ELECTRIC COMPRESSOR WITH INTEGRATED SENSOR(S)

Abstract

An electric scroll compressor (10) configured to compress a refrigerant comprises a housing (12) defining an intake volume (74), an exhaust volume (82), and an inverter cavity (30). The housing (12) has a generally cylindrical shape and a central axis. An inverter module (44) is mounted within the inverter cavity (30) of the housing (12) and is designed to convert direct current electrical power into alternating current electrical power. A motor (54) is mounted within the housing (12). A compression device (18) is coupled to the motor (54) to draw the refrigerant from the intake volume (74) and compress the refrigerant when the motor (54) is rotated.An internal housing partition (168) separates the intake volume (74) and the inverter cavity (30), the internal housing partition (168) including a passage (170) through it for receiving refrigerant from the intake volume (74), the passage (170) having an intake volume end (170A) and an inverter cavity end (170B). A pressure sensor (150A) is positioned within the inverter cavity (30) adjacent to the inverter cavity end (170B) of the passage (170) to detect a pressure associated with the refrigerant within the passage (170).

Description

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

[0002] Compressors have long been used in refrigeration systems. Scroll compressors, in particular, in which an orbiting scroll rotates in a circular motion relative to a stationary scroll to compress a refrigerant, are used in systems designed to cool specific areas. For example, such scroll compressors have long been used in the HVAC systems of motor vehicles, such as automobiles, for air conditioning. Conversely, such compressors can also be used in applications requiring a heat pump. These compressors are generally driven by a rotary motion derived from the automobile engine.

[0003] With the advent of battery-powered or electric vehicles and / or hybrid vehicles, where the vehicle can be powered exclusively by a battery for part of the time, such compressors must be powered by the battery or supplied with electricity instead of an engine. Such compressors can be referred to as electric compressors.

[0004] In addition to cooling a passenger compartment of the motor vehicle, electric compressors can be used to heat or cool other areas or components of the motor vehicle. For example, it may be desirable to heat or cool the electronic systems and the battery or battery compartment when the battery is being charged, particularly in fast-charge modes, as these generate heat that can damage or degrade the battery and / or another system. It can also be used to cool the battery during times when the battery is not being charged or in use, as heat can damage or degrade the battery. Because the electric compressor can operate at different times, including when the motor vehicle is not in use, such use naturally requires electrical energy from the battery, thereby reducing the battery's operating time.

[0005] In use, it may be necessary or advantageous to use the pressure and / or temperature of the refrigerant on a suction side and / or a discharge side of the compressor to control an electric compressor. In previous designs, the pressure and temperature on the suction and discharge sides are generally measured by sensors external to the electric compressor, e.g., within the refrigerant lines to and from the electric compressor. The use of external sensors can have several disadvantages, such as the use of outdated sensor technology, additional costs for raw materials and labor, and the need for an additional cable or wiring harness to connect the sensors to an engine control unit (ECU).

[0006] Therefore, it may be advantageous to integrate pressure and / or temperature sensors into the electric compressor. Such integration can serve to decouple pressure and temperature disturbances occurring between the line and the compressor, thus enabling more direct measurement. Furthermore, it allows the compressor to use this measurement data for optimized decisions (protection modes, speed changes, etc.).

[0007] It is therefore desirable to provide an electric compressor with high efficiency, low noise, and maximum service life. The present invention addresses one or more of the problems or advantages identified above.

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

[0009] The housing may include an inverter housing and an inverter back cover, wherein the inverter housing and the inverter back cover define the inverter cavity. The inverter module includes a printed circuit board, with the pressure sensor mounted on the printed circuit board.

[0010] The inner housing passage may be formed by the inverter housing.

[0011] A holder may further be provided, wherein the inverter housing includes a holder aperture for receiving the holder, the holder defining at least a portion of the internal housing partition and the passageway being located within the holder.

[0012] A temperature sensor may be positioned within the intake volume, with the sensor coupled to the circuit board via a plurality of wires.

[0013] The holder may include at least one aperture for receiving the plurality of wires.

[0014] A temperature sensor can be positioned within the intake volume and coupled to the circuit board via a plurality of wires.

[0015] The inner housing partition may include at least one aperture for receiving the plurality of wires.

[0016] In one embodiment, the housing defines a second passage for receiving pressurized refrigerant from the outlet volume. The second passage has an outlet volume end and an inverter cavity end. The electric scroll compressor further includes a second pressure sensor positioned within the inverter cavity adjacent to the inverter cavity end of the second passage for sensing a pressure associated with the refrigerant within the second passage.

[0017] The second passage may be provided within a rib positioned along an outer surface of the housing.

[0018] A temperature sensor may be further provided positioned within the outlet volume and coupled to the circuit board via a plurality of wires.

[0019] The plurality of wires is preferably guided through the second passage.

[0020] The electric scroll compressor may further include a pressure module including a pressure sensor module housing and a pressure sensor. The pressure sensor module housing has a pressure sensor cavity, and the pressure sensor module includes a pressure sensor module circuit board electrically coupled to the circuit board and located within the pressure sensor cavity. The pressure sensor is mounted to the pressure sensor module circuit board and is positioned within a pressure sensor cavity adjacent to the inverter cavity end of the passageway to sense a pressure associated with the refrigerant within the passageway.

[0021] The inverter housing may include a pressure sensor module aperture, the pressure sensor module positioned within the pressure sensor module cavity and including an intake volume sidewall defining at least a portion of the inner housing partition, the passageway being located within the intake volume sidewall.

[0022] The inverter housing may include a slot disposed around a perimeter of the pressure sensor module aperture to receive a bracket configured to retain the pressure sensor module within the pressure sensor module aperture.

[0023] The pressure module may include a temperature sensor coupled to the pressure module circuit board via a plurality of wires, the temperature sensor being located within the intake volume when the electric scroll compressor is assembled.

[0024] The pressure sensor module may include at least one aperture for receiving the plurality of wires.

[0025] The internal housing division can be formed by the inverter housing.

[0026] The housing may include an inverter housing and an inverter back cover, wherein the inverter housing and the inverter back cover define the inverter cavity, wherein the inverter module includes a circuit board, wherein the pressure sensor module circuit board is electrically coupled to the circuit board.

[0027] The inverter housing may include a pressure sensor module aperture for receiving the pressure sensor module, wherein the inverter housing includes a slot disposed around a perimeter of the pressure sensor module aperture for receiving a retainer configured to hold the pressure sensor module within the pressure sensor module aperture.

[0028] The pressure module may include a temperature sensor coupled to the pressure module circuit board via a plurality of wires. The temperature sensor is located within the intake volume when the electric scroll compressor is assembled.

[0029] The pressure sensor module may include at least one aperture for receiving the plurality of wires.

[0030] In a second aspect of the present invention, an electric scroll compressor configured to compress a refrigerant is provided. The electric scroll compressor includes a housing, an inverter module, a motor, a compression device, an internal housing partition, a retainer, a pressure sensor, and a temperature sensor. The housing defines a suction volume, a discharge volume, and an inverter cavity and has a generally cylindrical shape and a central axis. The housing includes an inverter case and an inverter back cover. The inverter case and the inverter back cover define the inverter cavity. The inverter case includes a retainer aperture. The inverter module is mounted within the inverter cavity of the housing and is configured to convert DC electrical power to AC electrical power.The inverter module includes a circuit board. The motor is mounted within the housing. The compression device is coupled to the motor, receives the refrigerant from the suction volume, and compresses the refrigerant when the motor is rotated. The inner housing partition separates the suction volume and the inverter cavity and includes a passageway for receiving refrigerant from the suction volume. The passageway has a suction volume end and an inverter cavity end. The retainer is located within the retainer aperture and defines at least a portion of the inner housing partition. The passageway is located within the retainer. The pressure sensor is mounted to the circuit board and is positioned within the inverter cavity adjacent the inverter cavity end of the passageway to sense a pressure associated with the refrigerant within the passageway.The temperature sensor is positioned within the intake volume and is coupled to the circuit board via a multitude of wires.

[0031] The holder preferably includes at least one aperture for receiving the plurality of wires.

[0032] The housing may define a second passage for receiving pressurized refrigerant from the outlet volume. The second passage has an outlet volume end and an inverter cavity end, wherein the electric scroll compressor may further include a second pressure sensor positioned within the inverter cavity adjacent to the inverter cavity end of the second passage for sensing a pressure associated with the refrigerant within the second passage.

[0033] The second passage may be positioned within a rib along an outer surface of the housing.

[0034] A temperature sensor may be positioned within the outlet volume and coupled to the circuit board via a plurality of wires.

[0035] The multitude of wires are passed through the second passage.

[0036] In a third aspect of the present invention, an electric scroll compressor configured to compress a refrigerant is provided. The electric scroll compressor includes a housing, an inverter module, a motor, a compression device, an internal housing partition, a pressure sensor housing partition, and a pressure sensor. The housing defines a suction volume, a discharge volume, and an inverter cavity and has a generally cylindrical shape and a central axis. The housing includes an inverter housing and an inverter back cover. The inverter housing and the inverter back cover define the inverter cavity. The inverter housing includes a pressure sensor module aperture. The inverter module includes a circuit board.The inverter module is mounted within the inverter cavity of the housing and is configured to convert DC electrical power into AC electrical power. The motor is mounted within the housing. The compression device is coupled to the motor to receive refrigerant from the suction volume and compress the refrigerant when the motor is rotated. The inner housing partition separates the suction volume and the inverter cavity and includes a passageway for receiving refrigerant from the suction volume. The passageway has a suction volume end and an inverter cavity end. The pressure sensor module housing has a pressure sensor cavity and a suction volume sidewall and is located within the pressure sensor module aperture. The suction volume sidewall defines at least a portion of the inner housing partition. The passageway is located within the suction volume sidewall.The pressure sensor module includes a pressure sensor module circuit board electrically coupled to the circuit board. The pressure sensor is positioned within a pressure sensor cavity and adjacent to the inverter cavity end of the passageway to sense a pressure associated with the refrigerant within the passageway.

[0037] The inverter housing may include a pressure sensor module aperture. The pressure sensor module may be positioned within the pressure sensor module cavity and include an intake volume sidewall defining at least a portion of the internal housing partition, wherein the passageway is located within the intake volume sidewall.

[0038] The inverter housing may include a slot disposed around a perimeter of the pressure sensor module aperture to receive a bracket configured to retain the pressure sensor module within the pressure sensor module aperture.

[0039] The pressure module includes a temperature sensor coupled to the pressure module circuit board via a plurality of wires. The temperature sensor is located within the intake volume when the electric scroll compressor is assembled.

[0040] The pressure sensor module may include at least one aperture for receiving the plurality of wires.

[0041] The internal housing division can be formed by the inverter housing.

[0042] The housing may define a second passage for receiving pressurized refrigerant from the outlet volume. The second passage has an outlet volume end and an inverter cavity end. The electric scroll compressor may further include a second pressure sensor positioned within the inverter cavity adjacent to the inverter cavity end of the second passage for sensing a pressure associated with the refrigerant within the second passage.

[0043] The second passage is disposed within a rib positioned along an outer surface of the housing.

[0044] A temperature sensor may be positioned within the outlet volume and coupled to the circuit board via a plurality of wires.

[0045] The multitude of wires are passed through the second passage. BRIEF DESCRIPTION OF THE DIFFERENT VIEWS OF THE DRAWINGS

[0046] These and other features and advantages of the present invention will be more readily understood when considered in conjunction with the following detailed description and the accompanying drawings. Fig. 1A is a first perspective view of an electric compressor according to an embodiment of the present invention. Fig. 1B is a partial view of the electric compressor of Fig. 1A with center housing removed. Fig. 2 is a second perspective view of the electric compressor of Fig. 1A. Fig. 3 is a first side view of the electric compressor of Fig. 1A. Fig. 4 is a second side view of the electric compressor of Fig. 1A. Fig. 5 is a front view of the electric compressor of Fig. 1A. Fig. 6 is a rear view of the electric compressor of Fig. 1A. Fig. 7 is a plan view of the electric compressor of Fig. 1A. Fig. 8 is a bottom view of the electric compressor of Fig. 1A. Fig. 9 is a first cross-sectional view of the electric compressor of Fig. 1A. Fig. 10 is a second cross-sectional view of the electric compressor of Fig. 1A. Fig. 11 is an exploded view of an inverter of the electric compressor of Fig. 1A. Fig. 12 is an exploded view of a portion of the electric compressor of Fig. 1, including a motor and a drive shaft. Fig. 13 is an exploded view of a compression device of the electric compressor of Fig. 1A. Fig. 14A is a first perspective view of a drive shaft of Fig. 12. Fig. 14B is a second perspective view of the drive shaft of Fig. 14A. Fig. 15A is a first perspective view of a rotor and counterweights of the engine of Fig. 12. Fig. 15B is a second perspective view of the rotor and counterweights of Fig. 15A. Fig. 16A is a first perspective view of a portion of the electric compressor of Fig. 1, including an orbiting scroll, a drive pin and a swing link mechanism. Fig. 16B is a second perspective view of the electric compressor portion of Fig. 16A. Fig. 16C is a perspective view of a plug of the compression device of Fig. 13. Fig. 16D is a second perspective view of the plug of Fig. 16C. Fig. 16E is a cross-sectional view of the plug of Fig. 16C. Fig. 16F is a perspective view of an inverter housing of the inverter of Fig. 11. Fig. 16G is a partially enlarged view of the compression device of Fig. 13. Fig. 17A-17J are graphic representations of a fixed scroll and an orbiting scroll of a compression device of the electric compressor of Fig. 1 according to an embodiment of the present invention. Fig. 18A is a first perspective view of a portion of the compression device of Fig. 13, comprising a fixed spiral and an orbiting spiral. Fig. 18B is a second perspective view of the compression device portion of Fig. 18A. Fig. 18C is a first perspective view of the fixed scroll of the compression device of Fig. 13. Fig. 18D is a second perspective view of the fixed scroll of the compression device of Fig. 13. Fig. 18E is a third perspective view of the fixed scroll of the compression device of Fig. 13. Fig. 18F is a perspective view of a tongue mechanism associated with the compression device of Fig. 13 is assigned. Fig. 18G is a cross-sectional view of the fixed scroll of the compression device of Fig. 13. Fig. 19A is a first perspective view of a front cover of an electric compressor forming an oil separator according to an embodiment of the present invention. Fig. 19B is a second perspective view of the front cover of Fig. 19A. Fig. 19C is a cross-sectional view of the front cover of Fig. 19A. Fig. 20A is a partial view of an electric compressor including a cross-sectional view of the housing and an isolation and containment system according to an embodiment of the present invention. Fig. 20B is a partial view of an isolation and restriction system for use with an electric compressor according to another embodiment of the present invention. Fig. 20C is a first perspective view of a thrust body according to an embodiment of the present invention. Fig. 20D is a second perspective view of the thrust body of Fig. 20C. Fig. 21 is a functional block diagram of an electric compressor with integrated pressure and temperature sensor according to an embodiment of the present invention. Fig. 22A is a cross-sectional view of an electric compressor with integrated pressure and temperature sensor according to a first embodiment of the present invention. Fig. 22B is a perspective cross-sectional view of the electric compressor of Fig. 22A. Fig. 22C is a partially exploded view of the electric compressor of Fig. 22A. Fig. 22D is a second perspective cross-sectional view of the electric compressor of Fig. 22A. Fig. 22E is a perspective view of an inverter housing of the electric compressor of Fig. 22A. Fig. 22F is a first perspective view of a holder of the electric compressor of Fig. 22A. Fig. 22G is a second perspective view of the holder from Fig. 22F. Fig. 22H is a third perspective view of the holder of Fig. 22F. Fig. 22I is a cross-sectional view of the holder of Fig. 22F. Fig. 23A is a cross-sectional view of an electric compressor with an integrated pressure sensor according to a second embodiment of the present invention. Fig. 23B is a perspective cross-sectional view of the electric compressor of Fig. 23A. Fig. 23C is a second perspective cross-sectional view of the electric compressor of Fig. 23A. Fig. 23D is a third perspective cross-sectional view of the electric compressor of Fig. 23A. Fig. 23E is a partial perspective view of the electric compressor of Fig. 23A, including an inverter housing. Fig. 23F is a first perspective view of the inverter housing of Fig. 23E. Fig. 23G is a second perspective view of the inverter housing from Fig. 23E. Fig. 24A is a cross-sectional view of an electric compressor with an integrated pressure sensor and an integrated temperature sensor according to a third embodiment of the present invention. Fig. 24B is a perspective cross-sectional view of the electric compressor of Fig. 24A. Fig. 24C is a partial perspective view of the electric compressor of Fig. 24A. Fig. 24D is a partially exploded view of the electric compressor of Fig. 24A. Fig. 24E is a first perspective view of an inverter housing of the electric compressor of Fig. 24A. Fig. 24F is a second perspective view of an inverter housing of Fig. 24E. Fig. 24G is a first perspective view of a pressure sensor module housing of the electric compressor of Fig. 24A. Fig. 24H is a second perspective view of the pressure sensor module housing of Fig. 24G. Fig. 25A is a cross-sectional view of an electric compressor with an integrated pressure sensor according to a fourth embodiment of the present invention. Fig. 25B is a perspective cross-sectional view of the electric compressor of Fig. 25A. Fig. 25C is a partial perspective view of the electric compressor of Fig. 25A. Fig. 25D is a first perspective view of an inverter housing of the electric compressor of Fig. 25A. Fig. 25E is a second perspective view of the inverter housing of Fig. 25D. Fig. 26A is a perspective view of an electric compressor with an integrated pressure sensor and a passage from a discharge chamber to the pressure sensor according to an embodiment of the present invention. Fig. 26B is a cross-sectional view of the electric compressor of Fig. 26A. DETAILED DESCRIPTION OF THE INVENTION

[0047] Referring to Fig. 1A-26C, wherein like reference numerals designate like or corresponding parts throughout the several views, an electric compressor 10 is provided with an outer casing 12. The electric compressor 10 is particularly suitable in a motor vehicle, such as an automobile (not shown). The electric compressor 10 may be used as a refrigeration device or as a heat pump (in reverse) to heat and / or cool various areas of the vehicle. For example, the electric compressor 10 may be used as part of the heating, ventilation, and air conditioning (HVAC) system in electric vehicles (not shown) to cool or heat a passenger compartment. In addition, the electric compressor 10 may be used to heat or cool the passenger compartment, onboard electronics, and / or a battery used to power the vehicle when the vehicle is not in operation, for example, during a charging cycle.The electric compressor 10 may also be used when the vehicle is not operating and when the battery is not being charged to maintain battery life or minimize battery degradation. In the illustrated embodiment, the electric compressor 10 has a capacity of 36 cubic centimeters (cc). Capacity refers to the initial volume accommodated within the compression device when the scrolls of the compression device first close or make contact (see below). It should be noted that the electric compressor 10 disclosed herein is not limited to such a volume and may be sized or scaled to meet particular required specifications.

[0048] In the illustrated embodiment, the electric compressor 10 is a scroll compressor designed to quickly and efficiently compress a refrigerant for use in various systems of a motor vehicle, such as an electric or hybrid vehicle. The electric compressor 10 includes an inverter section 14, a motor section 16, and a compression device (or compression assembly) 18 contained within the outer casing 12. The outer casing 12 includes an inverter back cover 20, an inverter housing 22, a center housing 24, and a front cover 28 (which may be referred to as a discharge head). The center housing 24 houses the motor section 16 and the compression device 18.

[0049] In a first aspect of the electric compressor 10 of the disclosure, an electric compressor 10 is provided with a fixed scroll compression device having a modified scroll base. In a second aspect of the electric compressor 10 of the disclosure, an electric compressor 10 is provided with an isolation and restriction system. In a third aspect of the electric compressor 10 of the disclosure, an electric compressor 10 is provided with a head configuration having a three-reed reed mechanism.

[0050] In one embodiment, the inverter back cover 20, the inverter housing 22, the center housing 24, and the front cover 28 are made of machined aluminum. The inverter 10 can be mounted via a plurality of mounting points 120, for example, within the body of a motor vehicle. General arrangement and operation of the electric compressor 10

[0051] The inverter back cover 20 and the inverter housing 22 form an inverter cavity 30. The inverter back cover 20 is mounted to the inverter housing 22 by a plurality of bolts 32. The inverter back cover 20 and the inverter housing 22 are mounted to the center housing 24 by a plurality of bolts 34 that extend through apertures 36 in the inverter back cover 20 and apertures 38 in the inverter housing 22 and thread into threaded apertures 40 in the center housing 24. An inverter seal 42, positioned between the inverter back cover 20 and the inverter housing 22, keeps moisture, dust, and other contaminants out of the interior cavity 30. A motor seal 54C is positioned between the inverter housing 22 and the center housing 24 to provide and maintain a refrigerant seal from the environment.

[0052] Referring to Fig. 11, an inverter module 44 is mounted within the inverter cavity 30 formed by the inverter back cover 20 and the inverter housing 22. The inverter module 44 includes an inverter or control circuit 46 mounted on a circuit board 48 mounted to the inverter housing 22. The inverter circuit 46 converts direct current (DC) received from outside the electric compressor 10 into three-phase alternating current (AC) to power the motor 54 (see below). The inverter circuit 46 also controls the speed of the electric compressor 10. High-voltage direct current is supplied to the inverter circuit 46 via a high-voltage connector 50.Low voltage direct current for driving the inverter circuit 46 and control signals for controlling the operation of the inverter circuit 46 and the motor portion 16 are provided via a low voltage connector 52.

[0053] The center housing 24 forms a motor cavity 56. The motor portion 16 includes a motor 54 located within the motor cavity 56. The motor cavity 56 is formed by a motor side 22A of the inverter housing 22 and an inner surface 24C of the center housing 22. Referring particularly to Fig. 12, the motor 54 is a three-phase AC motor having a stator 56. The stator 58 has a generally hollow cylindrical shape with six individual coils (two for each phase). The stator 58 is contained within and mounted to the motor housing 24 and remains stationary relative to the motor housing 24.

[0054] The motor 54 includes a rotor 60 located within and centered relative to the stator 58. The rotor 60 has a generally hollow cylindrical shape and is located within the stator 58. A plurality of counterbalance weights 60A, 60B are attached to the rotor 60. The counterbalance weights balance the motor 54 when the motor 54 drives the compression device 18 and may be made of brass.

[0055] The power supply to the motor 54 is via a set of terminals 54A, which is sealed from the motor cavity 56 by an O-ring 54B.

[0056] A drive shaft 90 is coupled to and rotates with the rotor 60. In the illustrated embodiment, the drive shaft 90 is press-fitted within a central aperture 60C of the rotor 60. The drive shaft 90 has a first end 90A and a second end 90B. The inverter housing 22 includes a first drive shaft support member 22B located on the motor side of the inverter housing 22. A first ball bearing 62, located within an aperture formed by the first drive shaft support member 22, supports the first end of the drive shaft 90 and enables rotation. The center housing 24 includes a second drive shaft support member 24A. A second ball bearing 64, located within an aperture formed by the second drive shaft support member 24A, enables rotation of the second end 90B of the drive shaft 90.In the illustrated embodiment, the first and second ball bearings 62, 64 are press-fitted into the apertures formed by the first drive shaft support member 22 of the inverter housing 22 and the second drive shaft support member 24A of the center housing 24, respectively.

[0057] As mentioned above, the electric compressor 10 is a scroll compressor. The compression device 18 includes the stationary scroll 26 and an orbiting scroll 66. The orbiting scroll 66 is attached to the second end of the rotor 60. The rotor 60 rotates with the drive shaft 90 to drive the orbiting scroll 66 under the control of the inverter module 44.

[0058] Referring to Fig. 14A, Fig. 14B, Fig. 16A and Fig. 16B, the drive shaft 90 has a central axis 90C about which the rotor 60 and the drive shaft 90 are rotated. The orbiting scroll 66 moves about the central axis 90C in an eccentric orbit, i.e., in a circular motion, while the orientation of the orbiting scroll 66 with respect to the stationary scroll 26 remains constant. The center of the orbiting scroll 66 is located along an offset axis 90D of the drive shaft 90, which is defined by an orbiting scroll aperture (or drive pin position) 90E (see Fig. 14A) located at the second end 90B of the drive shaft 90. When the drive shaft 90 is rotated by the motor 54, the orbiting scroll 66 follows the movement of the orbiting scroll aperture 90E via the drive pin 126 and the drive hub of the rocking link mechanism 124 and the bearing 108 as the drive shaft 90 is rotated about the central axis 90C.

[0059] With particular reference to Fig. 1, Fig. 2 and Fig. 9, mixed refrigerant and oil (at low pressure) enter the electric compressor 10 via a refrigerant inlet port 68 and exit the electric compressor 10 (at high pressure) via a refrigerant outlet port 70 after being compressed by the compression device 18. As shown in the cross-sectional view of Fig. 9, the refrigerant follows the refrigerant path 72 through the electric compressor 10. As shown, refrigerant enters the refrigerant inlet port 68 and enters a suction volume 74 formed between the motor side 22A of the inverter housing 22 and the center housing 24 adjacent to the refrigerant inlet port 68. The refrigerant is then drawn through the motor portion 16 and enters a compression suction volume 76 formed between an inner wall of the fixed scroll 26 and the orbiting scroll 66 (in Fig. 14A shown by arrow 92).

[0060] The fixed spiral 26 is mounted in the center housing 24. As shown in the Fig. 9 and Fig. 13, the fixed scroll 26 includes a fixed scroll base 26A and a fixed scroll overlap 26B extending from the fixed scroll base 26A toward the orbiting scroll 66. As shown in the Fig. 16A-16B, the orbiting scroll 66 includes an orbiting scroll base 66A and an orbiting scroll overlap 66B extending from the orbiting scroll base 66A toward the stationary scroll 26. The overlaps 26B, 66B have a trailing end 26C, 66C adjacent an outer edge of the respective scroll 26, 66 and curl inwardly toward a respective central end 26D, 66D.

[0061] Respective tip seals 94 are located within a slot (not shown) located on an upper surface of the stationary scroll 26 and the orbiting scroll 66, respectively. The tip seals 94 are made of a flexible material, such as a polyphenylene sulfide (PPS) plastic. When assembled, the tip seals 94 are pressed against the opposing base 26A, 66A to provide a seal therebetween. In one embodiment, the slots are longer than the length of the tip seals 94 to provide room for adjustment / movement along the length of the tip seals 94.

[0062] Referring to Fig. 17A-17I, refrigerant enters the compression device 12 from the compression intake volume 76. In the Fig. 17A-17I shows a cross-sectional view of the fixed scroll 26 and the top of the orbiting scroll 66.

[0063] As explained in detail below, the fixed scroll overlap 26B and the orbiting scroll overlap 66B form compression chambers 80 into which low-pressure or unpressurized (saturated pressure) refrigerant enters from the compression device 12. As the orbiting scroll 66 moves, the compression chambers 80 can be closed, and the volume of the compression chambers 80 is reduced to pressurize the refrigerant. At any time during the cycle, one or more compression chambers 80 are at different stages of the compression cycle. The following description refers to only one set of compression chambers 80 during a complete cycle of the electric compressor 10.

[0064] The refrigerant enters the compression chambers 80 formed between the orbiting scroll overlap 66B and the fixed scroll overlap 26B. During a cycle of the compressor 10, the refrigerant is transported toward the center of these chambers. The orbiting scroll 66 rotates in a circular motion during a cycle of the electric compressor 10, indicated by arrow 78 and formed by the relative position of the orbiting scroll 66 relative to the fixed scroll 26.

[0065] In Fig. 17A shows the position of the orbiting scroll 66 at the beginning of a cycle. As shown, in this initial position, the rear ends 26C, 66C are spaced from the other scroll overlaps 66B, 26B. At this point, the compression chambers 80 are open to the compression suction volume 76, allowing low-pressure refrigerant to fill the compression chambers 80 from the compression suction volume 76. As the orbiting scroll 66 moves along the path 78, the space between the rear ends 26C, 66C and the other scroll 66, 26B decreases until the compression chambers 80 are closed off from the compression suction volume 76 ( Fig. 17B-17E). As the orbiting scroll 66 continues to move along 78, the volume of the compression chambers 80 is further reduced, thereby pressurizing the refrigerant in both compression chambers 80 ( Fig. 17F-H). As in the Fig. As shown in Figures 17I-18J, the two compression chambers 80 are combined into a single volume as the orbiting scroll 66 continues to orbit. This volume is further reduced until the pressurized refrigerant is expelled from the compression device 18 (see below).

[0066] As explained below, the refrigerant enters chambers formed between the walls of the orbiting scroll 66 and the stationary scroll 26. During the cycle of the compressor 10, the refrigerant is transported toward the center of these chambers. The orbiting scroll 66 orbits or moves in a circular motion during a cycle of the electric compressor 10, indicated by arrow 78, which is formed by the relative position of the orbiting scroll 66 relative to the stationary scroll 26.

[0067] Returning to Fig. 1, the front cover 28 forms a discharge volume 82. The discharge volume 82 is in communication with the refrigerant outlet port 70. As explained in more detail below, pressurized refrigerant exits the compression device 18 through a central opening 84A and two side openings 84B in the fixed scroll 26 (see Fig. 18C and Fig. 18E). The release of pressurized refrigerant is controlled by a tongue mechanism 86. In the illustrated embodiment, the tongue mechanism 86 includes three tongues: a central tongue 87A and two side tongues 87B corresponding to the central opening 84A and the two side openings 84B (see below).

[0068] As in the Fig. 18D and Fig. 18E, the tongue mechanism 86 in the illustrated embodiment includes a discharge tongue 86A and a tongue retainer 86B. The discharge tongue 86A is made of a flexible material, such as steel. Properties such as material and strength are selected to control the pressure at which the pressurized refrigerant is released from the compression device 18. The tongue retainer 86B is made of a rigid, inflexible material, such as stamped steel. The tongue support 86B controls or limits the maximum displacement of the discharge tongue 86A relative to the stationary scroll 26. Generally, the oil is directed rearwardly through the motor portion 16 and provides lubrication and cooling to the rotating components of the electric compressor 10 such as the rotor 60, the drive shaft 90, and all bearings 62, 64, 108. The rotation of the rotor 60 draws oil upwardly to the top of the motor 54.From there, oil enters the interior of the motor 54 to lubricate the second ball bearing 64, and the oil can be forced against the motor side 22A of the inverter housing 22 by the rotational forces within the motor portion 16. The oil is further directed through the motor side 22A into the ball bearing 62, as further explained below.

[0069] In the illustrated embodiment, the tongue mechanism 86 is held or fixed in place by a separate fastener 89. As shown in the Fig. 18E and Fig. 18F, the tongue mechanism 86 includes a plurality of apertures 86C configured to receive associated pins 83A on the fixed scroll 26. As shown in Fig. 18E, the rear of the fixed scroll 26 includes a baffle 83B surrounding the openings 84A, 84B and helping to regulate the pressure at which the refrigerant exits the compression device 18. Additionally, a debris collection slot 83C collects debris near the openings 84A, 84B to prevent interference with the reed mechanism 86.

[0070] As in Fig. 9, the path of the refrigerant through the electric compressor is indicated by the dashed arrow 72.

[0071] The electric compressor 10 utilizes oil (not shown) to provide lubrication between the components of the compression device 18 and the motor 54, for example, between the orbiting scroll 66 and the stationary scroll 26 and within the ball bearings 62, 64. The oil mixes with the refrigerant within the compression device 18 and the motor 54 and exits the compression device 18 via the opening 84. As explained in more detail below, the oil is separated from the compressed refrigerant within the front cover 28 and returned to the compression device 18.

[0072] An oil separator 96 facilitates the separation of the mixed oil and refrigerant. In the illustrated embodiment, the oil separator 96 is integrated into the front cover 28. The front cover 28 further defines an oil reservoir 98 that collects oil from the oil separator 96 before the oil is recirculated through the motor 54 and the motor cavity 56 and the compression device 18. In use, the electric compressor 10 is generally as shown in FIGS. Fig. 3-5 so that gravity acts as indicated by arrow 106 and oil collects in the oil reservoir 98.

[0073] Referring to Fig. 9, the general path of oil passing from the bottom of the electric compressor 10 through the compression device 18, out of the opening 84 to the discharge volume 82 of the front cover 28 and back to the compression device 18 is shown by the arrow 88.

[0074] In the illustrated embodiment, the front cover 28 is mounted to the center housing 24 by a plurality of bolts 122 inserted through corresponding apertures therein and threaded into apertures in the center housing 24. A fixed head gasket 110 and a rear head gasket 112 are disposed between the center housing 24 and the fixed scroll 26 to provide a seal.

[0075] An oil separator 96 facilitates the separation of the mixed oil and refrigerant. Generally, the oil separator 96 removes only a portion of the oil from the mixed oil and refrigerant. The separator oil is stored in an oil reservoir and recirculated through the compression device 18, where the oil is remixed with the refrigerant.

[0076] In the illustrated embodiment, the oil separator 96 is integrated into the front cover 28. The front cover 28 further defines an oil reservoir 98 that collects oil from the oil separator 96 before the oil is recirculated through the motor 54 and the motor cavity 56 and the compression device 18. In use, the electric compressor 10 is generally as shown in the Fig. 3-5 so that gravity acts as indicated by arrow 106 and oil collects in the oil reservoir 98. Referring to Fig. In Figure 9, the general path of the oil from the bottom of the electric compressor 10, through the compression device 18, out of the opening 84 to the discharge volume 82 of the front cover 28, and back to the compression device 18 is shown by arrow 88. As shown, the oil is drawn back into the compression device 18, where the oil is remixed or blended with the refrigerant.

[0077] As mentioned above, the refrigerant, which is actually a mixture of refrigerant and oil, enters the electric compressor 10 through the refrigerant inlet port 68. The oil and refrigerant mixture is drawn into the motor portion 16, thereby providing lubrication and cooling to the rotating components of the electric compressor 10, such as the rotor 60 and the drive shaft 90. Oil and refrigerant enter the interior of the motor 54 to lubricate the second ball bearing 64, and the oil can be forced against the motor side 22A of the inverter housing 22 by the rotational forces within the motor portion 16. The refrigerant and oil are further directed from the motor side 22A into the ball bearing 62, as further explained below. Swing link mechanism and concentric projection of the drive shaft

[0078] With particular reference to Fig. 13-18B, in a first aspect of the electric compressor 10 of the disclosure, an electric compressor 10 includes a rocking link mechanism 124, and the drive shaft 90 has a concentric projection 90F. In one embodiment, the concentric projection 90F is integrally formed with the drive shaft 90. As explained below, the rocking link mechanism 124 is used to rotate the orbiting scroll 66 in an eccentric orbit about the drive shaft 90.

[0079] In the prior art, the drive shaft is coupled to a rocking link mechanism by a drive pin and a separate eccentric pin, both of which press into the drive shaft. The drive pin is used to rotate the rocking link mechanism 124, which moves the orbiting scroll 66 along its eccentric orbit. The drive pin and eccentric pin are inserted into corresponding apertures at the end of the drive shaft. The eccentric pin is used to limit the articulation of the orbiting scroll 66 as the orbiting scroll 66 moves along the eccentric orbit. Neither the drive pin nor the eccentric pin are located along the center axis of the drive shaft. When the drive shaft is rotated, the drive pin and eccentric pin are subjected to significant stress. Therefore, both pins are made of a hardened material, such as SAE 52100 bearing steel.In addition, an aluminum bushing or other plain bearing may be required for the eccentric pin to prevent damage to the eccentric pin, since the eccentric pin is used to limit the radial movement of the eccentric orbit of the orbiting scroll 66. Furthermore, the prior art eccentric pin requires additional machining on the surface of the drive shaft 90, including precise apertures for the drive pin and the eccentric pin.

[0080] As explained in more detail below, the prior art eccentric pin is replaced by a concentric projection 90F.

[0081] In the illustrated embodiment, the electric scroll compressor 10 includes the housing 12, the refrigerant inlet port 68, the refrigerant outlet port 70, the drive shaft 90, the concentric boss 90F, the motor 54, the compression device 18, the swing link mechanism 124, a drive pin 126, and a ball bearing 108. The housing 12 defines the suction volume 74 and the discharge volume 82. The refrigerant inlet port 68 is coupled to the housing 12 and configured to introduce refrigerant into the suction volume 74. The refrigerant outlet port 70 is coupled to the housing 12 and configured to allow compressed refrigerant to exit the electric scroll compressor 10 from the discharge volume 82. The drive shaft 90 is located within the housing 12 and has first and second ends 90A, 90B. The drive shaft 90 defines a central axis 90C and is centered thereon.

[0082] The concentric projection 90F is located at the second end 90B of the drive shaft 90 and is centered on the central axis 90C. The concentric projection 90F extends away from the drive shaft 90 along the central axis 90C. The concentric projection 90F includes a drive pin aperture 90E. The motor 54 is located within the housing 12 and is coupled to the drive shaft 90 to controllably rotate the drive shaft 90 about the central axis 90C. The drive pin 126 is located within the drive pin aperture 90E and extends away from the drive shaft 90. The drive pin 126 is parallel to the concentric projection 90F.

[0083] The concentric pin 90F may also include an undercut 90G, and the outer surface may be surface-hardened or post-treated with a coating or bearing surface. The concentric pin 90F may be further machined simultaneously with the drive shaft 90.

[0084] As explained above, the compression device 18 includes the fixed scroll 26 and the orbiting scroll 66. The fixed scroll 26 is located within the housing 12 and fixed relative thereto. The orbiting scroll 66 is coupled to the drive shaft 90. The orbiting scroll 66 and the fixed scroll 26 form compression chambers 80 (see above) for receiving the refrigerant from the suction volume 74 and compressing the refrigerant when the drive shaft 90 is rotated about the central axis 90C. The orbiting scroll 66 has an inner circumferential surface 66E.

[0085] The rocking link mechanism 124 is coupled to the drive shaft 90 and has first and second apertures 124A, 124B for receiving the concentric projection 90F and the drive pin 126. The rocking link mechanism 124 further includes an outer peripheral surface 124C.

[0086] The ball bearing 108 is positioned between and adjacent each of the inner peripheral surface 66E of the orbiting scroll 66 and the outer peripheral surface 124C of the swing link mechanism 124. The drive shaft 90, the drive pin 126, the orbiting scroll 66, and the swing link mechanism 124 are arranged to cause the orbiting scroll 66 to rotate in an eccentric orbit about the central axis 90C.

[0087] In one embodiment, the concentric projection 90F is formed integrally with the drive shaft 90. The drive shaft 90, the concentric projection 90F, and the swing link mechanism 124 may be made of steel. Since the concentric projection 90F is formed simultaneously and in the same machining operation with the drive shaft 90, manufacturing efficiency is further increased.

[0088] The expanded view of a portion of the compression device 18 shown in Fig. 16G further illustrates the concentric projection 90F. The concentric projection 90F interacts with and guides the rocking link mechanism 124. The concentric projection 90F is sized and machined to a controlled tolerance with the first aperture 124A to create a controlled gap that limits the radial movement of the eccentric orbit of the orbiting scroll 66. Unlike the prior art, the concentric projection 90F does not require a second pin or additional manufacturing operations. The concentric projection 90F also cooperates with the guide pins 24B and the slots 66I on a lower surface 66F of the orbiting scroll 66, as will be discussed in more detail below.

[0089] The electric scroll compressor 10 includes an inverter portion 14, a motor portion 16, and the compression device 18. The motor portion 16 includes a motor housing 24 defining a motor cavity 56. The compression portion 18 includes the fixed scroll 26. The housing 12 is formed at least partially from the fixed scroll 26 and the center housing 24.

[0090] With particular reference to Fig. 13, 16B, and 18A-18F, in the illustrated embodiment, the orbiting scroll 66 has a lower surface 66F. The lower surface 66F has a plurality of annular slots 66I. The center housing 24 includes a plurality of articulating guide pin apertures 155. The guide pins 24B are located within the guide pin apertures 155 and extend toward the compression device 18 and into the annular slots 66I. The guide pins 24B are configured to limit the articulating movement of the orbiting scroll 66 as the orbiting scroll 66 orbits about the central axis 90C. In one embodiment, each of the annular slots 66I includes a collar 118. A thrust plate 142 is located between the stationary scroll 26 and a thrust body 144 (see below) and provides a wear surface therebetween. Ejection head design with a three-tongue mechanism and an oil separator

[0091] In the illustrated embodiment, the electric compressor 10 includes a multi-cavity pulsation muffler system 159 and an oil separator 96, which may be located within the discharge volume 82 and integrally formed with the discharge head or the front cover 28. As discussed above, oil is used for lubrication between the moving components of the electric compressor 10. During operation, oil and refrigerant mix. The oil separator 96 is required to separate the mixed oil and refrigerant before the refrigerant exits the electric compressor 10.

[0092] Generally, during each cycle, i.e., each revolution (or orbit) of the orbiting scroll 66, refrigerant is released from the compression device 18. In the illustrated embodiment, the refrigerant exits the compression device 18 through the central opening 84A and two side openings 84B in the stationary scroll 26. The release of refrigerant through the openings 84A, 84B is controlled by the central tab 87A and two side tabs 87B, respectively. The multi-cavity pulsation muffler system 159 and the oil separator 96 are described in more detail below. Spiral bearing oil opening

[0093] The electric compressor 10 may include a scroll bearing oil injection port 138 (see Fig. 16C and Fig. 16E). As explained above, the compression device 18 of the present disclosure includes a ball bearing 108. In the illustrated embodiments, the ball bearing 108 is located between the rocking link mechanism 124 and the orbiting scroll 66. However, due to the location of the ball bearing 108 within the compression device 18, a restricted oil supply to the ball bearing 108 may occur, resulting in a reduced service life. As shown in Fig. 9, the oil port 138 allows oil (and refrigerant) to flow from the discharge chamber 82 along the path 73 (which may be referred to as the “nosebleed path”) to the ball bearing 108.

[0094] The electric scroll compressor 10 may include a housing 12, a refrigerant inlet port 68, a refrigerant outlet port 70, an inverter module 44, a motor 54, a drive shaft 90, and a compression device 18. The housing 12 defines a suction volume 74 and a discharge volume 82. The refrigerant inlet port 68 is coupled to the housing 12 and configured to introduce refrigerant into the suction volume 74. The refrigerant outlet port 70 is coupled to the housing 12 and configured to allow compressed refrigerant to exit the electric scroll compressor 10 from the discharge volume 82. The inverter module 44 is mounted within the housing 12 and configured to convert DC electrical power to AC electrical power. The motor 54 is mounted within the housing 12. The drive shaft 90 is coupled to the motor 54.The compression device 18 receives the refrigerant from the intake volume 74 and compresses the refrigerant when the drive shaft 90 is rotated by the motor 54. The compression device 18 includes a stationary scroll 26, an orbiting scroll 66, a rocking link mechanism 124, a ball bearing 108, and a plug 136.

[0095] The fixed scroll 26 is located within the housing 12 and is fixed relative thereto. The orbiting scroll 66 is coupled to the drive shaft 90. The orbiting scroll 66 and the fixed scroll 26 form compression chambers 80 for receiving the refrigerant from the suction volume 74 and compressing the refrigerant when the drive shaft 90 is rotated about the central axis 90C. The orbiting scroll 66 has a first side (or lower surface) 66F and a second side (or upper surface) 66G. The orbiting scroll 66 has an oil aperture 140 through the orbiting scroll 66 from the first side 66F to the second side 66G.

[0096] The oscillating link mechanism 124 is coupled to the drive shaft 90. The ball bearing 108 is positioned between and adjacent to each of the orbiting scroll 66 and the oscillating link mechanism 124. The drive shaft 90, the orbiting scroll 66, and the oscillating link mechanism 124 are arranged to cause the orbiting scroll 66 to orbit about the central axis 90C in an eccentric orbit.

[0097] As in the Fig. 16B-16E, the tip of the orbiting scroll 66 includes a plug 136 and has an oil opening 138. The plug 136 may be press-fitted within the oil aperture 140 of the orbiting scroll 66. The oil opening 138 is configured to allow controlled flow rate oil or compressed refrigerant to flow through the orbiting scroll 66 to the ball bearing 108.

[0098] The size of the oil opening 138 can be tailored to the specifications of the electric compressor 10. For example, given the specifications of the electric compressor 10, the diameter of the oil opening 138 can be selected to allow only oil to pass through and limit pressure equalization between the first and second sides of the orbiting scroll 66. Manufacturing efficiencies can be achieved by using a separate plug 136 rather than machining the oil opening 138 directly into the orbiting scroll 66. And the plug 136 can have an oil opening 138 specifically designed and tuned to allow for an increase or decrease in oil flow and refrigerant flow depending on the diameter and geometry of the oil opening 138.

[0099] As in the Fig. 16D-16E, in one embodiment, the oil port 138 may include a first bore 138A and a second bore 138B, wherein a diameter of the first bore 138A is smaller than a diameter of the second bore 138B. For example, in one application of this embodiment, the first bore 138A has a diameter of approximately 0.3 mm. The second bore 138B has a larger diameter than the first bore 138A and is used only to shorten the length of the first bore 138A. The flow of oil and refrigerant is designed to provide heat and lubricant to the ball bearing 108, which supports the radial forces generated by the eccentric orbit of the orbiting scroll 66.

[0100] Further, as discussed above, the orbiting scroll 66 includes an orbiting scroll base 66A and an orbiting scroll overlap 66B. The orbiting scroll overlap 66B may include an orbiting scroll trailing end 66C and an orbiting scroll middle end 66D. As shown, the oil aperture 140 is located within the orbiting scroll middle end 66D. The plug 136 may be secured in the oil aperture 140 by an interference fit or other method that secures the plug 136.

[0101] As in Fig. 9, the oil port 138 allows oil (and refrigerant) to flow from the discharge chamber 82 along the path 73 (which may be referred to as the “nosebleed path”) to the ball bearing 108. Bearing oil connection hole

[0102] The electric compressor 10 may include one or more bearing oil communication holes. As explained above, in the illustrated embodiment, a drive shaft 90 is rotated by the motor 54 to controllably actuate the compression device 18. The drive shaft 90 has a first end 90A and a second end 90B. The housing 10 of the electric compressor 10 defines a first drive shaft support member 22B and a second drive shaft support member 24A. In the illustrated embodiment, the first drive shaft support member 22B is formed in a motor side 22 of the inverter housing 22A, and the second drive shaft support member 24A is formed within the center housing 24. The first and second ball bearings 62, 64 are disposed within the first and second drive shaft support members 22B, 24A.

[0103] The position of the first drive shaft support members 22B is not a flow area for refrigerant (and oil). This may result in insufficient lubrication and affect the service life of the electric compressor 10.

[0104] As in Fig. 16F, the first drive shaft support member 22B may include one or more holes 22C to allow oil to enter the first drive shaft support member 22B and lubricate the first ball bearing 62.

[0105] In the illustrated embodiment, the electric scroll compressor 10 includes a housing 12, a first ball bearing 62, a second ball bearing 64, a refrigerant inlet port 68, a refrigerant outlet port 70, an inverter module 44, a motor 54, a drive shaft 90, and a compression device 18.

[0106] The housing 12 defines an intake volume 74 and a discharge volume 82 and includes first and second drive shaft support members 22B, 24A. The first ball bearing 62 is located within the first drive shaft support member 22B. The first drive shaft support member 22B of the housing 12 includes one or more oil communication holes 22C through which oil can enter the first ball bearing 62.

[0107] The second ball bearing 64 is located within the second drive shaft support member 24A. The refrigerant inlet port 68 is coupled to the housing 12 and configured to introduce refrigerant into the suction volume 74. The refrigerant outlet port 70 is coupled to the housing 12 and configured to allow compressed refrigerant from the electric scroll compressor 10 to exit the discharge volume 82. The inverter module 44 is mounted within the housing 12 and is configured to convert DC electrical power to AC electrical power. The motor 54 is mounted within the housing 12. The drive shaft 90 is coupled to the motor 54. The drive shaft 90 has a first end 90A and a second end 90B. The first end 90A of the drive shaft 90 is positioned within the first bearing 62, and the second end 90B of the drive shaft 90 is positioned within the second bearing 64.The compression device 18 receives the refrigerant from the suction volume 74 and compresses the refrigerant when the drive shaft 90 is rotated by the motor 54. As explained above, in the illustrated embodiment, the first drive shaft support member 22 may be formed on the motor side 22A of the inverter housing 22.

[0108] The rotational movement within the motor part 16 of the compression device 18 creates a flow path and movement to the oil from the oil reservoir 98, as indicated by the arrows 88 in Fig. 9. As shown, the oil flows from the oil reservoir 98 to the motor portion 16 and on to the stator 58 and rotor 60. The rotational movement of the orbiting scroll, rotor, and drive shaft draws the oil upward where it mixes with the inlet flow of the refrigerant path 72. The rotational movement of the rotor 60 and drive shaft 90 further forces the oil against the motor side 22A of the inverter housing 22. The motor side 22A surface also includes a series of ribs 22D which are in Fig. 16F. The ribs 22D provide the necessary rigidity to support the first drive shaft support member 22 and allow for a raised pad and pocket to secure the first bearing 62. The inverter housing 22 also defines an oil cavity 22E in which oil collected between the ribs 22D is directed downwardly by gravity into the oil cavity 22E. The ribs 22D and the inclined surface of the motor side 22A cooperate to capture and direct oil splashed or thrown against the motor side 22A by the rotor 60 or drive shaft 90, thereby increasing oil flow into the oil cavity 22E and the first bearing 62. Fig. 16F illustrates two connecting holes 22C, however, it should be noted that additional or less than 2

[0109] Oil communication holes 22C may be included above and between the ribs 22D on the motor side 22A of the inverter housing 22. For example, in the illustrated embodiment, the hole has a diameter of 3.5 mm, and the motor side 22A includes a sloped wall between the ribs 22D. Furthermore, the motor side 22A may include an external oil collection area. Curved inverter cover

[0110] The electric scroll compressor 10 of the present invention may include a domed inverter cover 20. The electric scroll compressor 10 includes the housing 12, the refrigerant inlet port 68, the refrigerant outlet port 70, the inverter module 44, the motor 54, the drive shaft 90, the compression device 18, and the inverter cover 20. The housing 12 defines the suction volume 74 and the discharge volume 82. The housing 12 has a generally cylindrical shape and the central axis 90C. The refrigerant inlet port 68 is coupled to the housing 12 and configured to introduce refrigerant into the suction volume 70. The refrigerant outlet port 70 is coupled to the housing 12 and configured to allow compressed refrigerant to exit the electric scroll compressor 10 from the discharge volume 82.

[0111] The inverter module 44 is mounted within the housing 12 and is configured to convert DC electrical power into AC electrical power. The motor 54 is mounted within the housing 12. The drive shaft 90 is coupled to the motor 54. The compression device 18 is coupled to the drive shaft 90 and is configured to receive the refrigerant from the intake volume and compress the refrigerant when the drive shaft 90 is rotated by the motor 54.

[0112] As discussed above, the compression device 18 can rotate at high speeds (>2,000 rpm), which can lead to undesirable noise, vibration, and harshness (NVH) exposure and reduced durability. In the prior art, the inverter cover 20 is generally flat and tends to amplify and / or concentrate vibrations from the compression device 18.

[0113] In order to disperse vibrations rather than concentrating the vibrations from the compression device 18, the inverter back cover 20 of the electric scroll compressor 10 of the fifth aspect of the disclosure is provided with a generally curved or arched profile.

[0114] As shown in FIGS., especially the Fig. 1, Fig. 3 and Fig. 6, the inverter cover 20 is located at one end of the electric scroll compressor 10 and includes a first portion 20A and a second portion 20B. The first portion 20A includes an apex or apex portion 20C and is generally perpendicular to the central axis 90C and has an apex 20C and an outer periphery 20D. The first portion 20A has a relatively domed shape such that the inverter cover 20 has a curved profile from the apex 20C to the outer periphery 20D. The extent and location of the curvature may be dictated or limited by other considerations, such as space constraints (i.e., the space in which the electric scroll compressor 10 must fit and internal component constraints (i.e., their location and size). The first portion 20A may also be required to include other features, such as apertures to accommodate mounting bolts.The second portion 20B may include a portion of the inverter cover 20 that is not curved, i.e., relatively flat, and is located around the perimeter of the inverter cover. Fixed spiral with modified spiral base

[0115] In a first aspect of the present invention, the electric scroll compressor 10 with a modified fixed scroll base is configured to compress a refrigerant. The electric scroll compressor 10 includes the housing 12, the refrigerant inlet port 68, the refrigerant outlet port 70, the inverter module 44, the motor 54, the drive shaft 90, and the compression device 18. The housing 12 defines a suction volume 74 and a discharge volume 82.

[0116] The refrigerant inlet port 68 is coupled to the housing 12 and configured to introduce refrigerant into the suction volume 74. The refrigerant outlet port 70 is coupled to the housing 12 and configured to allow compressed refrigerant from the electric scroll compressor 12 to exit the discharge volume 82. The inverter module 44 is mounted within the housing 12 and configured to convert DC electrical power to AC electrical power. The motor 54 is mounted within the housing 12, and the drive shaft 90 is coupled to the motor 54.

[0117] In general, as described above, the compression device 18 receives the refrigerant from the suction volume 74 and compresses the refrigerant when the drive shaft 90 is rotated by the motor 54.

[0118] The compression device 18 includes a fixed scroll 26 and an orbiting scroll 66. The compression device 18 defines a pre-chamber volume 134. The pre-chamber volume 134 (see Fig. 18C and Fig. 18G) supplies refrigerant to the chambers 80 at the beginning of a compression cycle. During the compression cycle, as the chambers 80 close (when the overlaps 26B, 66B come into contact), the pressure in the pre-chamber volume 134 decreases due to suction, which can impair the efficiency of the electric compressor 10. According to one aspect of the present invention, it is desirable to increase the volume of the pre-chamber (to provide additional refrigerant to the compression device 18). This increases the "capacitance" of the compression device 18 and smooths the compression cycle.

[0119] In the illustrated embodiment, the base 26A, 66A of either the fixed scroll 26 or the orbiting scroll 66 includes a recess 136 to increase the pre-chamber volume 134.

[0120] In the illustrated embodiment, the recess 136 is located in the bottom or base 26A of the fixed scroll 26.

[0121] As shown, the fixed scroll 26 has a first side 26F defined by the fixed scroll base 26A and a second side 26G defined by an upper surface of the fixed scroll overlap 26B. The fixed scroll overlap 26B extends from the fixed scroll base 26A toward the second side 26G of the fixed scroll 26. As shown in the Fig. 18C and Fig. 18G, the recess 136 in the bottom of the fixed spiral base 26A defines a first portion having a depth d 1which is greater than a depth d 2 of a second section 138.

[0122] The size of the first section or recess 136 may be limited by some constraints. First, the depth d 1leave sufficient material to maintain the structural integrity of the fixed scroll 26. Additionally, to ensure that the chamber 80 is sealed, the geometry of the recess must remain outside the orbiting overlap 66B to allow the chamber 80 to close and seal, as shown in Figure 17D. The recess 136 may provide additional volume within the pre-chamber 134 to allow the volumes within the chambers 80 in Figure 17D to be completely filled. The recess 136 is limited by the path of the orbiting scroll 66 and by floor and wall thickness constraints required for the fixed scroll 26. In addition, machine tooling and access to the floor of the fixed scroll may impose additional constraints on the size and areas outside the sealing region of the orbiting scroll 66. Isolation / Containment System

[0123] In a second aspect of the present invention, an isolation and restriction system 145 may be used to isolate the housing 12 from the vibrations and pulsations caused by the orbiting scroll 66.

[0124] In a typical electric scroll compressor, the motor and stationary scroll are directly connected to the housing. As discussed above, guide pins directly coupled to the housing can interact with annular slots on the orbiting scroll to limit the articulation of the orbiting scroll as it orbits the drive shaft. In this type of arrangement, vibrations and pumping pulsations can be transmitted from the orbiting scroll to the housing and, via the mountings, to the vehicle structure, for example.

[0125] The electric scroll compressor 10 is configured to compress a refrigerant. The electric scroll compressor includes the housing 12, the refrigerant inlet port 68, the refrigerant outlet port 70, the inverter module 44, the motor 54, the drive shaft 90, and the compression device 18. The housing 12 defines a suction volume 74 and a discharge volume 82 and has a generally cylindrical shape. The refrigerant inlet port 68 is coupled to the housing 12 and configured to introduce the refrigerant into the suction volume 74. The refrigerant outlet port 70 is coupled to the housing 12 and configured to allow compressed refrigerant to exit the electric scroll compressor 12 from the discharge volume 82. The inverter module 44 is mounted within the housing 12 and configured to convert DC electrical power to AC electrical power.The motor 54 is mounted within the housing 12. The drive shaft 90 is coupled to the motor 54. The compression device 18 is coupled to the drive shaft 90 to receive the refrigerant from the intake volume 74 and compress the refrigerant when the drive shaft 90 is rotated by the motor 54.

[0126] As explained above, the compression device 16 includes a fixed scroll 26 and an orbiting scroll 66. The fixed scroll 26 is located within the housing 12 and fixed relative thereto. The orbiting scroll 66 is coupled to the drive shaft 90. The orbiting scroll 66 and the fixed scroll 26 form compression chambers 80 for receiving the refrigerant from the suction volume 74 and compressing the refrigerant when the drive shaft 90 is rotated about the central axis 90C.

[0127] The orbiting scroll 66 has a lower surface with a plurality of annular slots 66I (see above).

[0128] With particular reference to FIG. 20A, the electric scroll compressor 10 further includes a thrust body 144, the plurality of articulating guide pins 24B, a plurality of mounting pins 148, and a plurality of insulating sleeves 146. The thrust body 144 has a plurality of guide pin apertures 155. The plurality of mounting pins 148 extend from the guide pin apertures 155. The guide pins 24B are configured to limit the articulating movement of the orbiting scroll 66 as the orbiting scroll 66 orbits about the central axis 90.

[0129] Each mounting pin 148 has a housing end 148A and a thrust body end 148B. The housing end 148A is press-fitted into corresponding receiving apertures in the housing 12. The thrust body end 148B is cylindrical with an outer surface. The plurality of insulating sleeves 146 are made of a flexible material, such as a chemically resistant synthetic rubber. One such material is ethylene propylene diene monomer (EPDM). The thrust body end 148B of each mounting pin 148 is encapsulated in a corresponding sleeve 146 and received in a corresponding slot 153 within the thrust body 144. In this manner, the only connection between the thrust body 144 and the housing 12 is via the mounting pins 148, which are isolated by the sleeves 146 to prevent or minimize the transmission of vibrations from the orbiting scroll 66 to the housing 12.

[0130] As in Fig. 20A, in one embodiment, the insulating sleeves 146 are formed integrally with a circular seal or ring 147.

[0131] As in Fig. 20B, in another embodiment, the thrust body end 148B of each mounting pin 148 is completely encapsulated by the flexible material, for example, using an overmolding process. The outer surface of the insulating sleeves 146 may be ribbed to assist in insulation. Design of the electric compressor head

[0132] In a third aspect of the electric compressor 10 of the disclosure, a configuration of the front cover 28 includes an oil separator 96 and a three-tongue mechanism 86. As explained below, the configuration of the front cover 28, the fixed scroll 26, and the tongue mechanism 86 defines a multi-cavity pulsation muffler system 159.

[0133] In current electric compressors, refrigerant is released from the compression device once per revolution (or circuit) of the orbiting scroll. This creates a first-order pulsation in the compressed refrigerant released by the electric compressor. The relatively high amplitude and low frequency of the pulsation generated in the refrigerant can excite other components (inside or outside the electric compressor), resulting in undesirable noise, vibration, and harshness (NVH) and reduced service life.

[0134] With reference to Fig. 18C-18F and Fig. 19A-19B, the compressed refrigerant of the multi-cavity pulsation muffler system 159 is released from the compression device 18 twice during one compression cycle. As explained in more detail below, the compression device 18 includes two smaller secondary discharge ports located in (adjacent) two secondary discharge chambers. The secondary discharge chambers are located downstream (in the discharge head) of the pressure drop from a central discharge port. As also described further below, the front cover 28 defines a parallel discharge path for the refrigerant exiting the compression device 18 to the refrigerant outlet port 70.

[0135] In the illustrated embodiment, the compressor 10 includes the housing 12, the inverter module 44, the motor 54, and a compression device 18. The housing 12 defines a suction volume 74 and a discharge volume 82. The housing 12 has a generally cylindrical shape and a central axis 90C. The inverter module 44 is mounted within the housing 12 and is configured to convert DC electrical power to AC electrical power. The motor 54 is mounted within the housing.

[0136] The compression device 18 is coupled to the motor 54 to receive the refrigerant from the intake volume 74 and compress the refrigerant when the motor 54 is rotated.

[0137] The compression device 18 includes a central compression device outlet opening 84A and first and second side compression device outlet openings 84B for controlled release of compressed refrigerant into the discharge volume 82 during a compression cycle. The compression device 18 is configured to release compressed refrigerant into the discharge volume 82 via the first and second side compression device outlet openings 84B earlier in the compression cycle than when refrigerant is released via the central discharge openings 84A.

[0138] In addition, the oil separator 96 utilizes two parallel paths between the compression device 18 and the refrigerant outlet port 70 to reduce the net pressure drop while maintaining the reduction of this pulsation.

[0139] In the illustrated embodiment, the oil separator 96 may be located within the discharge volume 82 and formed integrally with the discharge head or front cover 28. As explained above, oil is used for lubrication between the moving components of the electric compressor 10. During operation, the oil and refrigerant mix. The oil separator 96 is required to separate the mixed oil and refrigerant before the refrigerant exits the electric compressor 10.

[0140] Generally, during each cycle, i.e., each revolution (or orbit) of the orbiting scroll 66, refrigerant is released from the compression device 18. In the illustrated embodiment, the refrigerant exits the compression device 18 through the central opening 84A and two side openings 84B in the stationary scroll 26. The release of refrigerant through the openings 84A, 84B is controlled by the central tab 87A and two side tabs 87B, respectively (see below).

[0141] In the illustrated embodiment, the oil separator 96 connects the discharge chambers (see below) through relatively small channels to create pressure drops between the chambers. This smooths the flow of compressed refrigerant from the electric compressor 10. Furthermore, the oil separator 96 utilizes two parallel paths between the compression device 18 and the refrigerant outlet port 70 to reduce the net pressure drop while maintaining the reduction of this pulsation.

[0142] The oil separator 96 may include a series of walls 98A extending from an inner surface of the front cover 28. As shown, the walls 98A separate the discharge volume 82 into a central discharge chamber 82A, two side discharge chambers 82B, an upper discharge chamber 82C, and the oil reservoir 98. The central discharge chamber 82A is adjacent to the central tongue 87A and receives mixed, pressurized refrigerant and oil from the compression device 18 through the central opening 84A via the tongue 87A. The side discharge chamber 82B is adjacent to the respective side tongue 87B and receives mixed, pressurized refrigerant and oil from the compression device 18 through the side openings 84B via the respective tongues 87B. In general, the pressure of the refrigerant in the chambers is: middle discharge chamber 82A > side discharge chambers 82B > upper discharge chamber 82C.

[0143] The central discharge chamber 82A is in fluid communication with the two side discharge chambers 82B via corresponding side channels 100, which are in fluid communication with the upper discharge chamber 82C and the oil reservoir 98 via upper discharge channels 102 and lower discharge channels 104, respectively. In one embodiment, the side channels 100 extend at an acute angle to the side discharge chambers 82B. The angle of the channels 100 further directs the impact of the discharged refrigerant-oil mixture to further improve separation and increase the amount of oil separated by the oil separator 96. For example, in Fig. 19C, the side channels 100 extend at an angle of approximately 45 degrees relative to the inner wall of the center discharge chamber 82A through and down into the side discharge chambers 82B. However, the angle may vary depending on the application or surface contours of the side discharge chambers 82B and may increase to approximately 60 degrees in some variations. The angle may vary but is designed to direct the flow to create turbulence and direct the flow impingement to create a tortuous path within the side discharge chambers 82B to increase oil separation in the lower discharge channels 104.

[0144] As shown, the oil separator 96 includes the central discharge chamber 82A and a lower baffle 132. In the illustrated embodiment, the lower baffle 132 is angled (inverted "V") and is located between the central chamber 82 and the oil reservoir 98. The shape of the lower baffle 132 creates a low-pressure region directly below it. Mixed oil and refrigerant enter the central discharge chamber 82A and are drawn downward through the low-pressure region. The oil and refrigerant are separated when the mixed oil and refrigerant contact the upper surface of the lower baffle 132. The oil drips into the oil reservoir 98.

[0145] Refrigerant may enter the side discharge chambers 82B via the side channels 100 and / or the lower discharge channels 104. The refrigerant may then enter the upper discharge chamber 82C and then exit via the refrigerant outlet port 70.

[0146] The oil reservoir 98 is located below the pair of side chambers and is connected to them via the respective lower discharge channels 104. The oil reservoir is configured to receive oil separated from the compressed refrigerant in the side chambers. Gravity acting on the oil assists separation, and the oil falls into the oil reservoir 98 through the lower discharge channels 104 located in the side discharge chambers 82B.

[0147] As explained above, the tongue mechanism 86 includes a discharge tongue 86A and a tongue holder 86B defining the tongues 87A, 87B. The discharge tongue 86A is used to adjust the pressure at which the refrigerant can exit the compression device 18 through the central opening 84A and the two side openings 84B, respectively. Electric compressor with integrated sensor(s)

[0148] With reference to Fig. 21 and 22A-26C, in one aspect of the present invention, an electric scroll compressor 10 may include one or more integrated sensors 150. With particular reference to Fig. Figure 21 shows a functional block diagram of the electric compressor 10 with the integrated sensor(s) 150. In one embodiment, the integrated sensor(s) 150 includes an integrated first pressure sensor 150A. In another embodiment, the integrated sensor(s) 150 may also include an integrated first temperature sensor 150B. As shown, the integrated first pressure sensor 150A and the integrated first temperature sensor 150B are connected to a first filter circuit 152 for conditioning and filtering the raw sensor data from the integrated sensors 150A, 150B. The filter circuit 152 is coupled to an external electronic control unit 230 of the vehicle and provides filtered / conditioned sensor signals to the external electronic control unit 230 of the vehicle.The first temperature sensor 150B may be connected to the circuit board 48 by a pair of wires (see below) routed through the inner housing partition 168.

[0149] In one embodiment, the integrated first pressure sensor 150A and the filter circuit 152 are integrated into a single integrated circuit 156, e.g., a microelectromechanical system (MEMS). In the illustrated embodiment, the first integrated pressure sensor 150A and the first integrated temperature sensor 150B are configured to measure or determine a pressure or temperature associated with the intake volume 74, respectively.

[0150] The electric compressor 10 may also include an integrated second pressure sensor 150C and an integrated second temperature sensor 150D. The integrated second pressure sensor and the integrated second temperature sensor 150C, 150D are connected to a second filter circuit 158. As shown, the integrated second pressure sensor 150C and the second filter circuit 158 ​​may be integrated into a second integrated circuit 160, for example, a second MEMS.

[0151] As explained in more detail below, the first pressure sensor 150A and the first temperature sensor 150B may be configured to sense or determine a pressure or temperature, respectively, associated with the intake volume 74. The second pressure sensor 150C and the second temperature sensor 150D may be configured to sense or determine a pressure or temperature, respectively, associated with the discharge volume 82.

[0152] With reference to Fig. 22A-26C, several embodiments are explained below.

[0153] In a first embodiment, which is shown in the Fig. 22A-22I, the electric scroll compressor 10 includes the integrated first pressure sensor 150A and the integrated first temperature sensor 150B. As explained above, the inverter or control circuit 46 is mounted on a printed circuit board 48. In the embodiment shown in Fig. 22A-22I, the first pressure sensor 150 is mounted directly on the circuit board 48.

[0154] In a second embodiment, which is described in the Fig. 23A-23G, the electric scroll compressor 10 includes only the first pressure sensor 150A mounted on the circuit board 48.

[0155] As explained in more detail below, the electric compressor 10 in the third and fourth embodiments includes a pressure sensor module 162. The pressure sensor module 162 includes a pressure sensor module housing 162A. The pressure sensor module housing 162A defines a pressure sensor cavity 162C. A pressure sensor module circuit board (or a second circuit board) 162B is positioned within the pressure sensor cavity 162C and is electrically connected to the circuit board 48 via an electrical connector 166 used for communication between the sensor(s) 150A, 150B. The pressure sensor 150A is mounted directly to the pressure sensor module circuit board 162B.

[0156] The first temperature sensor 150B may be connected or wired to the second circuit board 162B. The removable pressure module, including the first pressure sensor 150A and the first temperature sensor 150B, may be prefabricated and installed as a prefabricated unit in the electric compressor 10.

[0157] As explained above, the electric compressor 10 includes an outer casing or housing 12. The housing 12 includes an inverter housing 22 and an inverter back cover 20. The inverter housing and the inverter back cover 20 define the inverter cavity 30. An inverter module 44 is arranged / positioned within the inverter cavity 30. The inverter module 44 includes an inverter or control circuit 46 that is at least partially mounted on a circuit board 48. As explained in more detail below, in each of the Fig. 22A-22I, Fig. 23A-23G, Fig. 24A-24H and Fig. 25A-25E, the electric compressor 10 includes an internal housing partition 168 separating a suction volume 74 and the inverter cavity 30. The internal housing partition 168 includes a passageway 170 for receiving refrigerant from the suction volume 74. The passageway 170 has a suction volume end 170A and an inverter cavity end 170B. The suction volume end 170A is open to the suction volume 74. As explained in more detail below, the first pressure sensor 150A is positioned within the inverter cavity 30 adjacent the inverter cavity end 170B of the passageway 170 to sense a pressure associated with the refrigerant within the passageway (and thus within the suction volume 74).

[0158] With reference to Fig. 26A-26C, the electric scroll compressor 10 includes the integrated second pressure sensor and the integrated second temperature sensor 150C, 150D. The Fig. The embodiment shown in Figures 26A-26C may be used with or adapted for use by any of the first, second, third, and fourth embodiments. First embodiment of an electric scroll compressor with integrated sensor(s)

[0159] With reference to Fig. 22A-22I, an electric scroll compressor 10 with an integrated first pressure sensor 150A and an integrated first temperature sensor 150B according to the first embodiment is shown. With particular reference to Fig. 22A, 22B, 22C and 22F-22I, the electric scroll compressor in the first embodiment includes a holder 180. As shown in Fig. 22E, the inverter housing 22 includes a retainer aperture 182 for receiving the retainer 180. In the illustrated embodiment, the retainer 180 includes an outer edge 180A located on an outer surface and extending from the retainer 180. The outer edge 180A is positioned between and held in position by a surface 22A of the inverter housing 22 and a bracket 184. Alternatively or additionally, the retainer 180 may be held in position relative to the inverter housing 22 by an interference fit. The retainer 180 may be made of a non-metallic material, such as a plastic. As shown, the retainer 180 defines at least a portion of the interior housing partition 168.

[0160] In the illustrated embodiment, the passage 170 is positioned within or located within the holder 180. The holder 180 may be cylindrical with a generally circular outer perimeter. The holder 180 may include an upper cavity 180B defined by an upper ridge 180C. As shown, in the illustrated embodiment, the upper ridge 180C surrounds an outer edge of a top surface of the holder 180.

[0161] As shown, the pressure sensor 150A and the filter circuit 152 may be embodied in an integrated MEMS circuit or MEMS package 156 mounted directly to the circuit board 48. The MEMS package 156 includes a pressure-sensitive plate 156A disposed adjacent the inverter cavity end 170B of the passageway 170. The pressure-sensitive plate 156A measures or senses a pressure associated with the refrigerant in the intake volume 74 and the passageway 170. As explained above, the filter circuit 152 conditions the signal from the pressure sensor 150A, which is communicated to the control circuit 46, which communicates a filtered or conditioned pressure signal to the vehicle's electronic control unit 230.

[0162] The MEMS package 156 may be sealed against a bottom surface of the upper cavity 180B of the holder 180 using adhesive 186. An O-ring 188 located between an outer surface of the holder 180 and an inner surface of the inverter housing 22 may be provided to seal the upper cavity 180B and the inverter cavity 30 from the intake volume 74 adjacent to a bottom surface of the holder 180 (opposite the upper cavity 180B).

[0163] In the illustrated first embodiment, the electric compressor 10 includes the first temperature 150B. However, it should be noted that the first temperature 150B is optional.

[0164] As shown, the first temperature sensor 150B is positioned with the intake volume 74 near or adjacent to the bottom surface of the holder 180. The first temperature sensor 150B may be a thermistor and may be connected or electrically coupled to the circuit board 48 by a pair of wires 150B-1. Referring to Fig. 22G, Fig. 22H and Fig. 22I, the pair of wires 150B-1 may be passed through respective apertures 180D. Each aperture 180D includes a first end 180D-1 within the bottom surface of the holder 180 and a second end 180D-2 within the upper cavity 180B.

[0165] The circuit board 48 may include one or more sub-boards. For example, the circuit board 48 may include a sub-board 48A. The MEMS package 156 may be mounted directly to the sub-board 48A, which, when the electric compressor 10 is assembled, fits into a complementary recess in the main board 48B of the circuit board. Suitable electrical contacts on the sub-board 48A and the main board 48B connect the MEMS package 156 to the inverter circuit 46 mounted on the main board 48B. It should also be noted that the support 184 may include two or more support sections 184A, 184B.

[0166] As mentioned above, the first temperature sensor 150B is optional. If no first temperature sensor 150B is used, the holder 180 does not include the apertures 180D. Second embodiment of an electric scroll compressor with integrated sensor(s)

[0167] With particular reference to Fig. 23A-23G, an electric compressor 10 according to a second embodiment is shown. In the second embodiment, the internal housing partition 168 consists of or is part of the inverter housing 22. In other words, the electric compressor 10 does not include the separate holder 180 (of the first embodiment). As in the first embodiment, the MEMS package 156 is mounted directly to the circuit board 48. With particular reference to Fig. 23A-23D, the inverter housing 22 includes a raised housing feature 200 that rises from the inverter housing 22 to mate with the MEMS package 156. The raised housing feature 200 is part of and integrally formed with the inverter housing 22. The passageway 22 is located within the raised housing structure 200, which extends from a bottom surface of the inverter housing 22 toward the inverter cavity 30. The passageway 170 includes an intake volume end 170A and an inverter cavity end 170B. The raised housing feature 200 includes a top surface 200A that is adjacent to and in contact with the MEMS package 156. The connection between the MEMS package 156 and the top surface 200A of the raised housing feature 200 may be sealed with an O-ring 202 and / or adhesive (in cavity 204).

[0168] In the illustrated embodiment, passageway 170 includes a lower portion 170-1, an intermediate portion 170-2, and an upper portion 170-3. The lower portion 170-1 extends from the lower surface of the inverter housing 22 and forms the intake volume end 170A of the passageway. The intermediate portion 170-2 is located at an opposite end of the lower portion 170-1. The upper portion 170-3 is positioned above the intermediate portion 170-2 and forms the inverter cavity end 170B of the passageway 170. The lower portion 170-1 has a diameter greater than a diameter of the upper portion 170-3. The intermediate portion 170-2 has a diameter equal to the diameter of the lower portion 170-1 at one end and a diameter equal to the diameter of the upper portion 170-3 at the opposite end.

[0169] As shown, the pressure sensor 150A and the filter circuit 152 may be embodied in an integrated MEMS circuit or MEMS package 156 mounted directly to the circuit board 48. The MEMS package 156 includes a pressure-sensitive plate 156A disposed adjacent the inverter cavity end 170B of the passageway 170. The pressure-sensitive plate 156A measures or senses a pressure associated with the refrigerant in the intake volume 74 and the passageway 170. As explained above, the filter circuit 152 conditions the signal from the pressure sensor 150A, which is communicated to the control circuit 46, which communicates a filtered or conditioned pressure signal to the vehicle's electronic control unit 230. Third embodiment of an electric scroll compressor with integrated sensor(s)

[0170] With reference to Fig. 24A-24H, an electric compressor 10 according to a third embodiment is shown. In the third embodiment, the electric compressor 10 includes the pressure sensor module 162. In one aspect of the present invention, the pressure sensor module 162 may be prefabricated and removable from the electric compressor 10.

[0171] In the illustrated embodiment, the pressure sensor module 162 of the third embodiment includes the first pressure sensor 150A and the first temperature sensor 150B. However, it should be noted that the first temperature sensor 150B is optional. In other words, the pressure sensor module 162 of the third embodiment may be equipped with only the first pressure sensor 150A. As explained above, the pressure sensor module 162 includes a pressure sensor housing 162A defining a pressure sensor cavity 162C. The pressure sensor housing 162A may further include an intake volume sidewall 162D. The passage 170 may be formed within the intake volume sidewall 162D.

[0172] As shown, in the illustrated embodiment, the pressure sensor module housing 162A may include a first portion 162A-1 and a second portion 162A-2. The first and second portions 162A-1, 162A-2 may be made of a non-metallic material, such as a plastic. The intake volume sidewall 162D may be formed in the first portion 162A-1 of the pressure sensor module housing 162A.

[0173] As shown, the inverter housing 22 may include a slot 22F disposed around a perimeter of the pressure sensor module aperture 22G to receive a bracket 164 configured to hold the pressure sensor module 162 within the pressure sensor module aperture 22G. The bracket 164 may be in the form of a C-clamp, as shown in Fig. 24D shown.

[0174] As shown, the pressure sensor module 162 may also include the first temperature sensor 150B. The first temperature sensor 150B may be coupled to the pressure module circuit board via a plurality of wires 210. The temperature sensor 150B is located within the intake volume 74 when the electric scroll compressor 10 is assembled. As shown, the pressure sensor module 162 may include one or more apertures 212 for receiving the plurality of wires 210. Fourth embodiment of an electric scroll compressor with integrated sensor(s)

[0175] With reference to Fig. 25A-25E, an electric compressor 10 according to the fourth embodiment is shown. In the fourth embodiment, the electric compressor 10 includes the pressure sensor module 162. In one aspect of the present invention, the pressure sensor module 162 may be prefabricated and removable from the electric compressor 10.

[0176] In the illustrated embodiment, the pressure sensor module 162 of the fourth embodiment includes the first pressure sensor 150A. As explained above, the pressure sensor module 162 includes the pressure sensor housing 162A, which defines a pressure sensor cavity 162C. The pressure sensor module circuit board 162B is positioned within the pressure sensor cavity 162C, and the first pressure sensor 150A is mounted thereon. As shown, in the fourth embodiment, the pressure sensor module housing 162A is open at one end (adjacent to the inverter housing 22), and the internal housing partition 168 is formed by the inverter housing 22. The passageway 170 is formed by the internal housing partition 168 within the inverter housing 22. In the illustrated embodiment, the passageway 170 includes a lower portion 170-1, an intermediate portion 170-2, and an upper portion 170-3.The lower portion 170-1 extends from the lower surface of the inverter housing 22 and forms the intake volume end 170A of the passageway. The intermediate portion 170-2 is located at an opposite end of the lower portion 170-1. The upper portion 170-3 is positioned above the intermediate portion 170-2 and forms the inverter cavity end 170B of the passageway 170. The lower portion 170-1 has a diameter greater than a diameter of the upper portion 170-3. The intermediate portion 170-2 has a diameter equal to the diameter of the lower portion 170-1 at one end and a diameter equal to the diameter of the upper portion 170-3 at the opposite end.

[0177] As explained above, passageway 170 includes an intake volume end 170A and an inverter cavity end 170B. A top surface of inverter housing 22 is adjacent to and in contact with MEMS package 156. The connection between MEMS package 156 and the top surface of inverter housing 22 may be sealed with an O-ring 202 and / or adhesive (in cavity 204). Electric scroll compressor with integrated sensor(s) on the discharge side

[0178] In the first, second, third, and fourth embodiments discussed above, the electric compressor 10 may include a first pressure sensor 150A and / or a first temperature sensor 150B for measuring a pressure and / or a temperature associated with the intake volume 74. In some applications, it may be desirable to determine a pressure and / or a temperature associated with the discharge side of the compressor 10, i.e., the discharge volume 82.

[0179] With particular reference to Fig. 26A-26C, the housing 12 of the electric compressor 10 may define a second passage 220. The second passage 220 includes a discharge cavity end 220A and an inverter cavity end 220B. The discharge cavity end 220A is located within the discharge cavity 82. The inverter cavity end 220B is located at / within or adjacent to the inverter housing 22. Pressurized refrigerant from the discharge volume 82. The second pressure sensor 150C may be located within the inverter cavity 30 and configured to determine a pressure associated with the pressurized refrigerant from the discharge volume 82 within the second passage 220. As shown in the Fig.26A, the second passage 220 may be formed in a rib 222 positioned along an outer surface of the housing 12. The second temperature sensor 150D, if used / provided, may be positioned within the ejection volume 82 and coupled to the circuit board 48 by a plurality of wires routed through the second passage 220.

[0180] The above invention has been described in accordance with the relevant legal standards; therefore, the description is exemplary rather than restrictive. Variations and modifications of the disclosed embodiment may be apparent to those skilled in the art and are within the scope of the invention.

Claims

[1] An electric scroll compressor (10) configured to compress a refrigerant, comprising: a housing (12) defining an intake volume (74), an exhaust volume (82) and an inverter cavity (30), the housing (12) having a generally cylindrical shape and having a central axis; an inverter module (44) mounted within the inverter cavity (30) of the housing (12) and configured to convert DC electrical power into AC electrical power; a motor (54) mounted within the housing (12); a compression device (18) coupled to the motor (54) for receiving the refrigerant from the intake volume (74) and compressing the refrigerant when the motor (54) is rotated; an inner housing partition (168) separating the suction volume (74) and the inverter cavity (30), the inner housing partition (168) including a passage (170) therethrough for receiving refrigerant from the suction volume (74), the passage (170) having a suction volume end (170A) and an inverter cavity end (170B); and a pressure sensor (150A) positioned within the inverter cavity (30) adjacent the inverter cavity end (170B) of the passage (170) for sensing a pressure associated with the refrigerant within the passage (170). [2] The electric scroll compressor (10) of claim 1, wherein the housing (12) includes an inverter housing (22) and an inverter back cover (20), the inverter housing (22) and the inverter back cover (20) defining the inverter cavity (30), the inverter module (44) including a circuit board (48), the pressure sensor (150A) being mounted on the circuit board (48). [3] The electric scroll compressor (10) according to claim 2, wherein the inner housing passage (170) is formed by the inverter housing (22). [4] The electric scroll compressor (10) of claim 2, further comprising a retainer (180), wherein the inverter housing (22) includes a retainer aperture (182) for receiving the retainer (180), the retainer (180) defining at least a portion of the inner housing partition (168), and the passageway (170) is located within the retainer (180). [5] The electric scroll compressor (10) of claim 4, further comprising a temperature sensor (150B) positioned within the intake volume (74) and coupled to the circuit board (48) by a plurality of wires (210). [6] The electric scroll compressor (10) of claim 5, wherein the holder (180) includes at least one aperture for receiving the plurality of wires (210). [7] The electric scroll compressor (10) of claim 1, further comprising a temperature sensor (150B) positioned within the suction volume (74) and coupled to the circuit board (48) by a plurality of wires. [8] The electric scroll compressor (10) of claim 7, wherein the inner housing partition (168) includes at least one aperture for receiving the plurality of wires. [9] The electric scroll compressor (10) of claim 1, wherein the housing (12) defines a second passage (220) therethrough for receiving pressurized refrigerant from the discharge volume (82), the second passage (220) having a discharge volume end (220A) and an inverter cavity end (220B), the electric scroll compressor (10) further comprising a second pressure sensor (150C) positioned within the inverter cavity (30) adjacent the inverter cavity end (220B) of the second passage (220) for sensing a pressure associated with the refrigerant within the second passage (220). [10] The electric scroll compressor (10) of claim 9, wherein the second passage (220) is located within a rib (222) positioned along an outer surface of the housing (12). [11] The electric scroll compressor (10) of claim 10, further comprising a temperature sensor (150B) positioned within the discharge volume (82) and coupled to the circuit board (48) by a plurality of wires (150B-1). [12] The electric scroll compressor (10) of claim 11, wherein the plurality of wires are passed through the second passage (220). [13] The electric scroll compressor (10) of claim 1, further comprising a pressure sensor module (162) including: a pressure sensor module housing (162A) having a pressure sensor cavity (162C), the pressure sensor module (162) including a pressure sensor module circuit board (162B) electrically coupled to the circuit board and located within the pressure sensor cavity (162C); and a pressure sensor (150A) mounted on the pressure sensor module circuit board (162B) and positioned within a pressure sensor cavity (162C) adjacent the inverter cavity end (170B) of the passageway (170) for sensing a pressure associated with the refrigerant within the passageway (170). [14] The electric scroll compressor of claim 13, wherein the inverter housing (22) includes a pressure sensor module aperture (22G), the pressure sensor module (162) positioned within the pressure sensor module cavity (162C) and including a suction volume sidewall (162D) defining at least a portion of the inner housing partition (168), the passage (170) being located within the suction volume sidewall. [15] The electric scroll compressor of claim 14, wherein the inverter housing (22) includes a slot (22F) disposed around a periphery of the pressure sensor module aperture (22G) for receiving a bracket configured to hold the pressure sensor module (162) within the pressure sensor module aperture (22G). [16] The electric scroll compressor (10) of claim 15, wherein the pressure sensor module includes a temperature sensor (150B) coupled to the pressure module circuit board (162B) via a plurality of wires, the temperature sensor (150B) being located within the intake volume (74) when the electric scroll compressor is assembled. [17] The electric scroll compressor (10) of claim 13, wherein the pressure sensor module (162) includes at least one aperture for receiving the plurality of wires (150B-1). [18] Electric scroll compressor (10) according to claim 14, wherein the inner housing partition (168) is formed by the inverter housing (22). [19] The electric scroll compressor (10) of claim 13, wherein the housing (12) includes an inverter housing (22) and an inverter back cover (20), the inverter housing (22) and the inverter back cover (20) defining the inverter cavity (30), the inverter module (44) including a circuit board (48), the pressure sensor module circuit board (162B) being electrically coupled to the circuit board (48). [20] The electric scroll compressor of claim 19, wherein the inverter housing (22) includes a pressure sensor module aperture (22G) for receiving the pressure sensor module (162), the inverter housing (22) including a slot (22F) disposed around a periphery of the pressure sensor module aperture (22G) for receiving a retainer (164) configured to hold the pressure sensor module (162) within the pressure sensor module aperture (22G). [21] The electric scroll compressor (10) of claim 19, wherein the pressure sensor module (162) includes a temperature sensor (150) coupled to the pressure module circuit board (162B) via a plurality of wires, the temperature sensor (150) being located within the intake volume when the electric scroll compressor is assembled. [22] The electric scroll compressor (10) of claim 21, wherein the pressure sensor module (162) includes at least one aperture for receiving the plurality of wires.

Images