High duty electric compressor

Abstract

This utility model discloses a high-load electric compressor, including a cylinder body. A stator is located at the center of the cylinder body, and a compressor intake port is provided on one side of the bottom of the cylinder body. Three arrayed heat dissipation fins are distributed around the center point on the inner side of the cylinder body bottom plate, forming a refrigerant flow channel between adjacent heat dissipation fins. The three heat dissipation fins are distributed close to the inner side of the compressor intake port. The refrigerant flow channel extends through the IGBT heat dissipation area. The two outer heat dissipation fins have flow guide sections at their ends near the compressor intake port, and the height of the flow guide sections is lower than the height of the heat dissipation fin body. By optimizing the heat dissipation fin layout, cylinder structure, refrigerant flow channel, and adding a thermally conductive silicone grease layer, the design achieves efficient refrigerant flow, precise heat dissipation, reduced thermal stress concentration, and improved overall heat dissipation efficiency, thereby significantly improving the compressor's performance and service life under high-load conditions.

Description

Technical Field

[0001] This utility model relates to the field of fluid machinery technology, specifically to electric compressors for high-load applications. Background Technology

[0002] In modern industry and transportation, the use of high-load electric compressors is becoming increasingly widespread, especially in scenarios such as thermal management systems for new energy vehicles and industrial refrigeration equipment. Their performance directly affects the overall efficiency and reliability of the system. However, as the compressor load continues to increase, the heat generated during operation increases dramatically, and heat dissipation has become a key factor restricting its performance and service life.

[0003] In existing technologies, the layout and structure of the heat dissipation fins inside the compressor are often not conducive to the efficient flow of refrigerant. For example, the traditional heat dissipation fins cannot accurately guide the refrigerant to the IGBT area with the highest temperature. Usually, after the refrigerant enters the compressor, the flow path is complicated, making it difficult to concentrate and effectively dissipate heat from the IGBT heat dissipation area. This results in the IGBT area being too hot due to insufficient heat dissipation, affecting its performance and service life, and may even cause failure, affecting the normal operation of the entire system.

[0004] In terms of cylinder block structure design, the traditional contact method between the cylinder block and corresponding components has defects. The cylinder block end face usually adopts a large area of ​​planar contact, which not only makes it difficult to guarantee the machining accuracy, but also may lead to unnecessary heat transfer and stress concentration in actual use due to the excessively large contact area. At the same time, the traditional design does not make reasonable design for non-contact areas and contact surfaces, resulting in low heat dissipation efficiency of the cylinder block when running under high load, which cannot meet the demand for rapid heat dissipation and further aggravates the temperature rise inside the compressor.

[0005] In addition, traditional structures also have shortcomings in the design of refrigerant flow channels. Common refrigerant flow channel shapes and sizes are not conducive to smooth refrigerant flow and heat dissipation. For example, the cross-section of the channel may not be the most suitable shape for refrigerant flow, resulting in greater resistance when the refrigerant flows in the channel, making it impossible to quickly and effectively remove heat and affecting the heat dissipation effect. Moreover, the angle between the refrigerant flow channel and the compressor intake port is not set reasonably, so that the refrigerant cannot flow at the optimal angle and flow distribution when entering the channel, making it difficult to achieve efficient heat dissipation of key heat dissipation areas.

[0006] Therefore, the application of electric compressors under high loads is proposed to address the problems mentioned above. Utility Model Content

[0007] The purpose of this invention is to provide an electric compressor for high-load applications, in order to solve the problems mentioned in the background art, that existing electric compressors have obvious defects in heat dissipation fin layout, cylinder structure and refrigerant flow channel design when facing high-load applications, resulting in low heat dissipation efficiency and poor operating stability, making it difficult to meet actual needs.

[0008] To achieve the above objectives, this utility model provides the following technical solution: a high-load electric compressor, including a cylinder, a stator disposed at the center of the cylinder, and a compressor intake port provided on one side of the bottom of the cylinder.

[0009] The cylinder bottom plate has three arrayed heat dissipation fins distributed around its center point on the inner side, and a refrigerant flow channel is formed between adjacent heat dissipation fins. The three heat dissipation fins are distributed close to the inner side of the compressor intake port.

[0010] The refrigerant flow channel extends through the IGBT heat dissipation area. Two of the three heat dissipation fins located on the outer side have flow guide sections at their ends near the compressor intake port. The height of the flow guide sections is lower than the height of the heat dissipation fin body.

[0011] The outer surface of the cylinder bottom plate is provided with a non-contact lowering surface that is recessed inward and a contact surface that protrudes from the lowering surface.

[0012] The projection area of ​​the cooling fins onto the bottom plate of the cylinder block at least partially covers the contact surface.

[0013] Preferably, the cross-section of the top of the heat dissipation fin has an arc-shaped structure.

[0014] Preferably, the cross-sectional shape of the refrigerant flow channel is an equidistant flow channel or a gradually narrowing flow channel.

[0015] Preferably, when the refrigerant flow channel is a tapered flow channel, its width at the end near the compressor intake port is 8mm, and its width at the end near the IGBT heat dissipation area is 6mm.

[0016] Preferably, the bottom surface of the refrigerant channel smoothly transitions to the inner wall of the cylinder through a rounded corner with a radius of 0.5 mm, and the sidewall of the channel is formed by the arc-shaped side surface of adjacent heat dissipation fins.

[0017] Preferably, the recessed area of ​​the non-contact lowering surface accounts for 40% to 50% of the total area of ​​the outer side of the cylinder block bottom plate.

[0018] Preferably, the cross-section of the top of the heat dissipation fin is a semi-circular structure.

[0019] Compared with the prior art, the beneficial effects of this utility model are as follows: This high-load electric compressor, through optimized heat dissipation fin layout, cylinder structure, refrigerant flow channels, and the addition of a thermally conductive silicone grease layer, achieves efficient refrigerant flow, precise heat dissipation, reduced thermal stress concentration, and improved overall heat dissipation efficiency, thereby significantly improving the compressor's performance and service life under high-load conditions. The specific details are as follows:

[0020] 1. Precise and efficient heat dissipation

[0021] The arc-shaped heat dissipation fins and refrigerant flow channels set on the inner side of the cylinder, together with the flow guide section of the outer heat dissipation fins, optimize the path of refrigerant flow to the IGBT heat dissipation area; among them, the refrigerant flow channel adopts a tapered trapezoidal structure, which can effectively guide the refrigerant to flow to the IGBT area, enhance the contact area and heat exchange efficiency between the refrigerant and the heat dissipation fins, and avoid performance degradation and failure risk caused by IGBT overheating.

[0022] 2. Improve machining and assembly performance

[0023] The non-contact lowered surface design at one end of the cylinder block controls the area of ​​the recessed region to 40%-50% of the total end face area, reducing the contact area with corresponding components, lowering the requirements for machining accuracy, and facilitating the flattening and overflow of thermal grease, thereby improving heat dissipation efficiency. At the same time, the contact surface and the heat dissipation fin are integrally formed, with the contact area at the connection reaching 60%-80% of the side area of ​​the heat dissipation fin, which enhances structural strength, reduces the risk of assembly deformation, and improves overall stability.

[0024] 3. Enhance heat transfer efficiency

[0025] The bottom surface of the refrigerant flow channel smoothly transitions to the inner wall of the cylinder with a 0.5mm rounded corner, reducing refrigerant flow resistance and ensuring the efficient operation of the heat dissipation system. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the side view of the cylinder block in this utility model;

[0027] Figure 2 This is a schematic diagram of a partial three-dimensional structure of the cylinder block in this utility model;

[0028] Figure 3 This is a top view of the internal structure of the cylinder block in this utility model;

[0029] Figure 4 This is a top view of the internal structure of the cylinder body from another angle in this utility model;

[0030] Figure 5 This utility model Figure 3 Enlarged structural diagram at point A in the middle;

[0031] In the diagram: 1. Cylinder block; 2. Compressor intake port; 3. Heat dissipation fins; 301. Refrigerant flow channel; 302. Flow guide section; 4. IGBT heat dissipation area; 5. Stator; 6. Non-contact lowering surface; 7. Contact surface. Detailed Implementation

[0032] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0033] Please see Figure 1-5 The present invention provides a technical solution: a high-load electric compressor, including a cylinder 1, a stator 5 is provided at the center of the cylinder 1, a compressor intake port 2 is provided on one side of the bottom of the cylinder 1, and three arrayed heat dissipation fins 3 are provided on the inner side of the bottom plate of the cylinder 1 around its center point, and a refrigerant guide channel 301 is formed between adjacent heat dissipation fins 3, and the distribution position of the three heat dissipation fins 3 is close to the inner side of the compressor intake port 2;

[0034] Three arc-shaped heat dissipation fins 3 are arranged in an array around the center point of the cylinder 1, increasing the heat dissipation area inside the cylinder. The heat generated during compression is carried away by the refrigerant flow, effectively reducing the cylinder temperature and preventing compressor efficiency degradation, lubricant carbonization, or component thermal deformation caused by high temperature. This extends the continuous operating life of the equipment under high load conditions. The arc-shaped contour reduces fluid flow resistance and, together with the refrigerant guide channel 301, forms an active heat exchange system. It can improve heat dissipation efficiency without additional power consumption, meeting energy-saving design requirements. The array-type heat dissipation fins can be formed in one piece by mold, with strong process compatibility.

[0035] The refrigerant flow channel 301 extends through the IGBT heat dissipation area 4. Two of the three heat dissipation fins 3 located on the outer side are provided with flow guide sections 302 at their ends near the compressor intake port 2. The height of the flow guide section 302 is lower than the height of the heat dissipation fin 3 body.

[0036] The extension path of the refrigerant flow channel 301 runs through the IGBT heat dissipation area 4, allowing the refrigerant to directly absorb the heat generated by the IGBT module during its flow. This layout optimizes heat exchange efficiency and avoids the heat dissipation delay caused by refrigerant detour in traditional designs, making it particularly suitable for the rapid cooling requirements of high power density compressors. By reducing the height of the flow guide section 302 (the vertical height of the flow guide section 302 is 2.5mm to 5mm lower than the rest of the heat dissipation fin 3), the obstruction of the motor stator 5 to the refrigerant is reduced, thereby reducing the refrigerant flow resistance and avoiding eddy currents caused by excessively high heat dissipation fins, thus improving the refrigerant flow efficiency near the intake port.

[0037] The outer surface of the bottom plate of the cylinder body 1 is provided with a non-contact lowering surface 6 that is recessed inward and a contact surface 7 that protrudes from the lowering surface; the orthographic projection area of ​​the heat dissipation rib 3 on the bottom plate of the cylinder body 1 at least partially covers the contact surface 7.

[0038] By limiting the machining area on the outer surface of the cylinder block 1 bottom plate to a locally protruding contact surface 7 (the remaining area is recessed to form a non-contact lowering surface 6), the planar area requiring high-precision machining is significantly reduced. This design reduces machining difficulty on the one hand, and improves the tightness of the fit between the two heat dissipation interfaces by reducing the ineffective machining area on the other hand.

[0039] A non-contact lowering surface 6 with a recessed depth of 0.5mm is set at the base plate position where there is no direct heat source. This provides a directional overflow space for thermal grease. This design not only avoids the local thermal resistance increase caused by uneven accumulation of thermal grease in traditional full-plane base plates, but also promotes the formation of a uniform thin layer of thermal grease under pressure through the containment effect of the recessed area, which improves heat dissipation efficiency compared with traditional structures.

[0040] The cross-section at the top of heat dissipation fin 3 has an arc-shaped structure;

[0041] The guiding effect of the arc-shaped tip makes the airflow more concentrated through the gaps in the heat dissipation fins;

[0042] The cross-sectional shape of the refrigerant flow channel 301 is either an equidistant flow channel or a tapered flow channel. When the refrigerant flow channel 301 is a tapered flow channel, its width at the end near the compressor intake port 2 is 8mm, and its width at the end near the IGBT heat dissipation area 4 is 6mm.

[0043] The cross-section of the refrigerant flow channel 301 gradually narrows from the intake end (8mm wide) to the IGBT heat dissipation area end (6mm), forming a Bernoulli effect to enhance convective heat transfer and improve the impact cooling effect on the IGBT heat dissipation area 4.

[0044] The bottom surface of the refrigerant channel 301 and the inner wall of the cylinder 1 are smoothly transitioned by a rounded corner with a radius of 0.5mm, and the side wall of the channel is formed by the arc-shaped side surface of the adjacent heat dissipation fins 3.

[0045] A smooth transition is achieved through a 0.5mm precision rounded corner, which significantly reduces the turbulence effect of refrigerant flow, reduces local pressure loss, avoids the formation of flow dead zones, and improves flow guiding efficiency; the arc-shaped side of heat dissipation fin 3 naturally forms the sidewall of the flow guiding channel, which increases the effective heat exchange area, and the arc-shaped structure induces secondary flow of refrigerant, which enhances the convective heat transfer coefficient.

[0046] The recessed area of ​​the non-contact lowering surface 6 accounts for 40% to 50% of the total area of ​​the outer side of the cylinder block 1 bottom plate;

[0047] A recessed area of ​​40% to 50% can form a reasonable non-contact area on the outside of the base plate, avoiding local overheating and reducing the risk of cylinder deformation caused by uneven thermal expansion; retaining 50% to 60% of the contact support area ensures the mechanical rigidity between the cylinder and the external mounting surface.

[0048] The cross-section at the top of heat dissipation fin 3 is a semi-circular structure;

[0049] The semi-circular top promotes the even distribution of heat along the ribs, avoiding localized overheating.

[0050] Working principle: Before using this high-load electric compressor, it is necessary to check the overall condition of the unit to ensure it can operate normally. Figure 1 - Figure 5 As shown: First, the refrigerant enters the cylinder 1 through the compressor suction port 2, and then, due to the obstruction of the stator 5, it flows in two separate paths:

[0051] Main path: flows along the gap between the stator 5 and the inner wall of the cylinder 1, participating in the compression cycle;

[0052] Heat dissipation path: Some of the refrigerant first flows through the refrigerant guide channel 301 formed by three arc-shaped heat dissipation fins 3. The gradually narrowing flow channel design (trapezoidal cross section, 8mm inlet → 6mm outlet) uses the principle of fluid dynamics to accelerate the flow of refrigerant to the IGBT heat dissipation area 4, forming the "Bernoulli effect", which increases the flow rate and enhances the impact heat dissipation effect.

[0053] Furthermore, by designing the flow guide section 302, the inlet height of the two outer heat dissipation fins 3 is reduced by 3mm to form a "flow guide step", which reduces refrigerant turbulence and ensures that the refrigerant is in full contact with the high-temperature area (such as the IGBT heat dissipation area 4). At the same time, a rounded transition (R0.5mm) is designed to reduce flow resistance, reduce energy loss caused by eddies, and make the refrigerant evenly distributed.

[0054] Meanwhile, the heat generated by the IGBT is conducted to the refrigerant channel through the arc-shaped side of the heat dissipation fin 3 (towards the central axis of the cylinder), utilizing the increased surface area of ​​the arc-shaped cross-section (to enhance heat exchange).

[0055] Then, the heat is further transferred to the outer surface through the integrally molded contact surface 7. Its thermal grease layer (0.15mm±0.05) is filled with silicone resin-based composite material to reduce the interfacial thermal resistance and accelerate the diffusion of heat to the external environment.

[0056] Furthermore, the 0.5mm recessed design forms an "air insulation layer," reducing the direct contact area between the cylinder and adjacent components (controlled at 40%-50%); the recessed area and the contact surface 7 form a "thermal bridge isolation," forcing heat to be conducted along a preset path (heat dissipation fins → protrusions), thus optimizing heat transfer efficiency.

[0057] The heat dissipation fin 3 and the contact surface 7 are integrally formed by casting, and the connection covers 60%-80% of the side area of ​​the heat dissipation fin, eliminating the contact thermal resistance of traditional welding or bolt connection.

[0058] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A high-load electric compressor, comprising a cylinder (1), wherein a stator (5) is disposed at the center of the cylinder (1), and a compressor intake port (2) is provided on one side of the bottom of the cylinder (1), characterized in that: The cylinder body (1) has three arrayed heat dissipation fins (3) distributed around its center point on the inner side of the bottom plate. A refrigerant flow channel (301) is formed between adjacent heat dissipation fins (3). The distribution position of the three heat dissipation fins (3) is close to the inner side of the compressor intake port (2). The refrigerant flow channel (301) extends through the IGBT heat dissipation area (4). Two of the three heat dissipation fins (3) located on the outside are provided with flow guide sections (302) at their ends near the compressor intake port (2). The height of the flow guide section (302) is lower than the height of the heat dissipation fin (3) body. The outer surface of the bottom plate of the cylinder body (1) is provided with a non-contact lowering surface (6) that is recessed inward and a contact surface (7) that protrudes from the lowering surface; The projection area of ​​the heat dissipation fin (3) on the bottom plate of the cylinder (1) at least partially covers the contact surface (7).

2. The high duty application electric compressor of claim 1, wherein: The cross-section at the top of the heat dissipation fin (3) is arc-shaped.

3. The high-load electric compressor according to claim 1, characterized in that: The cross-sectional shape of the refrigerant flow channel (301) is an equidistant flow channel or a gradually narrowing flow channel.

4. The high-load electric compressor according to claim 3, characterized in that: When the refrigerant flow channel (301) is a tapered flow channel, its width at the end near the compressor intake port (2) is 8mm, and its width at the end near the IGBT heat dissipation area (4) is 6mm.

5. The high-load electric compressor according to claim 1, characterized in that: The bottom surface of the refrigerant channel (301) and the inner wall of the cylinder (1) are smoothly transitioned by a rounded corner with a radius of 0.5 mm, and the side wall of the channel is formed by the arc-shaped side surface of the adjacent heat dissipation fins (3).

6. The high-load electric compressor according to claim 1, characterized in that: The recessed area of ​​the non-contact lowering surface (6) accounts for 40% to 50% of the total area of ​​the outer side of the cylinder body (1) bottom plate.

7. The high-load electric compressor according to claim 1, characterized in that: The cross-section at the top of the heat dissipation fin (3) is a semi-circular structure.

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