installed on one side of the cooling shell 14. A first oil inlet 26, a first oil outlet 27, several second oil inlets 28, and several second oil outlets 29 are fixedly installed on one side of the side cover 25. A connecting pipe 39 is fixedly installed at one end of the inlet and outlet of the first oil cooling plate 20 and the second oil cooling plate 23. The connecting pipe 39 is connected to the corresponding first oil inlet 26, first oil outlet 27, second oil inlet 28, and second oil outlet 29, respectively. An air inlet is opened on one side of the side cover 25. A dustproof mesh plate 31 is fixedly installed on the inner wall of the air inlet. An installation frame 32 is fixedly installed on the other side of the side cover 25. The position of the installation frame 32 corresponds to the position of the air inlet. A cooling fan 33 is fixedly installed on the inner wall of the installation frame 32. An air outlet is provided on the other side of the cooling shell 14.

[0037] Understandably, the side cover 25 is used to seal the side opening of the cooling shell 14, allowing the cooling oil pipes and cooling fan 33 to be integrated on the side cover 25, improving structural integration; the first oil inlet 26 and the first oil outlet 27 serve as external interfaces for the cooling oil to enter and exit the first oil cooling plate 20, respectively; several second oil inlets 28 and second oil outlets 29 correspond to two second oil cooling plates 23, serving as cooling oil inlet and outlet interfaces for each second oil cooling plate 23, realizing independent cooling oil circulation for each second oil cooling plate 23; the connecting pipe 39 seals and connects the oil cooling channel inside the oil cooling plate with the oil port interface on the side cover 25, ensuring smooth flow of cooling oil between the external pipes and the oil cooling plate, preventing leakage; the air inlet serves as a channel for external cooling air to enter the interior of the cooling shell 14; the dustproof mesh plate 31 is used for... The cooling fan 33 filters dust and impurities from the air entering the cooling shell 14, preventing dust from adhering to the surfaces of the first heat exchange fins 16 and the cooling cylinder 15 and reducing heat exchange efficiency, while also protecting the cooling fan 33 from dust. When the cooling fan 33 is running, it generates forced airflow, drawing external cooling air into the cooling shell 14 through the air inlet. The cooling air then flows over the outer walls of the first heat exchange fins 16 and the cooling cylinder 15, carrying away heat from their surfaces, thus achieving air-assisted heat dissipation. The air outlet serves as a channel for expelling the hot air after heat absorption, allowing the cooling air to flow in an orderly manner from the air inlet to the air outlet inside the cooling shell 14, improving the air-cooling effect. Through the forced air cooling of the cooling fan 33 and the combination of the oil cooling system, a composite heat dissipation system with oil cooling as the main component and air cooling as the auxiliary component is formed, further enhancing the overall cooling capacity of the intermediate cooling mechanism.

[0038] Example 2 This embodiment proposes an air compressor for a pure electric vehicle, which also includes a housing 34. Two mounting parts 38 are fixedly installed on the top of the housing 34. The first-stage cylinder 1 and the second-stage cylinder 2 are respectively fixedly connected to the top of the corresponding mounting parts 38. The bottom of the cooling shell 14 is fixedly connected to the top of the housing 34. An eccentric wheel 35 is rotatably installed on one side of the inner wall of the housing 34. A first rocker arm 36 and a second rocker arm 37 are rotatably installed on one end of the eccentric wheel 35. Bearings are provided at the connection between the first rocker arm 36 and the second rocker arm 37 and the eccentric wheel 35. The other end of the first rocker arm 36 is rotatably connected to the inner wall of the low-pressure piston 6, and the other end of the second rocker arm 37 is rotatably connected to the inner wall of the high-pressure piston 8. The diameter of the low-pressure piston 6 is larger than that of the high-pressure piston 8.

[0039] Understandably, the outer casing 34 provides installation space for the drive structure and supports the upper two-stage compression cylinder body; the two mounting parts 38 are used to support and fix the first-stage cylinder 1 and the second-stage cylinder 2 respectively, ensuring that the two cylinders are stably and reliably mounted on the outer casing 34; the bottom of the cooling shell 14 is fixedly connected to the top of the outer casing 34, so that the intermediate cooling mechanism is also supported by the outer casing 34, further improving the stability of the entire cylinder body structure; the eccentric wheel 35 rotates under the drive of the drive motor, which is a commonly used technology in existing electric drives, converting the rotational motion into the reciprocating swing of the rocker arm, providing... The piston compression provides the power input; the first rocker arm 36 and the second rocker arm 37 reciprocate with the rotation of the eccentric wheel 35, converting the rotational motion of the eccentric wheel 35 into the axial reciprocating motion of the low-pressure piston 6 and the high-pressure piston 8 in their respective compression cylinders, thereby compressing the gas; the diameter of the low-pressure piston 6 is larger than that of the high-pressure piston 8, making the volume of the first-stage compression chamber larger than that of the second-stage compression chamber, which meets the volume matching requirements of the two-stage compression. The first stage draws in a large volume of atmospheric pressure gas and compresses it into a smaller volume of medium-pressure gas, and the second stage further compresses the medium-pressure gas into an even smaller volume of high-pressure gas.

[0040] In practical applications, an external drive motor drives an eccentric wheel 35 to rotate. The eccentric wheel 35 drives a low-pressure piston 6 and a high-pressure piston 8 to reciprocate within a first compression cylinder 5 and a second compression cylinder 7 via a first rocker arm 36 and a second rocker arm 37, respectively. When the low-pressure piston 6 moves downward, a negative pressure is created in the first-stage cylinder 1, and external gas enters the first compression chamber through the inlet 3. When the low-pressure piston 6 moves upward, the volume of the first compression chamber decreases, and the gas is compressed into medium-pressure high-temperature gas. The compressed medium-pressure high-temperature gas then enters the cooling cylinder 15 through the first connecting port 11, which opens the valve 13 inside the first connecting shell 9. As the high-temperature gas flows within the cooling cylinder 15, the cooled medium-pressure gas flows out from the outlet of the cooling cylinder 15 and enters the second compression chamber of the second-stage cylinder 2 through the second connecting port 12. When the high-pressure piston 8 moves upward, it performs a second-stage compression on the medium-pressure gas, compressing it into high-pressure gas, which is finally output to the gas system of the pure electric vehicle through the outlet 4.

[0041] The above description is merely a preferred embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A two-stage compression cylinder block with an integrated intercooler, characterized in that, include: First-stage cylinder (1) and second-stage cylinder (2); An intermediate cooling mechanism is provided between the first-stage cylinder (1) and the second-stage cylinder (2). The intermediate cooling mechanism cools the high-pressure airflow during the transmission process from the first-stage cylinder (1) to the second-stage cylinder (2) through a cooling shell (14), a cooling cylinder (15), a plurality of first heat exchange plates (16), a plurality of second heat exchange plates (17), a heat exchange block (18), and a heat exchange base plate (19). A heat exchange system is provided on the cooling shell (14). The heat exchange system exchanges heat with the heat exchange block (18) and the heat exchange base plate (19) through the first oil cooling plate (20) and two second oil cooling plates (23). The first oil cooling plate (20) and the second oil cooling plate (23) are convenient to be connected to the intermediate cooling mechanism. The heat exchange system also includes: The connection structure is installed on the two second oil cooling plates (23) for quick assembly and disassembly of the second oil cooling plates (23); An auxiliary heat exchange structure is installed on the cooling shell (14) and is used to provide air-cooled auxiliary heat dissipation for the first heat exchange plate (16).

2. The two-stage compression cylinder block with an integrated intercooler according to claim 1, characterized in that, The intermediate cooling mechanism includes a cooling shell (14), a cooling cylinder (15), several supports (22), several first heat exchange plates (16), several second heat exchange plates (17), a heat exchange block (18), and a heat exchange base plate (19). The two ends of the cooling shell (14) are connected to the first-stage cylinder (1) and the second-stage cylinder (2), respectively. The cooling cylinder (15) is fixedly installed inside the cooling shell (14). Several supports (22) are fixedly installed on the outer wall of the cooling cylinder (15). Several first heat exchange plates (16) are fixedly installed on the inner wall of the cooling cylinder (15). Several second heat exchange plates (17) are fixedly installed on the first heat exchange plates (16). The bottom of the first heat exchange plates (16) extends to the bottom of the cooling cylinder (15). The heat exchange block (18) is fixedly installed on the bottom of the first heat exchange plates (16). The heat exchange base plate (19) is fixedly installed on the bottom of the heat exchange block (18). The top of the first heat exchange plate (16) is arc-shaped. The edge of the first heat exchange plate (16) located inside the cooling cylinder (15) is in contact with the inner wall of the cooling cylinder (15). An installation port is provided on one side of the top of the first heat exchange plate (16). The second heat exchange plate (17) is longitudinally distributed inside the installation port. The edge of the second heat exchange plate (17) is in contact with the inner wall of the cooling cylinder (15).

3. A two-stage compression cylinder block with an integrated intercooler according to claim 2, characterized in that, The heat exchange system includes a first oil cooling plate (20), a first oil cooling channel (21), two second oil cooling plates (23) and a second oil cooling channel (24). The first oil cooling channel (21) is fixedly installed on the bottom of the inner wall of the cooling shell (14). The first oil cooling channel (21) is opened inside the first oil cooling plate (20), and the inlet and outlet of the first oil cooling channel (21) are located on the same side of the first oil cooling plate (20). The two second oil cooling plates (23) are respectively arranged on both sides of the heat exchange block (18). The second oil cooling channel (24) is opened inside the second oil cooling plate (23), and the inlet and outlet of the second oil cooling channel (24) are located on the same side of the second oil cooling plate (23).

4. A two-stage compression cylinder block with an integrated intercooler according to claim 3, characterized in that; The connection structure includes a fixing bolt (30) and a plurality of fixing holes. The plurality of fixing holes are respectively opened on one side of the two second oil cooling plates (23). The positions of the fixing holes on the two second oil cooling plates (23) correspond one to one. The fixing bolt (30) is installed inside the corresponding fixing hole.

5. A two-stage compression cylinder block with an integrated intercooler according to claim 3, characterized in that, The top of the first oil cooling plate (20) is provided with a groove, and the bottom of the heat exchange base plate (19) is engaged with the groove. Heat exchange silicone grease is provided between the side wall of the second oil cooling plate (23) and the heat exchange block (18), and between the bottom of the heat exchange base plate (19) and the groove wall.

6. A two-stage compression cylinder block with an integrated intercooler according to claim 1, characterized in that, The first-stage cylinder (1) has a first compression cylinder (5) fixedly installed on its inner wall. A low-pressure piston (6) is slidably installed on the inner wall of the first compression cylinder (5). An air inlet (3) is fixedly installed on the outer wall of the first-stage cylinder (1). A second compression cylinder (7) is fixedly installed on the inner wall of the second-stage cylinder (2). A high-pressure piston (8) is slidably installed on the inner wall of the second compression cylinder (7). An air outlet (4) is fixedly installed on the outer wall of the second-stage cylinder (2).

7. A two-stage compression cylinder block with an integrated intercooler according to claim 2, characterized in that, The outer wall of the first-stage cylinder (1) is fixedly equipped with a first connecting shell (9) and a first connecting port (11), the first connecting port (11) being located inside the first connecting shell (9). The outer wall of the second-stage cylinder (2) is fixedly equipped with a second connecting shell (10) and a second connecting port (12), the second connecting port (12) being located inside the second connecting shell (10). The cooling shell (14) is fixedly connected to the first connecting shell (9) and the second connecting shell (10) on both sides respectively. The inner walls of the first connecting shell (9) and the second connecting shell (10) are... Valves (13) are fixedly installed at the bottom respectively. The inlet end of the valve (13) on the first connecting shell (9) is connected to the first connecting port (11). The outlet end of the valve (13) on the first connecting shell (9) is connected to the inlet end on one side of the cooling cylinder (15). The inlet end of the valve (13) on the second connecting shell (10) is connected to the outlet end on the other side of the cooling cylinder (15). The outlet end of the valve (13) on the second connecting shell (10) is connected to the second connecting port (12).

8. A two-stage compression cylinder block with an integrated intercooler according to claim 3, characterized in that, A side cover (25) is fixedly installed on one side of the cooling shell (14). A first oil inlet (26), a first oil outlet (27), a number of second oil inlets (28) and a number of second oil outlets (29) are fixedly installed on one side of the side cover (25). A connecting pipe (39) is fixedly installed at one end of the inlet and outlet of the first oil cooling plate (20) and the second oil cooling plate (23). The connecting pipe (39) is connected to the corresponding first oil inlet (26), first oil outlet (27), second oil inlet (28) and second oil outlet (29) respectively.

9. A two-stage compression cylinder block with an integrated intercooler according to claim 8, characterized in that, An air inlet is provided on one side of the side cover (25), and a dustproof mesh plate (31) is fixedly installed on the inner wall of the air inlet. An installation frame (32) is fixedly installed on the other side of the side cover (25). The position of the installation frame (32) corresponds to the position of the air inlet. A cooling fan (33) is fixedly installed on the inner wall of the installation frame (32). An air outlet is provided on the other side of the cooling shell (14).

10. An air compressor for pure electric vehicles, characterized in that, The dual-stage compression cylinder body including any one of claims 1-9 with an integrated intercooler further includes a housing (34), on the top of the housing (34) two mounting parts (38) are fixedly installed, the first-stage cylinder (1) and the second-stage cylinder (2) are respectively fixedly connected to the top of the corresponding mounting parts (38), the bottom of the cooling shell (14) is fixedly connected to the top of the housing (34), an eccentric wheel (35) is rotatably installed on one side of the inner wall of the housing (34), a first rocker arm (36) and a second rocker arm (37) are rotatably installed on one end of the eccentric wheel (35), a bearing is provided at the connection between the first rocker arm (36) and the second rocker arm (37) and the eccentric wheel (35), the other end of the first rocker arm (36) is rotatably connected to the inner wall of the low-pressure piston (6), and the other end of the second rocker arm (37) is rotatably connected to the inner wall of the high-pressure piston (8); The low-pressure piston (6) has a larger diameter than the high-pressure piston (8).

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