Magnetic debris filters for compressors and compressors with magnetic debris filters

Abstract

To provide an electric compressor with high efficiency, low noise, and maximum operating life. [Solution] The electric compressor includes a housing and a compression device. The housing defines the intake volume and the discharge volume. The compression device is a rotary compressor configured to compress a refrigerant. The compression device includes a piston device including a cylinder and a rolling piston. The cylinder is eccentrically coupled to the drive shaft. The rolling piston has an outer surface that contacts the inner surface of the compression chamber. The rolling piston rotates around the cylinder when the drive shaft and the piston device are rotated by a motor. A vane, which is movably coupled to the housing and has an end adjacent to the compression chamber, is biased so that the end of the vane contacts the rolling piston when the piston device is rotated by the drive shaft.

Description

Technical Field

[0001] The present invention generally relates to an electric compressor, and more particularly to an electric compressor having a magnetic debris filter.

[0002] Background Art Compressors have been used for a long time in cooling systems. Rotary compressors typically use a rotating drive shaft and a compression device connected to the drive shaft, and the compression device rotates with the drive shaft to compress the refrigerant. For example, particularly in a system designed to perform cooling in a specific area, a scroll compressor in which a swash scroll rotates in a circular motion with respect to a fixed scroll is used to compress the refrigerant. For example, such a scroll compressor has been used for a long time in the HVAC system of automotive vehicles such as automobiles for air conditioning. Such a compressor may also be used reversely in applications that require a heat pump. Generally, these compressors are driven using the rotational motion obtained from an automotive engine. Other types of rotary compressors such as reciprocating compressors are also used.

[0003] With the emergence of battery-driven vehicles or electric vehicles, and / or hybrid vehicles that may sometimes be powered solely by a battery, 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 an automated vehicle, electric compressors may be used to heat or cool other areas or components of the automated vehicle. For example, when the battery is being charged, especially during fast charging mode, heat is generated that can damage or degrade the battery and / or other systems, so it may be desirable to heat or cool the electronic systems and the battery or battery compartment. Electric compressors may also be used to cool the battery when it is not being charged or used, as heat can damage or degrade the battery. Since electric compressors may be operated at various times even when the automated vehicle is not in operation, such use requires electrical energy from the battery, and therefore shortens the battery's operating time.

[0005] Rotary-driven compressors must be balanced to reduce noise and vibration and maximize compressor efficiency and operating life.

[0006] Therefore, it is desirable to provide an electric compressor that is highly efficient, low-noise, and has a maximum operating life. The present invention aims to address one or more of the problems or advantages previously identified.

[0007] Summary of the Invention In one aspect of the present invention, a compressor has a compression device for compressing a refrigerant. The compressor operates via the rotation of the compression device within a compression chamber. The compression device includes a piston device having a cylinder and a rolling piston configured to rotate on the cylinder. The rolling piston is in contact with the inner surface of the compression chamber and, together with vanes, forms a sub-chamber in which the refrigerant is compressed as the piston device rotates within the compression chamber.

[0008] In a first embodiment of the present invention, a magnetic debris filter is provided for use with an electric compressor. The electric compressor is configured to compress a refrigerant and includes a housing, a refrigerant inlet port, a refrigerant outlet port, and a compressor. The housing defines an intake volume and has a central axis. The electric compressor includes a compression chamber. The compressor is located within the compression chamber. The refrigerant inlet port is coupled to the housing and configured to introduce refrigerant into the intake volume. The refrigerant outlet port is coupled to the housing and configured to allow compressed refrigerant to exit the electric compressor. The housing, compressor, and compression chamber define a refrigerant flow path between the refrigerant inlet port and the refrigerant outlet port. The housing has a filter mounting opening located after the compressor in the refrigerant flow path. The magnetic debris filter comprises a filter frame and a magnetic element. The filter frame is located within the filter mounting opening and has a magnetic opening. The magnetic element has magnetic properties and is configured to collect debris from the electric compressor and is located within the magnetic opening.

[0009] Optionally, the magnetic element is a magnet, or includes one or more magnets embedded in the substrate.

[0010] The magnetic element may be press-fitted into the magnet opening.

[0011] Optionally, the housing includes a cylinder housing, and a filter mounting opening is located within the cylinder housing.

[0012] The filter frame may be made of aluminum and may include at least one refrigerant opening.

[0013] A second embodiment of the present invention provides an electric compressor configured to compress a refrigerant. The electric compressor includes a housing, a refrigerant inlet port, a refrigerant outlet port, a compressor, and a magnetic debris filter. The housing defines an intake volume and a discharge volume and has a central axis. The housing further defines a compression chamber. The refrigerant inlet port is coupled to the housing and configured to introduce refrigerant into the intake volume. The refrigerant outlet port is coupled to the housing and configured to allow compressed refrigerant to exit the electric compressor from the discharge volume. The compressor is located within the compression chamber and coupled to a drive shaft. The compressor is configured to receive refrigerant from the intake volume and compress the refrigerant when the drive shaft is rotated. The housing, compressor, and compression chamber define a refrigerant flow path between the refrigerant inlet port and the refrigerant outlet port. The housing defines a filter mounting opening located after the compressor in the refrigerant flow path. The magnetic debris filter comprises a filter frame and a magnetic element. The filter frame is located within the filter mounting opening and has a magnetic opening. The magnetic element has magnetic properties and is configured to collect debris from the electric compressor, and is located within the magnetic opening.

[0014] Optionally, the magnetic element is a magnet or includes one or more magnets embedded in the substrate. The magnetic element may be press-fitted into the magnet opening.

[0015] Optionally, the housing may include a cylinder housing, and a filter mounting opening is located within the cylinder housing.

[0016] Optionally, the compressor may include a piston mechanism and vanes. The piston mechanism may include a cylinder and a rolling piston. The cylinder may be eccentrically coupled to the drive shaft. The cylinder may have a circular outer circumference, and the rolling piston may be tubular and concentric with the cylinder. The rolling piston may have an outer surface that contacts the inner surface of the compression chamber. The rolling piston may rotate around the cylinder when the drive shaft and piston mechanism are rotated by a motor. The vanes may be movably coupled to the housing and have ends adjacent to the compression chamber. The vanes may be biased so that the ends of the vanes contact the rolling piston when the piston mechanism is rotated by the drive shaft. The housing, piston mechanism, and vanes may form a variable subchamber within the compression chamber when the piston mechanism is rotated within the compression chamber. The refrigerant may enter one of the variable subchambers from the intake volume, be compressed as the piston mechanism rotates, and exit one of the subchambers into the discharge volume. The filter frame may include at least one refrigerant opening.

[0017] A third embodiment of the present invention provides an electric compressor configured to compress a refrigerant. The electric compressor includes a housing, a refrigerant inlet port, a refrigerant outlet port, a motor, a drive shaft, and a magnetic debris filter. The housing has a central axis defining an intake volume and a discharge volume. The housing further defines a compression chamber and includes a cylinder housing. The compression chamber is formed by the cylinder housing and has an open end adjacent to a first side of the cylinder housing. The compressed refrigerant exits the compression chamber through an orifice and enters the discharge chamber. The refrigerant inlet port is coupled to the housing and configured to introduce the refrigerant into the intake volume. The refrigerant outlet port is coupled to the housing and configured to allow the compressed refrigerant to exit the electric compressor from the discharge volume through an orifice. The motor is mounted inside the housing. The drive shaft is coupled to the motor and configured to rotate about a central axis. A compressor is located in the compression chamber and coupled to the drive shaft. The compressor receives the refrigerant from the intake volume and is configured to compress the refrigerant when the drive shaft is rotated by the motor. The housing, compressor, and compression chamber define a refrigerant flow path between the refrigerant inlet port and the refrigerant outlet port. The housing defines a filter mounting opening located after the compressor in the refrigerant flow path. The magnetic debris filter comprises a filter frame and a magnetic element. The filter frame is located within the filter mounting opening and has a magnetic opening. The magnetic element has magnetic properties and is configured to collect debris from the electric compressor and is located within the magnetic opening.

[0018] Optionally, the magnetic element is a magnet, or includes one or more magnets embedded in the substrate.

[0019] The magnetic element may be press-fitted into the magnet opening.

[0020] Optionally, the housing includes a cylinder housing, and a filter mounting opening is located within the cylinder housing. The filter frame may be made of aluminum.

[0021] Optionally, the compressor may include a piston mechanism and vanes. The piston mechanism may include a cylinder and a rolling piston. The cylinder may be eccentrically coupled to the drive shaft. The cylinder may have a circular outer circumference, and the rolling piston may be tubular and concentric with the cylinder. The rolling piston may have an outer surface that contacts the inner surface of the compression chamber. The rolling piston may rotate around the cylinder when the drive shaft and piston mechanism are rotated by a motor. The vanes may be movably coupled to the housing and have ends adjacent to the compression chamber. The vanes may be biased so that the ends of the vanes contact the rolling piston when the piston mechanism is rotated by the drive shaft. The housing, piston mechanism, and vanes may form a variable subchamber within the compression chamber when the piston mechanism is rotated within the compression chamber. The refrigerant may enter one of the variable subchambers from the intake volume, be compressed as the piston mechanism rotates, and exit one of the subchambers into the discharge volume. The filter frame may include at least one refrigerant opening.

[0022] Optionally, the housing may include a central housing and a rear head. The discharge volume may be at least partially formed by the central housing, the rear head, and the refrigerant outlet port.

[0023] Optionally, the housing includes an inverter cover. The central housing and the inverter cover may form an inverter cavity, and the electric compressor may further include an inverter module configured to convert DC power into AC power and mounted inside the inverter cavity. The cylinder may have an internal chamber, and the cylinder may have a center of mass of the rotating mass around the central axis. Optionally, the housing may include a vane slot, and the vane may be slidably positioned within the vane slot.

[0024] The vane slot may be connected to the discharge volume such that the vane is urged toward the piston device by the refrigerant within the discharge volume. The housing may include a cylinder housing, in which case the vane slot is disposed within the cylinder housing. The filter frame may include at least one refrigerant opening.

[0025] These and other features and advantages of the present invention will become more readily understood by consideration of the following detailed description in conjunction with the accompanying drawings.

Brief Description of the Drawings

[0026] [Figure 1A] It is a cross-sectional view of a compressor according to an embodiment of the present invention. [Figure 1B] It is a second cross-sectional view of the electric compressor of FIG. 1A. [Figure 2A] It is a cross-sectional view of the compression device of the electric compressor of FIG. 1A according to an embodiment of the present invention. [Figure 2B] It is a perspective view of the compression device of FIG. 2A. [Figure 2C] It is an exploded perspective view of a part of the compression device of FIG. 2A. [Figure 2D] It is a perspective view of a part of the compression device of FIG. 2C. [Figure 2E] It is a partial cross-sectional view of a part of the compression device of FIG. 2A. [Figure 2F] It is a perspective view of the vane and spring of the compression device of FIG. 2A according to an embodiment of the present invention. [Figure 3A] This is a cross-sectional view of the compressor shown in Figure 2A during the compression cycle. [Figure 3B] This is a cross-sectional view of the compressor shown in Figure 2A during the compression cycle. [Figure 3C] This is a cross-sectional view of the compressor shown in Figure 2A during the compression cycle. [Figure 3D] This is a cross-sectional view of the compressor shown in Figure 2A during the compression cycle. [Figure 3E] This is a cross-sectional view of the compressor shown in Figure 2A during the compression cycle. [Figure 3F] This is a cross-sectional view of the compressor shown in Figure 2A during the compression cycle. [Figure 3G] This is a cross-sectional view of the compressor shown in Figure 2A during the compression cycle. [Figure 4] This is an illustration of the piston device of the compressor shown in Figure 2A, according to one embodiment of the present invention. [Figure 5A] This is a side view of the drive shaft and piston device of an electric compressor according to one embodiment of the present invention. [Figure 5B] Figure 5A is a cross-sectional view of the drive shaft and piston device. [Figure 6A] This is a front view of a compression device having an integrated discharge chamber according to one embodiment of the present invention. [Figure 6B] This is a side view of the compressor and drive shaft shown in Figure 6A, according to one embodiment of the present invention. [Figure 6C] Figure 6A is a rear view of the compression device. [Figure 7A] Figure 6A is a perspective view of the compression device. [Figure 7B] This is a first perspective view of the cylinder housing of the compressor shown in Figure 6A, according to one embodiment of the present invention. [Figure 7C] Figure 7B is a second perspective view of the cylinder housing. [Figure 8] This is a rear view of a compression device and a magnetic debris filter according to one embodiment of the present invention. [Figure 9A] Figure 8 is an exploded view of the compression device and magnetic debris filter. [Figure 9B]Figure 8 is an exploded view of the magnetic debris filter assembly. [Figure 10A] This is a front view of the filter frame of the magnetic debris filter assembly shown in Figure 8, according to one embodiment of the present invention. [Figure 10B] Figure 10A is a side view of the filter frame. [Figure 10C] Figure 10A is a cross-sectional view of the filter frame. [Figure 11A] This is a cross-sectional view of a compressor and an oil separator in an electric compressor according to one embodiment of the present invention. [Figure 11B] Figure 11A is a front view of the compressor and oil separator. [Figure 12A] This is a side view of the disk of the oil separator shown in Figure 11A, according to one embodiment of the present invention. [Figure 12B] Figure 11A is a top view of the disk. [Figure 12C] Figure 11A is a perspective view of the disk. [Figure 13A] This is a side view of the vanes of a compressor with side seals according to one embodiment of the present invention. [Figure 13B] Figure 13A is a front view of the vane. [Figure 13C] Figure 13A is an exploded view of the vane. [Figure 13D] Figure 13A is a bar graph of test data related to vanes.

[0027] Modes for carrying out the invention Referring to the figures, similar reference numerals throughout several figures indicate similar or corresponding parts, and a compressor 10 having a housing 12 is provided. The electric compressor 10 is particularly suitable for automatic vehicles such as automobiles (not shown). The electric compressor 10 can be used as a cooling device or heating pump for heating and / or cooling various aspects of a vehicle. For example, the electric compressor 10 can 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.

[0028] In addition, the electric compressor 10 may be used, for example, during a charging cycle, to heat or cool the passenger compartment, onboard electronics, and / or the battery used to power the vehicle while the vehicle is not in operation. The electric compressor 10 may be used further while the vehicle is not in operation and the battery is not being charged to maintain the battery's lifespan or minimize its degradation.

[0029] In the illustrated embodiment, the electric compressor 10 is a rotary compressor that acts to rapidly and efficiently compress a refrigerant for use in different systems of an automatic vehicle, such as an electric or hybrid vehicle. When in use, a mixture of the refrigerant and oil (for lubrication) may be used. In one aspect of the present invention, the oil may be separated from the refrigerant before it leaves the compressor 10.

[0030] The electric compressor 10 includes a housing 12 and a compressor 18 located or housed within the housing 12. The compressor 10 has a central shaft 78. The compressor 18 will be described in more detail below.

[0031] In the illustrated embodiment, the electric compressor 10 may include an inverter unit 14 and a motor unit 16. The housing 12 may include a central housing 20, an inverter back cover 22, a rear head 24 (sometimes called a discharge head), and a cylinder housing 26. As shown, the central housing 20 may house the motor unit 16 and the compressor 18. In other embodiments, the inverter unit 14 and / or the motor unit 16 may be located outside the housing 12.

[0032] In one embodiment, the inverter back cover 22, central housing 20, cylinder housing 26, and rear head 24 may be made of machined aluminum. The compressor 10 may be mounted, for example, within the body of the automatic vehicle via a number of mounting points (not shown).

[0033] Overall configuration and operation of the electric compressor 10 The inverter back cover 22 and one end of the central housing 20 form an inverter cavity 28. The inverter back cover 22 is attached to the central housing 20 by a number of bolts 30 (only one of which is shown in Figure 1A). An inverter gasket (not shown) may be located between the inverter back cover 22 and the central housing 20 to prevent moisture, dust, and other contaminants from entering the inverter cavity 28. The rear head 24 may be attached to the central housing 20 by a number of bolts 82.

[0034] The inverter module 32 is mounted in an inverter cavity 28 formed by the inverter back cover 22 and the central housing 20. The inverter module 32 may include an inverter circuit 34 mounted on a printed circuit board attached to the central housing 20. The inverter circuit 34 converts direct current (DC) power received from outside the electric compressor 10 into three-phase alternating current (AC) power and supplies it to the motor 38 (see below). The inverter circuit may also control the rotational speed of the electric compressor 10. The inverter circuit is supplied with a high-voltage DC current via a high-voltage connector (not shown). A low-voltage DC current for driving the inverter circuit, as well as control signals for controlling the operation of the inverter circuit and the motor unit 16, may be supplied via a low-voltage connector (not shown).

[0035] The central housing 20 forms a motor cavity 36. The motor section 16 includes a motor 38 located within the motor cavity 36. In one embodiment, the motor 38 is a three-phase AC motor having a stator 40 and a rotor 42. The stator 40 has a substantially hollow cylindrical shape with six individual coils (two for each phase). The stator 42 is housed within the central housing 20, mounted to the central housing 20, and remains stationary relative to the central housing 20. The rotor 42 is located within the stator 40 and is centered relative to the stator 40.

[0036] The drive shaft 44 is coupled to the rotor 42 and rotates with the rotor 42. In the illustrated embodiment, the drive shaft 44 is press-fitted into the central opening 42A of the rotor 42. The drive shaft 44 has a first end 44A and a second end 44B. As shown, the central housing 20 includes a first drive shaft support member 20A within the motor cavity 36. A first ball bearing 46, positioned within the opening formed by the first drive shaft support member 20A, supports and allows the first end 44A of the drive shaft 44 to rotate. In the illustrated embodiment, the cylinder housing 26 has a second drive shaft support member 20B. A second ball bearing 48, positioned within the opening formed by the second drive shaft support member 20B, allows the second end 44B of the drive shaft 44 to rotate. In the illustrated embodiment, the first and second ball bearings 46 and 48 are press-fitted into openings formed by the first drive shaft support member 20A and the second drive shaft support member 20B, respectively.

[0037] As mentioned above, the electric compressor 10 is a rotary compressor. In one aspect of the present invention, the compression device 18 includes a piston device 50 eccentrically coupled to the second end 44B of the drive shaft 44, and vanes 56. As will be described in more detail below, the drive shaft 44 is rotated within the compression chamber 58 by the cylinder housing 26 of the housing 12. The vanes 56 are also biased inward.

[0038] Generally, the mixed refrigerant and oil (at low pressure) enter the electric compressor 10 through the refrigerant inlet port 60, are compressed by the compressor 18, and then exit the electric compressor 10 (at high pressure) through the refrigerant outlet port 62. The refrigerant follows the refrigerant path through the electric compressor 10. The refrigerant enters the refrigerant inlet port 60 and enters the suction volume 64 formed between the cylinder housing 26 adjacent to the refrigerant inlet port 60 and the rear head 24 (see Figures 1A-1B). The refrigerant is then drawn in through the motor unit 16 and enters the compression chamber 58 (see below).

[0039] The refrigerant is compressed by the compressor 18 and exits the compression chamber 58 into the discharge volume 66. The discharge volume 66 communicates with the refrigerant outlet port 62. The pressurized refrigerant exits the compressor 18 through one or more orifices 90 (see Figures 7B-7C). The release of the pressurized refrigerant can be controlled by the reed mechanism 72.

[0040] Compressor with balanced rolling piston Referring particularly to Figures 1A-1B, 2A-2B, 3A-3G, 4, and 5A-5B, a compressor 18 according to one embodiment of the present invention includes a cylinder housing 26 and a piston device 50 including a cylinder 52 and a rolling piston 54. The compressor 18 is located in a compression chamber 58 and is coupled to a drive shaft 44. Generally, the compressor 18 is configured to receive refrigerant from an intake volume 64 and compress the refrigerant when the drive shaft 44 is rotated by a motor 38.

[0041] The cylinder 52 has a circular cross-section and circumference and is eccentrically coupled to the drive shaft 44. The rolling piston 54 is tubular and concentric with the cylinder 52. The rolling piston 54 has an outer surface 54A that contacts the inner surface 58A of the compression chamber 58. The rolling piston 54 rotates around the cylinder 52 when the drive shaft 44 and the piston device 50 are rotated by the motor 38.

[0042] In the illustrated embodiment, the compressor 18 further includes a vane 56. The vane 56 is movably coupled to the housing 12. As shown, one end 56A of the vane 56 is adjacent to the compression chamber 58, and the vane is biased such that the end 56A of the vane 56 contacts the rolling piston 54 when the piston device 50 is rotated by the drive shaft 44. The vane 56 may be biased inward via a spring 134 (see Figures 2E and 2F) or other suitable mechanism. The housing 12, the piston device 50, and the vane 56 form variable sub-chambers 58B, 58C within the compression chamber 58 when the piston device 50 is rotated within the compression chamber 58. As will be described in more detail below, the refrigerant enters one of the variable sub-chambers from the intake volume 64, is compressed as the piston device 50 is rotated, exits one of the sub-chambers 58B, 58C and enters the discharge volume 66.

[0043] Referring to Figures 3A to 3G, the position or state of the compressor 18 during the compression cycle of the compressor 10 is shown. At the start of the compression cycle (as shown in Figure 3A), the vanes 56 are pressed outward by the outer surface 54A of the rolling piston 54 such that the ends 56A of the vanes 56 are flush with the inner surface 58A of the compression chamber 58. At this point in the compression cycle, the compression chamber 58 has a single sub-chamber 58C.

[0044] As the piston device 50 rotates, a sub-chamber 58B is formed by the outer surface 54A of the rolling piston 54, the vane 56, and the inner surface 58A of the compression chamber 58 (see Figure 3B). As shown in Figures 3A to 3F, the cylinder housing 26 of the housing 12 includes an internal suction chamber 26A connected to the suction volume 64 and the compression chamber 58 via a suction port 26B.

[0045] Returning to Figure 3B, the sub-chamber 58B opens into the suction chamber 26A, and refrigerant flows into the sub-chamber 58B. As shown in Figures 3C to 3D, when the piston device 50 is rotated by the drive shaft 44, the volume of the sub-chamber 58B increases, and the refrigerant continues to enter or fill the sub-chamber 58B.

[0046] As shown in Figure 3F, as the piston device 50 continues to rotate, the sub-chamber 58B is isolated from the internal suction chamber 26A and suction port 26B, and consequently from the suction volume 64. As shown in Figures 3A to 3G, in the illustrated embodiment, the cylinder housing 26 includes an internal discharge chamber 26C connected to the discharge volume 66 and the compression chamber 58 via a discharge port 26D.

[0047] As shown in Figure 3F, when the sub-chamber 58B is isolated or blocked from the suction volume 64, the sub-chamber is connected to the internal discharge chamber 26C and the discharge port 26D (see Figures 3F to 3G).

[0048] As the piston device 50 continues to rotate, the sub-chamber 58B decreases, thereby compressing the refrigerant. The release of the pressurized refrigerant is controlled by a reed mechanism 72 coupled to the rear side of the cylinder housing 26 (see Figure 6C). In the illustrated embodiment, a single reed mechanism 72 is used. However, it should be noted that two or more reed mechanisms may be used. In one embodiment, the reed mechanism 72 may include a discharge reed (not shown) and a reed retainer 72A. The discharge reed may be made of 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 compressor 18. The reed retainer 72A is made of a rigid, non-flexible material such as punched steel. The reed retainer 72A controls or limits the maximum displacement of the discharge reed relative to the cylinder housing 26. In the illustrated embodiment, the reed mechanism 72 is held or fixed to the cylinder housing 26 via fasteners 74.

[0049] As shown in Figures 2A-2B and 3A-3G, in the illustrated embodiment, the cylinder housing 26 includes a vane slot 76 configured to slidably receive a vane 56. The vane slot 76 has a first end 76A that opens into or is adjacent to the compression chamber 58, and a second end 76B that is located adjacent to the outer surface of the cylinder housing 26 (see Figure 2B). In the illustrated embodiment, the second end 76B of the vane slot 76 is coupled to the discharge volume 66. During operation, the pressurized refrigerant from the discharge volume 66 biases the vane 56 by applying force to it so that the end of the vane 56A remains in contact with the outer surface of the rolling piston 54A.

[0050] The cylinder 52 and the rolling piston 54 may be made of cast iron. As shown in Figures 1A, 1B, and 4, in the illustrated embodiment, the drive shaft 44 is centered on the central axis 78 of the compressor 10. The piston device 50 has a piston central axis 80 offset from the central axis 78 (see Figures 2B and 4).

[0051] In one aspect of the present invention, the cylinder 52 has a hollow internal chamber 52A. The cylinder 52 and the internal chamber 52A are configured such that their center of rotational mass aligns with the central axis 78 of the compressor 10 and the drive shaft 44. This configuration eliminates the need for other separate balancing components or mechanisms. As shown in the illustration, in the illustrated embodiment, the internal chamber 52A is located on the compression side of the cylinder housing 26.

[0052] In one embodiment of the present invention, a piston device 50 and a cylinder 52 are keyed to a drive shaft 44. As shown in Figures 2A, 4, and 5B, in the illustrated embodiment of the present invention, one end of the drive shaft 44 has a flat surface 44C. The cylinder 52 has an opening 52B with a flat side surface 52C configured to receive the end of the drive shaft 44. In one aspect of the present invention, the cylinder 52 and the drive shaft 44 have an interference fit between them.

[0053] As shown in Figure 6B, the cylinder 52 may include a lip 52D to help properly position the rolling piston 54 relative to the cylinder 52. The inner diameter of the rolling piston 54 may be slightly larger than the outer diameter of the cylinder 52 to allow coolant between them for lubrication purposes.

[0054] Returning to Figure 1A, in the illustrated embodiment, the compressor 18 may further include an inner cover 84. The inner cover 84 is configured to be located within the central housing 20 adjacent to the flange 20C of the central housing 20. As illustrated, when the compressor 10 is assembled, the compression chamber 58 is formed by the inner cover 84 and the cylinder housing 26, and the piston device 50 is positioned within the compression chamber 58. As illustrated, the inner cover 84 forms a third drive shaft support member 84A configured to receive a third ball bearing 86. The drive shaft 44 is positioned through the third ball bearing 86 and the third drive shaft support member 84A and is supported by the third ball bearing 86 and the third drive shaft support member 84A. As illustrated, the rear head 24 is fastened to the central housing 20 by bolts 82.

[0055] Referring particularly to Figures 1A-1B, 2A-2B, 3A-3G, 4, and 5A-5B, a compressor 18 according to one embodiment of the present invention includes a cylinder housing 26 and a piston device 50 including a cylinder 52 and a rolling piston 54. The compressor 18 is located in a compression chamber 58 and is coupled to a drive shaft 44. Generally, the compressor 18 is configured to receive refrigerant from an intake volume 64 and compress the refrigerant when the drive shaft 44 is rotated by a motor 38.

[0056] The cylinder 52 has a circular cross-section and circumference and is eccentrically coupled to the drive shaft 44. The rolling piston 54 is tubular and concentric with the cylinder 52. The rolling piston 54 has an outer surface 54A that contacts the inner surface 58A of the compression chamber 58. The rolling piston 54 rotates around the cylinder 52 when the drive shaft 44 and the piston device 50 are rotated by the motor 38.

[0057] In the illustrated embodiment, the compressor 18 further includes a vane 56. The vane 56 is movably coupled to the housing 12. As shown, one end 56A of the vane 56 is adjacent to the compression chamber 58, and the vane is biased such that the end 56A of the vane 56 contacts the rolling piston 54 when the piston device 50 is rotated by the drive shaft 44. The vane 56 may be biased inward via a spring 134 or other suitable mechanism. The housing 12, the piston device 50, and the vane 56 form variable subchambers 58B, 58C within the compression chamber 58 when the piston device 50 is rotated within the compression chamber 58. As will be described in more detail below, the refrigerant enters one of the variable subchambers from the intake volume 64, is compressed as the piston device 50 is rotated, exits one of the subchambers 58B, 58C and enters the discharge volume 66.

[0058] Referring to Figures 3A to 3G, the position or state of the compressor 18 during the compression cycle of the compressor 10 is shown. At the start of the compression cycle (as shown in Figure 3A), the vanes 56 are pressed outward by the outer surface 54A of the rolling piston 54 such that the ends 56A of the vanes 56 are flush with the inner surface 58A of the compression chamber 58. At this point in the compression cycle, the compression chamber 58 has a single sub-chamber 58C.

[0059] As the piston device 50 rotates, a sub-chamber 58B is formed by the outer surface 54A of the rolling piston 54, the vane 56, and the inner surface 58A of the compression chamber 58 (see Figure 3B). As shown in Figures 3A to 3F, the cylinder housing 26 of the housing 12 includes an internal suction chamber 26A connected to the suction volume 64 and the compression chamber 58 via a suction port 26B.

[0060] Returning to Figure 3B, the sub-chamber 58B opens into the suction chamber 26A, and refrigerant flows into the sub-chamber 58B. As shown in Figures 3C to 3D, when the piston device 50 is rotated by the drive shaft 44, the volume of the sub-chamber 58B increases, and the refrigerant continues to enter or fill the sub-chamber 58B.

[0061] As shown in Figure 3F, as the piston device 50 continues to rotate, the sub-chamber 58B is isolated from the internal suction chamber 26A and suction port 26B, and consequently from the suction volume 64. As shown in Figures 3A to 3G, in the illustrated embodiment, the cylinder housing 26 includes an internal discharge chamber 26C connected to the discharge volume 66 and the compression chamber 58 via a discharge port 26D.

[0062] As shown in Figure 3F, when the sub-chamber 58B is isolated or blocked from the suction volume 64, the sub-chamber is connected to the internal discharge chamber 26C and the discharge port 26D (see Figures 3F to 3G).

[0063] As the piston device 50 continues to rotate, the sub-chamber 58B decreases, thereby compressing the refrigerant. The release of the pressurized refrigerant is controlled by a reed mechanism 72 coupled to the rear side of the cylinder housing 26 (see Figure 6C). In the illustrated embodiment, a single reed mechanism 72 is used. However, it should be noted that two or more reed mechanisms may be used. In one embodiment, the reed mechanism 72 may include a discharge reed (not shown) and a reed retainer 72A. The discharge reed may be made of 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 compressor 18. The reed retainer 72A is made of a rigid, non-flexible material such as punched steel. The reed retainer 72A controls or limits the maximum displacement of the discharge reed relative to the cylinder housing 26. In the illustrated embodiment, the reed mechanism 72 is held or fixed to the cylinder housing 26 via fasteners 74.

[0064] As shown in Figures 2A-2B and 3A-3G, in the illustrated embodiment, the cylinder housing 26 includes a vane slot 76 configured to slidably receive a vane 56. The vane slot 76 has a first end 76A that opens into or is adjacent to the compression chamber 58, and a second end 76B that is located adjacent to the outer surface of the cylinder housing 26 (see Figure 2B). In the illustrated embodiment, the second end 76B of the vane slot 76 is coupled to the discharge volume 66. During operation, the pressurized refrigerant from the discharge volume 66 biases the vane 56 by applying force to it so that the end of the vane 56A remains in contact with the outer surface of the rolling piston 54A.

[0065] The cylinder 52 and the rolling piston 54 may be made of cast iron. As shown in Figures 1A, 1B, and 4, in the illustrated embodiment, the drive shaft 44 is centered on the central axis 78 of the compressor 10. The piston device 50 has a piston central axis 80 offset from the central axis 78 (see Figures 2B and 4).

[0066] In one aspect of the present invention, the cylinder 52 has a hollow internal chamber 52A. The cylinder 52 and the internal chamber 52A are configured such that their center of rotational mass aligns with the central axis 78 of the compressor 10 and the drive shaft 44. This configuration eliminates the need for other separate balancing components or mechanisms. As shown in the illustration, in the illustrated embodiment, the internal chamber 52A is located on the compression side of the cylinder housing 26.

[0067] In one embodiment of the present invention, a piston device 50 and a cylinder 52 are keyed to a drive shaft 44. As shown in Figures 2A, 4, and 5B, in the illustrated embodiment of the present invention, one end of the drive shaft 44 has a flat surface 44C. The cylinder 52 has an opening 52B with a flat side surface 52C configured to receive the end of the drive shaft 44. In one aspect of the present invention, the cylinder 52 and the drive shaft 44 have an interference fit between them.

[0068] As shown in Figure 6C, the cylinder housing 26 may include a lip 26E to help properly position the rolling piston 54 relative to the cylinder housing 26. The inner diameter of the rolling piston 54 may be slightly larger than the outer diameter of the cylinder 52 to allow coolant between them for lubrication purposes.

[0069] Returning to Figure 1A, in the illustrated embodiment, the compressor 18 may further include an inner cover 84. The inner cover 84 is configured to be located within the central housing 20 adjacent to the flange 20C of the central housing 20. As illustrated, when the compressor 10 is assembled, the compression chamber 58 is formed by the inner cover 84 and the cylinder housing 26, and the piston device 50 is positioned within the compression chamber 58. As illustrated, the inner cover 84 forms a third drive shaft support member 84A configured to receive a third ball bearing 86. The drive shaft 44 is positioned through the third ball bearing 86 and the third drive shaft support member 84A and is supported by the third ball bearing 86 and the third drive shaft support member 84A. As illustrated, the rear head 24 is fastened to the central housing 20 by bolts 82.

[0070] Compressor subassembly with integrated discharge chamber

[0071] Referring particularly to Figures 1A-1B, 7A-7C, and 8, in one aspect of the present invention, the electric compressor 10 appears to include a compressor subassembly 88 having one or more integrated discharge chambers or high-pressure side cavities 66A, 66B, 66C (see Figures 1A-1B). In the illustrated embodiment, the compressor subassembly 88 includes a cylinder housing 26 and a compressor 18.

[0072] As described above, the electric compressor 10 is configured to compress a refrigerant and includes a housing 12, a refrigerant inlet port 60, a refrigerant outlet port 62, a motor 38, and a drive shaft 44. The housing 12 defines an intake volume 64 and has a central axis 78. The refrigerant inlet port 60 is coupled to the housing 12 and configured to introduce refrigerant into the intake volume 64. The refrigerant outlet port 62 is coupled to the housing 12 and configured to allow the compressed refrigerant to exit the electric compressor 10. The motor 38 is mounted inside the housing 12. The drive shaft 44 is coupled to the motor 38 and configured to rotate about the central axis 78.

[0073] In the illustrated embodiment, the compressor subassembly includes a cylinder housing 26 (which may be part of the housing 12) and a piston device 50. The cylinder housing 26 and the piston device 50 may be referred to as the compressor 18.

[0074] Referring particularly to Figure 7A, the cylinder housing 26 has a first side surface 26F and a second side surface 26G. The cylinder housing 26 at least partially forms a compression chamber 58. The compression chamber 58 has an open end 58D adjacent to the first side surface 26F of the cylinder housing 26. One or more high-pressure side cavities 66A, 66B, 66C are at least partially formed within the second side surface 26G of the cylinder housing 26. One or more high-pressure side cavities 66A, 66B, 66C form at least a portion of the discharge chamber 66. The compressed refrigerant exits the compression chamber 18 through the orifice 90 and enters the discharge chamber 66 (or one or more high-pressure side cavities 66A, 66B, 66C). As shown in Figures 7B and 7C, in the illustrated embodiment, the orifice 90 has a first end 90A located within the compression chamber 18 and a second end 90B located within one of the high-pressure side cavities 66A, 66B, and 66C. The second end 90B of the orifice 90 is located adjacent to the reed mechanism 72. During operation, the compressed refrigerant is released from the compression chamber 18 during compression cycles when the refrigerant pressure exceeds a predetermined threshold. The predetermined threshold is determined by the reed mechanism 72.

[0075] The compressor subassembly 88 includes the compressor 18. In the illustrated embodiment, the piston device 50 may include a cylinder 52 and a rolling piston 54. As previously mentioned, the cylinder 52 is eccentrically coupled to the drive shaft 44 and has a circular outer circumference. The rolling piston 54 is tubular and may be concentric with the cylinder 52. The rolling piston 54 has an outer surface 54A that contacts the inner surface 58A of the compression chamber 58. During operation, the rolling piston 54 rotates around the cylinder 52 as the drive shaft 44 and the piston device 50 are rotated by the motor 38.

[0076] The overall package size of the compressor 10 can be reduced by at least partially integrating the high-pressure side cavities 66A, 66B, 66C and / or discharge cavity 66 within the cylinder housing 26.

[0077] In one aspect of the present invention, the rear head 24 may form the end of each high-pressure side cavity 66A, 66B, 66C. In the embodiment, the inside of the rear head 24 may be substantially (or relatively) flat. In other words, the discharge cavity 66 is configured or largely located within the cylinder housing 26, and the rear head 24 represents one side of each high-pressure side cavity 66A, 66B, 66C.

[0078] In another embodiment, one or more high-pressure side cavities 66A, 66B, 66C may be formed by the cylinder housing 26 and the rear head 24. Referring particularly to Figures 1A to 1B, the cylinder housing 26 may include one or more cylinder housing recesses 92A, 92B, 92C, and the rear head 24 may include one or more rear head recesses 94A, 94B, 94C. Each of the high-pressure side cavities 66A, 66B, 66C may include one of the cylinder housing recesses 92A, 92B, 92C and one of the rear head recesses 94A, 94B, 94C.

[0079] As described above, in the illustrated embodiment, the compressor 18 may further include a vane 56 movably coupled to the cylinder housing 26. The vane 56 has an end 56A adjacent to the compression chamber 58. The vane 56 is biased so that the end 56A of the vane 56 contacts the rolling piston 54 when the piston device 50 is rotated by the drive shaft 44. In the illustrated embodiment, the vane 56 is located in a vane slot 76 of the cylinder housing 26.

[0080] The housing 12 or cylinder housing 26, piston device 50, and vane 56 form variable subchambers 58B, 58C within the compression chamber 58 when the piston device 50 rotates within the compression chamber 58. As previously described, the refrigerant enters one of the variable subchambers 58B, 58C from the intake volume 64, is compressed as the piston device 50 rotates, exits one of the subchambers 58B, 58C and enters the discharge volume 66.

[0081] Referring particularly to Figures 7A and 7B, the cylinder housing 26 may further include a slot 96 between the high-pressure side cavities 66A, 66B, 66B, allowing the high-pressure refrigerant to flow between the cavities (as indicated by arrow 98).

[0082] Magnetic debris filter Referring particularly to Figures 8, 9A-9B, and 10A-10C, in another aspect of the present invention, the electric compressor 10 may include a magnetic debris filter 100. The magnetic debris filter 100 is configured to capture debris generated during the compression cycle of the electric compressor 10. Generally, as described above, the electric compressor 10 is configured to compress a refrigerant and includes a housing 12, a refrigerant inlet port 60, a refrigerant outlet port 62, and a compressor 18. The housing 12 defines an intake volume 64 and a discharge volume 66 and has a central axis 78. The housing 12 further defines a compression chamber 58. The refrigerant inlet port 60 is coupled to the housing 12 and is configured to introduce refrigerant into the intake volume 64. The refrigerant outlet port 62 is coupled to the housing 12 and is configured to allow the compressed refrigerant to exit the electric compressor 12 from the discharge volume 66. The compressor 18 is located within the compression chamber 58 and is coupled to a drive shaft 44. The compressor 18 is configured to receive refrigerant from the intake volume 64 and compress the refrigerant as the drive shaft 44 rotates. The housing 12, the compressor 18, and the compression chamber 58 define a refrigerant flow path 108 (partially shown in Figures 1A and 1B) between the refrigerant inlet port 60 and the refrigerant outlet port 62. As will be described in more detail below, the housing 12 defines a filter mounting opening 102 located after the compressor 18 in the refrigerant flow path 108.

[0083] In the illustrated embodiment, the housing 12 may include a cylinder housing 26. In one embodiment, the filter mounting opening 102 is located within the cylinder housing 26. For example, in the embodiment shown in Figure 7A, the cylinder housing 26 may include a plurality of high-pressure side cavities 66A, 66B, 66C that at least partially define the discharge volume 66. As previously mentioned, the compressed refrigerant can exit the compression chamber 58 through the orifice 90 (as controlled by the reed mechanism 72). The refrigerant flows through the slot 96 in the direction of arrow 98 through the high-pressure side cavities 66A, 66B, 66C (see Figure 7B). In the illustrated embodiment, the filter mounting opening 102 is located above the inner high-pressure side cavity 66C. As shown, the shape of the magnetic debris filter 100 may match the shape of the filter mounting opening 102. In one embodiment, the magnetic debris filter 100 is located between the cylinder housing 26 and the central housing 20 and is held in place when the electric compressor 10 is assembled. In another embodiment, the magnetic debris filter 100 may be press-fitted into the filter mounting opening 102.

[0084] Referring particularly to Figures 9A and 9B, the magnetic debris filter includes a filter frame 104 and a magnetic element 106. The filter frame 104 includes a magnet opening 104A that fits into a filter mounting opening 102 and is configured to receive the magnetic element 106. The filter mounting opening 102 may also include one or more refrigerant openings 104B. In the illustrated embodiment, compressed refrigerant enters the inner high-pressure side cavity 66C, and debris, such as iron debris, is captured by the magnetic element 106. The compressed refrigerant can then exit the inner high-pressure side cavity 66C through one or more refrigerant openings 104B.

[0085] In one embodiment of the present invention, the filter frame 104 may be made of aluminum. The magnetic element 106 may be a magnet. Alternatively, the magnetic element 106 may include one or more magnets 106A (shown by dotted lines in Figure 9B) embedded in the substrate 106B.

[0086] As shown in Figure 10C, the magnet opening 104A may be partially defined by the flange 104C. The magnetic element 106 may be held within the magnet opening 104A by press-fitting.

[0087] Spinning disc oil separator Referring particularly to Figures 11A-11B and 12A-12B, in another aspect of the present invention, the electric compressor 10 may include an oil separator mechanism 110. The electric compressor 10 is configured to compress a refrigerant. As previously stated, when in use, the refrigerant inside the electric compressor 10 may be a mixture of refrigerant and oil (for lubrication), and can be simply referred to as the "refrigerant" or "refrigerant mixture". It is desirable to separate or substantially separate the oil from the refrigerant before the compressed refrigerant exits the electric compressor 10 through the outlet port 62. The separated oil remains inside the housing 12, providing lubrication to the moving parts of the electric compressor 10.

[0088] As described above, the electric compressor 10 may include a housing 12, a refrigerant inlet port 60, a refrigerant outlet port 62, a drive shaft 44, and a compressor 18. The housing 12 defines an intake volume 64 and a discharge volume 66 and has a central axis 78. The housing 12 further defines a compression chamber 58. The refrigerant inlet port 60 is coupled to the housing 12 and configured to introduce refrigerant into the intake volume 64. The drive shaft 44 is located inside the housing 12. The refrigerant outlet port 62 is coupled to the housing 12 and configured to allow compressed refrigerant to exit the electric compressor 10 from the discharge volume 66. The compressor 18 is located inside the compression chamber 58 and is coupled to the drive shaft 44. The compressor 18 is configured to receive refrigerant from the intake volume 64 and compress the refrigerant when the drive shaft 44 is rotated. The housing 12, the compressor 18, and the compression chamber 58 define a refrigerant flow path 98 between the refrigerant inlet port 60 and the refrigerant outlet port 62.

[0089] Referring particularly to Figures 11A to 11B, in one embodiment the housing 12 includes a central housing 20 and an inner cover 84. The housing 12 may also include a rear head 24 (see Figures 1A to 1B). The rear head 24 is not shown in Figure 11A but is adjacent to and above the central housing 20.

[0090] In one aspect of the present invention, during operation, the electric compressor 10 is oriented vertically (as shown in Figure 11A) with the rear head 24 positioned at the upper end (indicated by arrow 112).

[0091] As shown in the illustration, in the illustrated embodiment, the oil separator mechanism 110 includes a disc-shaped oil separator 114. The disc-shaped oil separator 114 has a center 116 and is coupled to a drive shaft 44 and configured to rotate together with the drive shaft 44 around the center 116. As shown in the illustration, the disc-shaped oil separator 114 is located within the discharge volume 66. In the illustrated embodiment, the disc-shaped oil separator 114 is located within the inner high-pressure side cavity 66C. The oil separator mechanism 110 has a flange 118 that fits onto the upper end of the drive shaft 44. In one embodiment, the flange 118 is press-fitted onto the upper end of the drive shaft 44. In other embodiments, the oil separator mechanism 110 may be fastened to the upper end of the drive shaft 44 by any suitable means, such as fasteners (not shown).

[0092] Referring particularly to Figures 12A to 12C, the disc-shaped oil separator 114 has a continuous outer edge 120 and a plurality of trough-shaped feature portions 122. Each trough-shaped feature portion 122 has a first end 122A and a second end 122B. The first end 122A is located adjacent to the center 116 and extends outward toward the second end 122B. In the illustrated embodiment, the second end 122B of each trough-shaped feature portion 122 is located on the continuous outer edge 120 of the disc-shaped oil separator 114.

[0093] Each trough-shaped feature 122 has a corresponding width w. In one aspect of the present invention, the width w increases as the trough-shaped feature 122 extends from the center 116 of the disc-shaped oil separator 114. The disc-shaped oil separator 114 may be made of steel, plastic, aluminum, or other suitable material.

[0094] The oil separator mechanism 110 is configured to separate oil from the refrigerant before the refrigerant is discharged. The refrigerant may be in gaseous form, and when mixed with oil, the mixture may be immiscible due to its high temperature. In use, the oil separator 114 rotates with the drive shaft 44. When the compressed refrigerant / oil mixture enters the discharge volume 66 (or inner high-pressure side cavity 66C), the mixture is pushed upward in the direction of arrow 124. The rotating oil separator 114 and trough-shaped feature 122 disrupt the flow of the mixture. This interaction moves the oil to the outer wall of the discharge chamber 66, allowing the oil to accumulate at the bottom of the discharge volume 66, and then be introduced into the lower side of the compressor 10, i.e., the suction volume 64.

[0095] Cylindrical vane retainer sleeve Referring particularly to Figures 2C, 2D, and 2E, in another aspect of the present invention, a cylindrical vane retainer sleeve 128 may be positioned around the cylinder housing 26 and configured to hold the vanes 56 within the vane slots 76. The cylinder housing 26, the compressor 18, the vanes 56, and the cylindrical vane retainer sleeve 128 may be referred to as the assembly 126. Generally, the assembly 126 may be located within the housing 12 of the electric compressor 10.

[0096] As previously mentioned, the electric compressor 10 may be configured to compress the refrigerant. In the illustrated embodiment, the electric compressor 10 includes a housing 12, a refrigerant inlet port 60, a refrigerant outlet port 62, and a drive shaft 44. The housing 12 has a central axis 78 and defines an intake volume 64 and a discharge volume 66. The refrigerant inlet port 60 is coupled to the housing 12 and configured to introduce refrigerant into the intake volume 63. The refrigerant outlet port 62 is coupled to the housing 12 and configured to allow compressed refrigerant to exit the electric compressor 10 from the discharge volume 66. The drive shaft 44 is coupled to a motor 36 (which may be internal or external to the housing 12; see above). The drive shaft 44 is configured to rotate about the central axis 78.

[0097] Referring particularly to Figure 2C, the cylinder housing 26 has an inner surface 130 and an outer surface 132. The cylinder housing 26 defines at least partially the compression chamber 58 (see Figure 1B). In the illustrated embodiment, the cylinder housing 26 is located within the central housing 20, and the outer surface 132 is adjacent to the inner surface of the central housing 20 (see Figure 1A).

[0098] In the illustrated embodiment, the vane slot 76 is formed or defined by the cylinder housing 26. Returning to Figures 2C to 2E, the vane slot 76 has a first open end 76A and a second open end 76B located on the inner and outer surfaces 130, 132 of the cylinder housing 26, respectively.

[0099] As described above, the compressor 18 is configured to receive refrigerant from the intake volume 64. The refrigerant is compressed when the drive shaft 44 is rotated. In the illustrated embodiment, the compressor 18 includes a piston device 50. The piston device 50 includes a cylinder 52 and a rolling piston 54. The cylinder 52 is configured to be eccentrically coupled to the drive shaft 44. The rolling piston 54 is tubular and concentric with the cylinder 52. The rolling piston 54 has an outer surface 54A (see Figures 2A and 4) that contacts the inner surface of the cylinder housing 26. The rolling piston 54 is configured to rotate around the cylinder 52 when the drive shaft 44 and the piston device 50 are rotated. The vanes 56 are movably positioned within the vane slots 76.

[0100] As shown in Figure 2F, the vane 56 has an upper end 56B adjacent to the outer surface 132 of the cylinder housing 26 and a lower end 56A adjacent to the inner surface 130 of the cylinder housing 26. The vane 56 can be biased so that the lower end 56A of the vane 56 contacts the rolling piston 54 when the piston device 50 is rotated by the drive shaft 44.

[0101] Referring particularly to Figures 2C to 2E, the cylindrical vane retainer sleeve 128 is positioned around the outer surface 132 of the cylinder housing 26 and is configured to hold the vane 56 within the vane slot 76. As previously mentioned, the vane slot 76 can be connected to a discharge volume 66, and the vane 56 is biased toward the piston device 50 by the (compressed) refrigerant in the discharge volume 66. Alternatively or additionally, a spring 134 can be positioned between the cylindrical vane retainer sleeve 128 and the vane 56 to bias the vane 56 toward the piston device 50.

[0102] vanes with spring retention slots Referring particularly to Figure 2F, in one embodiment, the vane 56 includes a spring slot 140 having an open end 140A located at the upper end 56B of the vane 56. The spring slot 140 extends from the upper end 56B of the vane 56 toward the lower end 140B of the spring slot 140. A spring positioning pin 142 is located at the lower end 140B of the spring slot 140 and can receive and hold one end of a spring 134.

[0103] vanes with side seals Referring particularly to Figures 13A, 13B, and 13C, in another aspect of the present invention, a pair of vane side seals 148 may be coupled to the vane 140. The cylinder housing 26, the compressor 18, the vane 56, and the pair of side seals 146 may be referred to as assembly 144. Generally, assembly 146 may be located within the housing 12 of the electric compressor 10.

[0104] As previously mentioned, the electric compressor 10 may be configured to compress the refrigerant. In the illustrated embodiment, the electric compressor 10 includes a housing 12, a refrigerant inlet port 60, a refrigerant outlet port 62, and a drive shaft 44. The housing 12 has a central axis 78 and defines an intake volume 64 and a discharge volume 66. The refrigerant inlet port 60 is coupled to the housing 12 and configured to introduce refrigerant into the intake volume 63. The refrigerant outlet port 62 is coupled to the housing 12 and configured to allow compressed refrigerant to exit the electric compressor 10 from the discharge volume 66. The drive shaft 44 is coupled to a motor 36 (which may be internal or external to the housing 12; see above). The drive shaft 44 is configured to rotate about the central axis 78.

[0105] In the illustrated embodiment, the vane slot 76 is formed or defined by the cylinder housing 26. Returning to Figures 2C and 2E, the vane slot 76 has a first open end 76A and a second open end 76B located on the inner and outer surfaces 130, 132 of the cylinder housing 26, respectively. The vane slot 76 is closed or bounded on both sides to separate the differential pressure between the low-pressure and high-pressure sides of the compressor 10 during the compression cycle. In the illustrated embodiment, one side of the vane slot 76 may be formed by the cylinder housing 26 (see Figure 2C), and the other side of the vane slot 76 may be formed by the inner cover 84 (see Figure 1A). In the embodiment or configuration, both sides of the vane slot 76 may be formed by different parts of the compressor 10. In some prior art compressors, the seal across the sides of the vane relies on part tolerances and an oil film.

[0106] As described above, the compressor 18 is configured to receive refrigerant from the intake volume 64. The refrigerant is compressed when the drive shaft 44 is rotated. In the illustrated embodiment, the compressor 18 includes a piston device 50. The piston device 50 includes a cylinder 52 and a rolling piston 54. The cylinder 52 is configured to be eccentrically coupled to the drive shaft 44. The rolling piston 54 is tubular and concentric with the cylinder 52. The rolling piston 54 has an outer surface 54A (see Figures 2A and 4) that contacts the inner surface of the cylinder housing 26. The rolling piston 54 is configured to rotate around the cylinder 52 when the drive shaft 44 and the piston device 50 are rotated. The vanes 56 are movably positioned within the vane slots 76.

[0107] Returning to Figures 13A and 13C, in the illustrated embodiment, the vane 56 includes first and second side edges 56C and 56D between the ends 56A and 56B of the vane 56. As shown, one end of the side seal 146 is coupled to one of the first and second side edges 56C and 56D.

[0108] In one embodiment, the first and second seals 146 are made of a material having non-stick and heat-resistant properties, such as a synthetic fluoropolymer. One suitable material is polytetrafluoroethylene (PTFE).

[0109] In the illustrated embodiment, each of the first and second side edges 56C, 56D includes a side slot 56E (only one is shown) configured to receive the first and second seals 146, respectively. In one embodiment, the vane 56 may be made of aluminum, and the side slots 56E, 56F are formed on the side edges 56C, 56D using a milling process. The first and second seals 146 may be attached to the first and second side edges 56C, 56D by friction fitting and / or adhesive or other suitable means.

[0110] The first and second seals 146 are intended to improve compressor performance by minimizing leakage of internal refrigerant (and oil) across the low-pressure and high-pressure sides of the compressor 10. Referring particularly to Figure 13D, in one test, compressor performance (in terms of volumetric efficiency) was improved by approximately 10% at different compressor speeds.

[0111] The above description describes several features of an electronic compressor, including, but not limited to, a compressor with a rolling piston, a subassembly with an integrated discharge chamber, a magnetic debris filter, an oil separator, and vanes with cylindrical vane retainer sleeves and / or side seals. It should be noted that the features described above may be implemented independently or together in any combination.

[0112] The above invention is described in accordance with the relevant legal standards, and therefore the description is illustrative and not limiting in nature. Variations and modifications to the disclosed embodiments may be obvious to those skilled in the art and fall within the scope of the invention.

Claims

1. A magnetic debris filter (100) for use with an electric compressor (10), wherein the electric compressor (10) is configured to compress a refrigerant, and comprises a housing (12), a refrigerant inlet port (60), a refrigerant outlet port (62), and a compression device (18), wherein the housing (12) has a central axis (78) defining an intake volume (64), the electric compressor (10) includes a compression chamber (58), the compression device (18) is disposed within the compression chamber (58), and the refrigerant inlet port (60) is coupled to the housing (12) and is located in front of the intake volume (64). A magnetic debris filter (100) is configured to introduce a refrigerant, the refrigerant outlet port (62) is coupled to the housing (12), and the compressed refrigerant is configured to exit the electric compressor (10), the housing (12), the compressor (18), and the compression chamber (58) define a refrigerant flow path (98) between the refrigerant inlet port (60) and the refrigerant outlet port (62), and the housing (12) defines a filter mounting opening (102) located after the compressor (18) within the refrigerant flow path (98), A filter frame (104) disposed within the filter mounting opening (102), the filter frame (104) having a magnet opening (104A), A magnetic element (106) having magnetic properties configured to collect debris from the electric compressor (10), and located within the magnet opening (104A), A magnetic debris filter (100) equipped with the following.

2. The magnetic debris filter (100) according to claim 1, wherein the magnetic element (106) is a magnet (106A).

3. The magnetic debris filter (100) according to claim 1, wherein the magnetic element (106) includes one or more magnets (106A) embedded in a substrate.

4. The magnetic debris filter (100) according to claim 1, wherein the magnetic element (106) is press-fitted into the magnet opening (104A).

5. The magnetic debris filter (100) according to claim 1, wherein the housing (12) includes a cylinder housing and the filter mounting opening (102) is located within the cylinder housing (26).

6. The magnetic debris filter (100) according to claim 1, wherein the filter frame (104) is made of aluminum.

7. The magnetic debris filter (100) according to claim 1, wherein the filter frame (104) includes at least one refrigerant opening (104A).

8. An electric compressor (10) configured to compress a refrigerant, A housing (12) having a central axis (78) that defines an intake volume (64) and a discharge volume (66), and a housing (12) that further defines a compression chamber (58), A refrigerant inlet port (60) is coupled to the housing (12) and configured to introduce the refrigerant into the suction volume (64), A refrigerant outlet port (62) is coupled to the housing (12) and is configured to allow the compressed refrigerant to exit the electric compressor (10) from the discharge volume (66), A compressor (18) is disposed within the compression chamber (58) and coupled to a drive shaft (44), wherein the compressor (18) receives the refrigerant from the suction volume (64) and is configured to compress the refrigerant when the drive shaft (44) is rotated, and the housing (12), the compressor (18), and the compression chamber (58) define a refrigerant flow path (98) between the refrigerant inlet port (60) and the refrigerant outlet port (62), and the housing (12) defines a filter mounting opening (102) located after the compressor (18) in the refrigerant flow path (98), A magnetic debris filter (100), A filter frame (104) disposed within the filter mounting opening (102), the filter frame (104) having a magnet opening (104A), A magnetic element (106) having magnetic properties configured to collect debris from the electric compressor (10), and positioned within the magnet opening (104A), A magnetic debris filter (100) including, An electric compressor (10) equipped with the following features.

9. The electric compressor (10) according to claim 8, wherein the magnetic element (106) is a magnet (106A).

10. The electric compressor (10) according to claim 8, wherein the magnetic element (106) includes one or more magnets (106A) embedded in a substrate.

11. The electric compressor (10) according to claim 8, wherein the magnetic element (106) is press-fitted into the magnet opening (104A).

12. The electric compressor (10) according to claim 8, wherein the housing (12) includes a cylinder housing (26), and the filter mounting opening (102) is located within the cylinder housing (26).

13. The compression device (18) is A piston device (50) comprising a cylinder (52) and a rolling piston (54), wherein the cylinder (52) is eccentrically coupled to the drive shaft (44), the cylinder (52) has a circular outer circumference, the rolling piston (54) is tubular and concentric with the cylinder (52), the rolling piston (54) has an outer surface (54A) that contacts the inner surface (58A) of the compression chamber (58), and the drive shaft (44) and the piston device (50) are rotated by the motor, causing the rolling piston (54) to rotate around the cylinder (52), A vane (56) is movably coupled to the housing (12) and has an end (56A) adjacent to the compression chamber (58), wherein the vane (56) is biased such that the end (56A) of the vane (56) contacts the rolling piston (54) when the piston device (50) is rotated by the drive shaft (44), and when the piston device (50) rotates within the compression chamber (58), the housing The ng (12), the piston device (50), and the vane (56) form a variable sub-chamber (56A, 56B, 56C) within the compression chamber (58), and the refrigerant enters one of the variable sub-chambers (56A, 56B, 56C) from the suction volume (64), is compressed when the piston device (50) is rotated, exits one of the sub-chambers (56A, 56B, 56C) and enters the discharge volume (66), and the vane (56) The electric compressor (10) according to claim 8, including the following:

14. The electric compressor (10) according to claim 8, wherein the filter frame (104) includes at least one refrigerant opening (104A).

15. An electric compressor (10) configured to compress a refrigerant, A housing (12) having a central axis (78) defining an intake volume (64) and a discharge volume (66), wherein the housing (12) further defines a compression chamber (58), the housing (12) includes a cylinder housing (26), the compression chamber (58) is formed by the cylinder housing (26) and has an open end (56D) adjacent to a first side surface of the cylinder housing (26), and the compressed refrigerant exits the compression chamber (58) through an orifice (76C) and enters the discharge chamber, the housing (12), A refrigerant inlet port (60) is coupled to the housing (12) and configured to introduce the refrigerant into the suction volume (64), A refrigerant outlet port (62) is coupled to the housing (12) and is configured to allow the compressed refrigerant to exit the electric compressor (10) from the discharge volume (66) through the orifice (76C), A motor is mounted inside the housing (12), A drive shaft (44) is coupled to the motor and configured to rotate about the central axis (78), A compressor (18) is disposed within the compression chamber (58) and coupled to the drive shaft (44), wherein the compressor (18) receives the refrigerant from the suction volume (64) and is configured to compress the refrigerant when the drive shaft (44) is rotated by the motor, and the housing (12), the compressor (18), and the compression chamber (58) define a refrigerant flow path (98) between the refrigerant inlet port (60) and the refrigerant outlet port (62), and the housing (12) defines a filter mounting opening (102) located after the compressor (18) in the refrigerant flow path (98), A magnetic debris filter (100), A filter frame (104) disposed within the filter mounting opening (102), the filter frame (104) having a magnet opening (104A), A magnetic element (106) having magnetic properties configured to collect debris from the electric compressor (10), and positioned within the magnet opening (104A), A magnetic debris filter (100) including, An electric compressor (10) equipped with the following features.

16. The electric compressor (10) according to claim 15, wherein the magnetic element (106) is a magnet (106A).

17. The electric compressor (10) according to claim 15, wherein the magnetic element (106) includes one or more magnets (106A) embedded in a substrate.

18. The electric compressor (10) according to claim 15, wherein the magnetic element (106) is press-fitted into the magnet opening (104A).

19. The electric compressor (10) according to claim 15, wherein the housing (12) includes a cylinder housing (26), and the filter mounting opening (102) is located within the cylinder housing (26).

20. The electric compressor (10) according to claim 15, wherein the filter frame (104) is made of aluminum.

21. The compression device (18) is A piston device (50) comprising a cylinder (52) and a rolling piston (54), wherein the cylinder (52) is eccentrically coupled to the drive shaft (44), the cylinder (52) has a circular outer circumference, the rolling piston (54) is tubular and concentric with the cylinder (52), the rolling piston (54) has an outer surface (54A) that contacts the inner surface (58A) of the compression chamber (58), and the rolling piston (54) rotates around the cylinder (52) when the drive shaft (44) and the piston device (50) are rotated by the motor, A vane (56) is movably coupled to the housing (12) and has an end (56A) adjacent to the compression chamber (58), wherein the vane (56) is biased such that the end (56A) of the vane (56) contacts the rolling piston (54) when the piston device (50) is rotated by the drive shaft (44), and when the piston device (50) is rotated within the compression chamber (58), the housing (12) The sing (12), the piston device (50), and the vane (56) form a variable sub-chamber (56A, 56B, 56C) within the compression chamber (58), and the refrigerant enters one of the variable sub-chambers (56A, 56B, 56C) from the suction volume (64), is compressed when the piston device (50) is rotated, exits one of the sub-chambers (56A, 56B, 56C) and enters the discharge volume (66), the vane (56) and The electric compressor (10) according to claim 15, including the following:

22. The electric compressor (10) according to claim 15, wherein the housing (12) includes a central housing (20) and a rear head (24), and the discharge volume (66) is formed at least partially by the central housing (20), the rear head (24), and the refrigerant outlet port (62).

23. The electric compressor (10) according to claim 22, wherein the housing (12) includes an inverter cover, the central housing (20) and the inverter cover form an inverter cavity, and the electric compressor (10) further includes an inverter module mounted in the inverter cavity and configured to convert DC power to AC power.

24. The electric compressor (10) according to claim 21, wherein the cylinder (52) has an internal chamber (52A), and the cylinder (52) has a center of rotational mass about the central axis (78).

25. The electric compressor (10) according to claim 24, wherein the housing (12) includes vane slots, and the vanes (56) are slidably positioned within the vane slots.

26. The electric compressor (10) according to claim 25, wherein the vane slot is connected to the discharge volume (66), and the vane (56) is biased toward the piston device (50) by the refrigerant in the discharge volume (66).

27. The electric compressor (10) according to claim 23, wherein the housing (12) includes a cylinder housing (26), and the vane slots are located within the cylinder housing (26).

28. The electric compressor (10) according to claim 15, wherein the filter frame (104) includes at least one refrigerant opening (104A).

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