Compressor module

Abstract

To minimize the number of individual components and parts required for a refrigerant circuit by reducing complexity of an integrated module type component for the refrigerant circuit.SOLUTION: This invention relates to a compressor module (33) for a refrigerant circuit of an automobile air conditioning system. The compressor module includes a module type many-portion housing having a low pressure refrigerant inlet, a high pressure refrigerant outlet and a compressor (34). An internal heat exchanger (1) of the refrigerant circuit is manufactured to be integrated into the compressor module (33). The housing of the compressor module (33) completely surrounds the internal heat exchanger (1).SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present invention relates to a compressor module for a refrigerant circuit of an automotive air conditioning system. The compressor module embodies an integrated design of the various components and functions of the refrigerant circuit in a modular component. The compressor module is particularly suitable for use in the refrigerant circuit with R744, which uses carbon dioxide as the refrigerant. [Background technology]

[0002] The refrigerant circuit is made up of various technical components. It is desirable to develop these components as efficiently as possible, for example to design them as economically as possible. For this purpose, collectors are already known in the prior art which are integrated into the heat exchanger or into the refrigerant compressor. For example, a refrigerant compressor with an integrated collector is already known from US 2004 / 0141859 A1. However, the space savings which can be achieved here are limited. The advantages for the refrigerant circuit and the stability of the components which can be achieved by integrating the collector into the compressor housing are also not great. Summary of the Invention [Problem to be solved by the invention]

[0003] The object of the present invention is to reduce the complexity of integrated modular components, in particular for refrigerant circuits using R744 as refrigerant, and in addition to this, to achieve synergies between the individual components in order to minimize the number of individual components and parts required for the refrigerant circuit and to realize savings in terms of costs, which are generally required to ensure the necessary pressure resistance of such components. [Means for solving the problem]

[0004] The invention is solved in particular with a compressor module for a refrigerant circuit of a motor vehicle air conditioning system, which compressor module has a modular multi-part housing that can be assembled and represents a low pressure refrigerant inlet, a high pressure refrigerant outlet and a refrigerant compressor, the compressor module being characterized in that it is manufactured in such a way that the internal heat exchanger of the refrigerant circuit is integrated into the compressor module, the housing of the compressor module completely surrounding the internal heat exchanger and thereby housing both the internal heat exchanger and the actual compressor.

[0005] Thus, the conceptual design of the present invention is to manufacture the compressor components and the internal heat exchanger components in combination with each other in or on the compressor module.

[0006] This not only takes advantage of the simplified installation of the modules in the refrigerant circuit in a particularly advantageous manner, but also extends the compressor housing in a modular manner into a housing or housing part which accommodates the internal heat exchanger, so that this internal heat exchanger no longer requires its own separate dedicated pressure-resistant housing.

[0007] The compressor module preferably includes at least one refrigerant sensor that is manufactured to be integrated into the housing of the compressor module, and thus, preferably, the refrigerant sensors required at corresponding points in the circuit, along with the various refrigerant lines integrated into the housing, are also disposed within or surrounded by a pressure-tight housing that meets the requirements for the R744 refrigerant.

[0008] Also, the refrigerant collector of the refrigerant circuit, together with the internal heat exchanger, is preferably manufactured to be integrated into the housing of the compressor module. Housing the refrigerant collector in the compressor module reduces the number of individual components and connecting elements required for the refrigerant circuit, which not only simplifies assembly but also has the effect of ensuring an advantageous, compact design of the overall housing for the compressor module, thereby facilitating cost-effective manufacture.

[0009] According to a preferred embodiment, an additional heat exchanger of the refrigerant circuit is integrated into the housing of the compressor module, preferably a cooler as well as an expansion element installed upstream of the cooler, both of which are integrated into the housing of the compressor module and are surrounded by and housed within said housing, said housing ensuring external pressure tightness.

[0010] The design principle for the housing of the compressor module is illustrated, for example, by the housing parts of the compressor module being manufactured so that they are assembled as disk-shaped elements and thereby also expanded in a modular manner.

[0011] In an advantageous embodiment, the housing of the compressor module is manufactured with an inverter housing, a motor housing, a center housing and a high-pressure housing, and the refrigerant is guided from a low-pressure refrigerant inlet through the inverter housing, the motor housing and the center housing to the high-pressure housing, where the internal heat exchanger is arranged in the center housing.

[0012] In a particularly preferred embodiment, the compressor module housing is fabricated with a housing for a refrigerant collector, a housing for an internal heat exchanger, a motor housing, a center housing, and a high pressure housing. With this configuration, refrigerant flows serially from a low pressure refrigerant inlet through the refrigerant collector, the internal heat exchanger, the motor housing, the center housing, and the high pressure housing. The internal heat exchanger is disposed in the refrigerant collector and motor housing.

[0013] In an alternative embodiment of the compressor module, the housing of the compressor module is manufactured with a housing for the chiller and expansion element, a housing for the refrigerant collector, a housing for the internal heat exchanger, a motor housing, a center housing, and a high pressure housing. In these configurations, refrigerant flows from a low pressure refrigerant inlet through the expansion element and subsequent cooler, the refrigerant collector, the internal heat exchanger, the motor housing, and the center housing to the high pressure housing, where the internal heat exchanger is located between the refrigerant collector and the motor housing.

[0014] An advantageously modified compressor module is obtained by the housing of the compressor module being manufactured with an inverter housing, a motor housing, a housing for an internal heat exchanger, a center housing and a high pressure housing, where refrigerant flows from a low pressure refrigerant inlet through the motor housing and center housing to the high pressure housing, and the internal heat exchanger is disposed in the center housing between the motor housing and the high pressure housing.

[0015] The housing of the compressor module is preferably manufactured with an inverter housing, a housing for an internal heat exchanger, a motor housing, a central housing and a high-pressure housing. The refrigerant is guided from a low-pressure refrigerant inlet through the inverter housing, the housing for the internal heat exchanger, the motor housing and the central housing to the high-pressure housing. Here, the internal heat exchanger is disposed between the inverter housing and the motor housing.

[0016] Another alternative is for the housing of the compressor module to be advantageously manufactured into an inverter housing, a motor housing, a center housing and a high pressure housing, with the refrigerant being guided from a low pressure refrigerant inlet through the inverter housing, the internal heat exchanger, the motor housing and the center housing to the high pressure housing, or through the inverter housing, the internal heat exchanger and the high pressure housing to the high pressure housing, where the internal heat exchanger is located within the motor housing between the inverter housing and the center housing.

[0017] According to a further embodiment, the housing of the compressor module is advantageously manufactured with a housing for a refrigerant collector, a housing for an internal heat exchanger, a motor housing, a central housing and a high-pressure housing, whereby the refrigerant is guided from a low-pressure refrigerant inlet through the housing for the refrigerant collector, the housing for the internal heat exchanger, the motor housing and the central housing in the high-pressure housing, whereby the internal heat exchanger is arranged between the refrigerant collector and the motor housing.

[0018] According to an additional alternative embodiment, the housing of the compressor module is advantageously manufactured with a housing for the refrigerant collector, a housing for the internal heat exchanger, an inverter housing, a motor housing, a center housing and a high pressure housing, and the refrigerant is disposed between the housing for the low pressure refrigerant collector, the housing for the internal heat exchanger, and the motor housing, so that the internal heat exchanger is disposed between the refrigerant collector and the inverter housing.

[0019] In an advantageous and alternative embodiment, the housing of the compressor module is manufactured with a housing for a refrigerant collector, a housing for an internal heat exchanger, a motor housing, a central housing, and a high-pressure housing. The refrigerant is guided from a low-pressure refrigerant inlet through the housing for the refrigerant collector, the internal heat exchanger, the motor housing, and the central housing, and through the high-pressure housing. The internal heat exchanger is disposed between the motor housing and the central housing.

[0020] In other advantageous and alternative embodiments, the housing of the compressor module is manufactured with a housing for a refrigerant collector, a motor housing, a central housing and a high pressure housing, and the refrigerant is guided from a low pressure refrigerant inlet through the refrigerant collector, the internal heat exchanger, the motor housing and the central housing in the high pressure housing, or through the refrigerant collector, the motor housing and the central housing, or through the refrigerant collector, the motor housing and the internal heat exchanger, the internal heat exchanger being located within the motor housing between the refrigerant collector and the central housing.

[0021] A further advantageous embodiment is characterized in that the housing of the compressor module is vessel The refrigerant collector is connected to the high-pressure housing through the expansion element, the cooler, the refrigerant collector, the internal heat exchanger, the inverter housing, the motor housing, the central housing, and the high-pressure housing. Therefore, the refrigerant is guided from the low-pressure refrigerant inlet through the expansion element, the cooler, the refrigerant collector, the internal heat exchanger, the inverter housing, the motor housing, and the central housing to the high-pressure housing. The internal heat exchanger is disposed in the refrigerant collector and the inverter housing.

[0022] Alternatively, the housing of the compressor module may be vessel and a housing for the expansion element, a housing for the refrigerant collector, a motor housing, a housing for the internal heat exchanger, a central housing, and a high pressure housing. Therefore, the refrigerant is guided from a low pressure refrigerant inlet through the expansion element, the cooler, the refrigerant collector, the motor housing, the internal heat exchanger, and the central housing to the high pressure housing. The internal heat exchanger is disposed between the motor housing and the central housing.

[0023] Alternatively, the housing of the compressor module may be vesseland a housing for the expansion element, a housing for the refrigerant collector, a motor housing, a central housing, and a high pressure housing. The refrigerant is guided from a low pressure refrigerant inlet to the expansion element, the cooler, the refrigerant collector, the internal heat exchanger, the motor housing, and the central housing, or passes through the expansion element, the cooler, the refrigerant collector, the motor housing, the internal heat exchanger, and the high pressure housing, or passes through the expansion element, the cooler, the refrigerant collector, and the internal heat exchanger and the motor housing in parallel, or passes through the central housing. The internal heat exchanger in the motor housing is disposed between the refrigerant collector and the central housing within the motor housing.

[0024] In a preferred embodiment, the internal heat exchanger is manufactured as a cylindrical coil tube arranged coaxially with the axis of the compressor module, which conducts the high pressure refrigerant mass flow and is surrounded by a low pressure refrigerant mass flow, the suction pressure of the compressor.

[0025] According to another advantageous embodiment, the internal heat exchanger is partly accommodated in the axial direction by the motor housing and partly by the central housing and is radially surrounded by the motor housing and the central housing.

[0026] The internal heat exchanger is radially disposed coaxially between the outer and inner guide housings.

[0027] The refrigerant collector is preferably disposed within the central housing and a housing cover which defines the housing axially from the end, the refrigerant collector having a liquid separator used to capture refrigerant liquid from the refrigerant gas flow, a cup-shaped separation element and a gas suction pipe for the low pressure side of the internal heat exchanger.

[0028] The internal heat exchanger is advantageously arranged radially coaxially between the inner guide housing and the cylindrical part of the housing cover, with a disk-shaped dividing element arranged axially as a boundary to the refrigerant collector.

[0029] The internal heat exchanger is advantageously arranged radially coaxially between an outer guide housing and an inner guide housing, the outer guide housing having a disk-shaped dividing element as a boundary to the refrigerant collector in the axial direction.

[0030] The inner guide housing is preferably constructed to retain a filter material and has a filter for the coolant.

[0031] The compressor is preferably constructed as an electric compressor, and more preferably as a scroll compressor. Effect of the Invention

[0032] In summary, the advantages of the present invention can be explained as follows: Integrating parts or components of the refrigerant circuit into the compressor directly reduces the complexity of the overall system. Integrating the PT sensor into the compressor can eliminate connectors, housings, cable harnesses and installation work required for vehicle assembly, which leads to time, cost and installation space savings. Integration of the internal heat exchanger also leads to synergies from the pressure housing. Thus, at least one refrigerant line can be omitted and a reduction in the number of screw connections of the vehicle components is achieved.

[0033] A reduction in the amount of installation work required during vehicle manufacturing is also considered as an advantageous effect of component integration. Integration of the refrigerant collector means that an oil return with an oil reservoir can be implemented in the refrigerant collector on the low pressure side, without the oil having to be circulated through the entire system. In the refrigerant collector, the temperature is reduced from the hot gas temperature to the suction gas temperature, with the associated increase in the viscosity of the oil. This increased viscosity is beneficial for the operation of the compressor by increasing the lubrication capacity for the bearings and other components. Integration of the cooler also leads to synergies from the pressure housing, especially since no more refrigerant lines are required, and due to lower installation costs during vehicle assembly. [Brief description of the drawings]

[0034] Below are drawings of embodiments of the present invention. [Figure 1] FIG. 2 is a circuit diagram of a refrigerant circuit having a compressor module and an integrated internal heat exchanger. [Diagram 2] FIG. 2 is a schematic diagram of a compressor module having a multi-part housing. [Diagram 3] FIG. 2 is a schematic diagram of a refrigerant circuit having a heat exchanger and refrigerant collector integrated with a compressor module. [Figure 4] FIG. 2 is a schematic diagram of a compressor module having a multi-part housing. [Diagram 5] FIG. 2 is a circuit diagram of a refrigerant circuit having a compressor module, an internal heat exchanger, a refrigerant collector, and a cooler. [Figure 6] FIG. 2 is a schematic diagram of a compressor module having a multi-part housing. [Figure 7] FIG. 2 is a circuit diagram of a refrigerant circuit including a compressor module; [Figure 8] FIG. 2 is a schematic diagram of a compressor module having a multi-part housing. [Figure 9] FIG. 2 is a schematic diagram of a compressor module having a multi-part housing. [Figure 10] FIG. 2 is a circuit diagram of a refrigerant circuit including a compressor module; [Figure 11] FIG. 2 is a schematic diagram of a compressor module having a multi-part housing. [Figure 12] FIG. 2 is a schematic diagram of a compressor module having a multi-part housing. [Figure 13] FIG. 2 is a circuit diagram of a refrigerant circuit including a compressor module; [Figure 14] FIG. 2 is a schematic diagram of a compressor module having a multi-part housing. [Figure 15] FIG. 2 is a schematic diagram of a compressor module having a multi-part housing. [Figure 16] FIG. 2 is a cross-sectional end view of a compressor module with an integrated internal heat exchanger. [Figure 17] FIG. 2 is a partial longitudinal cross-sectional view of a compressor module with an integrated refrigerant collector and internal heat exchanger; [Figure 18] FIG. 1 is a cross-sectional end view of a compressor module with an internal heat exchanger located at the end. [Figure 19] FIG. 1 illustrates a compressor module with an internal heat exchanger within the motor housing. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0035] Figure 1 shows a circuit diagram of a refrigerant circuit for R744 with a compressor module (33). The compressor module (33) is assembled from a number of components. Along with the main components, namely the electric compressor (34) for the refrigerant and the internal heat exchanger (1), the compressor module also contains various refrigerant sensors, in particular pressure / temperature sensors (40).

[0036] Here, refrigerant sensors for pressure and temperature are arranged at the compressor outlet, while another refrigerant sensor (40) is arranged at the refrigerant inlet into the compressor module (33), downstream of the gas cooler (35) and upstream of the internal heat exchanger (1) inside the compressor module (33). Downstream of the high-pressure side of the internal heat exchanger (1), the refrigerant is guided in one way or another, depending on the operating mode and the position of the valves (not shown), arranged in parallel in the circuit, through the evaporator (36) to which the expansion element (37) is assigned, and the cooler (38) to which the expansion element (39) is assigned. After that, after the refrigerant vapor enters the compressor module (33), it is measured by the refrigerant sensor (40) on the low pressure side, before it is guided to the refrigerant collector (15) arranged outside the compressor module and subsequently into the internal heat exchanger (1) of the compressor module (33). The refrigerant vapor exiting the internal heat exchanger (1) is ultimately directed to the suction side of the compressor (34).

[0037] The circuit is completed by temperature sensors (41), which are used, for example, to measure the air temperature at the evaporator (36) and the refrigerant temperature at the cooler (38). The integration of the compressor (34), the internal heat exchanger (1) and the refrigerant sensor (40) components into the compressor module (33) allows a high level of integration and therefore reduces the total system cost. This is achieved by eliminating the separate components that comprise the cooling system for the R744 refrigerant, due to the high level of integration of the components. The internal heat exchanger (1) is integrated by accommodating it within the compressor housing, which is therefore referred to as the housing of the compressor module (33).

[0038] Here, the advantages of the existing pressure housing structure of the compressor (34) are used and the internal heat exchanger (1) can be integrated into the housing from the low pressure side at low cost. All necessary refrigerant sensors (40) are also integrated into the housing, so that no additional refrigerant sensors have to be located in the circuit at a different location. A central location of the refrigerant sensors inside the compressor module (33) can be made in part of the inverter board. This reduces the electrical connections of the product, which are less complicated. Furthermore, no special sensor housings are required for the sensors. The sensor signals are transmitted via the data network already present for the compressor, e.g. via CAN / CAN_FD or _LIN. In addition to this, better cooling of the compressor motor is achieved thanks to the integration, so that the motor efficiency of the inverter and / or the electric compressor (34) is improved as a result of the integration due to lower temperature levels.

[0039] Figure 2 shows a schematic diagram of a compressor module (33) made of disk-shaped housing modules. The disk-shaped housing modules are connected together using seals to form a compact overall compressor module housing. In the following, various versions and combinations of the housing modules are described in the embodiments.

[0040] According to the embodiment according to Fig. 2, the inverter housing is arranged in one stage inside the compressor module. The motor housing (20) leads to the low pressure refrigerant inlet (42). And the central housing houses the internal heat exchanger (1), while the high pressure housing (27) is arranged in one stage with the mechanical working elements of the compressor. In the embodiment shown with a scroll compressor, the working elements of the compressor are manufactured as fixed and orbiting scrolls.

[0041] In addition, a refrigerant sensor (40) is integrated into the housing. A high pressure refrigerant outlet (43) is located radially from the high pressure housing (27). An internal heat exchanger (1) is located in the central housing (22), and the low pressure refrigerant flows from the low pressure refrigerant inlet (42) through the inverter housing (23) and the electric motor in the motor housing (20), through the internal heat exchanger (1) in the central housing (22) to the high pressure housing (27), where the refrigerant vapor is compressed and finally through the high pressure refrigerant outlet (43) to the compressor (33). The flow of refrigerant through the mentioned components occurs from the inlet to the outlet, and these components are connected in series and are represented by arrows.

[0042] Figure 3 shows a circuit diagram of a refrigerant circuit having the same structure as that illustrated in Figure 1. However, in contrast to the circuit according to Figure 1, Figure 3 shows the compressor module (33) expanded by integrating a refrigerant collector (15) into the compressor module (33). All other components and the refrigerant circuit itself remain unchanged. The further increased level of integration of the compressor module (33) obtained by including the refrigerant collector (15) reduces the total cost of the system.

[0043] FIG. 4 shows a compressor module (33) with a design including a disk-type housing module as shown in FIG. 3 as a schematic diagram. Said compressor module (33) is limited in part by a refrigerant collector (15). The internal heat exchanger (1), the motor housing (20), the central housing (22) and finally the high-pressure housing (27) are arranged axially. The refrigerant sensor (40) is shown in a schematic manner and is integrated into the housing of the compressor module (33) at the corresponding point indicated. The refrigerant collector (15) (also called accumulator) is arranged at the refrigerant inlet, while the internal heat exchanger (1) is located between the refrigerant collector (15) and the electric motor of the compressor and his motor housing (20). On the low-pressure side, the refrigerant flows from the refrigerant inlet through the refrigerant collector (15), the low-pressure internal heat exchanger (1) and the electric motor in the motor housing (20) to the high-pressure housing (27) with the scroll compressor, and from there to the high-pressure refrigerant outlet (43).

[0044] On the other hand, Figure 5 shows a circuit diagram of a refrigerant circuit similar to the circuits of Figures 1 and 3. The refrigerant circuit according to Figure 5 shows a compressor module (33) to which an additional component has been added: a heat exchanger which is also integrated in the compressor module (33). In the embodiment shown, the heat exchanger is made as a cooler (38) with an assigned expansion element (39).

[0045] FIG. 6 shows an example of a compressor module (33) along the circuit shown in FIG. 5. The refrigerant collector (15), the cooler (38) and the associated expansion element (39) are also all integrated into the compressor module (33). Furthermore, the internal heat exchanger (1) is arranged between the refrigerant collector (15) and the motor housing (20). The central housing (22) and the high pressure housing (27) are connected. While the refrigerant collector (15) now has more than one refrigerant inlet, the refrigerant collector (15), the internal heat exchanger (1) and the cooler (38) and the expansion element (39) are all integrated into the housing of the compressor module (33). Thus, the refrigerant collector, the cooler and the internal heat exchanger utilize the pressure vessel structure of the compressor housing from the low pressure side, which reduces costs. In addition to this, all the necessary refrigerant sensors are integrated into the housing of the compressor module (33), which results in direct benefits as well as advantages associated with their placement on a part of the central control and inverter board.

[0046] This means in particular that leakage is reduced and the electrical circuit is less complicated, but no special sensor housing is required, thereby reducing costs considerably. Furthermore, in addition to the compressor signal, as already explained, the transmission of the signal is also possible via the corresponding network already present for the compressor control. This results in improved inverter and electric motor efficiency thanks to the lower temperatures inside the compressor module (33) as a result of suction gas cooling.

[0047] Refrigerant flow begins with high pressure refrigerant in the expansion element (39). The expanded low pressure refrigerant is then directed through the chiller (38), the refrigerant collector (15), the internal heat exchanger (1) and the electric motor in the motor housing (20) to the scroll compressor unit in the high pressure housing (27) and the high pressure refrigerant outlet (43).

[0048] 7 shows a refrigerant circuit with a compressor module (33) integrated into the circuit, where a refrigerant collector (15) is located in the low pressure section downstream of an evaporator (36) or in the high pressure section upstream of an expansion element (37) of the evaporator (36). Here, the compressor module (33) includes an inverter housing (23), a motor housing (20), a central housing (22) with an internal heat exchanger (1) and a high pressure housing (27). The refrigerant circuit is completed by a gas cooler (35).

[0049] In this embodiment, the refrigerant circuit can be used for a multiple evaporator system. The refrigerant flows in the direction of the arrow from the low pressure side through the inverter in the inverter housing (23), the electric motor in the motor housing (20) and the internal heat exchanger (1) in the center housing (22) to the high pressure housing (27) and to the refrigerant outlet.

[0050] Figure 8 shows a different arrangement of the heat exchanger (1) compared to the arrangement shown in Figure 7. Here, the positions of the heat exchanger (1) and the motor housing (20) are changed. According to another alternative, the internal heat exchanger (1) is replaced by the inverter housing (23), and the low-pressure refrigerant flows through the internal heat exchanger (1) and the inverter housing (23), and then is guided to the high-pressure housing (27) through the motor housing (20) and the central housing (22). Figure 9 shows a compressor module (33) that integrates an internal heat exchanger (1) into the alternative design. The internal heat exchanger (1) is placed in parallel with the electric motor of the compressor.

[0051] Therefore, the refrigerant can flow from the low pressure side in a variety of ways. One way is from the low pressure refrigerant inlet (42), through the inverter in the inverter housing (23), to the electric motor in the motor housing (20), and finally through the internal heat exchanger (1) and the central housing (22) to the high pressure housing (27) which contains the helical compressor unit. From the high pressure, the refrigerant leaves through the refrigerant outlet (43) and the compressor module (33).

[0052] Alternatively, the low pressure refrigerant can flow from the low pressure refrigerant inlet 42 through the interval in the inverter housing 23 to the internal heat exchanger 1, then through the electric motor in the motor housing 20, through the center housing, and into the high pressure housing 27. In another alternative, the refrigerant can flow at low pressure from the refrigerant inlet 42 through the interval in the inverter housing 23, and in parallel through the internal heat exchanger 1 and the electric motor in the motor housing 20, and into the high pressure housing 27.

[0053] Figure 10 shows a refrigerant circuit with a compressor module (33), similar to the circuit diagram of figure 7. Here the compressor module (33) is characterized by the fact that the refrigerant collector (15) is integrated into the housing of the compressor module (33). In addition to this, the internal heat exchanger (1) is integrated into the housing of the compressor module (33), and the advantage of using the existing pressure housing of the compressor housing for the refrigerant collector (15) and the internal heat exchanger (1) on the low pressure side is also used in this design, which reduces costs. Here, all the required refrigerant sensors are also integrated into the housing of the compressor module (33). The advantages with regard to reduced leakage, less complicated wiring and the possibility of not having special sensor housings, as well as the option of transmitting the sensor signals by the compressor signaling system, and the improved inverter and motor efficiency that can be achieved due to lower temperatures have already been referred to above. On the low pressure side, refrigerant flows from the refrigerant collector (15), through the internal heat exchanger (1), the inverter housing (23) and the electric motor in the motor housing (20) and the center housing (22) to the high pressure housing (27).

[0054] 11 shows a refrigerant collector (15) with a refrigerant inlet going into the compressor module (33), but with an internal heat exchanger (1) located between the electric motor and the helical compressor unit, and therefore between the motor housing (20) and the central housing (22) and high pressure housing (27). On the low pressure side, the refrigerant flows from the low pressure refrigerant inlet through the refrigerant collector (15), through the electric motor and internal heat exchanger (1) in the motor housing (20) to the high pressure housing (27), and then from the high pressure to the compressor outlet and refrigerant outlet (43). In addition to this, a refrigerant sensor (40) is integrated into the housing.

[0055] FIG. 12 is a schematic diagram of a compressor module (33) with a connection similar to that shown in FIG. 12, where the inverter with inverter housing (23) of FIG. 9 is replaced by a refrigerant collector (15) from FIG. 12. The refrigerant on the low pressure side again flows in three different ways (different versions). First, it goes through the refrigerant collector (15) to the electric motor in the motor housing (20) and then through the internal heat exchanger (1) in the high pressure housing (27) with the scroll compressor unit. In the next version of the refrigerant flow on the low pressure side, the positions of the internal heat exchanger (1) and the electric motor are changed and in another version, the refrigerant on the low pressure side flows in parallel through the electric motor and the internal heat exchanger (1).

[0056] Figure 13 shows a refrigerant circuit having a compressor module (33) similar to that shown in Figures 10 and 7. In contrast to the previously described embodiments, the low pressure side refrigerant flows through the inlet port of the compressor module (33) to the refrigerant collector (15), then through the inverter in the inverter housing (23), through the electric motor in the motor housing (20) and through the center housing (22) to the high pressure housing (27).

[0057] The compressor module (33) of Figures 1-3 is shown in more detail in Figures 1-4. vessel(38) and the associated expansion element (39) are integrated into the compressor module (33). The refrigerant collector (15), motor housing (20), internal heat exchanger (1), central housing (22) and high pressure housing (27) are then arranged in series. On the low pressure side, the refrigerant flow starts with high pressure refrigerant in the expansion element (39) of the cooler (38), passes through the refrigerant collector (15) to the electric motor in the motor housing (20), passes through the internal heat exchanger (1) to the central housing (22) and high pressure housing (27) and finally to the high pressure refrigerant outlet (43).

[0058] FIG. 15 finally shows a compressor module (33) using a design similar to the modules of FIGS. 12 and 9, with a cooling element (39) vessel (38), then the refrigerant collector (15), then the motor housing (20), the internal heat exchanger (1) and the central housing (22) and the high pressure housing (27) are arranged. Meanwhile, the flow of the refrigerant on the low pressure side starts with the refrigerant at the expansion element (39) of the cooler (38) with the refrigerant at high pressure. The internal heat exchanger is arranged in parallel with the electric motor in the motor housing (20). In three different operating modes, the expansion valve (39), the cooler (38) and the refrigerant collector (15) are previously flowed through, and in an alternative version, the electric motor in the motor housing (20), then the internal heat exchanger (1) and the scroll compressor unit in the high pressure housing (27) are flowed through.

[0059] In one version, the refrigerant collector (15) is followed by the internal heat exchanger (1) and the electric motor in the motor housing (20) and then the scroll compressor unit. In another alternative, the refrigerant flows in parallel through the electric motor and the internal heat exchanger (1) before being guided through the high pressure housing (27) with the scroll compressor unit.

[0060] FIG. 16 shows a cross-sectional end view of the compressor module (33). Here, the individual components of the compressor module (33) are shown along the centerline of the compressor shaft (4a). The compressor module (33) includes its main components, a refrigerant compressor and an internal heat exchanger (1). The internal heat exchanger has a coil tube (13) as a high-pressure line, and has an inlet (8) of the internal heat exchanger (1) for high-pressure refrigerant and an outlet (7) of the internal heat exchanger. A low-pressure flow path inside the compressor module (33) is formed from a low-pressure refrigerant inlet (42) to a high-pressure refrigerant outlet (43) along the compression of the refrigerant. In the path from the refrigerant inlet (42) to the refrigerant outlet (43), the refrigerant gas passes through the coil tube (13) with the refrigerant of the internal heat exchanger (1) at high pressure and absorbs heat from it.

[0061] The electronic components of the electric refrigerant compressor, which is manufactured as a scroll compressor, are located within the inverter housing (23). The inverter housing (23) is followed by the motor housing (20), which is located immediately downstream in the axial direction of the inverter housing (23). The compressor shaft (4a) is mounted in a motor bearing (4) within the motor housing (20).

[0062] The rotor (25) of the electric compressor electric motor is arranged around the shaft (4a) while the fixed part (24) is coaxially spaced radially from the shaft. In the motor housing (20), the shaft (4a) is supported on one stage in the motor bearing (4) while on the other stage the main bearing (31) is arranged in the central housing (22). The shaft (4a) drives the orbiting scroll (29), which is mounted on the orbiting scroll bearing (30). The fixed scroll (28) is mounted in the high pressure housing (27). The central housing (22) is arranged between the motor housing (20) and the high pressure housing (27).

[0063] The central housing houses the main bearing (31), the orbiting scroll bearing (30) and the counterweight (26). The flow path of the gaseous refrigerant is from the low pressure refrigerant inlet (42), through the motor components to cool them, over the coil tubes (13) of the internal heat exchanger (1), and finally between the scrolls (28, 29) where compression of the refrigerant occurs. The compressed refrigerant then exits the high pressure housing (27) through the high pressure refrigerant outlet (43) and thereby the compressor module (33).

[0064] Figure 17 shows an excerpt of the compressor module (33), the depiction of which is limited to the upstream part of the actual compression process. In this embodiment, the compressor module (33) design includes a housing cover (18), a central housing (19) and a motor housing (20). Housing seals (12) are placed between the individual housing modules, which together form the housing for the entire compressor module (33) in the form of segments and disks, making the housing pressure tight on the outside.

[0065] The housing cover (18) and the central housing (19) enclose a portion of the refrigerant collector (15) where the liquid refrigerant separates from the low pressure refrigerant vapor flow and collects. A cup-shaped separation element (16) is made in the refrigerant collector (15) into which the gas inlet pipe (17) of the internal heat exchanger (1) protrudes. The liquid separator (14) spans the separation element (16) from the outside like a funnel, and the refrigerant vapor, potentially representing the refrigerant liquid in droplet form, is guided through the low pressure refrigerant inlet (42) and the liquid separator (14) into the refrigerant collector (15). The stuck refrigerant liquid then falls down the wall of the liquid separator (14) and collects on the base of the refrigerant collector (15). The refrigerant vapor is then guided through the gas inlet pipe (17) into the internal heat exchanger (1) and flows over the coil tubes (13). The warm refrigerant flowing inside the coil tube (13) at high pressure is cooled by the cold refrigerant gas flowing over the coil tube (13) in the internal heat exchanger (1).

[0066] High pressure refrigerant flows through the inlet (8) into the internal heat exchanger (1) and, after passing over the coil tubes (13), leaves the compressor module (33) through the outlet (7). At the outlet (7) from the compressor module (33), the coil tubes (13) are fixed with a seal (10), and a corresponding seal (9) is also provided at the inlet (8). The internal heat exchanger (1) is defined on the outside by an outer guide housing (2) and an inner guide housing (3), and in the illustrated embodiment, the inner guide housing (3) is manufactured as a hollow cylinder in the axial direction and has a base (32). The axial boundary of the base (32) and the radial boundary of the hollow cylindrical wall together form a pot-shaped design for the inner guide housing (3).

[0067] The outer guide housing (2) is designed in a similar manner with a hollow cylindrical wall and has a base (44), resulting in a flowerpot-shaped design. These two flowerpot-shaped housings are arranged coaxially with the axis (4a) in the motor housing (20) and accommodate the coil tube (13) between their axially extending cylindrical walls. Before the refrigerant vapor is guided inside the inner guide housing (3), the refrigerant gas coming from the gas intake pipe (17) flows into the intermediate space between the flowerpot-shaped outer guide housing (2) and the flowerpot-shaped inner guide housing (3), and then flows axially over the coil tube (13), thereby transferring heat.

[0068] Here, a filter material (21) is placed to capture moisture potentially in the refrigerant vapor. The inner guide housing (3) is inserted into the outer guide housing (2) and the base (32) contacts the base (44). The two bases (32, 44) of the outer guide housing (2) and the inner guide housing (3) are mechanically connected to each other by screws (11). After flowing through the inner guide housing of the internal heat exchanger, the refrigerant gas is guided to the compressor through the suction pressure channel.

[0069] The depiction in Figure 17 shows the shaft (4a) and his motor bearing (4) at one end. The system is supplemented by a filter (5), which is typically a 100% particulate filter and is installed in the refrigerant circuit. The filter (5) can be located in several positions, for example between the internal heat exchanger (1) and the motor housing (20), at the inlet of the compressor or in different positions depending on the components in the installation space where the refrigerant is restricted.

[0070] Figure 18 shows a different embodiment of the compressor module (33). One important difference here lies in the fact that the refrigerant collector (15) is now relocated outside the housing cover (18) and inside the motor housing (20), while the internal heat exchanger (1) is relocated outside the motor housing (20) and inside the housing cover (18). The design of the refrigerant collector (15) with the liquid separator (14), the separation element (16) and the gas intake pipe (17) essentially corresponds to the refrigerant collector (15) already illustrated in Figure 17.

[0071] The internal heat exchanger (1) on the other hand is designed with a coil tube (13) which is arranged between the cylindrical part of the housing cover (18) and the inner guide housing (3) of the internal heat exchanger (1). To limit the space for the filter material (21), a disk-shaped dividing element (45) is manufactured as a limiting plate. This shows the corresponding mounting fixture for the inner guide housing (3). The base (32) of the inner guide housing (3) is fixed in position to the housing cover (18) by means of screws (11).

[0072] One special feature of these designs lies in the fact that the coil tube (13) is guided radially from the internal heat exchanger (18) into the housing cover for the inlet (8) and outlet (7). The ends of the coil tube (13) are sealed using seals (9, 10). A low pressure refrigerant inlet (42) is also located in the housing cover (18). A suction pressure channel guides the refrigerant gas to the compressor, which is shown only with its shaft and motor bearings. Therefore, the base (44) is reduced to just a bracket for the gas suction pipe (17). The housing seal (12) is placed between the housing cover (18) and the motor housing (20). A filter (5) is added to the system to protect the components from particulates.

[0073] Figure 19 shows another alternative embodiment of a compressor module (33), where the internal heat exchanger (1) is arranged in the motor housing (20) while the refrigerant collector (15) is arranged in the housing cover (18). The design of the components, i.e. the refrigerant collector (15) with the cup-shaped separating element (16), the gas inlet pipe (17) and the liquid separator (14) with the connection for the low pressure refrigerant inlet (42) corresponds to the design illustrated in Figures 17 and 18.

[0074] The internal heat exchanger (1) is designed with a cylindrical outer guide housing (2) with a base (44), a cylindrical inner guide housing (3) with a base (32), and a coil tube (13) arranged between the cylindrical sections for the high pressure refrigerant. In this embodiment, the base (32) of the pot-shaped inner guide housing (3) is arranged opposite the base (44) of the outer guide housing (2). A filter material is arranged in the intermediate space and is shown diagrammatically. A housing seal (12) is made between the housing cover (18) and the motor housing (20). The suction pressure channel to the compressor has a design similar to that shown in Figures 17 and 18. The coil tube (13) is integrated into the steps as the inlet (8) and outlet (7) of the internal heat exchanger (1) using seals (9, 10) to protrude axially through the base (32), and the corresponding connections are introduced from the outside into the compressor module (33). Similar to Figures 18 and 17, the compressor itself is shown with the shaft (4a) and motor bearings (4) not explicitly shown, but the filter (5) is present to protect the refrigerant circuit components from particulates. [Explanation of symbols]

[0075] 1 Internal heat exchanger 2 Outer guide housing 3 Inner guide housing 4 Motor Bearings 4a axis 5. Filters 7 Exit 8 Entrance 9 Seal 10 Seal 11 Screw 12 Housing seal 13 Coil tube 14 Liquid separator 15 Refrigerant collector 16 Cup-type separation element 17 Gas intake pipe 18 Housing cover 19 Central Housing 20 Motor housing 21 Filter Materials 22 Central Housing 23 Inverter housing 24 Fixed part 25 Rotor 26 Counterweight 27 High pressure housing 28 Fixed Scroll 29 Swivel Scroll 30 Bearings 31 Main bearing 32 Base 33 Compressor module 34 Compressor 35 Gas Cooler 36 Evaporator 37 Expansion Factor 38 Cooling vessel 39 Expansion Elements 40 Refrigerant Sensor 41 Temperature Sensor 42 Refrigerant inlet 43 High pressure refrigerant outlet 44 Base 45 Disk-type division element

Claims

1. A compressor module (33) for a refrigerant circuit of an automotive air conditioning system, comprising a housing having a low pressure refrigerant inlet, a high pressure refrigerant outlet and a compressor (34), an internal heat exchanger (1) of the refrigerant circuit is manufactured to be integrated into the compressor module (33), the housing of the compressor module (33) completely enclosing the internal heat exchanger (1), a refrigerant collector (15) of the refrigerant circuit is manufactured to be integrated into the housing of the compressor module (33); The housing includes a motor housing (20), a high voltage housing (27), and a center housing (22) disposed between the motor housing (20) and the high voltage housing (27); The refrigerant is guided past the refrigerant collector (15), the motor housing (20) and the central housing (22) to the high pressure housing (27); The compressor module (33) is characterized in that the internal heat exchanger (1) is arranged between the refrigerant collector (15) and the motor housing (20), or is arranged within the motor housing (20) between the refrigerant collector (15) and the central housing (22).

2. A compressor module (33) for a refrigerant circuit of a motor vehicle air conditioning system, comprising a housing having a low pressure refrigerant inlet, a high pressure refrigerant outlet, and a compressor (34), wherein an internal heat exchanger (1) of the refrigerant circuit is manufactured to be integrated into the compressor module (33), the housing of the compressor module (33) completely enclosing the internal heat exchanger (1), a refrigerant collector (15) of the refrigerant circuit is manufactured to be integrated into the housing of the compressor module (33); The housing includes an inverter housing (23), a motor housing (20), a high-voltage housing (27), and a central housing (22) disposed between the motor housing (20) and the high-voltage housing (27); The refrigerant passes through the refrigerant collector (15), the inverter housing (23), the motor housing (20), and the central housing (22) and is led to the high pressure housing (27); A compressor module (33) characterized in that the internal heat exchanger (1) is disposed between the refrigerant collector (15) and the inverter housing (23).

3. Compressor module (33) according to claim 1 or 2, characterized in that at least one refrigerant sensor (40) is manufactured to be integrated into a housing of the compressor module (33).

4. Compressor module (33) according to any one of claims 1 to 3, characterized in that further heat exchangers of the refrigerant circuit are manufactured to be integrated into the housing of the compressor module (33).

5. The compressor module (33) according to claim 4, characterized in that the heat exchanger is manufactured as a cooler (38) and an expansion element (39) located upstream of the cooler (38) is manufactured so as to be integrated into a housing of the compressor module (33).

6. Compressor module (33) according to any one of claims 1 to 5, characterized in that the housing of the compressor module (33) is manufactured from disk-shaped housing sections.

7. 7. The compressor module (33) according to claim 1, 2 or 3, characterized in that the housing of the compressor module (33) is manufactured by a housing for the refrigerant collector (15), a housing for the internal heat exchanger (1), the motor housing (20), the central housing (22) and the high pressure housing (27), and the refrigerant passes from the low pressure refrigerant inlet through the refrigerant collector (15), the internal heat exchanger (1), the motor housing (20) and the central housing (22) and is guided to the high pressure housing (27), and the internal heat exchanger (1) is disposed between the refrigerant collector (15) and the motor housing (20).

8. 7. The compressor module (33) according to claim 1, 2 or 3, characterized in that the housing of the compressor module (33) is manufactured by a housing for a cooler (38) and an expansion element (39), a housing for the refrigerant collector (15), a housing for the internal heat exchanger (1), the motor housing (20), the central housing (22) and the high pressure housing (27), and the refrigerant passes from the low pressure refrigerant inlet through the expansion element (39), the cooler (38), the refrigerant collector (15), the internal heat exchanger (1), the motor housing (20) and the central housing (22) and is guided to the high pressure housing (27), and the internal heat exchanger (1) is arranged between the refrigerant collector (15) and the motor housing (20).

9. the housing of the compressor module (33) is manufactured by the housing of the refrigerant collector (15), the housing of the internal heat exchanger (1), the inverter housing (23), the motor housing (20), the central housing (22) and the high pressure housing (27); The refrigerant is guided from the low pressure refrigerant inlet through the refrigerant collector (15), the internal heat exchanger (1), the inverter housing (23), the motor housing (20) and the central housing (22) to the high pressure housing (27); The compressor module (33) according to any one of claims 2 to 6, characterized in that the internal heat exchanger (1) is arranged between the refrigerant collector (15) and the inverter housing (23).

10. The housing of the compressor module (33) is manufactured from a housing for the refrigerant collector (15), the motor housing (20), the center housing (22) and the high pressure housing (27), The refrigerant is guided from the low pressure refrigerant inlet through the refrigerant collector (15), the internal heat exchanger (1), the motor housing (20) and the central housing (22) to the high pressure housing (27), or through the refrigerant collector (15), the motor housing (20), the internal heat exchanger (1) and the central housing (22) to the high pressure housing (27); or through the refrigerant collector (15) and, in parallel, through the internal heat exchanger (1) and the motor housing (20), then through the central housing (22) and into the high pressure housing (27); The compressor module (33) according to any one of claims 1, 3 to 6, characterized in that the internal heat exchanger (1) is arranged within the motor housing (20) between the refrigerant collector (15) and the central housing (22).

11. the housing of the compressor module (33) is composed of a housing for a cooler (38) and an expansion element (39), a housing for the refrigerant collector (15), a housing for the internal heat exchanger (1), the inverter housing (23), the motor housing (20), the central housing (22) and the high pressure housing (27); The refrigerant is guided from the low pressure refrigerant inlet through the expansion element (39), the cooler (38), the refrigerant collector (15), the internal heat exchanger (1), the inverter housing (23), the motor housing (20) and the central housing (22) to the high pressure housing (27); The compressor module (33) according to any one of claims 2 to 6, characterized in that the internal heat exchanger (1) is arranged between the refrigerant collector (15) and the inverter housing (23).

12. The housing of the compressor module (33) is manufactured from a housing for a cooler (38) and an expansion element (39), a housing for a refrigerant collector (15), the motor housing (20), the central housing (22) and the high pressure housing (27); The refrigerant is guided from the low pressure refrigerant inlet through the expansion element (39), the cooler (38), the refrigerant collector (15), the internal heat exchanger (1), the motor housing (20) and the central housing (22) to the high pressure housing (27); or or it is led to the high pressure housing (27) via the expansion element (39), the cooler (38), the refrigerant collector (15), the motor housing (20), the internal heat exchanger (1) and the central housing (22); or through the expansion element (39), the cooler (38), the refrigerant collector (15) and, in parallel, through the internal heat exchanger (1) and the motor housing (20), then through the central housing (22) and into the high pressure housing (27); The compressor module (33) according to any one of claims 1, 3 to 6, characterized in that the internal heat exchanger (1) is arranged within the motor housing (20) between the refrigerant collector (15) and the central housing (22).

13. 13. The compressor module (33) according to any one of claims 1 to 12, characterized in that the internal heat exchanger (1) is manufactured as a cylindrical coil tube (13) arranged coaxially with the compressor axis (4a).

14. 14. Compressor module (33) according to any one of claims 1 to 13, characterized in that the internal heat exchanger (1) is arranged radially coaxially between an outer guiding housing (2) and an inner guiding housing (3).

15. 3. The compressor module (33) according to claim 1 or 2, characterized in that the housing further comprises a housing cover (18) defining one end of the housing in the axial direction, and a central housing (19) arranged between the housing cover (18) and the motor housing (20), the refrigerant collector (15) being arranged within the central housing (19) and the housing cover (18), the refrigerant collector (15) having a liquid separator (14), a cup-shaped separation element (16) and a gas intake pipe (17) for the internal heat exchanger (1) for obtaining refrigerant liquid from a flow of refrigerant gas.

16. 3. The compressor module (33) according to claim 1 or 2, characterized in that the housing further comprises a housing cover (18) defining one end of the motor housing (20) in the axial direction, the internal heat exchanger (1) being arranged coaxially between an inner guide housing (3) and a cylindrical part of the housing cover (18) in the radial direction, and a disk-type dividing element (45) being arranged in the axial direction as a boundary to a refrigerant collector (15).

17. Compressor module (33) according to claim 14 or 16, characterized in that the inner guiding housing (3) is capable of holding a filter material (21) and is manufactured to carry a filter (5).

18. The compressor module (33) according to any one of the preceding claims, characterized in that the compressor (34) is manufactured as an electric compressor.

19. The compressor module (33) of any one of claims 1 to 18, wherein the compressor (34) is manufactured as a scroll compressor.

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