Rolling piston type rotary compressor

Abstract

The apparatus includes a semi-hermetic compressor housing, an electrically operated dual-cylinder rolling piston rotary compressor assembly housed within the housing, electric motor driver electronics, and an auxiliary housing. The auxiliary housing defines a semi-hermetic refrigerant inlet compartment having a wall. The auxiliary housing also defines an electronics compartment sharing a wall with the inlet compartment but semi-hermetically separated from the inlet compartment. The compressor housing is semi-hermetically coupled to and in fluid communication with the inlet compartment. The electronics compartment houses the electronics.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of priority to U.S. Provisional Patent Application No. 63 / 438,769, filed January 12, 2023, and to U.S. Provisional Patent Application No. 63 / 355,611, filed June 26, 2022, each of which is incorporated herein by reference.

[0002] Various embodiments herein relate to positive displacement compressors, and more particularly to semi-hermetic, electrically driven, rolling piston rotary compressors for compressing refrigerants in air conditioning, refrigeration, heat pump, and / or other cooling and / or heating systems for electric vehicles, internal combustion engine vehicles, aircraft, marine vessels, buildings, manufacturing systems, and / or other suitable applications. [Background technology]

[0003] Climate change mitigation requires a rethinking of historical paradigms. While rotating scroll refrigerant compressors typically outperform comparably sized rolling piston rotary compressors within a narrow range of load conditions, an increasing number of cooling and heating applications present a relatively wide range of dynamic load conditions, better accommodating the benefits of rolling piston rotary compressors. For example, internal combustion engine ("ICE") vehicles typically use scroll compressors in the vehicle's driver / passenger compartment heating, ventilation, and air conditioning ("HVAC") system. However, traditional ICE vehicles typically require significant power to operate the HVAC system, which has a fairly small and constant compressor load. Furthermore, ICE vehicles typically do not require much additional cooling. Meanwhile, electric vehicles are experiencing increased demands for battery cooling, brake cooling, and other thermal management demands for various drivetrain-related air and / or liquid heat exchange systems in addition to traditional driver / passenger compartment HVAC. Such additional loads can be much more dynamic than traditional HVAC systems.

[0004] Suitable rolling piston rotary compressors are needed to reduce overall HVAC power consumption and meet various battery cooling, brake cooling, and / or other electric vehicle cooling needs, ultimately producing more efficient (longer range) electric vehicles. Furthermore, in addition to supporting the cooling system, rolling piston compressors can typically operate as heat pumps, providing heat more efficiently than traditional resistance heating elements. As electric vehicle technology continues to develop and the number of electric vehicles on the road increases, the need for (and potential benefits of) efficient rolling piston rotary compressors continues to grow. Summary of the Invention

[0005] In some embodiments, the apparatus includes a semi-hermetic compressor housing, an electric dual-cylinder rolling piston rotary compressor assembly housed within the housing, electric motor driver electronics, and an auxiliary housing. The auxiliary housing defines a semi-hermetic refrigerant inlet compartment having a wall. The auxiliary housing also defines an electronics compartment sharing a wall with the inlet compartment but semi-hermetically separated from the inlet compartment. The compressor housing is semi-hermetically coupled to and in fluid communication with the inlet compartment. The electronics compartment houses the electronics.

[0006] In some embodiments, an apparatus includes a first rolling piston rotary compressor roller, a second rolling piston rotary compressor roller, a substantially hollow camshaft arranged to cooperate with the first and second rollers, an Archimedes screw, and a flexible coupling mechanically coupled internally to the camshaft, the flexible coupling having a first end extending from the camshaft in a first direction, a second end extending in a second direction to engage the Archimedes screw, and an intermediate portion extending between the first and second ends and bending from the first direction to the second direction.

[0007] In some embodiments, an apparatus includes a first rolling piston rotary compressor roller, a second rolling piston rotary compressor roller, a camshaft arranged to cooperate with the first roller and the second roller, and an electric motor including a rotor. The rotor is mechanically coupled to the camshaft and includes a first end and a second end. The rotor is generally cylindrical between the first end and the second end. A first generally disc-shaped counterweight is attached to the first end of the rotor. The first counterweight has a first generally C-shaped portion extending therefrom. A second generally disc-shaped counterweight is attached to the second end of the rotor. The second counterweight has a second generally C-shaped portion extending therefrom. The second generally C-shaped portion is disposed on the second end of the rotor at a rotational displacement of approximately 180 degrees relative to the first generally C-shaped portion. A first generally disc-shaped cap is attached to the first counterweight. The first cap has a third generally C-shaped portion extending therefrom. The third generally C-shaped portion is rotationally displaced approximately 180 degrees from the first generally C-shaped portion and faces the first counterweight. The second generally disk-shaped cap is attached to the second counterweight. The second cap has a fourth generally C-shaped portion extending therefrom. The fourth generally C-shaped portion is rotationally displaced approximately 180 degrees from the second generally C-shaped portion and faces the second counterweight.

[0008] In some embodiments, the apparatus includes a semi-hermetic compressor housing and a pair of rolling piston rotary compressor cylinders housed within the housing, the pair including a first rolling piston rotary compressor cylinder and a second rolling piston rotary compressor cylinder. The pair of compressor cylinder discharge valves include a first valve mechanically coupled to the first cylinder and a second valve mechanically coupled to the second cylinder. The pair of plates is interposed between the first cylinder and the second cylinder. The plates include a first plate. The first plate defines a first recess. The plates include a second plate. The second plate faces the first plate and defines a second recess. The first recess and the second recess together define a first acoustic muffler chamber. The valves are arranged to control refrigerant flow from the first cylinder and the second cylinder to the first chamber.

[0009] In some embodiments, the apparatus includes a semi-hermetic compressor housing and a pair of rolling piston rotary compressor cylinders housed within the housing, the pair including a first rolling piston rotary compressor cylinder and a second rolling piston rotary compressor cylinder. The pair of compressor cylinder discharge valves include a first valve mechanically coupled to the first cylinder and a second valve mechanically coupled to the second cylinder. A camshaft extends through the cylinders. The camshaft has a drive side and a non-drive side. A drive-side bearing supports the drive side of the camshaft. A first drive-side plate is disposed on the drive side of the bearing and defines a first acoustic muffler chamber having a pair of refrigerant flow holes therein. The holes include a first hole extending about a first respective axis and a second hole extending about a second respective axis. A second drive-side plate is disposed on the drive side of the first plate and defines a second acoustic muffler chamber having a first coolant discharge port therein. The first discharge port extends about a third respective axis. Valves are positioned to control coolant flow from the first and second cylinders to the first chamber. The second chamber is in fluid communication with the first chamber, but neither the first axis nor the second axis is aligned with the third axis.

[0010] It will be understood that the various embodiments described in this Summary section and elsewhere in this application can be expressed in many different combinations and subcombinations, and all such beneficial, novel, and inventive combinations and subcombinations are contemplated herein, without the understanding that each and every one of these combinations need not be expressly represented. [Brief explanation of the drawings]

[0011] Some of the figures disclosed herein may include dimensions. Additionally, the figures disclosed herein may be generated from scale drawings, scale models, or scalable photographs. It is understood that any such dimensions or relative scales within the figures are for purposes of example and should not be construed as limiting unless so recited in the claims. Those skilled in the art will also understand that computer-aided design ("CAD") renderings may include lines that relate to variations in surface geometry and not necessarily to component features.

[0012] [Figure 40] FIG. 40 illustrates a top front left perspective view of a semi-hermetic compressor according to an embodiment of the present disclosure. [Figure A] View A shows a top front left perspective, partially exploded view of the semi-hermetic compressor of FIG. [Figure B] FIG. 8B shows a top front left perspective, partially exploded view of the motorized dual cylinder rolling piston rotary compressor assembly of FIG. 8A. [Figure C] FIG. 3C shows an exploded view of the upper front left perspective of the dual cylinder rolling piston rotary compressor assembly of FIG. 3B. [Figure D] FIG. 5D shows an exploded view of the upper rear right perspective of the dual cylinder rolling piston rotary compressor assembly of FIG. 5C. [Figure 59] FIG. 59 shows a vertical cross-sectional view of the semi-hermetic compressor of FIG. 40 taken along line 59-59 of FIG. [Figure 61] FIG. 61 shows a vertical cross-sectional view of the semi-hermetic compressor of FIG. 40 taken along line 61-61 of FIG. [Figure 62] FIG. 62 shows an enlarged vertical cross-sectional cutaway view of the semi-hermetic coupling of the compressor housing to the auxiliary housing taken from FIG. [Figure 63] FIG. 63 shows a perspective view of a chamfered shim of the semi-hermetic coupling of FIG. [Figure F] View F shows a vertical cross-sectional view of an alternative semi-hermetic compressor according to an embodiment of the present disclosure, taken in the same direction as line 61-61 of FIG. [Figure 48]FIG. 48 shows a top front right perspective view of the non-drive side of the motorized dual cylinder rolling piston rotary compressor assembly of FIG. A. [Figure 47] FIG. 47 shows a vertical cross-sectional view of the semi-hermetic compressor of FIG. 40 taken along line 47-47 of FIG. [Figure 57] FIG. 57 shows an enlarged vertical cross-sectional cutaway view of the helical oil pump assembly of the semi-hermetic compressor of FIG. 40 taken from FIG. [Figure 56] FIG. 56 shows an enlarged perspective view of the helical oil pump assembly of the semi-hermetic compressor of FIG. [Figure 54] FIG. 54 shows an enlarged vertical cross-sectional view of the refrigerant discharge pipe of the semi-hermetic compressor of FIG. 40 taken from FIG. 47. [Figure 53] FIG. 53 shows a perspective view of the refrigerant discharge pipe of the semi-hermetic compressor of FIG. [Figure 51] FIG. 51 shows an enlarged vertical sectional view of the rear oil plug located at the rear end of the camshaft of the semi-hermetic compressor of FIG. 40 taken from FIG. 47. [Figure 50] FIG. 50 shows an enlarged vertical cross-sectional cutaway view of the rear oil plug of the semi-hermetic compressor of FIG. 40 taken from FIG. [Figure 49] FIG. 49 shows a perspective view of the rear oil plug of the semi-hermetic compressor of FIG. [Figure 45] FIG. 45 shows a top front left perspective view of the motor rotor assembly with counterweight of the electrically operated dual cylinder rolling piston rotary compressor of FIG. B. [Figure 44] FIG. 44 shows a top front left perspective partially exploded view of the motor rotor assembly with counterweight. [Figure 68] FIG. 68 shows an oblique cut-away cross-sectional view of the acoustic muffler system of the electrically operated dual cylinder rolling piston rotary compressor assembly of FIG. B taken along line 68-68 of FIG. [Figure 65] FIG. 65 shows a complementary perspective exploded view of the intermediate acoustic muffler plate of the semi-hermetic compressor of FIG. [Figure 69]FIG. 69 shows an isolated cross-sectional view of the drive end of an alternative acoustic muffler system for an alternative semi-hermetic compressor according to an embodiment of the present disclosure, looking in the same direction as FIG. 68. DETAILED DESCRIPTION OF THE INVENTION

[0013] To promote an understanding of the principles of the present invention, reference will now be made to the embodiments illustrated in the drawings, and specific language will be used to describe the embodiments. However, no limitation of the scope of the invention is intended thereby, and it will be understood that changes and further modifications in the illustrated devices, and further applications of the principles of the illustrated invention, as would normally occur to one skilled in the art to which the invention pertains, are contemplated. While at least one embodiment of the present invention has been described and disclosed, the present application may show and / or describe other embodiments of the present invention, and the reasonable and logical deduction of still other embodiments will be possible as would be understood by one skilled in the art. Unless expressly stated herein as being limited to one or more particular materials, any component of the present invention may be fabricated from any one or more suitable metals, plastics, wood, textiles, fibers, and / or combinations thereof (and / or any other suitable materials or combinations thereof) as would be understood by one skilled in the art.

[0014] Any reference to "the present invention" is a reference to a group of inventive embodiments, and it is understood that no single embodiment, including any device, process, or composition, is to be included in all embodiments unless otherwise specified. Furthermore, while "advantages" provided by some embodiments of the present invention may be described, it is understood that other embodiments may not include those same advantages, or may include even different advantages. Any advantages described herein should not be construed as limitations on the scope of any claims. The use of words indicating preferences, such as "various embodiments" or "preferred," refers to features and aspects presented in at least one embodiment, but which are optional in some embodiments, and thus, it is understood that use of the word "preferred" implies the term "optional."

[0015] Like reference numerals refer to like parts throughout the specification and drawings. Additionally, the use of an N-series prefix (NXX.XX) on an element number refers to the same element as the element without the prefix (XX.XX), except as shown and described. As an example, element 1020.1 is the same as element 20.1, except for the different features of element 1020.1 shown and described. Furthermore, common elements and common features of related elements may be depicted identically in different figures and / or use the same symbols in different figures. These common features are apparent to those skilled in the relevant art, so it is not necessary to describe identical features in 1020.1 and 20.1. Furthermore, some features 1020.1 and 20.1 may be backward compatible, and those skilled in the art will understand that features (NXX.XX) of the following embodiments may include features (MXX.XX) that are compatible with various other embodiments previously described. The rules for this description are the prime ('), double prime (''), triple prime (''') and star or asterisk ( * ) suffix. Thus, 20.1, 20.1', 20.1'', 20.1''', and 20 * The common features of the above will be apparent to those skilled in the relevant art, and therefore it is not necessary to describe these features.

[0016] Below are paragraphs describing specific embodiments of the present invention. In the following paragraphs, some element numbers are prefixed with "X" to indicate that the word relates to any similar feature disclosed in the drawings or described in the text. However, one skilled in the art will recognize various other element numbers without the X prefix that describe features applicable to other embodiments.

[0017] This specification may use different words to describe the same element number or to refer to an element number (NXX.XX) in a particular group of features. It is understood that such different words are not intended to provide a redefinition of any language in this specification. It is understood that such words indicate that certain features can be considered in various linguistic ways that are not necessarily additional or exclusive.

[0018] FIG. 40 shows a top front left perspective view of a semi-hermetic compressor 100 according to an embodiment of the present disclosure. The compressor 100 includes a semi-hermetic compressor housing 120. The compressor housing 120 is configured to semi-hermetically house an electric dual-cylinder rolling piston rotary compressor assembly 140 (not visible in FIG. 40 , but see view A) and is comprised primarily of a bolted aluminum casing with suitable gaskets. The compressor housing 120 includes a general refrigerant discharge port 160 configured for suitable semi-hermetic connection to a hose, tube, or the like (not shown) for supplying compressed refrigerant gas therein. The compressor 100 also includes an auxiliary housing 180 bolted to the compressor housing 120. The auxiliary housing 180 is also comprised primarily of a bolted aluminum casing with suitable gaskets and includes a general refrigerant inlet port 200 configured for suitable semi-hermetic connection to a hose, tube, or the like (not shown) for receiving relatively low-pressure refrigerant gas therefrom. Auxiliary housing 180 also includes a power receptacle or socket 220 suitably configured to electrically couple to a mating plug (not shown) for receiving electrical power (for powering compressor assembly 140) from an electric vehicle power system or other suitable external power supply (not shown). Auxiliary housing 180 also includes an electrical signal port 240 suitably configured to electrically couple to a mating port (not shown) for receiving electrical signals (for controlling operation of compressor assembly 140) from an electric vehicle power management system or other suitable external control system (not shown).

[0019] FIG. 1A shows a top front left perspective, partially exploded view of the semi-hermetic compressor assembly 100. The semi-hermetic compressor housing 120 includes a chamber body 260 and a rear, or back, cover plate 280. The motorized, dual-cylinder, rolling-piston rotary compressor assembly 140 fits within the chamber body 260. Bolts 300 extend through the cover plate 280 into the chamber body 260, and the cover plate 280 semi-hermetically seals against the compressor assembly 140 and the chamber body 260 under the bias of the bolts 300. The chamber body 260 further defines a mating slot 320 and an intermediate refrigerant receiving port 340. The auxiliary housing 180 includes a protrusion 360 that fits within the mating slot 320 and an intermediate refrigerant delivery port 380 that semi-hermetically connects to the receiving port 340 via a suction tube assembly 500 (not shown in FIG. 1A, see FIG. 1B). Bolts 400 secure the auxiliary housing 180 to the chamber body 260. The compressor assembly 100 also includes a general refrigerant discharge pipe 404 that extends upwardly through the discharge port 160.

[0020] View B shows a top front left perspective, partially exploded view of the motorized, dual-cylinder, rolling piston rotary compressor assembly 140. The compressor assembly 140 includes a core compressor assembly 420, a helical oil pump assembly 440, a gas flow deflector or baffle 460, a bolt 480, a suction tube assembly 500, an electric motor 540, and a hollow camshaft 560. The camshaft 560 extends through the compressor assembly 420 along an axis 580 and includes a forward end 600 and an aft end 620. The forward end 600 projects forward from the assembly 420. The aft end 620 projects rearward from the assembly 420. The oil pump assembly 440 includes a cup-shaped coupling 640. As will be further discussed in connection with FIGS. 57 and 56, the coupling 640 couples the assembly 440 to the forward end 600 of the camshaft 560. The baffle 460 arcs above the oil pump assembly 440 and is positioned between the discharge pipe 404 (not shown in FIG. B, but see FIG. A) and the oil pump assembly 440 (generally above the oil pump assembly 440 and below the discharge pipe 404). Bolts 480 secure the baffle 460 to the compressor assembly 420. The baffle 460 is designed to reduce refrigerant turbulence (and thus reduce oil agitation) proximate the oil pump assembly 440, which the inventors believe may improve the inlet conditions of the oil pump and, therefore, the efficiency / performance of the oil pump assembly 440. The suction pipe assembly 500 is semi-hermetically coupled to the compressor assembly 420 and extends generally laterally and downwardly therefrom. The electric motor 520 may be any suitable direct current ("DC") motor (brushed or brushless) or alternating current ("AC") motor. Motor 520 includes a counterweighted motor rotor assembly 660 mechanically coupled to a rear portion 620 of camshaft 560. It should be appreciated that motor 520 is operable to rotate counterweighted motor rotor assembly 660. It should also be appreciated that core compressor assembly 420 is operable to draw refrigerant therein through suction tube assembly 500 and compress the refrigerant in response to rotation of camshaft 560.

[0021] Views C and D show exploded top front left and top rear right perspective views, respectively, of the motorized dual cylinder rolling piston rotary compressor assembly 140. Compressor assembly 140 includes a front end cap 680, a leaf or reed valve 700, a first or forward cylinder cover plate 720, vanes 740, a first or forward compression cylinder 760, a suction tube assembly 500, a hollow camshaft 560, an axial flow impeller 780 internally fastened to camshaft 560, a rear oil plug 800 inserted substantially within rear portion 620 of camshaft 560 but nevertheless protruding therefrom, a first or front compression roller 820, a first or front intermediate cylinder cover plate 840, a second or rear intermediate cylinder cover plate 860, a second or rear compression roller 880, a second or rear compression cylinder 900, a plug or stop 920, a second or rear cylinder cover plate 940, a first or intermediate drive end cap 960, and a second or rear or back drive end cap 980.

[0022] FIG. 59 shows a vertical cross-sectional view of the semi-hermetic compressor 100 taken along line 59-59 of FIG. 40. The auxiliary housing 180 defines a semi-hermetic refrigerant inlet compartment 1000 having a wall 1020. The auxiliary housing 180 also includes a screen 1040 that spans diagonally across the inlet compartment 1000. The auxiliary housing 180 further defines an electronics compartment 1060. The electronics compartment 1060 shares a wall 1020 with the inlet compartment 1000. However, when the auxiliary housing 180 is fully assembled, the electronics compartment 1060 is not in fluid communication with the inlet compartment 1000. When the auxiliary housing 180 is fully assembled, the electronics compartment 1060 is semi-hermetically separated (or semi-hermetically sealed) from the inlet compartment 1000. Meanwhile, the semi-hermetic compressor housing 120 is semi-hermetically coupled to and in fluid communication with the inlet section 1000 via the suction tube assembly 500 .

[0023] The compressor 100 includes electric motor driver electronics 1080 housed within the electronics compartment 1060. The electric motor driver electronics 1080 may be one or more capacitors, inductor coils, transformers, resistors, transistors or other semiconductor devices, integrated circuits, inverter circuits, combinations thereof, or other electrical or electronic components or circuits for appropriately delivering power and / or control signals to the motor 520. During operation of the semi-hermetic compressor assembly 100, the compressor assembly 140 draws a refrigerant (not shown) into the inlet compartment 1000 through the refrigerant inlet port 200. As the refrigerant flows (generally downward) through the inlet compartment 1000, the refrigerant may effectively cool the electric motor driver electronics 1080 (by absorbing heat generated by the electronics 1080 and transferred through the wall 1020), which may desirably extend the life of the electronics 1080 and may partially evaporate any undesirable liquid from the refrigerant. Additionally, the sieve 1040 may filter undesirable impurities from the refrigerant. In other embodiments, the sieve 1040 may be oriented approximately perpendicular to the wall 1020, although it should be recognized that the diagonal orientation of the sieve 1040 increases the surface area of the sieve 1040 compared to a vertically oriented sieve.

[0024] FIG. 61 shows a vertical cross-sectional view of the semi-hermetic compressor 100 taken along line 61-61 in FIG. 40. The semi-hermetic compressor housing 120 includes a first outer wall 1100 having a generally convex cross-section. The auxiliary housing 180 includes a second outer wall 1120 having a generally concave cross-section. The second outer wall 1120 faces the first outer wall 1100 and is radially spaced from the first outer wall 1100. The generally concave cross-section mirrors the generally arcuate shape of the generally convex cross-section, and the second outer wall 1120 is radially spaced from the first outer wall 1100 by at least 10 mm. In other embodiments, the second outer wall 1120 is radially spaced from the first outer wall 1100 by approximately 0.1 mm to 15 mm.

[0025] FIG. 62 shows an enlarged vertical cross-sectional cutaway view of the semi-hermetic coupling (provided by the suction tube assembly 500) of the semi-hermetic compressor housing 120 to the auxiliary housing 180, taken from FIG. 61 . The suction tube assembly 500 includes a straight tube 1140 having a radial flange 1160. It should be appreciated that the flange 1160 facilitates insertion and sealing of the tube 1140 into the receiving port 340 of the chamber body 260 of the compressor housing 120. The suction tube assembly 500 also includes a truncated shim 1180. The shim 1180 distributes the pressure exerted by the suction volume across the entire area of the suction tube flange 1160. The suction tube assembly 500 also includes a radial sealing O-ring 1200 and a pair of first and second axial sealing O-rings 1220 and 1240. FIG. 63 shows a perspective view of the shim 1180.

[0026] View F shows a vertical cross-sectional view of an alternative semi-hermetic compressor 1260 according to an embodiment of the present disclosure, taken in the same direction as line 61-61 of Figure 40. Comparing View F with Figure 62, it will be appreciated that, relative to compressor 100, compressor 1260 replaces straight tube 1140 with a J-tube suction accumulator tube 1280. It will be appreciated that suction accumulator tube 1280 has a bore 1300 therein and has a generally J-shaped cross-section.

[0027] FIG. 48 shows a top front right perspective view of the non-drive side of the motorized dual cylinder rolling piston rotary compressor assembly 140.

[0028] FIG. 47 shows a vertical cross-sectional view of semi-hermetic compressor 100 taken along line 47-47 of FIG. 40. With reference to FIG. 47, it can be seen that axial flow impeller 780 (which is internally fixed and coupled to hollow camshaft 560) is positioned to encourage oil flow from helical oil pump assembly 440, through camshaft 560, toward and out of bung 800 as camshaft 560, impeller 780, and bung 800 rotate together during operation of semi-hermetic compressor 100. It can also be seen that camshaft 560 has intermediate side holes 1320 located forward of bung 800. It should further be appreciated that the side holes also distribute oil.

[0029] FIG. 57 shows an enlarged vertical cross-sectional exploded view of the helical oil pump assembly 440 of the semi-hermetic compressor 100, taken from FIG. 47. The oil pump assembly 440 is an Archimedes screw-type pump including a coil spring 1340, a screw 1360 made of plastic or any other suitable material, an outer sleeve or tube 1380, and a cup-shaped fitting 640 made of metal or any other suitable material. The tube 1380 is mechanically coupled to the cup-shaped fitting 640. The screw extends along an axis 1420, which is preferably inclined (neither coaxial nor parallel) to the axis 580 (of extension of the camshaft 560). The spring 1340 is fixedly coupled to the camshaft 560 at one end and transmits / redirects the rotational motion of the camshaft 560 to the screw 1360. Accordingly, the opposing portion or end 1440 of spring 1340 extends into and is fixedly coupled to screw 1360. Screw 1360 rotates within tube 1380 to pump fluid (oil in this case) in the manner of the Archimedes screw principle. Tube 1380 (which does not rotate) is fixedly coupled to bearing 1460 via coupling 640. Within coupling 640, bearing 1460 abuts camshaft 560 at camshaft lubrication hole or inlet 1480. Oil pumped by the screw 1360 flows into the spring 1340 (proximal to the camshaft 560) through gaps between the coils of the spring 1340 (it should be appreciated that such gaps are exaggerated where the spring 1340 bends from the axis 1420 (of the screw 1360) toward the camshaft lubrication inlet 1480), and then from the inside of the spring 1340 into the camshaft lubrication inlet 1480. The distal end 1500 of the spring (i.e., the end relatively farther from the crankshaft lubrication inlet 1480) is closed by a metal plug 1520, which may be fixedly coupled to the spring 1340 and the screw 1360. FIG. 56 shows an enlarged perspective view of the helical oil pump assembly 440. In an alternative embodiment, the coil spring 1340 may be replaced with a suitable flexible rod.

[0030] FIG. 54 shows an enlarged vertical cross-sectional isolated view of discharge pipe 404 taken from FIG. 47, and FIG. 53 shows a perspective view of discharge pipe 404. Discharge pipe 404 is designed to prevent lubricating oil (which circulates within compressor housing 120 during operation of compressor 100) from being swept away by refrigerant flow through discharge port 160. Discharge pipe 404 includes a sidewall 1540. Sidewall 1540 defines an inlet hole 1560 therethrough. Inlet hole 1560 receives the refrigerant flow, including refrigerant and / or oil, into discharge pipe 404. Discharge pipe 404 also includes a bottom end 1580 defining drip hole 1600. It should be appreciated that drip hole 1600 may drip or drop oil back into compressor housing 120 for recirculation by cooperation of oil pump assembly 440, impeller 780, and camshaft 560. Discharge pipe 404 also has a top upwardly facing outlet opening or orifice 1580 coupled to discharge port 160. It should be appreciated that outlet opening 1580 may deliver compressed refrigerant and / or compressed refrigerant with a relatively less oil content from compressor housing 120 through discharge port 160.

[0031] FIG. 51 shows an enlarged, vertical, cut-away view of rear oil plug 800 taken from FIG. 47. FIG. 50 shows an enlarged, vertical, cut-away view of rear oil plug 800 taken from FIG. 51. And FIG. 49 shows a perspective view of rear oil plug 800. As seen in FIG. 51 (and as discussed above), oil plug 800 is inserted into and protrudes from rear portion 620 of camshaft 560. As further seen in FIG. 51 and more easily seen in FIGS. 50 and 49, plug 800 is generally cup-shaped and tapered to facilitate insertion into camshaft 560, and has a sidewall 1640. Sidewall 1640 defines an oil release orifice or hole 1660 therein. It should be appreciated that although the plug 800 is substantially inserted into the camshaft 560, the plug 800 protrudes sufficiently from the camshaft 560 that the camshaft 560 does not block or seal the hole 1660, and therefore, as the camshaft 560 rotates during operation of the compressor 100, the plug 800 can release oil through the orifice 1160.

[0032] FIG. 45 shows a top front left perspective view of the motor rotor assembly 660 with counterweight, and FIG. 44 shows a top front left perspective partially exploded view of the motor rotor assembly 660 with counterweight. The rotor assembly 660 is generally cylindrical and has a first end 1680, a second end 1700, and a generally cylindrical core 1720 extending axially between the first end 1680 and the second end 1700. The core 1720 is suitably configured with conventional electrical wiring / windings, magnetic materials, and / or other conventional electric motor rotor materials and features to enable the rotor assembly 660 to operate to rotate appropriately in response to a magnetic / electromagnetic field. The rotor assembly 660 includes a first generally disc-shaped counterweight plate 1740 attached to a first end 1680 of the core 1720 and in general axial alignment with the core 1720, and the rotor assembly 660 includes a second generally disc-shaped counterweight plate 1760 attached to a second end 1700 of the core 1720 and in general axial alignment with the core 1720. The first plate 1740 has a first generally C-shaped portion 1780 extending therefrom. The second plate 1760 has a second generally C-shaped portion 1800 extending therefrom. The second portion 1800 is rotationally displaced approximately 180 degrees relative to the first portion 1780.

[0033] Assembly 660 also includes a first generally disc-shaped cap 1820 attached to first plate 1740. First cap 1820 has a third generally C-shaped portion 1840 extending therefrom. Third portion 1840 faces first plate 1740 at approximately 180 degrees rotational displacement relative to first portion 1780. Assembly 660 further includes a second generally disc-shaped cap 1860 attached to second plate 1760. Second cap 1860 has a fourth generally C-shaped portion 1880 extending therefrom. Fourth portion 1880 faces second plate 1760 at approximately 180 degrees rotational displacement relative to second portion 1800.

[0034] Rotor cap 1820 and rotor cap 1860 may be made of plastic (or any other suitable material) to reduce weight (and thus reduce the impact on the dimensions of the balancing counterweight). In some embodiments, the mass of third portion 1840 is at least five times less than the mass of first portion 1780, and the mass of fourth portion 1880 is at least five times less than the mass of second portion 1800.

[0035] FIG. 68 shows an oblique cutaway cross-sectional view of an acoustic muffler system 1900 for a motorized dual cylinder rolling piston rotary compressor assembly 140.

[0036] As shown in Figure 68, the muffler system 1900 includes: 1.) Non-drive side or front camshaft bearing 1920; 2.) Front end cap 680 (see also Figure C) and 3.) a first intermediate plate 840 (see also Figure C); 4.) A second intermediate plate 860 (see also Figure C); 5.) drive side or relatively rear camshaft bearing 1940; 6.) First drive end cap 960 (see also Figure C); 7.) A second drive end cap 980 (see also Figure C); Includes:

[0037] The non-drive side bearing 1920 and front end cap 680 define a first acoustic muffler chamber or volume 1960. The first intermediate plate 840 and second intermediate plate 860 define a second acoustic muffler chamber or volume 1980. The drive side bearing 1940 and first drive side end cap 960 define a third acoustic muffler chamber or volume 2000. The first drive side end cap 960 and second drive side end cap 980 define a fourth acoustic muffler chamber or volume 2020. The first acoustic muffler chamber 1960, the second acoustic muffler chamber 1980, the third acoustic muffler chamber 2000 and the fourth acoustic muffler chamber 2020 maintain uninterrupted fluid communication with each other via holes 2040 through the non-drive side bearing 1920, holes 2060 through the first intermediate plate 840, respective channels 2080 extending between holes 2040 and 2060, holes 2100 through the second intermediate plate 860, holes 2120 through the drive side bearing 1940, respective channels 2140 extending between holes 2100 and 2120, and holes 2160 in the first drive side end cap 960.

[0038] The non-drive-side bearing 1920 and the front end cap 680 are semi-hermetically coupled. The second drive-side end cap 980 includes a drive-side collar 2180. The collar 2180 surrounds but is radially spaced from the drive side 2200 of each of the drive-side bearings 1940, such that the collar 2180 and the drive side 2200 together form an annular refrigerant discharge orifice 2220.

[0039] During operation of the compressor assembly 140, the compressed refrigerant is instead discharged by the first cylinder 760 and the second cylinder 900 into the muffler system 1900. The refrigerant is acoustically attenuated by the muffler system 1900, circulates within and flows through the muffler system 1900, and is discharged into the semi-hermetic compressor housing 120 through the annular orifice 2220.

[0040] 65 shows a complementary perspective exploded view of the first intermediate acoustic muffler plate 840 and the second intermediate acoustic muffler plate 860. The intermediate plates 840, 860 are undercut to form an acoustic cavity 2240 that reduces the emission of undesired sound / noise. It should be recognized that in some embodiments, the exact shape of the cavity 2240 may differ from that shown herein, provided the overall geometry provides suitable acoustic damping.

[0041] Figure 69 shows an isolated cross-sectional view of the drive-side end of an alternative acoustic muffler system 2260 of an alternative semi-hermetic compressor according to an embodiment of the present disclosure, taken in the same orientation as Figure 68. Muffler system 2260 includes an outer cap 2280 having two side-by-side holes 2300 (only one of which is visible in Figure 69) for discharging refrigerant, the holes being offset from holes 2320 in a smaller drive-side cap 2340 and located at the bottom of the alternative compressor to facilitate cleaning of its lubricant.

[0042] It should be appreciated that aspects of the present disclosure may be incorporated into air conditioning, refrigeration, heat pumps, and / or other cooling and / or heating systems that exchange heat with air and / or liquid for electric vehicles, internal combustion engine vehicles, aircraft, marine vessels, buildings, manufacturing systems, and / or any other suitable applications.

[0043] While the invention has been illustrated and described in detail in the drawings and foregoing description, it is to be considered exemplary and not limiting in character, it being understood that only certain embodiments have been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected.

Claims

1. a semi-hermetic compressor housing; an electrically operated dual cylinder rolling piston rotary compressor assembly housed within said housing; an electric motor driver electronic device; a secondary housing defining a semi-hermetic coolant inlet compartment having a wall, and defining an electronics compartment sharing the wall with, but semi-hermetically separated from, the inlet compartment; An apparatus comprising: The apparatus, wherein the compressor housing is semi-hermetically coupled to and in fluid communication with the inlet compartment, and the electronics compartment houses electronics.

2. the compressor housing includes a first outer wall portion having a first convex cross-section; the auxiliary housing includes a second outer wall portion having a generally concave cross-section; 2. The device of claim 1, wherein the second outer wall portion faces the first outer wall portion, the second outer wall portion is radially spaced from the first outer wall portion, and the generally concave cross-section mirrors the generally convex cross-section in a generally arcuate manner.

3. The device of claim 1 , wherein the second outer wall portion is radially spaced from the first outer wall portion by about 0.1 mm to 15 mm.

4. 4. The device of claim 3, wherein the second outer wall is radially spaced at least 10 mm from the first outer wall.

5. a suction accumulator extending into the inlet compartment; The apparatus of claim 4 , wherein the compressor housing is semi-hermetically connected to the inlet compartment through the suction accumulator.

6. The apparatus of claim 5 , wherein the suction accumulator comprises a tube having a generally J-shaped cross section.

7. 4. The apparatus of claim 3, wherein the compressor housing is comprised essentially of aluminum.

8. The apparatus of claim 5 , wherein the compressor housing is comprised essentially of aluminum.

9. a roller of a first rolling piston type rotary compressor; a roller of a second rolling piston type rotary compressor; a substantially hollow camshaft arranged to cooperate with the first roller and the second roller; Archimedes screw and a flexible coupling internally mechanically connected to the camshaft, the flexible coupling having a first end extending from the camshaft in a first direction, a second end extending in a second direction and engaging the Archimedes screw, and an intermediate portion extending between the first end and the second end and bending from the first direction to the second direction; 1. An apparatus comprising:

10. The apparatus of claim 9 , wherein the flexible coupling comprises a flexible rod.

11. The apparatus of claim 9 , wherein the flexible coupling comprises a flexible coil.

12. The apparatus of claim 11 including an oil flow tube covering the middle portion of the coil.

13. The apparatus of claim 12 , wherein the first direction is generally vertical and the second direction is generally downward.

14. an axial flow impeller internally fastened to the camshaft; The apparatus of claim 13 , wherein the first end of the coil is fastened to the axial flow impeller.

15. a semi-hermetic compressor housing; a baffle disposed generally above the oil flow tube, the baffle including a bottom surface and a top surface; a refrigerant discharge pipe located generally above the top surface of the baffle, the refrigerant discharge pipe opening into the compressor housing, passing through the compressor housing, and also opening out of the compressor housing; and Including, 14. The apparatus of claim 13, wherein the oil flow tube and the baffle are contained within the compressor housing, and the bottom surface of the baffle is in fluid communication with the top surface of the baffle within the compressor housing.

16. The apparatus of claim 15 , wherein the baffle is generally arcuate above the oil flow tube.

17. 17. The apparatus of claim 16, wherein the compressor housing includes a first portion having an inner diameter, the baffle is disposed generally within the first portion of the compressor housing, and the baffle extends laterally across a substantial portion of the inner diameter.

18. 18. The apparatus of claim 17, wherein the baffle includes a notched left portion and a notched right portion.

19. 20. The apparatus of claim 18, wherein the baffle is substantially laterally symmetrical.

20. the refrigerant discharge pipe includes a bottom portion defining a refrigerant drip hole, a top portion defining a refrigerant discharge port, and a generally longitudinal portion extending between the bottom portion and the top portion and defining a refrigerant receiving hole; 17. The device of claim 16, wherein the drip hole is smaller than the discharge port and the drip hole is smaller than the receiving hole.

21. a roller of a first rolling piston type rotary compressor; a roller of a second rolling piston type rotary compressor; a camshaft arranged to cooperate with the first roller and the second roller; an electric motor including a rotor mechanically coupled to the camshaft, the rotor including a first end and a second end, and the rotor being generally cylindrical between the first end and the second end; a first generally disc-shaped counterweight attached to the first end of the rotor, the first generally disc-shaped counterweight having a first generally C-shaped portion extending therefrom; a second generally disc-shaped counterweight attached to the second end of the rotor and having a second generally C-shaped portion extending therefrom, the second generally C-shaped portion being positioned on the second end of the rotor at approximately 180 degrees of rotational displacement relative to the first generally C-shaped portion; a first generally disc-shaped cap attached to a first counterweight, the first generally disc-shaped cap having a third generally C-shaped portion extending therefrom, the third generally C-shaped portion being rotationally displaced approximately 180 degrees relative to the first generally C-shaped portion and facing the first counterweight; a second generally disc-shaped cap attached to the second counterweight, the second generally disc-shaped cap having a fourth generally C-shaped portion extending therefrom, the fourth generally C-shaped portion being rotationally displaced approximately 180 degrees relative to the second generally C-shaped portion and facing the second counterweight; 1. An apparatus comprising:

22. 22. The apparatus of claim 21, wherein the first generally C-shaped portion has a first mass, the second generally C-shaped portion has a second mass, the third generally C-shaped portion has a third mass, and the fourth generally C-shaped portion has a fourth mass, and the first mass is at least five times the third mass.

23. a semi-hermetic compressor housing; a pair of rolling piston type rotary compressor cylinders housed within the housing, the pair including a first rolling piston type rotary compressor cylinder and a second rolling piston type rotary compressor cylinder; a pair of compressor cylinder discharge valves, the pair of compressor cylinder discharge valves including a first valve mechanically coupled to the first cylinder and a second valve mechanically coupled to the second cylinder; a pair of plates interposed between the first cylinder and the second cylinder, the plates including a first plate defining a first recess and a second plate facing the first plate and defining a second recess, the first recess and the second recess together defining a first acoustic muffler chamber; An apparatus comprising: The apparatus, wherein the valve is positioned to control refrigerant flow from the first cylinder and the second cylinder to the first chamber.

24. 24. The device of claim 23, wherein the second recess generally coincides with the first recess.

25. 25. The apparatus of claim 24, wherein each of the plates is disk-shaped.

26. 26. The apparatus of claim 25, wherein the valves are arranged to alternate refrigerant flow from the first cylinder and the second cylinder, respectively, to the first chamber.

27. a camshaft extending through the cylinder, the camshaft having a drive side and a non-drive side; a counter-drive-side bearing supporting the counter-drive-side portion of the camshaft; a non-drive side plate disposed on a non-drive side of the bearing and defining a second acoustic muffler chamber; Including, 27. The device of claim 26, wherein the second chamber is in fluid communication with the first chamber.

28. a semi-hermetic compressor housing; a pair of rolling piston type rotary compressor cylinders housed within the housing, the pair including a first rolling piston type rotary compressor cylinder and a second rolling piston type rotary compressor cylinder; a pair of compressor cylinder discharge valves, the pair of compressor cylinder discharge valves including a first valve mechanically coupled to the first cylinder and a second valve mechanically coupled to the second cylinder; a camshaft extending through the cylinder, the camshaft having a drive side and a non-drive side; a drive-side bearing supporting the drive-side portion of the camshaft; a first drive-side plate disposed on a drive side of the bearing and defining a first acoustic muffler chamber having a pair of coolant flow holes therein, the holes including a first hole extending about a first respective axis and a second hole extending about a second respective axis; a second drive-side plate disposed on the drive side of the first plate and defining a second acoustic muffler chamber having a first coolant discharge port therein, the first discharge port extending about a third respective axis; An apparatus comprising: the valve is positioned to control refrigerant flow from the first cylinder and the second cylinder to the first chamber; The second chamber is in fluid communication with the first chamber, but neither the first axis nor the second axis is aligned with the third axis.

29. The camshaft extends longitudinally about a fourth axis; 30. The apparatus of claim 28, wherein the third axis is aligned with the fourth axis.

30. the first discharge port has an inner diameter; the drive-side bearing has an outer diameter and includes a bearing portion extending into the first discharge port; 30. The apparatus of claim 29, wherein the outer diameter of the bearing portion is smaller than the inner diameter of the first discharge port.

31. the second drive-side plate defines a second discharge port within the second chamber; The first discharge port is disposed relatively lower than the camshaft, 31. The apparatus of claim 30, wherein the second discharge port is located relatively lower than the camshaft.

32. a pair of intermediate plates interposed between the first cylinder and the second cylinder, the pair including a first intermediate plate defining a first recess and a second intermediate plate facing the first intermediate plate and defining a second recess, the first recess and the second recess together defining a third acoustic muffler chamber; Including, 30. The apparatus of claim 28, wherein the valve is positioned to control refrigerant flow from the first cylinder and the second cylinder to the third chamber, the third chamber being in fluid communication with the first chamber.

33. a counter-drive-side bearing supporting the counter-drive-side portion of the camshaft; a non-drive side plate disposed on a non-drive side of the bearing and defining a fourth acoustic muffler chamber; Including, 33. The device of claim 32, wherein the fourth chamber is in fluid communication with the third chamber.

Images