Electric compressor with insulation restraint system

Abstract

The electric compressor includes a housing, a refrigerant inlet port, a refrigerant outlet port, an inverter unit, a motor unit, a compression device, and a front cover. The housing defines a suction volume and a discharge volume. The refrigerant inlet port is coupled to the housing and configured to introduce refrigerant into the suction volume. The compression device is a scroll-type compression device configured to compress the refrigerant. The refrigerant outlet port is coupled to the housing and configured to allow the compressed refrigerant to exit the scroll-type electric compressor from the discharge volume.

Description

[Technical Field]

[0001] The present invention relates generally to electric compressors, and more particularly to electric compressors that use scroll compression devices to compress refrigerants.

[0002] Background technology Compressors have long been used in refrigeration systems. Systems designed to provide cooling in specific areas typically 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, scroll-type compressors have long been used in HVAC systems in automobiles to provide air conditioning. Such compressors may also be used in reverse in applications requiring heat pumps. These compressors are typically driven using rotary motion obtained from the automobile's engine.

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

[0004] In addition to cooling the passenger compartment of a 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 battery or battery compartment when the battery is charging, especially during fast charge modes, thereby generating heat that may damage or degrade the battery and / or other systems. Because heat may damage or degrade the battery, it may also be used to cool the battery when it is not being charged or used. Because the electric compressor may operate at various times, such use obviously requires electrical energy from the battery, even when the vehicle is not running, thus reducing the battery's operating time.

[0005] Additionally, electric compressors can operate at extremely high speeds, for example, 2,000 RPM (or higher), which can generate undesirable levels of noise.

[0006] It is therefore desirable to provide an electrically driven compressor that has high efficiency, low noise, and maximum lifespan.The present invention is directed to overcoming one or more of the problems or advantages identified above.

[0007] Summary of the Invention In a first aspect of the present invention, there is provided an electric scroll compressor configured to compress a refrigerant. The electric scroll compressor includes a housing, a refrigerant inlet port, a refrigerant outlet port, an inverter module, a motor, a drive shaft, and a compression device. The housing defines a suction volume and a discharge volume, has a generally cylindrical shape, and has a central axis. The refrigerant inlet port is coupled to the housing and configured to introduce refrigerant into the suction volume. The refrigerant outlet port is coupled to the housing and configured to allow compressed refrigerant to exit the compressor from the discharge volume. The inverter module is mounted inside the housing and adapted to convert direct current power to alternating current power. The motor is mounted inside the housing. The drive shaft is coupled to the motor. The compression device is coupled to the drive shaft to receive refrigerant from the suction volume and compress the refrigerant when the drive shaft is rotated by the motor.

[0008] The compression device includes a fixed scroll and an orbiting scroll. The fixed scroll is positioned within and fixed relative to the housing. The orbiting scroll is coupled to a drive shaft. The orbiting and fixed scrolls form a compression chamber that receives refrigerant from a suction volume and compresses the refrigerant as the drive shaft rotates about a central axis. The orbiting scroll has a lower surface with a plurality of ring-shaped slots.

[0009] The scroll-type electric compressor further includes a thrust body, a plurality of articulating guide pins, a plurality of mounting pins, and a plurality of insulating sleeves. The thrust body has a plurality of guide pin openings. The plurality of articulating guide pin openings extend from the guide pin openings and into the ring-shaped slot toward the compression section. The guide pins are configured to limit articulation of the orbiting scroll as the orbiting scroll orbits about the central axis. Each mounting pin has a housing end and a thrust body end. The housing end is press-fit into a respective receiving opening in the housing. The thrust body end is cylindrical with an outer surface. The plurality of insulating sleeves are constructed of a flexible material. The thrust body end of each mounting pin is enclosed within a respective sleeve and received in a respective slot in the thrust body.

[0010] In a second embodiment of the present invention, there is provided an electric scroll compressor having a central axis and configured to compress a refrigerant. The electric scroll compressor includes a housing, a refrigerant inlet port, a refrigerant outlet port, an inverter unit, a motor unit, a compression device, a plurality of articulated guide pins, and a plurality of insulating sleeves. The housing defines a suction volume and a discharge volume. The refrigerant inlet port is coupled to the housing and configured to introduce refrigerant into the suction volume. The refrigerant outlet port is coupled to the housing and configured to allow compressed refrigerant to exit the electric scroll compressor from the discharge volume.

[0011] The inverter unit includes an inverter housing, an inverter back cover, and an inverter module. The inverter back cover is connected to the inverter housing to form an inverter cavity. The inverter module is mounted in the inverter cavity and adapted to convert DC power into AC power.

[0012] The motor portion includes a drive shaft positioned within the housing, the drive shaft having first and second ends and defining a central axis, and a motor positioned within the housing for controllably rotating the drive shaft about the central axis.

[0013] A compressor is coupled to the drive shaft for receiving refrigerant from the suction volume and compressing the refrigerant as the drive shaft is rotated by the motor. The compressor includes a fixed scroll positioned within and fixed relative to the housing and an orbiting scroll coupled to the drive shaft. The orbiting scroll and the fixed scroll form a compression chamber for receiving refrigerant from the suction volume and compressing the refrigerant as the drive shaft is rotated about its central axis. The orbiting scroll has a lower surface with a plurality of ring-shaped slots.

[0014] The scroll-type electric compressor further includes a thrust body, a plurality of articulating guide pins, a plurality of mounting pins, and a plurality of insulating sleeves. The thrust body has a plurality of guide pin openings. The plurality of articulating guide pins extend from the guide pin openings and into the ring-shaped slot toward the compression section. The guide pins are configured to limit articulation of the orbiting scroll as the orbiting scroll orbits about the central axis. Each mounting pin has a housing end and a thrust body end. The housing end is press-fit into a respective receiving opening in the housing. The thrust body end is cylindrical with an outer surface. The plurality of insulating sleeves are constructed of a flexible material. The thrust body end of each mounting pin is enclosed within a respective sleeve and received in a respective slot in the thrust body.

[0015] 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 explanation of the drawings]

[0016] [Figure 1A]FIG. 1 is a first perspective view of an electric compressor according to an embodiment of the present invention. [Figure 1B] FIG. 1B is a partial view of the electric compressor of FIG. 1A with the center housing removed. [Figure 2] FIG. 1B is a second perspective view of the electric compressor of FIG. 1A. [Figure 3] FIG. 1B is a first side view of the electric compressor of FIG. 1A. [Figure 4] FIG. 1B is a second side view of the electric compressor of FIG. 1A. [Figure 5] FIG. 1B is a front view of the electric compressor of FIG. 1A. [Figure 6] FIG. 1B is a rear view of the electric compressor of FIG. 1A. [Figure 7] FIG. 1B is a top view of the electric compressor of FIG. 1A. [Figure 8] FIG. 1B is a bottom view of the electric compressor of FIG. 1A. [Figure 9] FIG. 1B is a first cross-sectional view of the electric compressor of FIG. 1A. [Figure 10] FIG. 1B is a second cross-sectional view of the electric compressor of FIG. 1A. [Figure 11] FIG. 1B is an exploded view of the inverter of the electric compressor of FIG. 1A. [Figure 12] 2 is an exploded view of a portion of the electric compressor of FIG. 1, including the motor and drive shaft. [Figure 13] FIG. 1B is an exploded view of the compression device of the electric compressor of FIG. 1A. [Figure 14A] FIG. 13 is a first perspective view of the drive shaft of FIG. 12. [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. 12. [Figure 15B] FIG. 15B is a second perspective view of the rotor and counterweight of FIG. 15A. [Figure 16A] 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; FIG. [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 the 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] 2 is a graph of a fixed scroll and an orbiting scroll of a compression device of the electric compressor of FIG. 1 in accordance with one embodiment of the present invention. [Figure 17B] 2 is a graph of a fixed scroll and an orbiting scroll of a compression device of the electric compressor of FIG. 1 in accordance with one embodiment of the present invention. [Figure 17C] 2 is a graph of a fixed scroll and an orbiting scroll of a compression device of the electric compressor of FIG. 1 in accordance with one embodiment of the present invention. [Figure 17D] 2 is a graph of a fixed scroll and an orbiting scroll of a compression device of the electric compressor of FIG. 1 in accordance with one embodiment of the present invention. [Figure 17E] 2 is a graph of a fixed scroll and an orbiting scroll of a compression device of the electric compressor of FIG. 1 in accordance with one embodiment of the present invention. [Figure 17F] 2 is a graph of a fixed scroll and an orbiting scroll of a compression device of the electric compressor of FIG. 1 in accordance with one embodiment of the present invention. [Figure 17G] 2 is a graph of a fixed scroll and an orbiting scroll of a compression device of the electric compressor of FIG. 1 in accordance with one embodiment of the present invention. [Figure 17H] 2 is a graph of a fixed scroll and an orbiting scroll of a compression device of the electric compressor of FIG. 1 in accordance with one embodiment of the present invention. [Figure 17I] 2 is a graph of a fixed scroll and an orbiting scroll of a compression device of the electric compressor of FIG. 1 in accordance with one embodiment of the present invention. [Figure 17J]2 is a graph of a fixed scroll and an orbiting scroll of a compression device 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 the 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 18G] FIG. 14 is a cross-sectional view of a fixed scroll of the compression device of FIG. 13. [Figure 19A] FIG. 1 is a first perspective view of a front cover of an electric compressor forming an oil separator, according to one embodiment of the present invention. [Figure 19B] FIG. 19B is a second perspective view of the front cover of FIG. 19A. [Figure 19C] FIG. 19B is a cross-sectional view of the front cover of FIG. 19A. [Figure 20A] FIG. 1 is a partial view of an electric compressor with a cross-sectional view of a housing and an isolation and restraint system according to one embodiment of the present invention. [Figure 20B] FIG. 10 is a partial view of an isolation and restraint system for use with an electric compressor according to another embodiment of the present invention. [Figure 20C] FIG. 1 is a first perspective view of a thrust body according to one embodiment of the present invention. [Figure 20D] FIG. 20D is a second perspective view of the thrust body of FIG. 20C.

[0017] MODE FOR CARRYING OUT THE INVENTION 1A-20D, where like reference numerals indicate like or corresponding parts throughout the several views, a motor-driven compressor 10 having an outer housing 12 is provided. The motor-driven compressor 10 is particularly suited for an automotive vehicle, such as an automobile (not shown). The motor-driven compressor 10 may be used as a chiller or (reverse) heat pump to heat and / or cool various aspects of the vehicle. For example, the motor-driven 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. Additionally, the motor-driven compressor 10 may be used to heat or cool the passenger compartment, onboard electronics, and / or the battery used to power the vehicle while the vehicle is not operating, for example, during a charging cycle. The motor-driven compressor 10 may further be used while the vehicle is not operating and while the battery is not being charged to preserve battery life or minimize degradation. In the illustrated embodiment, the motor-driven compressor 10 has a capacity of 36 cubic centimeters (cc). Capacity refers to the initial volume captured within the compressor when the scrolls of the compressor initially close or meet (see below). Note that the electric compressor 10 disclosed herein is not limited to any such volume and may be sized or scaled to meet particular required specifications.

[0018] In the illustrated embodiment, the electric compressor 10 is a scroll-type compressor that operates to quickly and efficiently compress refrigerant for use in various systems in motor vehicles, such as electric or hybrid vehicles. 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 center housing 24, and a front cover 28 (which may be referred to as a discharge head). The center housing 24 houses the motor section 16 and the compression device 28.

[0019] In a first aspect of the electric compressor 10 of the present disclosure, an electric compressor 10 is provided having a compression device with a fixed scroll having a modified scroll bed. In a second aspect of the electric compressor 10 of the present disclosure, an electric compressor 10 is provided having an isolation and restraint system. In a third aspect of the electric compressor 10 of the present disclosure, an electric compressor 10 is provided having a head design with a reed mechanism with three reeds.

[0020] In one embodiment, the inverter back cover 20, inverter housing 22, center housing 24, and front cover 28 are constructed from machined aluminum. The inverter 10 may be mounted within the body of the automobile, for example, via multiple mounting points 120. Overall configuration and operation of electric compressor 10

[0021] 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 center 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 center housing 24. An inverter gasket 42, disposed between the inverter back cover 20 and the inverter housing 22, keeps moisture, dust, and other contaminants from the interior cavity 30. A motor gasket 54A is disposed between the inverter housing 22 and the center housing 24 and provides maintenance of a refrigerant seal against the environment.

[0022] Referring to FIG. 11 , an inverter module 44 is mounted within the inverter cavity 30 formed by the inverter back cover 20 and the inverter housing 22. The inverter module 44 includes an inverter 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 rotational 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 and control signals for controlling the operation of the inverter circuit 46 and the motor section 16 are supplied via a low-voltage connector 52.

[0023] The center housing 24 defines a motor cavity 56. The motor section 16 includes a motor 54 positioned within the motor cavity 56. The motor cavity 56 is defined by the motor side 22A of the inverter housing 22 and the inner surface 24A of the center housing 22. With particular reference to FIG. 12 , the motor 54 is a three-phase AC motor having a stator 56. The stator 56 has a generally hollow cylindrical shape with six individual coils (two per phase). The stator 56 is housed within and attached to the motor housing 22 and remains stationary relative to the motor housing 22.

[0024] Motor 54 includes a rotor 60 positioned within and centrally disposed relative to stator 58. Rotor 60 has a generally hollow cylindrical shape and is positioned within stator 56. Rotor 60 has several counterweights 60A, 60B attached thereto. The counterweights balance motor 54 as it drives compressor 18 and may be machined from brass.

[0025] The motor 54 is powered through a set of terminals 54A that are sealed from the motor cavity 56 by an O-ring 54B.

[0026] 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 the 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 positioned on the motor side of the inverter housing 22. A first ball bearing 62 positioned in the opening formed by the first drive shaft support member 22 supports and rotates the first end of the drive shaft 90. The center housing 24 includes a second drive shaft support member 24A. A second ball bearing 64 positioned in the opening formed by the second drive shaft support member 24A enables the second end 90B of the drive shaft 90 to rotate. 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 22A of the inverter housing 22 and the second drive shaft support member 24A of the center housing 24, respectively.

[0027] As described above, the electric compressor 10 is a scroll-type 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 60B. The rotor 60B, which includes a drive shaft 90, rotates under the control of the rotation of the inverter module 44 to drive the movement of the orbiting scroll 66.

[0028] 14A, 14B, 16A, and 16B, the drive shaft 90 has a central axis 90C about which the rotor 60 and drive shaft 90 rotate. The orbiting scroll 66 moves about the central axis 90C in an eccentric orbit, i.e., a 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 located along an offset axis 90D of the drive shaft 90, which is defined by an orbiting scroll opening (or drive pin location) 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 bearing 108 of the swing linkage 124 as the drive shaft 90 rotates about the central axis 90C.

[0029] With particular reference to FIGS. 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 FIG. 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 a suction volume 74 formed between the motor side 22A of the inverter housing 22 adjacent the refrigerant inlet port 68 and the center housing 24. The refrigerant is then drawn through the motor section 16 and enters the compression suction volume 76 formed between the inner wall of the fixed scroll 26 and the orbiting scroll 66 (as demonstrated by arrow 92 in FIG. 14A).

[0030] The fixed scroll 26 is mounted within the central housing 24. As shown in FIGS. 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 and 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 26A, 66B, and scroll inward toward their respective center ends 26D, 66D.

[0031] Each tip seal 94 is positioned within a slot 26E, 66E located in the top surface of the fixed scroll 26 and the orbiting scroll 66, respectively. The tip seals 94 comprise 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.

[0032] 17A-17I, refrigerant enters the compressor 12 through the compression suction volume 76. In FIGS. 17A-17I, cross-sectional views of the top of the fixed scroll 26 and orbiting scroll 66 are shown.

[0033] As described in detail below, the fixed scroll wrap 26A and the orbiting scroll wrap 66A form compression chambers 80 into which low or unpressurized (saturation pressure) refrigerant enters from the compressor 12. 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 various 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.

[0034] Refrigerant enters compression chamber 80 formed between orbiting scroll wrap 66A and fixed scroll wrap 26A. 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 electric compressor 10.

[0035] 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 16B, 66B is spaced apart from the other scroll wrap 66B. At this point, the compression chamber 80 is open to the compression suction volume 76, allowing refrigerant under low pressure to fill the compression chamber 80 from the compression suction volume 76. As the orbiting scroll 66 moves along passage 78, the space between the tail end 16A, 66A and the other scroll 66, 16B decreases until the compression chamber 80 is closed off from the compression suction volume 76 (FIGS. 17B-17E). As the orbiting scroll 66 continues to move along passage 78, the volume of the compression chamber 80 is further reduced, 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-17J. This volume is further reduced until pressurized refrigerant is discharged from the compression device 18 (see below).

[0036] As will be explained below, refrigerant enters chambers formed between the walls of orbiting scroll 66 and fixed scroll 26. During a cycle of compressor 10, refrigerant is transported toward the center of these chambers. Orbiting scroll 66 is shown orbiting or moving in a circular motion indicated by arrow 78, which is formed by the relative position of orbiting scroll 66 with respect to fixed scroll 26, during one cycle of electric compressor 10.

[0037] Returning to FIG. 1 , the front cover 28 defines a discharge volume 82. The discharge volume 82 communicates with the refrigerant output port 70. As will be explained in detail below, the pressurized refrigerant exits the compression device 18 through a central orifice 84A and two side orifices 84B 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, the reed mechanism 86 includes three reeds: a central reed 87A and two side reeds 87B, corresponding to the central orifice 84A and the two side orifices 84B (see below).

[0038] As shown in FIGS. 18D and 18E , in the illustrated embodiment, the reed mechanism 86 includes a discharge reed 86A and a reed holddown 86B. The discharge reed 86A is made of a flexible material, such as steel. The material and its properties, such as strength, are selected to control the pressure at which the pressurized refrigerant is discharged from the compressor 18. The reed holddown 86B is made of a rigid, non-flexible material, such as stamped steel. The reed holddown 86 controls or limits the maximum displacement of the discharge reed 86A relative to the fixed scroll 26. Generally, oil is directed rearward through the motor section 16 to lubricate and cool the rotating components of the electric compressor 10, such as the rotor 60, drive shaft 90, and all bearings 62, 64, and 108. The oil is drawn upward toward the top of the motor 54 by the rotation of the rotor 60. From there, the oil enters the interior of the motor 54, lubricating the second ball bearing 64, and the oil due to rotational forces within the motor section 16 may impinge on the motor side 22A of the inverter housing 22. The oil is further directed by the motor side 22A to the ball bearing 62, which will be further described below.

[0039] In the illustrated embodiment, the lead mechanism 86 is held or secured via separate fasteners 89. As shown in FIGS. 18E and 18F, the lead mechanism 86 includes a plurality of openings 86C configured to receive associated posts 83A on the fixed scroll 26. As shown in FIG. 18E, the back surface of the fixed scroll 26 includes a bezel 83B that surrounds orifices 84 that help regulate the pressure at which the refrigerant exits the compression device 18. Additionally, a debris collection slot 83C collects debris near the orifices 84A, 84B to prevent interference with the lead mechanism 86.

[0040] As shown in FIG. 9, the path of the refrigerant through the electric compressor is indicated by dashed arrows 72 .

[0041] Electric compressor 10 utilizes oil (not shown) to provide lubrication between components of compressor 18 and motor 54, such as between orbiting scroll 66 and fixed scroll 26, and within ball bearings 62, 64. The oil mixes with refrigerant within compressor 18 and motor 54 and exits compressor 18 through orifice 84. As described in more detail below, the oil is separated from the compressed refrigerant within front cover 28 and returned to compressor 18.

[0042] The oil separator 96 facilitates separation of the mixed oil and refrigerant. 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. During use, the electric compressor 10 is generally oriented as shown in FIGS. 3-5 such that gravity acts as indicated by arrow 106 to cause oil to collect in the oil reservoir 98.

[0043] Referring to FIG. 9, the typical oil path is shown by arrow 88 as it travels from the bottom of the electric compressor 10 through the compressor 18, through the orifice 84 to the discharge volume 82 in the front cover 28, and back to the compressor 18.

[0044] In the illustrated embodiment, the front cover 28 is attached to the center housing 24 by a plurality of bolts 122 that are inserted into respective openings in the front cover 28 and threaded into openings in the center housing 24. A stationary head gasket 110 and a rear hair gasket 112 are positioned between the center housing 24 and the fixed scroll 26 to provide sealing.

[0045] 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 compressor 18, where it is mixed with the refrigerant and returned.

[0046] 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 it is recirculated through the motor 54 and motor cavity 56 and the compressor 18. During use, the electric compressor 10 is generally oriented as shown in FIGS. 3-5 such that gravity acts as indicated by arrow 106 to cause oil to collect in the oil reservoir 98. Referring to FIG. 9, the typical oil path is indicated by arrow 88 as traveling from the bottom of the electric compressor 10, through the compressor 18, through the orifice 84 to the discharge volume 82 in the front cover 28, and back to the compressor 18. As shown, the oil is drawn back into the compressor 18, where it is returned to, or mixed with, the refrigerant.

[0047] As mentioned above, refrigerant, which is actually a mixture of refrigerant and oil, enters the electric compressor 10 through the refrigerant inlet port 70. 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 and drive shaft 90. Rotational forces within the motor section 16 cause the oil and refrigerant to enter the interior of the motor 54 to lubricate the second ball bearing 64 and the oil. They 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.

[0048] Concentric projections of swing link mechanism and drive shaft 13 to 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 126. In one embodiment, the concentric protrusion 126 is integrally formed with the drive shaft 90. As described below, the swing link mechanism 124 is used to rotate the orbiting scroll 66 about the drive shaft 90 in an eccentric orbit.

[0049] 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 eccentric pin are inserted into respective openings in the end 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 is positioned along the central axis of the drive shaft. As the drive shaft rotates, the drive pin and eccentric pin are placed under significant stress. Therefore, both pins are constructed of a hardened material, such as SAE 52100 bearing steel. Additionally, because the eccentric pin is used to limit the radial movement of the orbiting scroll 66's eccentric orbit, 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 and eccentric pin.

[0050] As will be explained in detail below, the eccentric pin of the prior art is replaced with a concentric protrusion 90F.

[0051] In the illustrated embodiment, the electric scroll 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 a suction volume 74 and a discharge volume 82. The refrigerant inlet port 68 is coupled to the housing 12 and configured to introduce refrigerant into the suction volume 74. The refrigerant outlet port 70 is coupled to the housing 12 and configured to allow compressed refrigerant to exit the electric scroll compressor 10 from the discharge volume 82. The drive shaft 90 is positioned within the housing 12 and has first and second ends 90A, 90B. The drive shaft 90 is centered and defines a central axis 90C.

[0052] A concentric protrusion 90F is positioned on the second end 90B of the drive shaft 90 and is centered about a central axis 90C. The concentric protrusion 90F extends away from the drive shaft 90 along the central axis 90C. The concentric protrusion 90F includes a drive pin opening 90E. The motor 54 is positioned 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 positioned within the drive pin opening 90E and extends away from the drive shaft 90. The drive pin 126 is parallel to the concentric protrusion 90F.

[0053] The concentric pin 90F may further include an undercut 90G, and the outer surface may be surface hardened or treated with a coating or bearing surface. The concentric pin 90F may be further machined at the same time as the drive shaft 90.

[0054] As described above, the compression device 18 includes the fixed scroll 26 and the orbiting scroll 66. The fixed scroll 26 is positioned within and fixed relative to the housing 12. The orbiting scroll 66 is coupled to the drive shaft 90. As the drive shaft 90 rotates about a central axis 90C, the orbiting scroll 66 and the fixed scroll 26 form a compression chamber 80 (see above) for receiving and compressing refrigerant from the suction volume 74. The orbiting scroll 66 has an inner circumferential surface 66E.

[0055] Swing linkage 124 is coupled to drive shaft 90 and has first and second openings 124A, 124B for receiving concentric projection 90F and drive pin 126. Swing linkage 124 further includes an outer periphery 124C.

[0056] The ball bearings 108 are disposed adjacent to and between the inner peripheral surface 66E of the orbiting scroll 66 and the outer peripheral surface 124C of the swing link mechanism 124. The drive shaft 90, drive pin 126, the orbiting scroll 66, and the swing link mechanism 124 are arranged so as to rotate the orbiting scroll 66 in an eccentric orbit about the central axis 90C.

[0057] 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 simultaneously with and in the same machining operation as the drive shaft 90 further improves manufacturing efficiency.

[0058] The enlarged view of a portion of the compression device 18 shown in FIG. 16G further illustrates the concentric protrusion 90F. The concentric protrusion 90F interacts with and guides the swing linkage 124. The concentric protrusion 90F is sized and machined to a controlled tolerance using the first opening 124A to create a controlled gap that limits radial movement of the eccentric orbit of the orbiting scroll 66. Unlike the prior art, the concentric protrusion 90F does not require a second pin or any additional machining operation. The concentric protrusion 90F further cooperates with the guide pin 24B and slot 66G on the lower surface 66F of the orbiting scroll 66, as further described below.

[0059] The electric scroll compressor 10 includes an inverter section 14, a motor section 16, and a compression device 18. The motor section 16 includes a central housing 54 that defines a motor cavity 56. The compression section 18 includes a fixed scroll 26. The housing 12 is formed, at least in part, by the fixed scroll 26 and the central housing 24.

[0060] With particular reference to FIGS. 13 , 16B , 18A-18F, and 20A-20D , in the illustrated embodiment, the orbiting scroll 66 has a lower surface 66F. The lower surface 66F has a plurality of ring-shaped slots 66G. A thrust plate 150 within the central housing 24 includes a plurality of articulating guide pin openings 155. The articulating guide pins 24B are positioned within the guide pin openings 66G and extend into the ring-shaped slots 66G toward the compression device 18. The articulating guide pins 24B are configured to limit articulating movement of the orbiting scroll 66 as it orbits about the central axis 90C. In one embodiment, each of the ring-shaped slots 66G includes a ring sleeve 118. The thrust plate 130 is positioned between the fixed scroll 26 and the thrust body 150 (see below) and provides a wear surface therebetween.

[0061] Discharge head design with 3-lead mechanism and oil separator In the illustrated embodiment, the electric compressor 10 includes a multicavity pulsation muffler system 160 and an oil separator 96 positioned within 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 refrigerant are mixed. The oil separator 96 is necessary to separate the mixed oil and refrigerant before the refrigerant exits the electric compressor 10.

[0062] Generally, refrigerant is discharged from the compression device 18 during each cycle, i.e., each rotation (or orbit), of the orbiting scroll 66. In the illustrated embodiment, the refrigerant exits the compression device 18 through a central orifice 84A and two side orifices 84B in the fixed scroll 26. The discharge of refrigerant through the orifices 84A, 84B is controlled by a central reed 87A and two side reeds 87B, respectively. The multi-cavity pulsation muffler system 160 and the oil separator 96 are described in more detail below.

[0063] Scroll bearing oil orifice The electric compressor 10 may include a scroll bearing oil injection orifice 138 (see FIGS. 16C and 16E). As mentioned above, the compression device 18 of the present disclosure includes a ball bearing 108. In the illustrated embodiment, the ball bearing 108 is positioned between the swing linkage 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 restricted, reducing its durability. As shown in FIG. 9, the oil orifice 138 allows oil (and refrigerant) to travel from the discharge chamber 82 along passage 73 (sometimes referred to as the "nosebleed" passage) to the ball bearing 108.

[0064] The electric scroll 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 compressor 18. The housing 12 defines a suction volume 74 and a discharge volume 82. The refrigerant inlet port 68 is coupled to the housing 12 and configured to introduce refrigerant into the suction volume 74. The refrigerant outlet port 70 is coupled to the housing 12 and configured to allow compressed refrigerant to exit the electric scroll compressor 10 from the discharge volume 82. The inverter module 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 compressor 18 receives refrigerant from the suction volume 74 and compresses the refrigerant as the drive shaft 90 is rotated 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 or plug 136 .

[0065] The fixed scroll 26 is positioned within and fixed relative to the housing 12. The orbiting scroll 66 is coupled to a drive shaft 90. As the drive shaft 90 rotates about a central axis 90C, the orbiting scroll 66 and the fixed scroll 26 form a compression chamber 80 for receiving and compressing refrigerant from the suction volume 72. 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.

[0066] The swing link mechanism 124 is coupled to the drive shaft 90. Ball bearings 108 are disposed between and adjacent to 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 in an eccentric orbit about the central axis 90C.

[0067] 16B-16E, 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 to pass through the orbiting scroll 66 to the ball bearings 108.

[0068] 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 through 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. Additionally, the plug 136 may have a specially designed and tailored oil orifice 138 that may increase or decrease oil flow and refrigerant flow depending on the diameter and geometry of the oil orifice 138.

[0069] 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 approximately 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 flow is designed to provide heat and lubrication to the ball bearings 108, which support the radial force generated by the eccentric orbit of the orbiting scroll 66.

[0070] Further, as described above, the orbiting scroll 66 includes an orbiting scroll base 66A and an orbiting scroll wrap 66B. The orbiting scroll wrap 66B may include an orbiting scroll tail end 66C and an orbiting scroll center end 66D. As shown, the oil opening 140 is located within the orbiting scroll center 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.

[0071] As shown in FIG. 9, oil orifice 138 allows oil (and refrigerant) to travel from discharge chamber 82 along passage 73 (sometimes referred to as the "nosebleed" passage) to ball bearing 108.

[0072] Bearing oil communication hole The electric compressor 10 may include one or more bearing oil communication holes. 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 10 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 22 of the inverter housing 22A, and the second drive shaft support member 24A is formed within the center housing 24. First and second ball bearings 62, 64 are positioned within the first and second drive shaft support members 22B, 24A.

[0073] The position of the first drive shaft support member 22B is not in the 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.

[0074] As shown in FIG. 16F, the first drive support member 22B may include one or more holes 22C to allow oil to enter the first drive support member 22B and lubricate the first ball bearing 62.

[0075] In the illustrated embodiment, the electric scroll compressor 10 includes a housing 12, a first ball bearing 62, a second ball bearing 64, a refrigerant inlet port 68, a refrigerant outlet port 70, an inverter module 44, a motor 54, a drive shaft 90, and a compressor 18.

[0076] The housing 12 defines an intake volume 74 and a discharge volume 82 and includes first and second drive shaft support members 22B, 24A. The first ball bearing 62 is positioned within the first drive shaft support member 22B. The first drive shaft support member 22B of the housing 12 includes one or more oil communication holes 22C to allow oil to enter the first ball bearing 62.

[0077] The second ball bearing 64 is positioned within the second drive shaft support member 24A. The refrigerant inlet port 68 is coupled to the housing 12 and configured to introduce refrigerant into the suction volume 74. The refrigerant outlet port 70 is coupled to the housing 12 and configured to allow compressed refrigerant to exit the electric scroll 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. A 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 refrigerant from the suction volume 74 and compresses the refrigerant as the drive shaft 90 is rotated by the motor 54. As described above, in the illustrated embodiment, the first drive shaft support member 22 may be formed on the motor side 22A of the inverter housing 22.

[0078] Rotational motion within the motor section 16 of the compressor 18 creates a path and movement for oil from the oil reservoir 98, as indicated by arrow 88 in FIG. 9 . As shown, 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, where it mixes 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 surface of 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 22, and the raised backing and pockets allow the first bearing 62 to be secured. The inverter housing 22 further defines an oil cavity (not shown) into which oil collected between the ribs 22D is directed downward by gravity. The ribs 22D and the sloped surfaces 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. While FIG. 16F shows two oil communication holes 22C, it is understood that additional, or fewer than two, 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 holes are 3.5 mm in diameter, and the motor side 22A includes sloped walls between the ribs 22D. Additionally, the motor side 22A may include an outer oil collection area 22.

[0079] Dome-shaped inverter cover The electric scroll compressor 10 of the present invention may include a dome-shaped inverter cover 20. The electric scroll 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 compressor 18, and the inverter cover 20. The housing 12 defines a suction volume 70 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 suction volume 70. The refrigerant outlet port 82 is coupled to the housing 12 and configured to allow compressed refrigerant to exit the electric scroll compressor 10 from the discharge volume 82.

[0080] Inverter module 44 is mounted within housing 12 and adapted to convert DC power to AC power. Motor 54 is mounted within housing 12. Drive shaft 90 is coupled to motor 54. Compressor 18 is coupled to drive shaft 90 and configured to receive refrigerant from the suction volume and compress the refrigerant as drive shaft 90 is rotated by motor 54.

[0081] 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.

[0082] To disperse rather than focus vibrations, the inverter back cover 20 of the electric scroll compressor 10 of the fifth embodiment of the present disclosure has a generally curved or dome-shaped profile that disperses vibrations from the compressor 18.

[0083] As shown in each figure, particularly FIGS. 1, 3, and 6, the inverter cover 20 is positioned at one end of the electric scroll compressor 10 and includes a first portion 20A and a second portion 20B. The first portion 20A includes an apex or apex portion 20C, is generally perpendicular to the central axis 90C, and has an apex 20C and an outer periphery 20D. The first portion 20A has a relatively dome-shaped 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 the electric scroll compressor 10 must fit into, and constraints placed by internal components, i.e., location and size. The first portion 20A may also need to incorporate other features, such as 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 is positioned around the periphery of the inverter cover.

[0084] Fixed scroll with modified scroll bed In a first aspect of the present invention, an electric scroll compressor 10 with a modified fixed scroll bed is configured to compress a refrigerant. The electric scroll 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, and a compressor 18. The housing 12 defines a suction volume 74 and a discharge volume 82.

[0085] The refrigerant inlet port 68 is coupled to the housing 12 and configured to introduce refrigerant into the suction volume 74. The refrigerant outlet port 70 is coupled to the housing 12 and configured to allow compressed refrigerant to exit the electric scroll compressor 12 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, and the drive shaft 90 is coupled to the motor 54.

[0086] Generally, and as described above, the compression device 18 receives refrigerant from the suction volume 74 and compresses the refrigerant as the drive shaft 90 is rotated by the motor 54 .

[0087] Compressor 18 includes fixed scroll 26 and orbiting scroll 66. Compressor 18 defines an antechamber volume 134. Antechamber volume 134 (see FIGS. 18C and 18G) supplies refrigerant to chamber 80 at the start of the compression cycle. During the compression cycle, when chamber 80 closes (if wraps 26B, 66B contact), pressure within antechamber volume 134 drops due to suction, which can affect the efficiency of electric compressor 10. In one aspect of the present invention, it is desirable to increase the antechamber volume (making additional refrigerant available to compressor 18), thereby increasing the "capacity" of compressor 18 and smoothing the compression cycle.

[0088] In the illustrated embodiment, the bases 26A, 66A of one of the fixed scroll 26 and the orbiting scroll 66 have a notch 136 for increasing the sub-chamber volume 134.

[0089] In the illustrated embodiment, the notch 136 is located in the floor or base 26A of the fixed scroll 26.

[0090] As shown, the fixed scroll 26 has a first side 26F defined by the fixed scroll base 26A and a second side 26G defined by the upper surface of the fixed scroll wrap 26B. The fixed scroll wrap 26B extends from the fixed scroll base 26A toward the second side 26G of the fixed scroll 26. As shown in FIGS. 18C and 18G, the notch 136 in the floor of the fixed scroll base 26 defines a first portion having a depth d1 that is deeper than the depth d2 of the second portion 138.

[0091] The size of the first portion or notch 136 may be limited by integration constraints. First, the depth d1 must leave enough material to maintain the structural integrity of the fixed scroll 26. Furthermore, to ensure that the chamber 80 is sealed, the shape of the notch must remain outside of the orbiting wrap 66B and allow the chamber 80 to close and seal as shown in 17D. The notch 136 may provide additional volume within the subchamber 134 so that the volume within the chamber 80 in 17D can be completely filled. The notch 136 is limited by the passage of the orbiting scroll 66B and the limitations of the floor and wall thickness required for the fixed scroll 26. Furthermore, machining and access to the floor of the fixed scroll may provide additional limitations on the size and area outside the sealing region of the orbiting scroll 66B.

[0092] Isolation / Constraint Systems In a second aspect of the present invention, an isolation and restraint system 148 may be used to isolate the housing 12 from vibrations and pulsations caused by the orbiting scroll 66 .

[0093] In a typical scroll-type electric compressor, the motor and fixed scroll are directly coupled to the housing. As mentioned above, a guide pin directly coupled to the housing may cooperate with a ring-shaped slot in the orbiting scroll to limit articulation of the orbiting scroll as it orbits the drive shaft. In this type of configuration, vibrations and pumping pulsations from the orbiting scroll may be transmitted to the housing, through the mounting, and into, for example, the vehicle structure.

[0094] The electric scroll compressor 10 is configured to compress a refrigerant. The electric scroll compressor includes 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 compressor 18. The housing 12 defines a suction volume 74 and a discharge volume 82 and has a generally cylindrical shape. The refrigerant inlet port 68 is coupled to the housing 12 and configured to introduce refrigerant into the suction volume 74. The refrigerant outlet port 70 is coupled to the housing 12 and configured to allow compressed refrigerant to exit the scroll compressor 12 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 compressor 18 is coupled to the drive shaft 90 and receives refrigerant from the suction volume 74 and compresses the refrigerant when the drive shaft 90 is rotated by the motor 54.

[0095] As described above, the compression device 16 includes the fixed scroll 26 and the orbiting scroll 66. The fixed scroll 26 is positioned within and fixed relative to the housing 12. The orbiting scroll 66 is coupled to a drive shaft 90. As the drive shaft 90 rotates about a central axis 90C, the orbiting scroll 66 and the fixed scroll 26 form a compression chamber 80 for receiving refrigerant from the suction volume 74 and compressing the refrigerant.

[0096] The orbiting scroll 66 has a lower surface with a plurality of ring-shaped slots 66G (see above).

[0097] 20A-20D, the electric scroll compressor 10 further includes a thrust body 150, a plurality of articulating guide pins 24B 128, a plurality of mounting pins 152, and a plurality of insulating sleeves 154. The thrust body 150 has a plurality of articulating guide pin openings 155. The plurality of mounting pins 152 extend from guide pin openings 157 in the central housing 24 of the housing 12. The articulating guide pin 24B 128 is configured to limit articulation of the orbiting scroll 66 as the orbiting scroll 66 orbits about the central axis 90.

[0098] Each mounting pin 152 has a housing end 152A and a thrust body end 152B. The housing ends 152 are press-fit into respective guide pin openings 157 in the housing 12. The thrust body ends 152B are cylindrical with an outer surface. A plurality of insulating sleeves 154 are constructed from a flexible material, such as a chemically resistant synthetic rubber. One such material is ethylene propylene diene monomer (EPDM). The thrust body ends 152 of each mounting pin 152 are enclosed within respective sleeves 154 and received in respective slots 153 in the thrust body 150. In this manner, the only connection between the thrust body 150 and the housing 12 is through the mounting pins 152, which are insulated or isolated by the sleeves 154 to prevent or minimize the transmission of vibrations from the orbiting scroll 66 to the housing 12.

[0099] As shown in FIG. 20A, in one embodiment, insulating sleeve 154 is integrally formed with a circular gasket or ring 156 .

[0100] 20B, in another embodiment, the thrust body end 152B of each mounting pin 152 is completely encapsulated by a flexible material using, for example, an overmolding process. The outer surface of the insulating sleeve 154 may be ribbed to aid in insulation.

[0101] Electric compressor head design In a third aspect of the electric compressor 10 of the present disclosure, the design of the front cover 28 includes an oil separator 96 and a three-reed reed mechanism 86. As described below, the design of the front cover 28, the fixed scroll 26, and the reed mechanism 86 define a multi-cavity pulsation muffler system.

[0102] In prior art electric compressors, the refrigerant is discharged from the compressor once per revolution (or orbit) of the orbiting scroll. This generates primary pulsations in the compressed refrigerant discharged by the electric compressor. The relatively strong amplitude and low frequency of the pulsations generated in the refrigerant can excite other components (inside or outside the electric compressor), which can create undesirable noise, vibration, and harshness (NVH) and poor durability conditions.

[0103] 18C-18F and 19A-19B, the compressed refrigerant in the multi-cavity pulsation muffler system 160 is discharged twice from the compressor 18 during the compression cycle. As described in detail below, the compressor 18 includes two small secondary discharge ports disposed (adjacently) in two secondary discharge chambers, the secondary discharge chambers being downstream (in the discharge head) of the pressure drop from the central discharge port. As described further below, the front cover 28 defines parallel discharge paths for the refrigerant exiting the compressor 18 to the refrigerant outlet port 70.

[0104] In the illustrated embodiment, compressor 10 includes a housing 12, an inverter module 44, a motor 54, and a compression device 18. Housing 12 defines a suction volume 74 and a discharge volume 82. Housing 12 has a generally cylindrical shape and a central axis 90C. Inverter module 44 is mounted inside housing 12 and adapted to convert DC power to AC power. Motor 54 is mounted inside the housing.

[0105] Compressor 18 receives refrigerant from suction volume 74 and is coupled to motor 54 for compressing the refrigerant as motor 54 rotates.

[0106] Compression device 18 has a central compressor outlet orifice 84A and first and second lateral compressor outlet orifices 84B for controllably discharging compressed refrigerant to discharge volume 82 during a compression cycle. Compression device 18 is configured to discharge compressed refrigerant to discharge volume 82 through first and second lateral compressor outlet orifices 84B earlier during a compression cycle than refrigerant is discharged through central discharge orifice 84A.

[0107] Additionally, oil separator 96 utilizes two parallel passages between compressor 18 and refrigerant outlet port 70 to reduce the net pressure drop while maintaining this reduction in pulsation.

[0108] In the illustrated embodiment, the oil separator 96 is located within the discharge volume 82 and 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 refrigerant are mixed. The oil separator 96 is necessary to separate the mixed oil and refrigerant before the refrigerant exits the electric compressor 10.

[0109] Generally, refrigerant is discharged from the compression device 18 during each cycle, i.e., each rotation (or orbit), of the orbiting scroll 66. In the illustrated embodiment, the refrigerant exits the compression device 18 through a central orifice 84A and two side orifices 84B in the fixed scroll 26. The discharge of refrigerant through the orifices 84A, 84B is controlled by a central reed 87A and two side reeds 87B, respectively (see below).

[0110] In the illustrated embodiment, the oil separator 96 connects the discharge chambers with a relatively small channel (see below) to create a pressure drop between the chambers, thereby facilitating a smooth flow of compressed refrigerant from the electric compressor 10. Additionally, 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 reduced pulsation.

[0111] The oil separator 96 may include a series of partitions 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 87A and receives mixed pressurized refrigerant and oil from the compressor 18 through the central orifice 84 via the reed mechanism 87A. The side discharge chambers 82B are adjacent to their respective side reeds 87B and receive mixed pressurized refrigerant and oil from the compressor 18 through their respective reeds 87B via their respective side orifices 84B. Generally, the refrigerant pressures within the chambers are as follows: central discharge chamber 82A > side discharge chamber 82B > upper discharge chamber 82C.

[0112] The central discharge chamber 82A is in fluid communication with 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, as well as via upper and lower discharge channels 102 and 104, respectively. In one embodiment, the side channels 100 extend at an acute angle into the side discharge chambers 82B. The angle of the channels 100 further directs the refrigerant and oil discharge mixture, further improving separation and increasing the amount of oil separated by the oil separator 96. For example, in FIG. 19C, the side channels 100 extend downward through the side discharge chambers 82B at an angle of approximately 45 degrees relative to the inner wall of the central discharge chamber 82A. However, the angle may vary depending on the application or surface contour of the side discharge chamber 82C, and in some variations, may be increased to approximately 60 degrees. The angle may be varied but is designed to direct the flow to create turbulence, direct the flow impact, create a tortuous path within the side discharge chamber 82C, and increase oil separation into the lower discharge channel 104.

[0113] As shown, the oil separator 96 includes a central discharge chamber 82A and a lower baffle 132. In the illustrated embodiment, the lower baffle 132 is chevron-shaped (an inverted "v") and is positioned between the central chamber 82 and the oil reservoir 98. The shape of the lower baffle 132 creates a low-pressure area directly below it. The mixed oil and refrigerant enter the central discharge chamber 82A and are drawn downward by the low-pressure area. When the mixed oil and refrigerant contact the upper surface of the lower baffle 132, the oil and refrigerant separate. The oil falls into the oil reservoir 98.

[0114] The refrigerant may enter the side discharge chamber 82B via the side channel 100 and / or the lower discharge channel 104. The refrigerant may then enter the upper discharge chamber 82B and then exit via the refrigerant outlet port 70.

[0115] The oil reservoir 98 is located below the pair of side chambers and is connected to them via respective lower discharge channels 104. The oil reservoir is configured to receive oil that is separated from the refrigerant compressed in the side chambers. Gravity acts on the oil to assist the separation, and the oil falls through the lower discharge channel 104 located in the side discharge chamber 82B into the oil reservoir 98.

[0116] As mentioned above, the reed mechanism 86 includes a discharge reed 86A and a reed retainer 86B, which define reeds 87A and 87B. The discharge reed 86A is used to regulate the pressure at which refrigerant can exit the compressor 18 through the central orifice 84A and two side orifices 84B, respectively.

[0117] 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 are within the scope of the invention.

Claims

1. An electric scroll compressor configured to compress a refrigerant, a housing defining an intake volume and a discharge volume, the housing having a generally cylindrical shape and a central axis; a refrigerant inlet port coupled to the housing and configured to introduce the refrigerant into the suction volume; a refrigerant outlet port coupled to the housing and configured to allow compressed refrigerant to exit the motorized scroll compressor from the discharge volume; an inverter module mounted within the housing and adapted to convert DC power to AC power; a motor mounted inside the housing; a drive shaft coupled to the motor; a compression device coupled to the drive shaft, receiving the refrigerant from the suction volume and compressing the refrigerant as the drive shaft is rotated by the motor, the compression device comprising: a fixed scroll positioned within the housing and fixed relative to the housing; an orbiting scroll coupled to the drive shaft, the orbiting scroll and the fixed scroll defining a compression chamber that receives the refrigerant from the suction volume and compresses the refrigerant as the drive shaft rotates about the central axis, the orbiting scroll having a lower surface with a plurality of ring-shaped slots; a compression device including: a thrust body having a plurality of guide pin openings; a plurality of articulating guide pins extending from the articulating guide pin openings and into the ring-shaped slot toward the compression device, the guide pins configured to limit articulation of the orbiting scroll as the orbiting scroll orbits about the central axis; and a plurality of mounting pins, each having a housing end and a thrust body end, the housing end being press fit into a respective receiving opening in the housing, the thrust body end being a cylinder having an outer surface; a plurality of insulating sleeves constructed from a flexible material, the thrust body end of each mounting pin being enclosed within a respective sleeve and received within a respective slot in the thrust body; An electric scroll compressor comprising:

2. 2. The electric scroll compressor according to claim 1, wherein the insulating sleeve is integrally formed with a circular gasket.

3. 2. The motorized scroll compressor of claim 1, wherein said thrust body end of each mounting pin is completely encapsulated by said flexible material.

4. 2. The electric scroll compressor according to claim 1, wherein the outer surface of the insulating sleeve is ribbed.

5. 2. The electric scroll compressor according to claim 1, further comprising an inverter cover positioned at one end of the electric scroll compressor, the inverter cover having a first portion and a second portion, the first portion being substantially perpendicular to the central axis and having an apex and an outer periphery, the first portion having a relatively dome-shaped shape such that the inverter cover has a curved profile from the apex toward the outer periphery.

6. The compression device is a swing link mechanism coupled to the drive shaft; ball bearings disposed between the orbiting scroll and the swing link mechanism and adjacent to each of the orbiting scroll and the swing link mechanism, the drive shaft and drive pin, the orbiting scroll, and the swing link mechanism being disposed so as to orbit the orbiting scroll in an eccentric orbit relative to the central axis; and 2. The electric scroll compressor according to claim 1, comprising:

7. The motorized scroll compressor of claim 1 , including a plurality of ring inserts positioned within said plurality of ring slots.

8. the housing includes a first drive shaft support member and a second drive shaft support member; a first ball bearing positioned within the first drive shaft support member and configured to receive a first end of the drive shaft; a second ball bearing positioned within the second drive shaft support member and configured to receive a second end of the drive shaft; and The electric scroll compressor of claim 1 further comprising:

9. 2. The electric scroll compressor of claim 1, wherein the housing includes a front cover that defines the discharge volume, the electric scroll compressor utilizes oil to lubricate the motor, the drive shaft, and a portion of the compression device, and the electric scroll compressor further includes an oil separator for separating the mixed oil and refrigerant as the mixed oil and refrigerant exit the compression device and enter the discharge volume.

10. An electric scroll compressor having a central axis and configured to compress a refrigerant, a housing defining an intake volume and a discharge volume; a refrigerant inlet port coupled to the housing and configured to introduce the refrigerant into the suction volume; a refrigerant outlet port coupled to the housing and configured to allow compressed refrigerant to exit the motorized scroll compressor from the discharge volume; An inverter unit, An inverter housing; an inverter back cover connected to the inverter housing and forming an inverter cavity; an inverter module mounted within the inverter cavity and adapted to convert DC power to AC power; an inverter unit including: A motor unit, a drive shaft positioned within the housing, the drive shaft having first and second ends and defining a central axis; a motor positioned within the housing for controllably rotating the drive shaft about the central axis; a motor unit including: a compression device coupled to the drive shaft, receiving the refrigerant from the suction volume and compressing the refrigerant as the drive shaft is rotated by the motor, the compression device comprising: a fixed scroll positioned within the housing and fixed relative to the housing; an orbiting scroll coupled to the drive shaft, the orbiting scroll and the fixed scroll defining a compression chamber that receives the refrigerant from the suction volume and compresses the refrigerant as the drive shaft rotates about the central axis, the orbiting scroll having a lower surface, the lower surface having a plurality of ring shapes; a compression device including: a thrust body having a plurality of articulating guide pin openings; a plurality of articulating guide pins extending from the articulating guide pin openings and into the ring-shaped slot toward the compression device, the guide pins configured to limit articulation of the orbiting scroll as the orbiting scroll orbits about the central axis; and a plurality of mounting pins, each having a housing end and a thrust body end, the housing end being press fit into a respective receiving opening in the housing, the thrust body end being a cylinder having an outer surface; a plurality of insulating sleeves constructed from a flexible material, the thrust body end of each mounting pin being enclosed within a respective sleeve and received within a respective slot in the thrust body; An electric scroll compressor comprising:

11. The electric scroll compressor according to claim 10 , wherein the insulating sleeve is integrally formed with a circular gasket.

12. 11. The motorized scroll compressor of claim 10, wherein the thrust body end of each mounting pin is completely encapsulated by the flexible material.

13. 11. The electric scroll compressor according to claim 10, wherein the outer surface of each of said insulating sleeves is ribbed.

14. 11. The electric scroll compressor according to claim 10, further comprising an inverter cover positioned at one end of the electric scroll compressor and including an apex, an outer periphery, a first portion, and a second portion, wherein the first portion is perpendicular to the central axis and has the apex and the outer periphery, and the first portion is dome-shaped so that the inverter cover has a curved profile from the apex toward the outer periphery.

15. The compression device is a swing link mechanism coupled to the drive shaft; ball bearings disposed between the orbiting scroll and the swing link mechanism and adjacent to each of the orbiting scroll and the swing link mechanism, the drive shaft, drive pin, the orbiting scroll, and the swing link mechanism being disposed so as to orbit the orbiting scroll in an eccentric orbit relative to the central axis; and The electric scroll compressor according to claim 10, comprising:

16. The motorized scroll compressor of claim 10 including a plurality of ring inserts positioned within said ring slots.

17. the housing includes a first drive shaft support member and a second drive shaft support member; a first ball bearing positioned within the first drive shaft support member and configured to receive a first end of the drive shaft; a second ball bearing positioned within the second drive shaft support member and configured to receive a second end of the drive shaft; and The electric scroll compressor according to claim 10, further comprising:

18. 11. The electric scroll compressor of claim 10, wherein the housing includes a front cover that defines the discharge volume, the electric scroll compressor utilizes oil to lubricate the motor, the drive shaft, and a portion of the compression device, and the electric scroll compressor further includes an oil separator for separating the mixed oil and refrigerant as the mixed oil and refrigerant exit the compression device and enter the discharge volume.

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