Electric compressor with swing link and integral limit pin and swing link and integral limit pin for use in an electric compressor - Patents.com

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, such 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, a drive shaft, a concentric projection, a motor, a drive pin, a compression device, a swing link mechanism, and a ball bearing. 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 compressor from the discharge volume. The drive shaft is positioned within the housing and has first and second ends. The drive shaft defines a central axis and is centered.

[0008] A concentric protrusion is positioned at a second end of the drive shaft and is centered about the central axis. The concentric protrusion extends away from the drive shaft along the central axis. The concentric protrusion includes a drive pin opening. A motor is positioned within the housing and coupled to the drive shaft to controllably rotate the drive shaft about the central axis. The drive pin is positioned within the drive pin opening and extends away from the drive shaft. The drive pin is parallel to the concentric protrusion.

[0009] The compressor 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 an inner peripheral surface.

[0010] The swing link mechanism is coupled to the drive shaft and has first and second openings for receiving the concentric projection and the drive pin. The swing link mechanism further includes an outer periphery.

[0011] The ball bearings are disposed adjacent to the inner circumferential surface of the orbiting scroll and the outer circumferential surface of the swing link mechanism, and the drive shaft, drive pin, orbiting scroll, and swing link mechanism are arranged to rotate the orbiting scroll about the central axis in an eccentric orbit.

[0012] In a second 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 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 refrigerant outlet port is coupled to the housing and configured to allow compressed refrigerant to exit the electric scroll compressor from the discharge volume.

[0013] 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.

[0014] The motor section includes a motor housing, a drive shaft, a concentric protrusion, a motor, and a drive pin. The motor housing defines a motor cavity and is attached to the inverter housing. The drive shaft is positioned within the motor housing, has first and second ends, and defines a central axis. The concentric protrusion is positioned at the second end of the drive shaft, is centered on the central axis, and extends away from the concentric protrusion along the central axis. The concentric protrusion includes a drive pin opening. The motor is positioned within the motor housing to controllably rotate the drive shaft about the central axis. The drive pin is positioned within the drive pin opening and extends away from the drive shaft. The drive pin is parallel to the concentric protrusion.

[0015] The compression device includes a fixed scroll, an orbiting scroll, a swing link mechanism, and a ball bearing. The fixed scroll is positioned within and fixed relative to the housing. The orbiting scroll is coupled to a drive shaft. The orbiting scroll and the fixed scroll receive refrigerant from the suction volume and form a compression chamber for compressing the refrigerant when the drive shaft rotates about a central axis. The orbiting scroll has an inner peripheral surface. The swing link mechanism is coupled to the drive shaft and has first and second openings for receiving the concentric protrusion and the drive pin, and an outer peripheral surface. The ball bearings are disposed adjacent to and between the inner peripheral surface of the orbiting scroll and the outer peripheral surface of the swing link mechanism. The drive shaft, drive pin, orbiting scroll, and swing link mechanism are arranged to rotate the orbiting scroll about the central axis in an eccentric orbit.

[0016] The housing is formed by an inverter back cover, an inverter housing, a motor housing, a fixed scroll, and a front cover.

[0017] In a third embodiment of the present invention, an apparatus is provided for use in an electric scroll compressor configured to compress a refrigerant. The electric scroll compressor includes a housing, a motor, and a compression device. The housing defines a suction volume and a discharge volume. The motor is positioned within the housing. The compression device includes a fixed scroll and an orbiting scroll. The fixed scroll is positioned within the housing and is fixed relative to the housing. The orbiting scroll and the fixed scroll form a compression chamber that receives refrigerant from the suction volume and compresses the refrigerant as the drive shaft rotates about a central axis. The orbiting scroll has an inner circumferential surface.

[0018] The device includes a drive shaft, a concentric protrusion, a swing link mechanism, and a ball bearing. The drive shaft is positioned within the housing, has first and second ends, and defines a central axis. The drive shaft is coupled to a rotor of the motor and is centered on the central axis. The concentric protrusion is positioned at the second end of the drive shaft, is centered on the central axis, and extends away from the concentric protrusion along the central axis. The concentric protrusion includes a drive pin opening. The drive pin is positioned within the drive pin opening and extends away from the drive shaft. The drive pin is parallel to the concentric protrusion.

[0019] The swing link mechanism is coupled to the drive shaft and has first and second openings for receiving the concentric projection and the drive pin. The swing link mechanism includes an outer peripheral surface. The ball bearings are disposed adjacent to and between the inner peripheral surface of the orbiting scroll and the outer peripheral surface of the swing link mechanism. The drive shaft, drive pin, and swing link mechanism are disposed on the orbiting scroll to rotate the orbiting scroll in an eccentric orbit about the central axis.

[0020] 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]

[0021] [Figure 1] FIG. 1 is a first perspective view of an electric compressor according to an embodiment of the present invention. [Figure 2] FIG. 2 is a second perspective view of the electric compressor of FIG. 1. [Figure 3A] 2 is a first side view of the electric compressor of FIG. 1, showing an inverter back cover of the inverter unit. FIG. [Figure 3B] FIG. 3B is a perspective view of the inverter back cover of FIG. 3A. [Figure 3C] FIG. 10 is a first perspective view of an inverter back cover according to an alternative embodiment of the present invention. [Figure 3D] FIG. 3D is a second perspective view of the inverter back cover of FIG. 3C. [Figure 4] FIG. 2 is a second side view of the electric compressor of FIG. 1. [Figure 5] FIG. 2 is a front view of the electric compressor of FIG. [Figure 6] FIG. 2 is a rear view of the electric compressor of FIG. [Figure 7] FIG. 2 is a top view of the electric compressor of FIG. 1. [Figure 8] FIG. 2 is a bottom view of the electric compressor of FIG. 1. [Figure 9] FIG. 2 is a first cross-sectional view of the electric compressor of FIG. 1. [Figure 10] FIG. 2 is a second cross-sectional view of the electric compressor of FIG. 1. [Figure 11] FIG. 2 is an exploded view of the inverter of the electric compressor of FIG. [Figure 12] 2 is an exploded view of a portion of the electric compressor of FIG. 1, including the motor and drive shaft. [Figure 13] FIG. 2 is an exploded view of the compression device of the electric compressor of FIG. [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 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 20] FIG. 10 is a first perspective view of a front cover of an electric compressor forming an oil separator according to a second embodiment of the present invention;

[0022] MODE FOR CARRYING OUT THE INVENTION Referring to the drawings, wherein like reference numerals indicate like or corresponding parts throughout the several views, an electric compressor 10 is provided having an outer housing 12. The electric compressor 10 is particularly suited for an automotive vehicle, such as an automobile (not shown). The electric 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 electric 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 electric 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, e.g., during a charging cycle. The electric 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 electric compressor 10 has a displacement of 57 cubic centimeters (cc). Displacement refers to the initial volume captured within the compressor when the scrolls of the compressor initially close or contact (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.

[0023] In the illustrated embodiment, the electric compressor 10 is a scroll-type compressor that serves to quickly and efficiently compress refrigerants for use in various systems in an automotive vehicle, such as an electric or hybrid vehicle. The electric compressor 10 may use a mixture of refrigerant and oil, which may be simply referred to as "refrigerant," throughout its operation.

[0024] The electric compressor includes an inverter section 14, a motor section 16, and a compression device (or compression assembly) 18 housed within an outer housing 12. The outer housing 12 includes an inverter back cover 20, an inverter housing 22, a motor housing 24, a fixed scroll 26, and a front cover 28 (which may be referred to as a discharge head).

[0025] A first aspect of the electric compressor 10 of the present disclosure provides an electric compressor 10 having a swing link mechanism and a drive shaft with an integrated limiting pin. A second aspect of the electric compressor 10 of the present disclosure provides an electric compressor 10 having an oil separator. A third aspect of the electric compressor 10 of the present disclosure provides an electric compressor 10 having scroll bearing oil injection. A fourth aspect of the electric compressor 10 of the present disclosure provides an electric compressor 10 having a bearing oil communication hole. A fifth aspect of the present disclosure provides an electric compressor 10 having a dome-shaped inverter cover.

[0026] In one embodiment, inverter back cover 20, inverter housing 22, motor housing 24, fixed scroll 26, and front cover 28 are constructed from machined aluminum. Inverter 10 may be mounted within the body of a vehicle, for example, via multiple mounting points 120.

[0027] Overall configuration and operation of electric compressor 10 The inverter back cover 20 and the inverter housing 22 form an inverter cavity 30. The inverter back cover 20 is attached to the inverter housing 22 by a plurality of bolts 32. The inverter back cover 20 and the inverter housing 22 are attached to the motor housing 24 by a plurality of bolts 34 that extend through openings 36 in the inverter back cover 20 and openings 38 in the inverter housing 22 and thread into threaded openings 40 in the motor housing 24. An inverter gasket 42, disposed between the inverter back cover 20 and the inverter housing 22, keeps moisture, dust, and other contaminants from the interior cavity 30. A motor gasket 54A, disposed between the inverter housing 22 and the motor housing 24, keeps moisture, dust, and other contaminants from the interior of the motor housing 24.

[0028] 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.

[0029] The motor section 16 includes a motor 54 positioned within a 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 motor 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.

[0030] 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.

[0031] The motor 54 is powered through a set of terminals 54A that are sealed from the motor cavity 56 by an O-ring 54B.

[0032] 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 motor 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 motor housing 24, respectively.

[0033] 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 64 is fixed to a second end of the rotor 60B. The rotor 60B and the orbiting scroll 64 rotate under the control of the inverter module 44.

[0034] 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 rotates 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 positioned along an offset axis 90D of the drive shaft 90, which is defined by an orbiting scroll opening 90E (see FIG. 14A) located at a second end 90D of the drive shaft 90. When the drive shaft 90 is rotated by the motor 54, the center of the orbiting scroll 66 follows the movement of the orbiting scroll opening 90E as it rotates about the central axis 90C.

[0035] With particular reference to FIGS. 1, 2, and 9, which will be used below, 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 to the refrigerant inlet port 68 and the motor 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).

[0036] 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.

[0037] 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.

[0038] 17A-17I, mixed refrigerant enters compression device 12 through compression suction volume 76. In FIGS. 17A-17I, cross-sectional views of the top of fixed scroll 16 and orbiting scroll 66 are shown.

[0039] As will be explained in detail below, the fixed scroll wrap 16A and the orbiting scroll wrap 66A form compression chambers 80 into which low, or unpressurized, refrigerant enters from the compressor 12. As the orbiting scroll 66 rotates, these compression chambers 80 are closed and the volume of the compression chambers 80 decreases, 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 discussion relates to only one set of compression chambers 80 during a complete cycle of the electric compressor 10.

[0040] 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 rotating 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.

[0041] 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 66BA, 16. 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 rotates or moves along passage 78, the space between the tail end 16A, 66A and the other scroll 66, 16 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 rotate along passage 78, the volume of the compression chamber 80 further decreases, thus pressurizing the refrigerant in both compression chambers 80 (FIGS. 17F-17H). As the orbiting scroll 66 continues to rotate, 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).

[0042] 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 rotating 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.

[0043] 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 more detail below, the pressurized refrigerant exits the compression device 18 through an orifice 84 in the fixed scroll 26 (see FIGS. 18C and 18E). The release of the pressurized refrigerant is controlled by a reed mechanism 86. In the illustrated embodiment, a single reed mechanism 86 is used. However, it should be noted that two or more reed mechanisms may be used.

[0044] 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 from a flexible material, such as steel. The material and properties, such as strength, are selected to control the pressure at which the pressurized refrigerant is released from the compression device 18. The reed holddown 86B is made from a rigid, non-flexible material, such as stamped steel. The reed holddown 86B controls or limits the maximum displacement of the discharge reed 86A relative to the fixed scroll 26.

[0045] In the illustrated embodiment, the lead mechanism 86 is held or secured in place without separate fasteners. As shown in FIGS. 18E and 18F , the lead mechanism 86 includes a pair of openings 86C configured to receive associated posts 84A on the fixed scroll 26. When the electric compressor 10 is assembled, the lead mechanism 86 is held in place adjacent to and by the front cover 28. As shown in FIG. 18E , the back surface of the fixed scroll 26 includes a bezel 84B that surrounds the orifice 84 to help regulate the pressure at which the refrigerant exits the compressor 18. Additionally, the debris collection slot 84B collects debris near the orifice 84 to prevent interference with the lead mechanism 86.

[0046] As shown in FIG. 9, the path of the refrigerant through the electric compressor is indicated by dashed arrows 72 .

[0047] 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.

[0048] 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.

[0049] 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.

[0050] As mentioned above, refrigerant, which is actually a mixture of refrigerant and oil, enters electric compressor 10 through refrigerant inlet port 68. The oil and refrigerant mixture is drawn into motor section 16, thereby providing lubrication and cooling to rotating components of electric compressor 10, such as rotor 60, drive shaft 90, etc. Inside motor 54, the rotational forces within motor section 16 cause the oil and refrigerant to enter second ball bearing 64 and lubricate the oil. The oil may impinge on motor side 22A of inverter housing 22. The refrigerant and oil are further directed by motor side 22A to ball bearing 62, which will be further described below.

[0051] In the illustrated embodiment, front cover 28 and fixed scroll 26 are attached to motor housing 24 by a plurality of bolts 122 that are inserted into respective openings and threaded into openings in motor housing 24. Stationary head gasket 110 and rear head gasket 112 are positioned between motor housing 24 and fixed scroll 26 to provide sealing.

[0052] 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 90F. In one embodiment, the concentric protrusion 90F is integrally formed with the drive shaft 90. As described below, the swing link mechanism 124 is used to rotate the orbiting scroll 66 about the drive shaft 90 in an eccentric orbit.

[0053] 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.

[0054] As will be explained in detail below, the eccentric pin of the prior art is replaced with a concentric protrusion 90F.

[0055] 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.

[0056] A concentric projection 90F is positioned on the second end 90B of the drive shaft 90 and is centered about a central axis 90C. The concentric projection 90F extends away from the drive shaft 90 along the central axis 90C. The concentric projection 90F includes a drive pin opening 90E. 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 centered about an offset axis 90D. The offset axis is parallel to the central axis 90C.

[0057] The concentric projections 90F may further include undercuts 90G, and the outer surface may be surface hardened or treated with a coating or bearing surface. The concentric projections 90F may be further machined simultaneously with the drive shaft 90.

[0058] 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.

[0059] 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.

[0060] 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.

[0061] 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.

[0062] 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 a guide pin 128 and slot 66G on the lower surface 66F of the orbiting scroll 66, as will be further described below.

[0063] 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 motor housing 24.

[0064] With particular reference to 13, 16B, and 18A-18F in the illustrated embodiment, the orbiting scroll 66 has a lower surface 66F. The lower surface 66F has a plurality of ring-shaped slots 66G. The motor housing 24 includes a plurality of articulating guide pin openings 128. The guide pins 128 are positioned within the guide pin openings 66G and extend into the ring-shaped slots 66G toward the compressor 18. The guide pins 128 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. A thrust plate 130 is positioned between the motor housing 24 and the fixed scroll 26 to provide a wear surface therebetween.

[0065] Discharge head design with oil separator In a second embodiment of the electric compressor 10 of the present disclosure, the electric compressor 10 includes an oil separator 96 positioned in the discharge volume 82, which may be integrally formed with the discharge head or front cover 28. As mentioned above, oil is used to provide lubrication between the moving components of the electric compressor 10. During operation, the oil and refrigerant are mixed. The oil separator 96 is necessary to separate a portion of the oil from the oil-refrigerant mixture before the refrigerant exits the electric compressor 10.

[0066] Generally, refrigerant is discharged from the compression device 18 once per revolution (or orbit) of the orbiting scroll 66. This generates primary pulsations in the compressed refrigerant discharged by the electric compressor 10. The relatively strong amplitude and low frequency of the pulsations generated in the refrigerant may excite other components (internal or external to the electric compressor 10), which may create undesirable noise, vibration, and harshness (NVH) and poor durability conditions. A second embodiment oil separator 96 (described below) connects the discharge chambers (see below) through a relatively small channel, creating a pressure drop between the chambers. This allows for 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.

[0067] 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 86 and receives mixed pressurized refrigerant and oil from the compressor 18 through the reed mechanism 86 and through the slots 84. The central discharge chamber 82A is in fluid communication with the two side discharge chambers 82B via respective side channels 100, which are in fluid communication with the upper discharge chamber 82C and the oil reservoir 98, and via upper discharge channel 102 and lower discharge channel 104, respectively.

[0068] In the illustrated embodiment, the oil separator 96 is formed within the discharge chamber 82 of the housing 12 between the compressor 18 and the refrigerant outlet port 70. As shown, the oil separator 96 includes a central discharge chamber 82A, a pair of side discharge chambers 82B, an oil reservoir 98, and an upper discharge chamber 82C. The central discharge chamber 82A is formed adjacent the compressor outlet port or slot 84 to receive the mixed oil and compressed refrigerant. The pair of side discharge chambers 82B are positioned on either side of the central discharge chamber 82A and are connected to the central discharge chamber 82A via respective side discharge channels 100.

[0069] The side chambers 82B are configured to separate the mixed oil and compressed refrigerant. Generally, the mixed oil and compressed refrigerant exit the central discharge chamber 82 at high velocity through the side channels 100. Separation of the oil and compressed refrigerant occurs as the mixed oil and compressed refrigerant impinge on the interior and exterior walls of the respective side chambers 82B.

[0070] 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.

[0071] The upper discharge chamber 82C is formed above the pair of side chambers 82B and is connected to them via respective upper discharge channels 102. After the refrigerant is separated from the oil, it is positioned at the top of the side discharge chambers 82 and rises through the upper discharge channels 102, entering the upper discharge chamber 82 before passing through the refrigerant outlet port 70.

[0072] As shown, each side discharge channel 100 is configured to direct the mixed oil and compressed refrigerant toward the opposite interior wall of the respective side channel 82B, e.g., the side discharge channels are generally at a 90 degree angle from the opposite wall of the side discharge chamber 82B.

[0073] In an alternative embodiment, as shown in FIG. 20 , each side discharge chamber 82B may include a side baffle 132 positioned within the interior portion of the respective side chamber 82B. The side discharge channels 100 are configured to direct the mixed oil and compressed refrigerant toward the respective side baffle. The side baffle 132 creates a low-pressure region within the side discharge chamber 82B on the back side opposite the discharge channel 100, which aids in the separation of the oil and refrigerant. The low-pressure region may further assist gravity and reduce the upward transport of oil toward the upper discharge channel 102. The side discharge channel 100 may incorporate a downward angle, which may further assist gravity with the oil, by directing the discharge of the mixture toward a lower region of the side discharge chamber 82B adjacent to the lower discharge channel 104, further increasing the distance the oil falls from the compressed mixture and forming a long, tortuous path that separates the oil downward and away from the high-velocity compressed refrigerant entering the upper discharge channel 102. Additionally, the side baffles 132 may be positioned to create a perpendicular impingement surface to the angled discharge flow path of the oil and refrigerant exiting the side discharge channel 100. The perpendicular impingement surface on the side baffles 132 creates additional turbulence in the discharge mixture, and the low pressure area behind the side baffles 132 may further increase the gravitational effect on the heavier oil, causing it to separate and channel into the lower discharge channel 104.

[0074] 20, the oil reservoir 98 may include an oil reservoir baffle 134 positioned below each lower discharge channel 104. The oil reservoir baffle 134 helps prevent oil in the oil reservoir 98 from being drawn back from the oil reservoir into the side discharge chamber 82B. The side baffles 132 and the oil reservoir baffle 134 may be used in combination or separately to reduce the upward movement of oil along the walls of the side discharge chamber 82B, creating a low-pressure side, thereby further reducing a throttling or Venturi effect that may be created due to the high velocity flow of refrigerant exiting through the upper discharge channel 102.

[0075] Scroll bearing oil orifice In a third aspect of the electric compressor 10 of the present disclosure, an electric compressor 10 having scroll bearing oil injection orifices is provided. As described above, the compression device 18 of the present disclosure includes a ball bearing 108. In the illustrated embodiment, the ball bearing 108 is 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 limited, reducing its durability.

[0076] 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 link mechanism 124 , a ball bearing 108 , and a pin 136 .

[0077] 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.

[0078] 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.

[0079] 16C, the tip of the orbiting scroll 66 includes a plug 136 with 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.

[0080] 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.

[0081] 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.

[0082] 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.

[0083] As shown in FIG. 9, oil orifice 138 allows oil (and refrigerant) to travel from discharge chamber 82 along bath 73 (sometimes referred to as the "nosebleed" passage) to ball bearing 108.

[0084] Bearing oil communication hole

[0085] In a fourth aspect of the present disclosure, an electric compressor 10 having a bearing oil communication hole is provided. As described above, in the illustrated embodiment, the drive shaft 90 is rotated by the motor 54 to controllably operate the compression device 18. The drive shaft 90 has a first end 90A and a second end 90B. The housing 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 motor housing 24. First and second ball bearings 62, 64 are positioned within the first and second drive shaft support members 22B, 24A.

[0086] 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.

[0087] As shown in FIG. 16F, the first drive support member 22B may include one or more holes 22C to allow oil and refrigerant to enter the first drive support member 22B and lubricate the first ball bearing 62.

[0088] 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.

[0089] 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 an oil communication hole 22C that allows oil to enter the first ball bearing 62.

[0090] 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 mentioned 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. Rotational motion within the motor section 16 of the compression device 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 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. Inverter housing 22 further defines an oil cavity 22E in which oil collected between ribs 22D is directed downwardly by gravity into oil cavity 22E.The rib 22D and the sloped surface of the motor side 22A cooperate to capture and direct oil splashed or propelled against the motor side 22A by the rotor 60 or drive shaft 90, helping to increase oil flow to the oil cavity 22E and the first bearing 62. While FIG. 16F shows only one oil communication hole 22C, it is understood that additional oil communication holes 22C may be included above and between the ribs 22D on the motor side 22A of the inverter housing 22. For example, in the illustrated embodiment, the communication hole 22C is 3.5 mm in diameter, and the motor side 22A includes sloped walls between the ribs 22D. Additionally, the motor side 22A may include an outer oil collection area or recess 22F surrounding the communication hole 22C.

[0091] Dome-shaped inverter cover In a fifth aspect of the electric compressor 10 of the present disclosure, the scroll-type electric compressor 10 is configured to compress a refrigerant. The scroll-type electric compressor 10 includes a housing 12, a refrigerant inlet port 68, a refrigerant outlet port 70, an inverter module 44, a motor 54, a drive shaft 90, a compression device 18, and an inverter cover 20. The housing 12 defines 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 scroll-type electric compressor 10 from the discharge volume 82.

[0092] 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.

[0093] 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.

[0094] As shown in FIGS. 3A-3D, 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 to disperse rather than focus vibrations from the compressor 18.

[0095] As shown in each figure, particularly FIGS. 1, 3A-3B, and 6, the inverter cover 20 is positioned at one end of the scroll-type electric compressor 10 and includes a first portion 20A and a second portion 20B. The first portion 20A includes an apex or apex portion 20C, is 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 scroll-type electric 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.

[0096] 3B, the back side of the inverter cover 20 may include a plurality of radial ribs 20E extending outward from a central circular rib 20F to provide rigidity and support to the curved first portion 20A of the inverter back cover 20. As shown, the radial ribs 20E are not evenly spaced around the central circular rib 20F. The inverter back cover 20 may also include additional ribs 20G to add additional strength.

[0097] 3C and 3D, an alternative embodiment is shown for the inverter cover 20. In some applications, the inverter cover 20, and in particular the first portion 20A, may need to be modified to take into account external constraints, such as packaging or size constraints. In the illustrated embodiment, the illustrated embodiment includes a channel 20H through the first portion 20A that is necessary to accommodate external support structures.

[0098] 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. A scroll-type electric compressor 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 electric scroll compressor from the discharge volume; a drive shaft positioned within the housing, the drive shaft having first and second ends and defining a central axis, the drive shaft being centered about the central axis; a concentric protrusion located at the second end of the drive shaft, centered on the central axis and extending away from the drive shaft along the central axis, the second end of the drive shaft including a drive pin opening having an offset axis, the offset axis being parallel to the central axis; and a motor positioned within the housing and coupled to the drive shaft to controllably rotate the drive shaft about the central axis; a drive pin positioned within the drive pin opening and extending away from the drive shaft, the drive pin being centered about the offset axis; and a compression device including 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 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 an inner circumferential surface; a swing link mechanism coupled to the drive shaft, the swing link mechanism having first and second openings for receiving the concentric projection and the drive pin, and an outer circumferential surface; a ball bearing disposed between the inner peripheral surface of the orbiting scroll and the outer peripheral surface of the swing link mechanism, and adjacent to each of the inner peripheral surface of the orbiting scroll and the outer peripheral surface of the swing link mechanism, wherein the drive shaft, drive pin, orbiting scroll, and swing link mechanism are disposed so as to rotate the orbiting scroll in an eccentric orbit about the central axis; and A scroll-type electric compressor comprising:

2. 2. The electric scroll compressor according to claim 1, wherein the concentric projection is integrally formed with the drive shaft.

3. 2. The electric scroll compressor according to claim 1, wherein the housing includes a motor section and a compression section, the motor section having a motor housing defining a motor cavity for accommodating the motor, and the compression section includes the fixed scroll, the fixed scroll forming a part of the housing.

4. 4. The electric scroll compressor of claim 3, wherein the fixed scroll is attached to the motor housing, the orbiting scroll has a lower surface, the lower surface having a plurality of ring-shaped slots, the motor housing including a plurality of articulating guide pin openings, the motor housing further including a plurality of guide pins positioned in the guide pin openings and extending into the ring-shaped slots toward the compression section, the guide pins configured to limit articulation of the orbiting scroll as it orbits about the central axis.

5. 5. The electric scroll compressor of claim 4, including a plurality of ring inserts positioned within said ring slots.

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

7. 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 components of a 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.

8. 2. The electric scroll compressor according to claim 1, further comprising an inverter unit having an inverter circuit for converting DC power into AC power.

9. 9. The electric scroll compressor according to claim 8, further comprising: an inverter housing; and an inverter back cover, wherein the inverter housing and the housing back cover form a part of the housing and define an inverter cavity, and the inverter circuit is mounted within the inverter cavity.

10. A scroll-type electric compressor 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 electric 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 motor housing defining a motor cavity and attached to the inverter housing; a drive shaft positioned within the motor housing, the drive shaft having first and second ends and defining a central axis; a concentric protrusion located at the second end, centered on the central axis and extending away from the concentric protrusion along the central axis, the second end of the drive shaft including a drive pin opening having an offset axis, the offset axis being parallel to the central axis; and a motor positioned within the motor housing to controllably rotate the drive shaft about the central axis; a drive pin positioned within the drive pin opening and extending away from the drive shaft, the drive pin being centered on the offset axis; a motor unit including: A compression device, 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 an inner circumferential surface; a swing link mechanism coupled to the drive shaft, the swing link mechanism having first and second openings for receiving the concentric projection and the drive pin, and an outer circumferential surface; a ball bearing disposed between the inner peripheral surface of the orbiting scroll and the outer peripheral surface of the swing link mechanism, and adjacent to each of the inner peripheral surface of the orbiting scroll and the outer peripheral surface of the swing link mechanism, wherein the drive shaft, drive pin, orbiting scroll, and swing link mechanism are disposed so as to orbit the orbiting scroll in an eccentric orbit about the central axis; and a compression device including: a front cover, wherein the housing is formed by the inverter back cover, the inverter housing, the motor housing, the fixed scroll, and the front cover; A scroll-type electric compressor comprising:

11. 11. The electric scroll compressor according to claim 10, wherein the concentric projection is integrally formed with the drive shaft.

12. 12. The electric scroll compressor of claim 11, wherein the fixed scroll is attached to the motor housing, the orbiting scroll has a lower surface, the lower surface having a plurality of ring-shaped slots, the motor housing including a plurality of articulating guide pin openings, and further including a plurality of guide pins positioned in the articulating guide pin openings and extending into the ring-shaped slots toward the compression section, the plurality of guide pins being configured to limit articulation of the orbiting scroll as it orbits about the central axis.

13. The electric scroll compressor of claim 12 including a plurality of ring inserts positioned within said ring slots.

14. 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 the first end of the drive shaft; a second ball bearing positioned within the second drive shaft support member and configured to receive the delivery end of the drive shaft; and The electric scroll compressor according to claim 12, further comprising:

15. 11. The electric scroll compressor of claim 10, wherein the front cover defines the discharge volume, the electric scroll compressor utilizing oil to lubricate the motor, drive shaft, and compression device components, and the electric scroll compressor further including 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.

16. 1. An apparatus for use in an electric scroll compressor configured to compress a refrigerant, the electric scroll compressor including: a housing defining a suction volume and a discharge volume; a motor; and a compression device, the motor being positioned within the housing; the compression device being positioned within the housing and including a fixed scroll and an orbiting scroll fixed relative to the housing; 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 an inner circumferential surface; and a drive shaft positioned within the housing, the drive shaft having first and second ends and defining a central axis, the drive shaft coupled to a rotor of the motor, the drive shaft centered about the central axis; a concentric protrusion located on the second end of the drive shaft, the concentric protrusion being centered on the central axis and extending away from the concentric protrusion along the central axis, the second end of the drive shaft including a drive pin opening having an offset axis, the offset axis being parallel to the central axis; a drive pin positioned within the drive pin opening and extending away from the drive shaft, the drive pin being centered about the offset axis; and a swing link mechanism coupled to the drive shaft, the swing link mechanism having first and second openings for receiving the concentric projection and the drive pin, and an outer circumferential surface; a ball bearing disposed between the inner peripheral surface of the orbiting scroll and the outer peripheral surface of the swing link mechanism, and adjacent to each of the inner peripheral surface of the orbiting scroll and the outer peripheral surface of the swing link mechanism, wherein the drive shaft, drive pin, and swing link mechanism are disposed on the orbiting scroll so as to orbit the orbiting scroll in an eccentric orbit about the central axis; and An apparatus comprising:

17. 17. The electric scroll compressor according to claim 16, wherein the concentric projection is integrally formed with the drive shaft.

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