Electric scroll compressor with motor connector assembly, and motor connector assembly for electric scroll compressor

Abstract

To provide an electric scroll compressor with a motor connector assembly, and a motor connector assembly for an electric scroll compressor.SOLUTION: An electric compressor includes a housing, a refrigerant inlet port, a refrigerant outlet port, an inverter part, a motor part, a compression device, and a front cover. The housing defines intake volume and discharge volume. The refrigerant inlet port is united to the housing and is configured to introduce a refrigerant to the intake volume. The compression device is configured to compress the refrigerant. The refrigerant outlet port is united to the housing, and is configured to permit the compressed refrigerant to go out from the discharge volume and the electric compressor.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates generally to electric compressors, and more particularly to electric compressors that compress refrigerant using a scroll compression device. [Background technology]

[0002] Compressors have long been used in refrigeration systems. In particular, systems designed to provide cooling in a specific area use scroll-type compressors, in which an orbiting scroll rotates in a circular motion relative to a fixed scroll to compress a refrigerant. For example, such scroll-type compressors have long been used in HVAC systems in automobiles and other vehicles to provide air conditioning. Such compressors may also be used in reverse in applications requiring a heat pump. Typically, these compressors are driven using the rotary motion available from the automobile's engine.

[0003] With the advent of battery powered or electric and / or hybrid vehicles, such compressors must be driven or powered by a battery rather than an engine, since the vehicle may sometimes be powered solely by a battery. Such compressors may be referred to as electric compressors.

[0004] In addition to cooling the passenger compartment of the vehicle, the electric compressor may be used to provide heating or cooling to other areas or components of the 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, especially during fast charge modes, which may generate heat that may damage or degrade the battery and / or other systems. It may also be used to cool the battery when it is not being charged or used, since the heat may damage or degrade the battery. Since the electric compressor may operate at various times, such use obviously requires electrical energy from the battery, even when the vehicle is not operating, thus reducing the operating time of the battery. Additionally, the electric compressor may operate at very high speeds, for example, 2,000 RPM (or higher). Such high speeds may generate undesirable levels of noise.

[0005] Such scroll-type compressors may be driven using an electric motor, such as a three-phase alternating current (AC) motor. The electric motor may be located within the compressor housing and surrounded by coolant. The windings of the electric motor must then pass through the coolant and be connected to a drive circuit, which may be located internal or external to the compressor. Such configurations may be subject to current leakage and / or losses. Summary of the Invention [Problem to be solved by the invention]

[0006] It is therefore desirable to provide an electrically powered compressor having high efficiency, low noise and maximum life.The present invention is directed to one or more of the problems or advantages identified above. [Means for solving the problem]

[0007] In a first aspect of the present invention, a motor-driven compressor configured for compressing a refrigerant is provided. The motor-driven compressor includes a housing, an inverter module, a compression device, and a motor connector assembly. The housing defines an intake volume, a discharge volume, and an inverter cavity and has a generally cylindrical shape with a central axis. The housing further defines a motor connector opening disposed between the intake volume and the inverter cavity. The inverter module is mounted within the inverter cavity of the housing and adapted to convert direct current power to alternating current power. The motor has a plurality of motor windings and is mounted to the interior of the housing. The compression device is coupled to the motor for receiving refrigerant from the intake volume and compressing the refrigerant as the motor rotates. The motor connector assembly includes a motor connector housing, a first motor connector, and a second motor connector. The motor connector housing has an inverter end adjacent the inverter cavity and an intake end within the intake volume. The motor connector housing is disposed within the motor connector opening and includes an inner wall having an intake side and an inverter side. An inner wall is disposed between the inverter end and the intake end separating the intake volume and the inverter cavity. A first motor connector extends through the inner wall and has a first end disposed adjacent the intake side of the inner wall and a second end disposed adjacent the inverter side of the inner wall. One of the motor windings is electrically connected to the first end of the first motor connector. A second motor connector is coupled to the inverter module and configured to be removably coupled to the second end of the first motor connector.

[0008] In a second aspect of the present invention, a motor-driven compressor configured for compressing a refrigerant is provided. The motor-driven compressor includes a housing, an inverter module, a motor, a compression device, and a motor connector assembly. The housing defines an intake volume, a discharge volume, and an inverter cavity. The housing has a generally cylindrical shape and a central axis. The housing defines a motor connector opening disposed between the intake volume and the inverter cavity. The inverter module is mounted within the inverter cavity of the housing and adapted to convert direct current power to alternating current power. The motor has a plurality of motor windings and is mounted to the interior of the housing. The compression device is coupled to the motor for receiving refrigerant from the intake volume and compressing the refrigerant as the motor rotates. The motor connector assembly includes a motor connector housing, a first motor connector, and a second motor connector. The motor connector housing has an inverter end adjacent the inverter cavity and an intake end within the intake volume and is disposed within the motor connector opening. The motor connector housing includes an inner wall having an intake side and an inverter side and is disposed between the inverter end and the intake end separating the intake volume and the inverter cavity. The motor connector housing defines a connector intake cavity disposed within the intake volume, and a connector inverter cavity. A first end of a first motor connector is disposed at least partially within the connector intake cavity and a second end of the first motor connector is disposed at least partially within the connector inverter cavity. The first motor connector passes through the inner wall and has a first end disposed adjacent the intake side of the inner wall and a second end disposed adjacent the inverter side of the inner wall. One of the motor windings is electrically connected to the first end of the first motor connector. The second motor connector is coupled to the inverter module and configured to be removably coupled to the second end of the first motor connector. The second motor connector has a first end and a second end. The first end of the second motor connector is configured to removably contact the inverter module.The second end of the second motor connector is configured to releasably contact the second end of the first motor connector.

[0009] In a third aspect of the present invention, a motor connector for use with an electric compressor is provided. The electric compressor is configured to compress a refrigerant and includes a housing, an inverter module, a motor, and a compression device, the housing defines an intake volume, a discharge volume, and an inverter cavity, the housing has a generally cylindrical shape and has a central axis, the housing defines a motor connector opening disposed between the intake volume and the inverter cavity, the inverter module is mounted inside the inverter cavity of the housing and adapted to convert direct current power to alternating current power. The motor has a plurality of motor windings and is mounted inside the housing. The compression device is coupled to the motor for receiving refrigerant from the intake volume and compressing the refrigerant as the motor rotates. The motor connector includes a motor connector housing, a first motor connector, and a second motor connector. The motor connector housing has an inverter end adjacent the inverter cavity and an intake end within the intake volume and is disposed within the motor connector opening. The motor connector housing includes an inner wall having an intake side and an inverter side and is disposed between the inverter end and the intake end separating the intake volume and the inverter cavity. A first motor connector passes through the inner wall and has a first end disposed adjacent the intake side of the inner wall and a second end disposed adjacent the inverter side of the inner wall. One of the motor windings is electrically connected to the first end of the first motor connector. A second motor connector is coupled to the inverter module and configured to be removably coupled to the second end of the first motor connector.

[0010] In a fourth aspect of the invention, a method is provided relating to a motor connector for use with an electric compressor. The electric compressor is configured to compress a refrigerant and includes a housing, an inverter module, a motor, and a compression device. The housing defines an intake volume, a discharge volume, and an inverter cavity. The housing has a generally cylindrical shape and a central axis. The housing defines a motor connector opening disposed between the intake volume and the inverter cavity. The inverter module is mounted within the inverter cavity of the housing and adapted to convert direct current power to alternating current power. The motor has a plurality of motor windings and is mounted to the interior of the housing. The compression device is coupled to the motor for receiving refrigerant from the intake volume and compressing the refrigerant as the motor rotates. The motor connector assembly includes a motor connector housing, a first motor connector, and a second motor connector. The motor connector housing has an inverter end adjacent the inverter cavity and an intake end within the intake volume and is disposed within the motor connector opening. The motor connector housing includes an inner wall having an intake side and an inverter side and is disposed between the inverter end and the intake end separating the intake volume and the inverter cavity to define a connector intake cavity. A first motor connector penetrates the inner wall and has a first end disposed adjacent the intake side of the inner wall and a second end disposed adjacent the inverter side of the inner wall. One of the motor windings is electrically connected to the first end of the first motor connector. The second motor connector is coupled to the inverter module and configured to be removably coupled to the second end of the first motor connector. The method includes the steps of (1) clamping the motor connector housing to a stator of the motor, (2) inserting the first connector into the connector housing, (3) filling the connector intake cavity with a potting material, (4) installing the motor in the housing, and (5) closing the inverter module by installing an inverter cover.

[0011] 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. [Brief description of the drawings]

[0012] [Figure 1] FIG. 1 is a first perspective view of an electric compressor in accordance with an embodiment of the present invention. [Diagram 2] FIG. 2 is a second perspective view of the electric compressor of FIG. 1. [Figure 3A] 2 is a first side view of the electric compressor of FIG. 1, showing an inverter back cover of the inverter unit. FIG. [Figure 3B] FIG. 3B is a perspective view of the inverter back cover of FIG. 3A. [Figure 3C] FIG. 13 is a first perspective view of an inverter back cover according to an alternative embodiment of the present invention. [Figure 3D] FIG. 3D is a second perspective view of the inverter back cover of FIG. 3C. [Figure 4] FIG. 2 is a second side view of the electric compressor of FIG. [Diagram 5] FIG. 2 is a front view of the electric compressor of FIG. [Figure 6] FIG. 2 is a rear view of the electric compressor of FIG. [Figure 7] FIG. 2 is a top view of the electric compressor of FIG. [Figure 8] FIG. 2 is a bottom view of the electric compressor of FIG. [Figure 9] FIG. 2 is a first cross-sectional view of the electric compressor of FIG. [Figure 10] 2 is a second sectional view of the electric compressor of FIG. 1. [Figure 11] FIG. 2 is an exploded view of the inverter of the electric compressor of FIG. [Figure 12] FIG. 2 is an exploded view of a portion of the electric compressor of FIG. 1, including the motor and drive shaft. [Figure 13] FIG. 2 is an exploded view of a compression device of the electric compressor of FIG. [Figure 14A] FIG. 13 is a first perspective view of the drive shaft of FIG. [Figure 14B] FIG. 14B is a second perspective view of the drive shaft of FIG. 14A. [Figure 15A] FIG. 13 is a first perspective view of the rotor and counterweight of the motor of FIG. [Figure 15B] FIG. 15B is a second perspective view of the rotor and counterweight of FIG. [Figure 16A] FIG. 2 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 linkage. [Figure 16B] FIG. 16B is a second perspective view of a portion of the electric compressor of FIG. 16A. [Figure 16C] FIG. 14 is a perspective view of a plug of the compression device of FIG. 13. [Figure 16D] FIG. 16D is a second perspective view of the plug of FIG. 16C. [Figure 16E] FIG. 16D is a cross-sectional view of the plug of FIG. 16C. [Figure 16F] FIG. 12 is a perspective view of an inverter housing of the inverter of FIG. [Figure 16G] FIG. 14 is a partial enlarged view of the compression device of FIG. 13. [Figure 17A] FIG. 2 is a graph of a fixed scroll and an orbiting scroll of a compression unit of the electric compressor of FIG. 1 in accordance with one embodiment of the present invention. [Figure 17B] FIG. 2 is a graph of a fixed scroll and an orbiting scroll of a compression unit of the electric compressor of FIG. 1 in accordance with one embodiment of the present invention. [Figure 17C] FIG. 2 is a graph of a fixed scroll and an orbiting scroll of a compression unit of the electric compressor of FIG. 1 in accordance with one embodiment of the present invention. [Figure 17D] FIG. 2 is a graph of a fixed scroll and an orbiting scroll of a compression unit of the electric compressor of FIG. 1 in accordance with one embodiment of the present invention. [Figure 17E] FIG. 2 is a graph of a fixed scroll and an orbiting scroll of a compression unit of the electric compressor of FIG. 1 in accordance with one embodiment of the present invention. [Figure 17F] FIG. 2 is a graph of a fixed scroll and an orbiting scroll of a compression unit of the electric compressor of FIG. 1 in accordance with one embodiment of the present invention. [Figure 17G]FIG. 2 is a graph of a fixed scroll and an orbiting scroll of a compression unit of the electric compressor of FIG. 1 in accordance with one embodiment of the present invention. [Figure 17H] FIG. 2 is a graph of a fixed scroll and an orbiting scroll of a compression unit of the electric compressor of FIG. 1 in accordance with one embodiment of the present invention. [Figure 17I] FIG. 2 is a graph of a fixed scroll and an orbiting scroll of a compression unit of the electric compressor of FIG. 1 in accordance with one embodiment of the present invention. [Figure 17J] FIG. 2 is a graph of a fixed scroll and an orbiting scroll of a compression unit of the electric compressor of FIG. 1 in accordance with one embodiment of the present invention. [Figure 18A] FIG. 14 is a first perspective view of a portion of the compression device of FIG. 13, including a fixed scroll and an orbiting scroll. [Figure 18B] FIG. 18B is a second perspective view of a portion of the compression device of FIG. 18A. [Figure 18C] FIG. 14 is a first perspective view of a fixed scroll of the compression device of FIG. 13. [Figure 18D] FIG. 14 is a second perspective view of the fixed scroll of the compression device of FIG. 13. [Figure 18E] FIG. 14 is a third perspective view of the fixed scroll of the compression device of FIG. 13. [Figure 18F] FIG. 14 is a perspective view of a lead mechanism associated with the compression device of FIG. 13. [Figure 19A] FIG. 2 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. [Figure 19B] FIG. 19B is a second perspective view of the front cover of FIG. 19A. [Figure 20] FIG. 11 is a first perspective view of a front cover of an electric compressor forming an oil separator according to a second embodiment of the present invention; [Figure 21] FIG. 2 is a top and bottom view of an electric motor of the electric compressor. [Figure 22A] FIG. 1 is a first perspective view of an electric motor for an electric compressor, in accordance with an embodiment of the present invention; [Figure 22B] FIG. 2 is a second perspective view of the electric motor including three motor assemblies according to the first embodiment of the present invention. [Figure 22C] FIG. 22C is a partial cross-sectional view of one of the motor connector assemblies of FIG. 22B. [Figure 22D] FIG. 22C is a perspective view of a second motor connector of the motor connector assembly of FIG. 22B. [Figure 22E] FIG. 22C is a perspective view of a first motor connector of the motor connector assembly of FIG. 22B. [Figure 22F] FIG. 22C is a cross-sectional view of a motor connector housing of the motor connector assembly of FIG. 22B. [Figure 22G] FIG. 22F is a perspective view of the motor connector housing of FIG. [Fig. 22H] FIG. 22B is a wiring diagram associated with the electric motor of FIG. 22A, in accordance with one embodiment of the present invention. [Figure 22I] FIG. 22C is a partial cross-sectional view of one of the motor connector assemblies of FIG. 22B in accordance with an alternative embodiment of the present invention. [Figure 22J] FIG. 22I is a perspective view of the first and second motor connectors and blades of the motor connector assembly of FIG. [Figure 23A] FIG. 2 is a first perspective view of an electric motor for an electric compressor according to another embodiment of the present invention. [Figure 23B] FIG. 11 is a second perspective view of an electric motor including three motor assemblies according to a second embodiment of the present invention. [Figure 23C] FIG. 23C is a partial cross-sectional view of one of the motor connector assemblies of FIG. 23B. [Figure 23D] FIG. 23D is a first cross-sectional view of a motor connector housing of the motor connector assembly of FIG. 23C. [Figure 23E] FIG. 23D is a second cross-sectional view of the motor connector housing of the motor connector assembly of FIG. 23C. [Figure 23F] FIG. 23D is a first perspective view of a motor connector housing of the motor connector assembly of FIG. 23C in accordance with one embodiment of the present invention. [Figure 23G] FIG. 23D is a second perspective view of the motor connector housing of the motor connector assembly of FIG. 23C. [Figure 24]FIG. 1 is a partial flow diagram of an electric compressor with a motor connector assembly according to one embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] Referring to the drawings, in which like numerals indicate like or corresponding parts throughout the several views, a motorized compressor 10 is provided having an outer housing 12. The motorized compressor 10 is particularly suited for an automobile, such as a motor vehicle (not shown). The motorized compressor 10 may be used as a cooling device or (reverse) heat pump to heat and / or cool different aspects of the vehicle. For example, the motorized compressor 10 may be used as part of a heating, ventilation, and air conditioning (HVAC) system in an electric vehicle (not shown) to cool or heat the passenger compartment. In addition, the motorized compressor 10 may be used to heat or cool the passenger compartment, on-board electronics, and / or the battery used to power the vehicle while the vehicle is not operating, for example, during a charging cycle. The motorized compressor 10 may further be used while the vehicle is not operating and while the battery is not charging to preserve or minimize degradation of the battery life. In the illustrated embodiment, the motorized compressor 10 has a displacement of 57 cubic centimeters (cc). Displacement refers to the initial volume captured within the compressor when the scrolls of the compressor first close or contact (see below). It should be noted that the electric compressor 10 disclosed herein is not limited to any such volume, but may be sized or scaled to meet particular required specifications.

[0014] In the illustrated embodiment, the motorized compressor 10 is a compressor that serves to quickly and efficiently compress refrigerants for use in different systems in an automobile, such as an electric or hybrid automobile. The motorized compressor 10 may use a mixture of refrigerant and oil, which may simply be referred to as "refrigerant," throughout its operation.

[0015] The electric compressor includes an inverter section 14, a motor section 16, and a compression device (or compression assembly) 18 housed within an outer housing 12. The outer housing 12 includes an inverter back cover 20, an inverter housing 22, a motor housing 24, a fixed scroll 26, and a front cover 28 (which may be referred to as a discharge head).

[0016] In a first aspect of the electric compressor 10 of the present disclosure, an electric compressor 10 having a swing link mechanism and a drive shaft with an integrated limit pin is provided. In a second aspect of the electric compressor 10 of the present disclosure, an electric compressor 10 with an oil separator is provided. In a third aspect of the electric compressor 10 of the present disclosure, an electric compressor 10 having scroll bearing oil injection is provided. In a fourth aspect of the electric compressor 10 of the present disclosure, an electric compressor 10 having a bearing oil communication hole is provided. In a fifth aspect of the present invention, an electric compressor 10 having a dome-shaped inverter cover is provided.

[0017] In one embodiment, the inverter back cover 20, inverter housing 22, motor housing 24, fixed scroll 26, and front cover 28 are constructed from machined aluminum. The inverter 10 may be mounted within the body of the automobile, for example, via a number of mounting points 120.

[0018] Overall configuration and operation of electric compressor 10 The inverter back cover 20 and the inverter housing 22 form an inverter cavity 30. The inverter back cover 20 is attached to the inverter housing 22 by a plurality of bolts 32. The inverter back cover 20 and the inverter housing 22 are attached to the motor housing 24 by a plurality of bolts 34 that extend through openings 36 in the inverter back cover 20 and openings 38 in the inverter housing 22 and thread into threaded openings 40 in the motor housing 24. An inverter gasket 42, disposed 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 gasket 54A is disposed between the inverter housing 22 and the motor housing 24 and provides maintenance of a refrigerant seal against the environment.

[0019] Referring to FIG. 11, the inverter module 44 is mounted in the inverter cavity 30 formed by the inverter back cover 20 and the inverter housing 22. The inverter module 44 includes an inverter circuit 46 mounted on a printed circuit board 48 mounted on the inverter housing 22. The inverter circuit 46 converts direct current (DC) power received from outside the electric compressor 10 into three-phase alternating current (AC) power to supply / power a motor 54 (see below). The inverter circuit 46 also controls the rotation speed of the electric compressor 10. A high-voltage DC current is supplied to the inverter circuit 46 via a high-voltage connector 50. A low-voltage DC current for driving the inverter circuit 46, as well as control signals for controlling the operation of the inverter circuit 46 and the motor section 16, are supplied via a low-voltage connector 52.

[0020] The motor section 16 includes a motor 54 disposed within a motor cavity 56. The motor cavity 56 is formed by the motor side 22A of the inverter housing 22 and the inner side 24B of the motor housing 24. With particular reference to FIG. 12, the motor 54 is a three-phase AC motor having a stator 58. The stator 58 has a generally hollow cylindrical shape with six individual coils (two per phase). The stator 58 is housed within and attached to the motor housing 24 and remains stationary relative to the motor housing.

[0021] The motor 54 includes a rotor 60 disposed within and centrally disposed relative to a stator 58. The rotor 60 has a generally hollow cylindrical shape and is disposed within the stator 58. The rotor 60 has a number of counterbalance weights 60A, 60B attached thereto. The counterbalance weights balance the motor 54 as it drives the compressor 18, and may be machined from brass.

[0022] Power is supplied to the motor 54 through a set of terminals 54 B that are sealed from the motor cavity 56 by O-rings 178 .

[0023] The drive shaft 90 is coupled to the rotor 60 and rotates therewith. In the illustrated embodiment, the draft shaft 90 is press-fit into a central opening 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 disposed on the motor side of the inverter housing 22. A first ball bearing 62 disposed in an opening formed by the first drive shaft support member 22B supports one end of the drive shaft 90 for rotation. The motor housing 24 includes a second drive shaft support member 24A. A second ball bearing 64 disposed in an opening formed by the second drive shaft support member 24A for rotation of a second end 90B of the drive shaft 90. In the illustrated embodiment, the first and second ball bearings 62, 64 are press-fit into openings formed by the first drive shaft support member 22B of the inverter housing 22 and the second drive shaft support member 24A of the motor housing 24, respectively.

[0024] As described above, the electric compressor 10 is a compressor. The compression device 18 includes a fixed scroll 26 and an orbiting scroll 66. The orbiting scroll 66 is fixed to a second end of the rotor 60. The rotor 60 with a drive shaft 90 rotates to drive the movement of the orbiting scroll 66 under the control of the inverter module 44.

[0025] 14A, 14B, 16A and 16B, the drive shaft 90 has a central axis 90C about which the rotor 60 and the drive shaft 90 rotate. The orbiting scroll 66 moves about the central axis 90C in an eccentric orbit, i.e., circular motion, while the orientation of the orbiting scroll 66 remains constant relative to the fixed scroll 26. The center of the orbiting scroll 66 is disposed along the offset axis 60D of the drive shaft 90 defined by an orbiting scroll opening 90E (see FIG. 14A) located at a 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 opening 90E through the drive pin 126 and the drive hub and bearings 108 of the oscillating mechanism 124 as the drive shaft 90 is rotated about the central axis 90C.

[0026] With particular reference to Figures 1, 2 and 9, after the mixed refrigerant and oil is compressed by the compression device 18, it enters the electric compressor 10 (at low pressure) through the refrigerant inlet port 68 and exits the electric compressor 10 (at high pressure) through the refrigerant outlet port 70. As shown in the cross-sectional view of Figure 9, the refrigerant follows a refrigerant passage 72 through the electric compressor 10. As shown, the refrigerant enters the refrigerant inlet port 68 and enters an intake volume 74 formed between the motor side 22A of the inverter housing 22 adjacent the refrigerant inlet port 68 and the motor housing 24. The refrigerant is then drawn through the motor section 16 and enters the compressed intake volume 76 formed between the inner wall of the fixed scroll 26 and the orbiting scroll 66 (demonstrated by arrow 92 in Figure 14A).

[0027] 9 and 13, the fixed scroll 26 has a fixed scroll base 26A and a fixed scroll wrap 26B extending from the fixed scroll base 26A toward the orbiting scroll 66. As shown in FIGS. 16A-16B, the orbiting scroll 66 has an orbiting scroll base 66A and an orbiting scroll wrap 66B extending from the orbiting scroll base 66A toward the fixed scroll 26. The wraps 26A, 66A have tail ends 26C, 66C adjacent to the outer edges of the respective scrolls 26, 66, and scroll inward toward their respective center ends 26D, 66D.

[0028] Each tip seal 94 is disposed within a slot 26E, 66E disposed in the top surface of the fixed scroll 26 and the orbiting scroll 66, respectively. The tip seals 94 are made of a flexible material, such as polyphenylene sulfide (PPS) plastic. When assembled, the tip seals 94 press against the opposing bases 26A, 66A to provide a seal therebetween. In one embodiment, the slots 26E, 66E are longer than the length of the tip seals 94 to provide room for adjustment / movement along the length of the tip seals 94.

[0029] 17A-17I, mixed refrigerant enters the compression device 18 at the compression suction volume 76. In Figures 17A-17I, a cross-sectional view of the top of the fixed scroll 26 and orbiting scroll 66 is shown.

[0030] As described in more detail below, the fixed scroll wrap 26B and the orbiting scroll wrap 66B form compression chambers 80 into which low or unpressurized (saturation pressure) refrigerant enters from the compression device 18. The orbiting scroll 66 moves to allow the compression chambers 80 to close, reducing the volume of the compression chambers 80 and pressurizing the refrigerant. At any point during the cycle, one or more compression chambers 80 are at different stages of the compression cycle. The following description relates to only one set of compression chambers 80 during a complete cycle of the electric compressor 10.

[0031] Refrigerant enters compression chamber 80 formed between orbiting scroll wrap 66B and fixed scroll wrap 26B. Refrigerant is transported toward the center of these chambers during a cycle of compressor 10. Orbiting scroll 66 is shown orbiting in a circular motion indicated by arrow 78 formed by the relative position of orbiting scroll 66 with respect to fixed scroll 26 during one cycle of motorized compressor 10.

[0032] FIG. 17A shows the position of the orbiting scroll 66 at the start of the cycle. As shown, in this initial position, the tail end 26C, 66C is spaced from the other scroll wrap 26B, 66B. At this point, the compression chamber 80 is open to the compression intake volume 76, allowing refrigerant under low pressure to fill the compression chamber 80 from the compression intake volume 76. As the orbiting scroll 66 moves along the passage 78, the space between the tail end 26C, 66C and the other scroll 26, 66 decreases until the compression chamber 80 is closed off from the compression intake volume 76 (FIGS. 17B-17E). As the orbiting scroll 66 continues to move along 78, the volume of the compression chamber 80 decreases further, thus pressurizing the refrigerant in both compression chambers 80 (FIGS. 17F-17H). As the orbiting scroll 66 continues to orbit, the two compression chambers 80 are combined into a single volume, as shown in FIGS. 17I-18J. This volume decreases further until the pressurized refrigerant is discharged from the compression device 18 (see below).

[0033] As will be described below, refrigerant enters chambers formed between the walls of the orbiting scroll 66 and the fixed scroll 26. During a cycle of the compressor 10, the refrigerant is transported toward the center of these chambers. The orbiting scroll 66 is shown during one cycle of the electric compressor 10 orbiting or moving in a circular motion indicated by arrow 78 formed by the relative position of the orbiting scroll 66 with respect to the fixed scroll 26.

[0034] Returning to FIG. 1 , the front cover 28 defines a discharge volume 82. The discharge volume 82 is in communication with the refrigerant output port 70. As will be explained in more detail below, the pressurized refrigerant exits the compression device 18 through an orifice 84 in the fixed scroll 26 (see FIGS. 18C and 18E). The release of the pressurized refrigerant is controlled by a reed mechanism 86. In the illustrated embodiment, a single reed mechanism 86 is used. However, it should be noted that two or more reed mechanisms may be used.

[0035] 18D and 18E, in the illustrated embodiment, the lead mechanism 86 includes a discharge lead 86A and a reed holddown 86B. The discharge lead 86A is made from a flexible material, such as steel. The material and properties, such as strength, are selected to control the pressure at which the pressurized refrigerant is discharged from the compression device 18. The reed holddown 86B is made from a rigid, non-flexible material, such as stamped steel. The reed holddown 86B controls or limits the maximum displacement of the discharge lead 86A relative to the fixed scroll 26.

[0036] In the illustrated embodiment, the lead mechanism 86 is held or secured in place without separate fasteners. As shown in Figures 18E and 18F, the lead mechanism 86 includes a pair of openings 86C configured to receive associated posts 84A on the fixed scroll 26. When the motorized compressor 10 is assembled, the lead mechanism 86 is held in place adjacent the front cover 28. As shown in Figure 18E, the rear surface of the fixed scroll 26 includes a bezel 84B that surrounds the orifice 84 to help regulate the pressure at which the refrigerant exits the compressor 18. Additionally, a debris collection slot 84C collects debris near the orifice 84 to prevent interference with the lead mechanism 86.

[0037] As shown in FIG. 9, the path of the refrigerant through the electric compressor is indicated by dashed arrows 72 .

[0038] The electric compressor 10 utilizes oil (not shown) to provide lubrication between components of the compression device 18 and the motor 54, such as between the orbiting scroll 66 and the fixed scroll 26, and within the ball bearings 62, 64. The oil mixes with the refrigerant in the compression device 18 and motor 54 and exits the compression device 18 through the orifice 84. As described in more detail below, the oil is separated from the compressed refrigerant in the front cover 28 and returned to the compression device 18.

[0039] The oil separator 96 facilitates separation of the mixed oil and refrigerant. Typically, the oil separator 96 removes only a portion of the oil in the mixed oil and refrigerant. The separator oil is stored in an oil reservoir and circulated back through the compression device 18 where it is mixed with the refrigerant and returned.

[0040] In the illustrated embodiment, the oil separator 96 is integrated within 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 motor cavity 56 and the compression device 18. In use, the electric compressor 10 is generally oriented as shown in FIGS. 3-5 such that gravity acts on the oil and the oil collects in the oil reservoir 98. With reference to FIG. 9, the general path of oil is shown by arrow 88 moving from the bottom of the electric compressor 10, through the compression device 18, through the orifice 84, to the discharge volume 82 in the front cover 28, and back to the compression device 18. As shown, the oil is drawn back into the compression device 18 where it is returned to, or mixed with, the refrigerant.

[0041] As mentioned above, refrigerant, which is actually a mixture of refrigerant and oil, enters the electric compressor 10 via the refrigerant inlet port 68. The oil and refrigerant mixture is drawn into the motor section 16, thereby providing lubrication and cooling to the rotating components of the electric compressor 10, such as the rotor 60, the drive shaft 90, etc. Inside the motor 54, the oil and refrigerant enter the second ball bearing 64 and the oil due to the rotational forces within the motor section 16. The oil may impinge on the motor side 22A of the inverter housing 22. The refrigerant and oil are further directed by the motor side 22A to the ball bearing 62, which will be further described below.

[0042] In the illustrated embodiment, the front cover 28 and fixed scroll 26 are attached to the motor housing 24 by a number of bolts 122 that are inserted into their respective openings and threaded into openings in the motor housing 24. A stationary head gasket 110 and a rear head gasket 112 are disposed between the motor housing 24 and the fixed scroll 26 to provide a seal.

[0043] Swing link mechanism and concentric protrusion of drive shaft 13-18B, in a first aspect of the electric compressor 10 of the present disclosure, the electric compressor 10 includes a swing link mechanism 124, and the drive shaft 90 has a concentric protrusion 90F. In one embodiment, the concentric protrusion 90F is integrally formed with the drive shaft 90. As described below, the swing link mechanism 124 is used to rotate the orbiting scroll 66 in an eccentric orbit about the drive shaft 90.

[0044] In the prior art, the drive shaft is coupled to the swing linkage by a drive pin and a separate eccentric pin, both of which press against the drive shaft. The drive pin is used to rotate the swing linkage 124 which moves the orbiting scroll 66 along its eccentric orbit. The drive pin and the eccentric pin are inserted into respective openings in the ends of the drive shaft. The eccentric pin is used to limit the articulation of the orbiting scroll 66 as it moves along its eccentric orbit. Neither the drive pin nor the eccentric pin are located along the central axis of the drive shaft. As the drive shaft rotates, the drive pin and the eccentric pin are placed under significant stress. Therefore, both pins are constructed of a hardened material, such as SAE 52100 bearing steel. In addition, since the eccentric pin is used to limit the radial movement of the eccentric orbit of the orbiting scroll 66, an aluminum bushing or other sliding bearing may be required to prevent damage to the eccentric pin. Also, the prior art eccentric pins require additional machining on the face of the drive shaft 90 to include precise openings for the drive pin 126 and the eccentric pin.

[0045] As will be explained in more detail below, the eccentric pin of the prior art is replaced with a concentric protrusion 90F.

[0046] In the illustrated embodiment, the electric compressor 10 includes a housing 12, a refrigerant inlet port 68, a refrigerant outlet port 70, a drive shaft 90, a concentric projection 90F, a motor 54, a compression device 18, a swing linkage 124, a drive pin 126, and a ball bearing 108. The housing 12 defines an intake 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 intake volume 74. The refrigerant outlet port 70 is coupled to the housing 12 and configured to allow compressed refrigerant to exit the electric compressor 10 from the discharge volume 82. The drive shaft 90 is disposed within the housing 12 and has first and second ends 90A, 90B. The drive shaft 90 defines a central axis 90C and is centered.

[0047] A concentric projection 90F is disposed at a second end 90B of the drive shaft 90 and is centered about a 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 opening 90E. A motor 54 is disposed within the housing 12 and coupled to the drive shaft 90 to controllably rotate the drive shaft 90 about the central axis 90C. A drive pin 126 is disposed within the drive pin opening 90E and extends away from the drive shaft 90. The drive pin 126 is parallel to the concentric projection 90F.

[0048] The concentric projections 90F may further include undercuts 90G, and the outer surface may be case hardened or subsequently treated with a coating or bearing surface. The concentric projections 90F may be further machined simultaneously with the drive shaft 90.

[0049] As described above, the compression device 18 includes the fixed scroll 26 and the orbiting scroll 66. The fixed scroll 26 is disposed within the housing 12 and is fixed relative to the housing. The orbiting scroll 66 is coupled to the drive shaft 90. The orbiting scroll 66 and the fixed scroll 26 receive refrigerant from the intake volume 74 as the drive shaft 90 rotates about a central axis 90C to form a compression chamber 80 (see above) for compressing the refrigerant. The orbiting scroll 66 has an inner circumferential surface 66E.

[0050] The swing link mechanism 124 is coupled to the drive shaft 90 and has first and second openings 124A, 124B for receiving the concentric projection 90F and the drive pin 126. The swing link mechanism 124 further includes an outer periphery 124C.

[0051] The ball bearings 108 are disposed adjacent to and between an inner peripheral surface 66E of the orbiting scroll 66 and an 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 rotate the orbiting scroll 66 about the central axis 90C in an eccentric orbit.

[0052] In one embodiment, the concentric projection 90F is integrally formed with the drive shaft 90. The drive shaft 90, the concentric projection 90F, and the swing linkage 124 may be machined from steel. Forming the concentric projection 90F at the same time as the drive shaft 90 and in the same machining operation further improves manufacturing efficiency.

[0053] An enlarged 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 swing linkage 124. The concentric projection 90F is sized and machined to a controlled tolerance with the first opening 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 any additional machining operation. The concentric projection 90F further cooperates with a guide pin 128 and slot 116 in the lower surface 66F of the orbiting scroll 66, as will be further described below.

[0054] The electric compressor 10 includes an inverter section 14, a motor section 16, and a compression device 18. The motor section 16 includes a motor housing 24 that defines a motor cavity 56. The compression section 18 includes a fixed scroll 26. The housing 12 is defined, at least in part, by the fixed scroll 26 and the motor housing 24.

[0055] With particular reference to 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 ring-shaped slots 116. The motor housing 24 includes a plurality of articulating guide pin openings (not shown). The guide pins 128 are disposed within the guide pin openings and extend into the ring-shaped slots 116 toward the compression device 18. The guide pins 128 are configured to limit articulation of the orbiting scroll 66 as it orbits about the central axis 90C. In one embodiment, each of the ring-shaped slots 116 includes a ring sleeve 118. A thrust plate 130 is disposed between the motor housing 24 and the fixed scroll 26 to provide a wear surface therebetween.

[0056] Discharge head design with oil separator In a second aspect of the electric compressor 10 of the present disclosure, the electric compressor 10 includes an oil separator 96 disposed in the discharge volume 82, which may be integrally formed with the discharge head or front cover 28. As mentioned above, oil is used to provide lubrication between the moving components of the electric compressor 10. During operation, the oil and the refrigerant are mixed. The oil separator 96 is necessary to separate a portion of the oil from the oil and refrigerant mixture before the refrigerant exits the electric compressor 10.

[0057] Generally, the refrigerant is discharged from the compression device 18 once per revolution (or orbit) of the orbiting scroll 66. This creates a first pulsation in the compressed refrigerant discharged by the electric compressor 10. The relatively strong amplitude and low frequency of the pulsation created in the refrigerant may excite other components (internal or external to the electric compressor 10), which may create undesirable noise, vibration and harshness (NVH) and poor durability conditions. The second embodiment oil separator 96 (described below) connects the discharge chambers (see below) by a relatively small channel, creating a pressure drop between the chambers. This allows for a smooth flow of the compressed refrigerant from the electric compressor 10. In addition, the oil separator 96 utilizes two parallel passages between the compression device 18 and the refrigerant outlet port 70 to reduce the net pressure drop while maintaining this reduction in pulsation.

[0058] The oil separator 96 may include a series of dividers or walls 98A extending from the 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 an oil reservoir 98. The central discharge chamber 82A is adjacent to the reed mechanism 86 and receives mixed pressurized refrigerant and oil from the compression device 18 through the reed mechanism 86 and through slots 84. The central discharge chamber 82A is in fluid communication with the two side discharge chambers 82B via respective side channels 100, which are in fluid communication with the upper discharge chamber 82C and the oil reservoir 98, and via upper discharge channel 102 and lower discharge channel 104, respectively.

[0059] In the illustrated embodiment, the oil separator 96 is formed within the discharge chamber 82 of the housing 12 between the compression device 18 and the refrigerant outlet port 70. As illustrated, the oil separator 96 includes a central discharge chamber 82A, a pair of side discharge chambers 82B, an oil reservoir 98, and an upper discharge chamber 82C. The central discharge chamber 82A is formed adjacent the compression device outlet port or slot 84 for receiving mixed oil and compressed refrigerant. The pair of side discharge chambers 82B are disposed on either side of the central discharge chamber 82A and are connected to the central discharge chamber 82A via respective side discharge channels 100.

[0060] The side chambers 82B are configured to separate the mixed oil and the compressed refrigerant. Generally, the mixed oil and compressed refrigerant exit the central discharge chamber 82 through the side channels 100 at high velocity. Separation of the oil and compressed refrigerant occurs as the mixed oil and compressed refrigerant impinge on the interior exterior walls of the respective side chambers 82B.

[0061] The oil reservoir 98 is disposed below the pair of side chambers and connected via respective lower drain 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 the separation, and the oil falls through the lower drain channel 104 disposed in the side drain chamber 82B into the oil reservoir 98.

[0062] The upper discharge chamber 82C is formed above the pair of side chambers 82B and is connected to them via respective upper discharge channels 102. After the refrigerant is separated from the oil, it rises through the upper discharge channel 102, located at the top of the side discharge chamber 82B, and enters the upper discharge chamber 82C before passing through the refrigerant outlet port 70.

[0063] As shown, each side exhaust channel 100 is configured to direct the mixed oil and compressed refrigerant toward an opposing inner wall of the respective side channel 82B. For example, the side exhaust channels are at a generally 90 degree angle from the opposing wall of the side exhaust chamber 82B.

[0064] In an alternative embodiment, as shown in FIG. 20, each side discharge chamber 82B may include a side baffle 132 disposed within an interior portion of the respective side chamber 82B. The side discharge channels 100 are configured to direct the mixed oil and compressed refrigerant toward the respective side baffle. The side baffle 132 creates a low pressure area in the side discharge chamber 82B on the back side opposite the discharge channel 100 that aids in the separation of the oil and the refrigerant. The low pressure area may further aid gravity and reduce the oil from being conveyed upward toward the upper discharge channel 102. The side discharge channel 100 may incorporate a downward angle that may further aid gravity on the oil, further increasing the distance the oil falls from the compressed mixture by directing the discharge of the mixture toward a lower region of the side discharge chamber 82B adjacent the lower discharge channel 104, forming a longer tortuous path to separate the oil downward and away from the high velocity compressed refrigerant entering the upper discharge channel 102. The side baffles 132 may also be positioned to create a perpendicular impingement surface to the angled exhaust flow path of the oil and refrigerant exiting the side exhaust channel 100. The perpendicular impingement surface on the side baffles 132 creates additional turbulence in the exhaust mixture, and the lower pressure area behind the side baffles 132 may further increase the gravitational effect on the heavier oil to separate and direct the oil into the lower exhaust channel 104.

[0065] 20, the oil reservoir 98 may include an oil reservoir baffle 134 disposed below each lower exhaust channel 104. The oil reservoir baffle 134 helps prevent oil in the oil reservoir 98 from being drawn back out of the oil reservoir into the side exhaust chamber 82B. The side baffles 132 and the oil reservoir baffle 134 may be used in combination or separately to reduce oil from migrating upward along the walls of the side exhaust chamber 82B, creating a low pressure side, thereby further reducing a throttling or Venturi effect that may be created due to the high velocity flow of refrigerant exiting through the upper exhaust channel 102.

[0066] Scroll Bearing Oil Orifice In a third aspect of the electric compressor 10 of the present disclosure, an electric compressor 10 having scroll bearing oil injection orifices is provided. As described above, the compression device 18 of the present disclosure includes a ball bearing 108. In the illustrated embodiment, the ball bearing 108 is disposed between the swing link mechanism 124 and the orbiting scroll 66. However, as a result of the location of the ball bearing 108 within the compression device 18, the oil supply to the ball bearing 108 may be limited, reducing durability.

[0067] The electric compressor 10 may include a housing 12, a refrigerant inlet port 68, a refrigerant outlet port 70, an inverter module 144, a motor 54, a drive shaft 90, and a compression device 18. The housing 12 defines an intake 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 intake volume 74. The refrigerant outlet port 70 is coupled to the housing 12 and configured to allow compressed refrigerant to exit the electric compressor 10 from the discharge volume 82. The inverter module 144 is mounted inside the housing 12 and adapted to convert DC power to AC power. The motor 54 is mounted inside the housing 12. The drive shaft 90 is coupled to the motor 54. The compression device 18 receives refrigerant from the intake volume 74 and compresses the refrigerant by rotation of the drive shaft 90 by the motor 54. The compression device 18 includes a fixed scroll 26 , an orbiting scroll 66 , a swing linkage 124 , ball bearings 108 , and a pin 136 .

[0068] The fixed scroll 26 is disposed within the housing 12 and is fixed relative to the housing. The orbiting scroll 66 is coupled to the drive shaft 90. The orbiting scroll 66 and the fixed scroll 26 form a compression chamber 80 for receiving refrigerant from the intake volume 74 and compressing the refrigerant as the drive shaft 90 rotates about a 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 opening 140 passing through the orbiting scroll 66 from the first side 66F to the second side 66G.

[0069] The swing link mechanism 124 is coupled to the drive shaft 90. The ball bearings 108 are disposed adjacent to each of the orbiting scroll 66 and the swing link mechanism 124. The drive shaft 90, the orbiting scroll 66 and the swing link mechanism 124 are arranged to cause the orbiting scroll 66 to orbit about the central axis 90C in an eccentric orbit.

[0070] 16C, the tip of the orbiting scroll 66 includes a plug 136 and has an oil orifice 138. The plug 136 may be press fit into an oil opening 140 in the orbiting scroll 66. The oil orifice 138 is configured to allow a controlled flow of oil with compressed refrigerant through the orbiting scroll 66 to the ball bearings 108.

[0071] The size of the oil orifice 138 may 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 orifice 138 may be selected to allow only oil to pass and limit pressure equalization between the first and second sides of the orbiting scroll 66. Manufacturing efficiencies may be achieved by using a separate plug 136 rather than machining the oil orifice 138 directly into the orbiting scroll 66. Also, the plug 136 may have a specifically designed and tailored oil orifice 138 to allow for increased or decreased oil and refrigerant flow depending on the diameter and geometry of the oil orifice 138.

[0072] As shown in Figures 16D-16E, in one embodiment, the oil orifice 138 may have a first bore 138A and a second bore 138B, with the diameter of the first bore 138A being smaller than the diameter of the second bore 138B. For example, in one application of this embodiment, the first bore 138A has a diameter of about 0.3 mm. The second bore 138B has a diameter larger than the diameter of the first bore 138A and is used only to shorten the length of the first bore 138A. The oil and coolant flows are designed to provide heat and lubrication to the ball bearings 108 that support the radial forces generated by the eccentric orbit of the orbiting scroll 66.

[0073] Further, as described above, the orbiting scroll 66 has an orbiting scroll base 66A and an orbiting scroll wrap 66B. The orbiting scroll wrap 66B may have an orbiting scroll tail end 66C and an orbiting scroll central end 66D. As shown, the oil opening 140 is disposed within the orbiting scroll central end 66D. The plug 136 may be secured within the oil opening 140 by a press fit or any other method of securing the plug 136.

[0074] As shown in FIG. 9, oil orifice 138 allows oil (and refrigerant) to travel from exhaust chamber 82 along passage 73 (sometimes referred to as the "nosebleed" passage) to ball bearing 108.

[0075] Bearing oil passage According to a fourth aspect of the electric compressor 10 of the present disclosure, an electric compressor 10 having a bearing oil communication hole is provided. As described above, in the illustrated embodiment, the drive shaft 90 is rotated by the motor 54 to controllably operate the compression device 18. The drive shaft 90 has a first end 90A and a second end 90B. The housing 12 of the electric compressor 10 forms 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 on the motor side 22A of the inverter housing 22, and the second drive shaft support member 24A is formed in the motor housing 24. The first and second ball bearings 62, 64 are disposed in the first and second drive shaft support members 22B, 24A.

[0076] The position of the first drive shaft support member 22B is not in an area where the refrigerant (and oil) flows, which may result in a decrease in lubrication conditions and affect the durability of the electric compressor 10.

[0077] As shown in FIG. 16F, the first drive support member 22B may have one or more holes 22C to allow oil and refrigerant to enter the first drive support member 22B and lubricate the first ball bearing 62.

[0078] In the illustrated embodiment, the electric 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 .

[0079] The housing 12 defines an intake volume 74 and an exhaust volume 82 and includes first and second drive shaft support members 22B, 24A. The first ball bearing 62 is disposed within the first drive shaft support member 22B. The first drive shaft support member 22B of the housing 12 includes an oil passage 22C for allowing oil to enter the first ball bearing 62.

[0080] The second ball bearing 64 is disposed 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 intake volume 74. The refrigerant outlet port 70 is coupled to the housing 12 and configured to allow compressed refrigerant to exit the electric compressor 10 from the discharge volume 82. The inverter module 144 is mounted within the housing 12 and adapted to convert DC power to AC 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 disposed within the first bearing 62 and the second end 90B of the drive shaft 90 is disposed within the second bearing 64. The compression device 18 receives the refrigerant from the intake volume 74 and compresses the refrigerant by rotation of the drive shaft 90 by the motor 54. As mentioned above, in the illustrated embodiment, the first drive shaft support member 22B may be formed on the motor side 22A of the inverter housing 22. Rotational motion within the motor section 16 of the compression device 18 creates a flow path and movement for oil from the oil reservoir 98, as shown by arrow 88 in FIG. 9. As shown, the oil flows from the oil reservoir 98 toward the motor section 16 and continues toward the stator 58 and rotor 60. The rotational motion of the orbiting scroll, rotor, and drive shaft pulls the oil upward to mix with the inlet flow of the refrigerant passage 72. The rotational motion of the rotor 60 and drive shaft 90 further propels the oil against the motor side 22A of the inverter housing 22. The motor side 22A further includes a series of ribs 22D, shown in FIG. 16F. The ribs 22D provide the necessary rigidity to support the first drive shaft support member 22B and allow the raised backing and pockets to secure the first bearing 62. Inverter housing 22 further defines an oil cavity 22E in which oil collected between ribs 22D is directed downwardly by gravity into oil cavity 22E.The rib 22D and the angled surface of the motor side 22A cooperate to capture and direct oil splashed or propelled against the motor side 22A by the rotor 60 or drive shaft 90, helping to increase oil flow to the oil cavity 22E and the first bearing 62. Although FIG. 16F shows only one oil communication hole 22C, it is understood that additional 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 communication hole 22C is 3.5 mm in diameter, and the motor side 22A includes angled walls between the ribs 22D. In addition, the motor side 22A may include an outer oil collection area or recess 22F surrounding the communication hole 22C.

[0081] Dome-shaped inverter cover According to a fifth aspect of the electric compressor 10 of the present disclosure, the electric compressor 10 is configured to compress a refrigerant. The electric compressor 10 includes a housing 12, a refrigerant inlet port 68, a refrigerant outlet port 70, an inverter module 44, a motor 54, a drive shaft 90, a compression device 18, and an inverter cover 20. The housing 12 defines an intake volume 74 and a discharge volume 82. The housing 12 has a generally cylindrical shape and a central axis 90C. The refrigerant inlet port 68 is coupled to the housing 12 and configured to introduce refrigerant into the intake volume 74. The refrigerant outlet port 70 is coupled to the housing 12 and configured to allow compressed refrigerant to exit the electric compressor 10 from the discharge volume 82.

[0082] The inverter module 144 is mounted within the housing 12 and adapted to convert DC power to AC 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 configured to receive refrigerant from the intake volume and compress the refrigerant upon rotation of the drive shaft 90 by the motor 54.

[0083] As mentioned above, the compressor 18 may rotate at high speeds (>2,000 RPM) that may create undesirable noise, vibration, and harshness (NVH) and poor durability conditions. In the prior art, the inverter cover 20 is generally flat and tends to amplify and / or focus vibrations from the compressor 18.

[0084] As shown in FIGS. 3A-3D, the vibrations from the compressor 18, inverter back cover 20 of the electric scroll compressor 10 of the fifth embodiment of the present disclosure have a generally curved or dome-shaped profile in order to disperse the vibrations rather than focus them.

[0085] As shown in each of the figures, particularly in FIG. 1, FIG. 3A-FIG. 3B and FIG. 6, the inverter cover 20 is disposed at one end of the electric compressor 10 and includes a first portion 20A and a second portion 20B. The first portion 20A includes an apex or apex portion 20C, is approximately perpendicular to the central axis 90C, and has an apex 20C and an outer periphery 20D. The first portion 20A has a relatively dome shape such that the inverter cover 20 has a curved profile from the apex 20C to the outer periphery 20D. The amount and location of the curvature may be determined or limited by other considerations such as packaging constraints, i.e., the space in which the electric compressor 10 must fit, as well as constraints placed by internal components, i.e., location and size. The first portion 20A may also need to incorporate other features, e.g., openings for receiving fastening bolts. The second portion 20B may include a portion of the inverter cover 20 that is not dome-shaped, i.e., is relatively flat and disposed around the outer periphery of the inverter cover.

[0086] 3B, the back side of the inverter cover 20 may include a plurality of radial ribs 20E extending outwardly from a central circular rib 20F to provide stiffness and support to the curved first portion 20A of the inverter back cover 20. As shown, the radial ribs 20E are not equally spaced around the central circular rib 20F. The inverter back cover 20 may also include additional ribs 20G to add additional strength.

[0087] 3C and 3D, an alternative embodiment of the inverter cover 20 is shown. In some applications, the inverter cover 20, and particularly the first portion 20A, may have to be modified to take into account external constraints, such as packaging or size constraints. In the illustrated embodiment, the illustrated embodiment includes a channel 20H through the first portion 20A that is necessary to accommodate an external support structure.

[0088] Motor Connector Assembly 21, 22A-22H, and 23A-23G (where like components are numbered the same as in the above embodiments), in one aspect of the invention, the compressor 10 may include one or more motor connector assemblies 152. As described in more detail below, the motor connector assemblies 152 allow for quick and removable connection of the windings 55 of the motor 54 to the inverter module 44. Additionally, the motor connector assemblies 152 may be configured to allow for easy insulation of the winding connections to reduce or minimize current leakage.

[0089] With particular reference to FIG. 21, in the illustrated embodiment, the motor 54 is a three-phase AC motor 54. Each phase includes multiple, e.g., four, windings 55. In the illustrated embodiment, a first phase includes windings 55A-1, 55A-2, 55A-3, 55A-4, a second phase includes windings 55B-1, 55B-2, 55B-3, 55B-4, and a third phase includes windings 55C-1, 55C-2, 55C-3, 55C-4. Electrically, the windings 55 are connected in series in the following order: 55A-1, 55A-2, 55A-3, 55A-4, 55B-1, 55B-2, 55B-3, 55B-4, 55C-1, 55C-2, 55C-3, 55C-4 (see FIG. 22H). The junctions between each phase 57 are connected to the PC board 48 via respective connector assemblies 152 .

[0090] With particular reference to Figures 22A-22G, a motor connector assembly 152 according to a first embodiment is shown. With particular reference to Figures 22A-22G, the electric compressor 10 includes a three-phase electric motor 54 with joints 57 between each phase. Each joint 57 is connected to the PC board 48 via a respective connector assembly 152. A set of locating pins 59 assists in precisely locating each motor connector assembly 152 relative to the motor 54. In the illustrated embodiment, the joints 57 and connector assemblies 152 are spaced 120 degrees apart along the electric motor 54, however, it should be noted that other configurations may be utilized that require different wiring of the electric motor 54. For purposes of illustration, only one motor connector assembly 152 is shown in Figures 22C-22G. However, the other motor connector assemblies 152 are the same or similar.

[0091] As described in further detail below, each motor connector assembly 152 includes a motor connector housing 154, a first motor connector 162, and a second motor connector 168. The motor connector housing 154 is disposed or positioned within a motor connector opening 150 in the housing 12 of the compressor 10. In the illustrated embodiment, the electric compressor 10 includes an inverter housing 22 that separates the intake volume 74 from the inverter cavity 30. As shown, the motor connector opening 150 is within the inverter housing 22.

[0092] The motor connector housing 154 includes an inverter end 156 adjacent the inverter cavity 30, and an intake end 158 within the intake volume 74. The motor connector housing 154 includes an inner wall 160. The inner wall 160 includes an intake side 160A and an inverter side 160B and is disposed between the inverter end 156 and the intake end 158, thereby separating the intake volume 74 and the inverter cavity 30.

[0093] A first motor connector 162 passes through an inner wall 160 of the motor connector housing 154 and has a first end 164 disposed adjacent an intake side 160A of the inner wall 160 and a second end 166 disposed adjacent an inverter side 160B of the inner wall 160. One of the motor windings 55 is electrically connected to the first end 164 of the first motor connector 162.

[0094] The second motor connector 168 is coupled to the inverter module 44 and is configured to be removably coupled to the second end 166 of the first motor connector 162 .

[0095] In the illustrated embodiment, the motor connector housing 154 defines a connector intake cavity 170 disposed within the intake volume 74, and a connector inverter cavity 172. A first end 164 of the first motor connector 162 is at least partially disposed within the connector intake cavity 170, and a second end 166 of the first motor connector 162 is at least partially disposed within the connector inverter cavity 172.

[0096] 22I-22J, a motor connector assembly 152 having an alternative configuration is shown. The alternative motor connector assembly 152 of FIGS. 22I-22J includes an alternative first connector 162', an alternative second connector 168', and a separate blade 169. The alternative first and second connectors 162', 168' are configured to receive the separate blade 169 to provide an electrical connection therebetween.

[0097] As described in more detail below, the motor connector housing 154 further includes a port 174 that allows for the injection of a potting material, such as an epoxy or silicone-based material, into the connector intake cavity 170 after the motor windings 55 are connected to the first motor connector 162 (see below). In the illustrated embodiment, the port 174 is disposed within a sidewall of the motor connector housing 154. The potting material electrically insulates the connection between the windings 55 and the first motor connector 162. A recess 176 is disposed on the outer periphery of the motor connector housing 154. The recess 176 is configured to receive an O-ring 178 that provides a seal between the motor connector housing 154 and the motor connector opening 150 of the housing 12 of the electric compressor 10. The potting material and O-ring 178 help provide a seal between the relatively high pressure of the refrigerant in the intake volume 74 and the inverter cavity 30.

[0098] 22D in particular, in the illustrated embodiment, the second motor connector 168 includes a first end 168A and a second end 168B. The first end 168A is configured to be connected to the PC board 48 and in the illustrated embodiment includes a number of connection pins 168A-1 that directly connect to the PC board 48 when the motorized compressor 10 is assembled. The second end 168B is configured to be removably connected to the first connector 162 and in the illustrated embodiment is in the shape of a blade as shown.

[0099] With particular reference to FIG. 22E, the first end 164 of the first motor connector 162 includes a receptacle 166A for receiving a blade or second end 168B of the second motor connector 168. The plurality of flexible members 166B are biased toward the center of the receptacle 166A to ensure electrical contact between the second end 166 of the second motor connector 168 and the first motor connector 162. The second end 166 of the first motor connector 162 includes a slot 166 forming an insulation displacement connector. The slot 166 includes an open end 166A and a connecting end 166B. As shown, the slot 166 narrows from the open end 166A toward the connecting end 166B. The slot 166 is configured to receive one of the windings 55 of the motor 54 and slice or cut the insulation of the winding 55 to provide an electrical connection. Each motor connector housing 154 includes one or more openings 180 for receiving a respective pin 59 .

[0100] With particular reference to Figures 23A-23G (where like elements are numbered like in Figures 22A-22G), a motor connector assembly 152' according to a second embodiment is shown. As described above, the motor-driven compressor 10 includes a three-phase electric motor 54 with joints 57 between each phase. Each joint 57 is connected to the PC board 48 via a respective connector assembly 152'. A set of locating pins 59 assists in precisely locating each motor connector assembly 152' relative to the motor 54. For purposes of illustration, only one motor connector 152' is shown in Figures 23C-23G. However, the other motor connectors 152' are the same or similar.

[0101] As described in further detail below, each motor connector assembly 152' includes a motor connector housing 154', a first motor connector 162', and a second motor connector 168'. The motor connector housing 154' is disposed or positioned within a motor connector opening 150' in the housing 12 of the compressor 10. In the illustrated embodiment, the electric compressor 10 includes an inverter housing 22 that separates the intake volume 74 from the inverter cavity 30. As shown, the motor connector opening 150' is within the inverter housing 22.

[0102] The motor connector housing 154' includes an inverter end 156' adjacent the inverter cavity 30, and an intake end 158' within the intake volume 74. The motor connector housing 154' includes an inner wall 160'. The inner wall 160' includes an intake side 160A' and an inverter side 160B' and is disposed between the inverter end 156' and the intake end 158', thereby separating the intake volume 74 and the inverter cavity 30.

[0103] A first motor connector 162' passes through an inner wall 160' of the motor connector housing 154' and has a first end 164' disposed adjacent an intake side 160A' of the inner wall 160' and a second end 166' disposed adjacent an inverter side 160B' of the inner wall 160'. One of the motor windings 55' is electrically connected to the first end 164' of the first motor connector 162'.

[0104] The second motor connector 168' is coupled to the inverter module 44' and is configured to be removably coupled to the second end 166' of the first motor connector 162'.

[0105] In the illustrated embodiment, the motor connector housing 154' defines a connector intake cavity 170' disposed within the intake volume 74', and a connector inverter cavity 172'. A first end 164' of the first motor connector 162' is at least partially disposed within the connector intake cavity 170', and a second end 166' of the first motor connector 162' is at least partially disposed within the connector inverter cavity 172'.

[0106] As described in more detail below, during assembly, a potting material, such as an epoxy or silicone-based material, may be injected directly into the connector inlet cavity 170' after the motor windings 55 are connected to the first motor connector 162' (see below). The potting material insulates the connection between the windings 55 and the first motor connector 162'. A recess 176' is disposed on the outer periphery of the motor connector housing 154'. The recess 176' is configured to receive an O-ring 178' that provides a seal between the motor connector housing 154' and the motor connector opening 150 of the housing 12 of the electric compressor 10.

[0107] The first and second motor connectors 162', 168' are similar to the first and second motor connectors 162, 168 shown in Figures 22D-22E. Each of the motor connector housings 154' includes one or more openings 180' for receiving a respective pin 59.

[0108] Assembling the Motor Connector Assembly Referring to FIG. 24, a partial flow diagram of a process or method M10 for assembling an electric compressor 10 having at least one motor connector assembly 152, 152' is shown. In a first step S12, each connector housing 154, 154' is clamped to the stator 58, for example through a welding process. A second motor connector 168, 168' is pre-assembled with the connector housing 154, 154'. Then, in a second step S14, the first motor connector 162, 162' is installed in the connector housing 154, 154'. This step creates a connection between the motor winding 55 and the first motor connection 162, 162' by mechanically removing the insulating layer of the winding 55.

[0109] In a third step, the connector intake cavity 170 with potting material. In a first embodiment, the potting material is injected into the connector intake cavity 170 via port 174. In a second embodiment, the potting material is injected directly into the connector intake cavity 170. The connector assembly 152 is positioned such that the intake end 158 of the motor connector housing 154 is above the inverter end 156 of the motor connector housing 154. This allows gravity to assist in filling the connector intake cavity 170 with the potting material.

[0110] The above invention has been described in accordance with the relevant legal standards, and therefore the description is exemplary rather than limiting in nature. Variations and modifications to the disclosed embodiments may become apparent to those skilled in the art and fall within the scope of the invention.

Claims

1. 1. An electric compressor configured to compress a refrigerant, a housing defining an intake volume, a exhaust volume, and an inverter cavity, the housing having a generally cylindrical shape and a central axis, the housing defining a motor connector opening disposed between the intake volume and the inverter cavity; an inverter module mounted within the inverter cavity of the housing and adapted to convert DC power to AC power; a motor having a plurality of motor windings mounted within the housing; a compression device coupled to the motor to receive the refrigerant from the intake volume and to compress the refrigerant as the motor rotates; 1. A motor connector assembly comprising: a motor connector housing disposed within the motor connector opening, the motor connector housing having an inverter end adjacent the inverter cavity and an intake end within the intake volume, the motor connector housing including an inner wall having an intake side and an inverter side, the motor connector housing disposed between the inverter end and the intake end separating the intake volume and the inverter cavity; a first motor connector extending through the inner wall and having a first end disposed adjacent the intake side of the inner wall and a second end disposed adjacent the inverter side of the inner wall, one of the motor windings being electrically connected to the first end of the first motor connector; a second motor connector coupled to the inverter module and configured to be removably coupled to the second end of the first motor connector; a motor connector assembly including:

2. An electric compressor comprising:

2. 2. The electric compressor of claim 1, wherein the motor connector housing defines a connector intake cavity and a connector inverter cavity disposed within the intake volume, the first end of the first motor connector being at least partially disposed within the connector intake cavity and the second end of the first motor connector being at least partially disposed within the connector inverter cavity.

3. 3. The electric compressor of claim 2, wherein the connector intake cavity is configured to receive a potting material for electrically insulating a joint between the first end of the first motor connector and the one of the motor windings.

4. 4. The electric compressor of claim 3, wherein the motor connector housing includes a port to facilitate the injection of the potting material.

5. 2. The electric compressor of claim 1, wherein the second motor connector has a first end and a second end, the first end of the second motor connector configured to releasably contact the inverter module and the second end of the second motor connector configured to releasably contact the second end of the first motor connector.

6. 6. The electric compressor of claim 5, wherein the second end of the second motor connector is in the shape of a blade, and the second end of the first motor connector includes a receptacle configured to receive the second end of the second motor connector.

7. The electric compressor of claim 6 , wherein the second end of the first motor connector includes a plurality of flexible fingers disposed with the receptacle.

8. The electric compressor of claim 6 , wherein the first end of the second motor connector includes one or more connection pins.

9. The electric compressor of claim 1 , wherein the first end of the first motor connector forms an insulation displacement connector.

10. The electric compressor of claim 1 , wherein the motor connector housing includes at least one opening configured to receive a locating pin.

11. 10. The electric compressor of claim 1, wherein said motor is a three-phase AC motor and said electric compressor includes three motor connector assemblies.

12. 1. An electric compressor configured to compress a refrigerant, a housing defining an intake volume, a exhaust volume, and an inverter cavity, the housing having a generally cylindrical shape and a central axis, the housing defining a motor connector opening disposed between the intake volume and the inverter cavity; an inverter module mounted within the inverter cavity of the housing and adapted to convert DC power to AC power; a motor having a plurality of motor windings mounted within the housing; a compression device coupled to the motor for receiving the refrigerant from the intake volume and compressing the refrigerant as the motor rotates; 1. A motor connector assembly comprising: a motor connector housing disposed within the motor connector opening having an inverter end adjacent the inverter cavity and an intake end within the intake volume, the motor connector housing having an intake side and an inverter side and including an interior wall disposed between the inverter end and the intake end separating the intake volume and the inverter cavity, the motor connector housing defining a connector intake cavity disposed within the intake volume and a connector inverter cavity, the first end of the first motor connector being at least partially disposed within the connector intake cavity and the second end of the first motor connector being at least partially disposed within the connector inverter cavity; a first motor connector extending through the inner wall and having a first end disposed adjacent the intake side of the inner wall and a second end disposed adjacent the inverter side of the inner wall, one of the motor windings being electrically connected to the first end of the first motor connector; a second motor connector coupled to the inverter module and configured to be removably coupled to the second end of the first motor connector, the second motor connector having a first end and a second end, the first end of the second motor connector configured to removably contact the inverter module and the second end of the second motor connector configured to removably contact the second end of the first motor connector; a motor connector assembly including:

2. An electric compressor comprising:

13. 13. The electric compressor of claim 12, wherein the connector intake cavity is configured to receive a potting material for electrically insulating a joint between the first end of the first motor connector and the one of the motor windings.

14. 14. The electric compressor of claim 13, wherein the motor connector housing includes a port to facilitate the injection of the potting material.

15. 13. The electric compressor of claim 12, wherein the second end of the second motor connector is in the shape of a blade, and the second end of the first motor connector includes a receptacle configured to receive the second end of the second motor connector.

16. 16. The electric compressor of claim 15, wherein the second end of the first motor connector includes a plurality of flexible fingers disposed with the receptacle.

17. The electric compressor of claim 15 , wherein the first end of the second motor connector includes one or more contact pins.

18. 13. The electric compressor of claim 12, wherein the first end of the first motor connector forms an insulation displacement connector.

19. The electric compressor of claim 12 , wherein the motor connector housing includes at least one opening configured to receive a locating pin.

20. 13. The electric compressor of claim 12, wherein the motor is a three-phase AC motor and the electric compressor includes three motor connector assemblies.

21. 1. A motor connector for use with an electric compressor configured to compress a refrigerant, the motor connector including a housing, an inverter module, a motor, and a compression device, the housing defining an intake volume, a discharge volume, and an inverter cavity, the housing having a generally cylindrical shape and having a central axis, the housing defining a motor connector opening disposed between the intake volume and the inverter cavity, the inverter module mounted within the inverter cavity of the housing and adapted to convert direct current power to alternating current power, the motor having a plurality of motor windings and mounted within the housing, the compression device coupled to the motor for receiving the refrigerant from the intake volume and compressing the refrigerant as the motor rotates, a motor connector housing disposed within the motor connector opening, the motor connector housing having an inverter end adjacent the inverter cavity and an intake end within the intake volume, the motor connector housing including an inner wall having an intake side and an inverter side, the motor connector housing disposed between the inverter end and the intake end; a first motor connector extending through the inner wall and having a first end disposed adjacent the intake side of the inner wall and a second end disposed adjacent the inverter side of the inner wall, one of the motor windings being electrically connected to the first end of the first motor connector; a second motor connector coupled to the inverter module and configured to be removably coupled to the second end of the first motor connector; A motor connector comprising:

22. 22. The motor connector of claim 21, wherein the motor connector housing defines a connector intake cavity and a connector inverter cavity disposed within the intake volume, the first end of the first motor connector being at least partially disposed within the connector intake cavity and the second end of the first motor connector being at least partially disposed within the connector inverter cavity.

23. 23. The motor connector of claim 22, wherein the connector intake cavity is configured to receive a potting material for electrically insulating a joint between the first end of the first motor connector and the one of the motor windings.

24. 24. The motor connector of claim 23, wherein the motor connector housing includes a port to allow for the injection of the potting material.

25. 22. The motor connector of claim 21, wherein the second motor connector has a first end and a second end, the first end of the second motor connector configured for releasable contact with the inverter module and the second end of the second motor connector configured for releasable contact with the second end of the first motor connector.

26. 26. The motor connector of claim 25, wherein the second end of the second motor connector is blade-shaped, and the second end of the first motor connector includes a receptacle configured to receive the second end of the second motor connector.

27. 27. The motor connector of claim 26, wherein the second end of the first motor connector includes a plurality of flexible fingers disposed with the receptacle.

28. 27. The motor connector of claim 26, wherein the first end of the second motor connector includes one or more contact pins.

29. 22. The motor connector of claim 21, wherein the first end of the first motor connector forms an insulation displacement connector.

30. The motor connector of claim 1 , wherein the motor connector housing includes at least one opening configured to receive a locating pin.

31. 11. A method relating to a motor connector for use with an electric compressor configured to compress a refrigerant, the electric compressor including a housing, an inverter module, a motor, and a compression device, the housing defining an intake volume, a discharge volume, and an inverter cavity, the housing having a generally cylindrical shape and having a central axis, the housing defining a motor connector opening disposed between the intake volume and the inverter cavity, the inverter module mounted inside the inverter cavity of the housing and adapted to convert direct current power to alternating current power, the motor having a plurality of motor windings and mounted within the housing, the compression device receiving the refrigerant from the intake volume as the motor rotates and coupled to the motor to compress the refrigerant, the motor connector assembly including a motor connector housing and a first motor connector. and a second motor connector, the motor connector housing having an inverter end adjacent the inverter cavity and an intake end within the intake volume and disposed within the motor connector opening, the motor connector housing having an intake side and an inverter side and disposed between the inverter end and the intake end separating the intake volume and the inverter cavity, the first motor connector extending through the inner wall and having a first end disposed adjacent the intake side of the inner wall and a second end disposed adjacent the inverter side of the inner wall, one of the motor windings being electrically connected to the first end of the first motor connector, the second motor connector being coupled to the inverter module and configured to be removably coupled to the second end of the first motor connector, the method comprising: clamping the motor connector housing to a stator of the motor; inserting the first connector into the connector housing; filling the connector intake cavity with a potting material; mounting the motor in the housing; closing the inverter module by installing an inverter cover; The method includes:

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