Compressor having cold air passage and coolant passage in axial heat exchanger configuration

Abstract

To provide a compressor having a bearing cooling system providing improved cooling performance.SOLUTION: A compressor device includes a motor cooling system that provides a first flow of a first fluid through a housing for cooling a motor. The motor cooling system includes a first fluid flow section at a first axial position. The first fluid flow section extends in a downstream direction radially with respect to the axis of rotation. Also, the device includes a bearing cooling system that provides a second flow of a second fluid through the housing for cooling the bearing. The bearing cooling system includes a second flow section at a second axial position spaced apart axially from the first axial position. The second flow section extends in a downstream direction radially with respect to the axis of rotation. The first flow section and the second flow section are disposed in a heat exchanger arrangement configured to transfer heat between the second fluid and the first fluid.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001]

[0001] The present disclosure relates generally to compressors, and more particularly to compressors having cold air passages and coolant passages arranged in an axial heat exchanger configuration. [Background technology]

[0002]

[0002] Various systems include compressors to provide compressed fluids. For example, fuel cell systems often include a fuel cell compressor to compress air before it is supplied to the fuel cell stack. This can increase the operating efficiency of the fuel cell system.

[0003] However, conventional compressors can suffer from various deficiencies. For example, some compressors may include fluid-cooled bearings. Cooling the bearings can be difficult, resulting in inefficient operation and / or premature wear. Additionally, the cooling systems within conventional compressors can be large. Furthermore, manufacturing these compressors can be costly and inefficient.

[0004]

[0004] It is therefore desirable to provide a compressor having a bearing cooling system that provides improved cooling performance. It is further desirable that the bearing cooling system be highly compact and highly manufacturable. Other desirable features and characteristics of the present disclosure will become apparent from the subsequent detailed description and appended claims, taken in conjunction with the accompanying drawings and this description of the background art. Summary of the Invention

[0005] In one embodiment, a compressor device is disclosed that includes a housing, a rotating group having a compressor wheel, and a bearing that supports rotation of the rotating group within the housing about a rotational axis. The compressor device also includes a motor that drives rotation of the rotating group about the rotational axis. The compressor device further includes a motor cooling system that provides a first flow of a first fluid through the housing to cool the motor. The motor cooling system includes a first fluid flow portion at a first axial location. The first fluid flow portion extends radially downstream relative to the rotational axis. The compressor device further includes a bearing cooling system that provides a second flow of a second fluid through the housing to cool the bearings. The bearing cooling system includes a second flow portion at a second axial location axially spaced from the first axial location. The second flow portion extends radially downstream relative to the rotational axis. The first flow portion and the second flow portion are arranged in a heat exchanger configuration configured to transfer heat between the second fluid and the first fluid.

[0006] In another embodiment, a method of manufacturing a compressor device is disclosed. The method includes enclosing a rotating group of the compressor device within a housing of the compressor device, the rotating group including a compressor wheel. The method also includes enclosing a motor of the compressor device within the housing, the motor configured to drive rotation of the rotating group about an axis of rotation. The method further includes supporting rotation of the rotating group within the housing about the axis of rotation with a bearing of the compressor device. The method also includes providing a motor cooling system that provides a first flow of a first fluid through the housing to cool the motor. The motor cooling system includes a first fluid flow portion at a first axial location. The first fluid flow portion extends radially downstream relative to the axis of rotation. The method further includes providing a bearing cooling system that provides a second flow of a second fluid through the housing to cool the bearing. The bearing cooling system includes a second flow portion at a second axial location axially spaced from the first axial location. The second flow portion extends radially downstream relative to the axis of rotation. The method additionally includes disposing the first flow portion and the second flow portion in a heat exchanger arrangement configured to transfer heat between the second fluid and the first fluid.

[0007] In a further embodiment, a compressor device includes a housing including a compressor housing, a motor housing, and an inner member, wherein the compressor housing has an inlet, a diffusion region, and a spiral passage, and the inner member has a diffusion portion adjacent to the diffusion region and a thrust bearing portion. The compressor device also includes a rotating group having a compressor wheel and a bearing supporting rotation of the rotating group within the housing about a rotational axis. The compressor device further includes a motor driving rotation of the rotating group about the rotational axis such that the compressor wheel compresses air flowing from the inlet, through the diffusion region, and into the spiral passage. The compressor device further includes a motor cooling system providing a first flow of coolant through the motor housing and partially through the inner member of the housing to cool the motor. The motor cooling system includes a first fluid flow portion at a first axial location. The first fluid flow portion extends radially downstream relative to the rotational axis. The compressor device further includes a bearing cooling system receiving a quantity of air from the spiral passage and providing a second flow of air through the housing to cool the bearings. The bearing cooling system includes a second flow portion at a second axial location axially spaced from the first axial location, the second flow portion extending radially downstream relative to the axis of rotation, and the first and second flow portions arranged in a heat exchanger arrangement configured to transfer heat from air to a cooling liquid.

[0008]

[0008] The present disclosure is hereinafter described in conjunction with the following drawings, in which like numerals refer to like elements and in which: [Brief explanation of the drawings]

[0009] [Figure 1]

[0009] FIG. 1 is a schematic diagram of a compressor device according to an exemplary embodiment of the present disclosure shown incorporated within a fuel cell system. [Figure 2]

[0010] FIG. 2 is a first longitudinal cross-sectional view of the compressor device of FIG. 1; [Figure 3]

[0011] FIG. 2 is a second longitudinal cross-sectional view of the compressor device of FIG. 1; [Figure 4]

[0012] 4 is an axial cross-sectional view of the compressor device taken along line 4-4 of FIG. 1. [Figure 5]

[0013] 10 is an axial cross-sectional view of a compressor device according to an additional example embodiment; [Figure 6]

[0014] 10 is an axial cross-sectional view of a compressor device according to an additional example embodiment; [Figure 7]

[0015] 10 is an axial cross-sectional view of a compressor device according to an additional example embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0010]

[0016] The following detailed description is merely exemplary in nature and is not intended to limit the present disclosure or the application and uses of the present disclosure. Furthermore, there is no intention to be bound by the preceding background or any theory presented in the following detailed description.

[0011]

[0017] Broadly, example embodiments disclosed herein include compressor devices, such as e-chargers or electric compressors, having bearing cooling systems that provide improved bearing cooling and, therefore, improved operation and wear protection for the bearings of the compressor devices. The compressor devices are also compact and highly manufacturable.

[0012]

[0018] The compressor device may include a housing and a rotating group that rotates within the housing about a rotational axis. The compressor device may include a bearing, such as an air bearing, that supports rotation of the rotating group within the housing. The compressor device may further include a motor, such as an electric motor, that drives rotation of the rotating group about the rotational axis. Furthermore, the compressor device may include a motor cooling system through which a first coolant flows to cool the motor. The compressor device may additionally include a bearing cooling system through which a second coolant flows to cool the bearings. The motor cooling system and the bearing cooling system may include respective portions that are arranged together in a heat exchanger configuration within the housing to transfer heat between the first and second fluids. In some embodiments, one or more flow portions of the motor cooling system may be arranged in a heat exchanger configuration with one or more flow portions of the bearing cooling system, the flow portions being spaced apart along the axis of the compressor device. In further embodiments, a flow portion may be arranged between the first and second flow portions of the motor cooling system relative to the rotational axis. The motor cooling system and the bearing cooling system may be configured such that heat is transferred from the second coolant (of the bearing cooling system) to the first coolant (of the motor cooling system) to cool the second coolant, which may ultimately increase operating efficiency and provide wear protection for the compressor device.

[0013]

[0019] Also, in some embodiments, one or more parts may define multiple regions of the compressor device. For example, a single part may define at least a portion of the compressor flow passage (e.g., a diverging region and / or a portion of the volute flow passage) and may also define a portion that supports the bearings of the compressor device. Furthermore, in some embodiments, the part may define a portion of the bearing cooling system and / or the motor cooling system. These features may improve manufacturability, reduce part count, and / or provide additional benefits.

[0014]

[0020] 1 , a compressor device 102 is shown in accordance with an exemplary embodiment. The compressor device 102 may be an e-charger or an electric compressor device. Also, as shown, the compressor device 102 may be incorporated within a fuel cell system 100, although it should be understood that the compressor device 102 may be incorporated into another system without departing from the scope of the present disclosure.

[0015]

[0021] In some embodiments, fuel cell system 100 may be included in a vehicle such as an automobile, truck, sport utility vehicle, van, motorcycle, etc. However, it should be understood that fuel cell system 100 may be configured for different uses without departing from the scope of the present disclosure.

[0016]

[0022] Fuel cell system 100 may include a fuel cell stack 104 containing multiple fuel cells. Hydrogen may be supplied to fuel cell stack 104 from tank 106, and oxygen may be supplied to fuel cell stack 104 to produce electricity through known chemical reactions. Fuel cell stack 104 may generate electricity for an electric device, such as an electric motor 105. As mentioned, fuel cell system 100 may be included in a vehicle, and thus, in some embodiments, electric motor 105 may convert electrical power to mechanical power to drive and rotate an axle (and thus one or more wheels) of the vehicle. Oxygen may be provided to fuel cell stack 104, at least in part, by compressor device 102.

[0017]

[0023] 1-3, compressor device 102 may generally include a rotating group 118 and a housing 119 that houses and encloses rotating group 118. Rotating group 118 is supported for rotation within housing 119 about a rotational axis 120 by one or more bearings 121.

[0018]

[0024] Rotating group 118 may generally include an elongated cylindrical shaft 140 having a first end 142 and a second end 144. Rotating group 118 may also include a compressor wheel 130 secured to first end 142 of shaft 140. Compressor wheel 130 may include a front side 146 having a plurality of blades 147 and an opposite back side 148 facing toward second end 144. In some embodiments, bearing 121 may be configured as a plain bearing, an air bearing, and / or an oil-free bearing.

[0019]

[0025] The compressor device 102 may define a motor portion 112. The motor portion 112 may include an electric motor 134 housed within a motor housing 150 of the housing 119. The motor 134 may generally include a rotor 136 and a stator 138 of known types. The rotor 136 may be mounted on a shaft 140, and the stator 138 may surround the rotor 136. The rotor 136 and the stator 138 may be housed and contained within a thin-walled motor case 139. The motor case 139 of the motor 134 may be fixed and supported within the motor housing 150, with one or more air gaps therebetween. A first end 142 and a second end 144 of the shaft 140 may extend out to respective sides of the motor case 139 and may be supported within the motor housing 150 by bearings 121. Thus, motor 134 may be operatively attached to rotating group 118 to drive rotation of rotating group 118 within housing 119 about axis 120 .

[0020]

[0026] The compressor device 102 may also include a compressor portion 110. The compressor portion 110 may include a compressor wheel 130 housed within a compressor housing 152 of the housing 119. The compressor housing 152 may define a compressor flowpath 151 having a tubular inlet 153 centered about the axis 120. The inlet 153 may have various shapes and contours without departing from the scope of the present disclosure. The flowpath 151 of the compressor housing 152 may also define at least a portion of a spiral passage 154 extending around the axis 120. In some embodiments, the compressor housing 152 may be a unitary (single-piece) component manufactured by a casting operation, an additive manufacturing process, or other method. The compressor housing 152 may be fixedly attached to an axial face 156 of the motor housing 150 and may cover the front side 146 of the compressor wheel 130. Compressor wheel 130 may be driven to rotate by motor 134 about shaft 120 within compressor housing 152 of compressor section 110 .

[0021]

[0027] In some embodiments, the compressor device 102 may include an intermediate housing member 158. The intermediate housing member 158 may define a portion of the housing 119 and, in some embodiments, a portion of the bearing 121. Accordingly, the intermediate housing member 158 may be, and will be, referred to hereinafter as a “thrust cover.” The thrust cover 158 may, in some embodiments, be a unitary, one-piece, disk-like component. The thrust cover 158 may include a first axial surface 160 and a second axial surface 162. The thrust cover 158 may be disposed between the compressor portion 110 and the motor portion 112 and / or at a transition between the compressor portion 110 and the motor portion 112. The first axial surface 160 may face toward the compressor housing 152 and the backside 148 of the compressor wheel 130. The first outer radial edge 163 may face, engage, and / or be fixedly attached to the compressor housing 152, and the second outer radial edge 164 may face, engage, and / or be fixedly attached to the motor housing 150. The second axial surface 162 may face, engage, and / or be fixedly attached to the axial surface 156 of the motor housing 150. As such, the diverging portion 170 of the thrust cover 158 may cooperate with the compressor housing 152 to define a diverging region 172 of the compressor device 102 that is disposed radially outward from the outer radial edge of the compressor wheel 130. Further outward, the first axial surface 160 of the thrust cover 158 may cooperate to define an entrance into the spiral passage 154. Second axial surface 162 and other portions of thrust cover 158 may also define one or more fluid passages, regions, chambers, etc., as described in detail below. Additionally, thrust cover 158 may include a thrust bearing portion 174 on its inner radial portion for defining and / or supporting bearing 121. As shown, thrust bearing portion 174 may be axially received between an annular compressor collar 176 and a thrust disk 178 of bearing 121.

[0022]

[0028] During operation of the compressor device 102, an inlet airflow (represented in FIG. 1 by arrow 122) may flow into the inlet 153, and the inlet airflow 122 may be compressed as it flows downstream between the compressor wheel 130 and the compressor housing 152, through the diffusion region 172, and into the spiral passage 154. The compressed airflow (represented by arrow 124) may exit the spiral passage 154 and be directed to the intercooler 128 and then to the fuel cell stack 104 to increase the operating efficiency of the fuel cell system 100.

[0023]

[0029] Additionally, the exhaust gas flow (represented by arrow 132) from the fuel cell stack 104 may be exhausted to the atmosphere, as depicted in FIG. 1 . Stated differently, the exhaust gas flow 132 may be directed away from the compressor device 102. Thus, the rotating group 118 may be driven to rotate without the need for a turbine. In other words, the rotating group 118 may be turbine-less and, in some embodiments, may be driven solely by the electric motor 134. In other embodiments, the exhaust gas flow 132 may be directed back toward the compressor device 102 to drive the rotation of, for example, a turbine wheel included in the rotating group 118. This, in turn, may drive the rotation of the compressor wheel 130, assisting, for example, the electric motor 134.

[0024]

[0030] Additionally, compressor device 102 may include motor cooling system 180. Generally, motor cooling system 180 may provide a first flow of a first fluid (e.g., a coolant) through housing 119 to cool motor 134. Motor cooling system 180 may also route through housing 119 to cool bearings 121 and surrounding structure, as discussed. Motor cooling system 180 may include an inlet 181 and an outlet 182 (both shown schematically in FIG. 1 ), as well as multiple passages, chambers, etc., forming one or more continuous fluid paths connecting inlet 181 and outlet 182.

[0025]

[0031] As shown in FIG. 1 , the motor cooling system 180 may include a coolant jacket 184 defined by the gap between the motor case 139 and the motor housing 150. The coolant jacket 184 may be subdivided into an outer diameter 186, a first axial end 188, and a second axial end 189, which collectively surround the motor 134. As shown in FIG. 3 , the motor cooling system 180 may further include a first axial channel 190 extending generally axially from the outer diameter 186 through the motor housing 150 toward the compressor section 110. The first axial channel 190 may be straight or may have a rounded (circular) cross-section (perpendicular to the flow direction). The first axial channel 190 may also extend axially at an angle 191 to the axis 120 toward the axial face 156 of the motor housing 150. The first axial channel 190 may be open at the axial face 156 where the first axial channel 190 fluidly connects with and intersects with a radial flow portion 192 of the motor cooling system 180 .

[0026]

[0032] The radial flow portion 192 may be at least partially defined by an annular groove 194 in the thrust cover 158. The groove 194 may be defined between the first and second outer radial edges 163, 164 of the thrust cover 158. As such, the groove 194 may extend radially inward from the outer diameter edge of the thrust cover 158. The radial flow portion 192 may also extend circumferentially around the shaft 120. The radial flow portion 192 may be fluidly connected with a second axial channel 196 ( FIG. 3 ) of the motor cooling system 180. The second axial channel 196 may extend generally axially from the axial face 156 into the motor housing 150, away from the compressor portion 110, and may be fluidly connected with the outer diameter portion 186 of the cooling jacket 184. 3, the second axial channel 196 may be disposed on the opposite side of the axis 120 from the first axial channel 190 (e.g., spaced 180 degrees around the axis 120). The second axial channel 196 may also be disposed at an angle (e.g., the reciprocal of the angle 191 of the first axial channel 190).

[0027]

[0033] Thus, motor cooling system 180 may define one or more fluid flow paths for a first coolant (e.g., a coolant liquid) to flow downstream from inlet 181 to outlet 182. During operation, the first fluid may flow from inlet 181 to coolant jacket 184. From there, the first fluid may flow through first axial channel 190 and into radial flow portion 192. There, the fluid may flow circumferentially around shaft 120 and radially inward toward shaft 120 through thrust cover 158. Moving further downstream, the fluid may flow to second axial channel 196, back to coolant jacket 184, and then to outlet 182.

[0028]

[0034] Additionally, compressor device 102 may include bearing cooling system 200. Generally, bearing cooling system 200 may provide a second flow of a second fluid (e.g., air or other gas coolant) through housing 119 to cool bearings 121. Bearing cooling system 200 may also be routed through housing 119 such that it is arranged in a heat exchanger configuration with motor cooling system 180, as discussed.

[0029]

[0035] Bearing cooling system 200 may include an inlet 202 and an outlet 204. In some embodiments, inlet 202 and / or outlet 204 may be in fluid communication with compressor flowpath 151. For example, as shown in FIG. 1 , inlet 202 may be fluidly connected to compressor flowpath 151 (e.g., at spiral passage 154) to receive airflow therefrom, and outlet 204 may be fluidly connected to a return flow back to compressor flowpath 151 (e.g., at inlet 153). Bearing cooling system 200 may also include multiple passages, chambers, etc. that form one or more continuous fluid paths connecting inlet 202 and outlet 204.

[0030]

[0036] 2, the inlet 202 may include a Pitot tube (a "reverse" Pitot tube) disposed within and fluidly connected to the spiral passage 154. The bearing cooling system 200 also includes one or more holes 206 that form a passageway extending radially inward from the axial face 156 and through the motor housing 150.

[0031]

[0037] The bearing cooling system 200 may further include a flow portion 210. In some embodiments, the flow portion 210 may be cooperatively defined by the second axial surface 162 of the thrust cover 158 and the axial surface 156 of the motor housing 150. For example, the second axial surface 162 and / or the axial surface 156 may include one or more recesses 212 defined between one or more walls 214. In the illustrated embodiment, for example, both the axial surfaces 156, 162 include respective recesses 212 and walls 214 that are aligned axially (i.e., along the axis 120) to define various zones through the flow portion 210 of the bearing cooling system 200. Stated differently, as shown in FIG. 2 , the axial surface 156 may include a first recess 220 that is axially aligned with the second recess 222 of the axial surface 162 to cooperatively define a zone 224 of the flow portion 210. As shown, there may be multiple sections 224 of the flow portion 210 defined between the axial surfaces 156, 162.

[0032]

[0038] As depicted in FIGS. 4-7 , the sections 224 of the flow section 210 can be arranged together as a continuous flow path. As shown, the sections 224 can have various configurations without departing from the scope of the present disclosure. The flow path through the flow section 210, as well as the downstream direction of the flow path, is indicated in each of the embodiments of FIGS. 4-7 by arrow 226. As shown, the flow path 226 can extend radially downstream relative to the rotational axis 120. More specifically, in some embodiments, the flow path 226 can extend radially inward relative to the rotational axis 120. Also, the flow path 226 of the flow section 210 can extend from one side of the rotational axis 120 to the opposite side of the rotational axis 120, as shown in FIGS. 4-7 . In some embodiments, the flow path 226 can extend both radially and circumferentially around the rotational axis 120. The flow path 226 can extend in an arcuate and / or linear manner, as well as straight when it extends downstream.

[0033]

[0039] 4 , the flow path 226 through the flow section 210 includes a plurality of arcuate sections, including a first arcuate section 232, a second arcuate section 234, and a third arcuate section 236, each extending arcuately around the axis 120. The arcuate sections 232, 234, 236 may each have a different radius, and the radius of each may remain substantially constant relative to the axis of rotation 120. The arcuate sections 232, 234, 236 may be concentric, with the second arcuate section 234 radially disposed between the first arcuate section 232 and the third arcuate section 236 about the axis 120. Also, a first circumferential gap 238 may be present in one of the walls 214, and the gap 238 may fluidly connect the first and second arcuate sections 232, 234. Similarly, a second circumferential gap 240 may be present in another wall 214, and the gap 240 may fluidly connect the second and third arcuate sections 234, 236. The flow path 226 may have an input region 228 defined in the first (outer) arcuate section 232, and the flow path 226 may extend downstream along a serpentine path in an opposite circumferential direction through the first arcuate section 232, then radially inward through the gap 238 into the second arcuate section 234, then circumferentially in an opposite direction through the second arcuate section 234, then radially inward through the gap 240 into the third arcuate section 236, and finally to the output region 230 of the flow portion 210.

[0034]

[0040] In an additional embodiment depicted in FIG. 5 , the flow portion 210 may include an arcuate section 242 extending circumferentially and radially inward, spiraling from its input region 228 to its output region 230 toward the axis 120. In a further embodiment depicted in FIG. 6 , the flow portion 210 may include a plurality of longitudinally straight sections 244 connected end-to-end to extend from one side of the axis 120 to the other from its input region 228 to its output region 230. As shown in FIG. 6 , the flow passages 226 may gradually extend radially inward relative to the axis 120 (i.e., gradually closer to the axis 120) as the flow passages 226 extend around the axis 120. Furthermore, in an embodiment depicted in FIG. 7 , the flow portion 210 may include a plurality of longitudinally straight sections 246 connected end-to-end to extend from one side of the axis 120 to the other and back. As shown, the input region 228 may be on one side and disposed radially outward. The flow passages 226 may branch off in the opposite direction from the input region 228, make a vertical turn, extend to the opposite side of the axis 120, and then make another vertical turn and extend back to the original side of the axis 120. As shown, the flow passages 226 may extend gradually radially inward relative to the axis 120 (i.e., gradually closer to the axis 120).

[0035]

[0041] 3 , bearing cooling system 200 may further include a first bearing injection passage 250 fluidly connecting power region 230 to thrust and / or journal components of bearing 121. For example, first bearing injection passage 250 may be a passage extending radially inward through an inner diameter of thrust cover 158 to fluidly connect power region 230 of flow portion 210 to a gap on one axial side of thrust disk 178. Thus, fluid (air) from compressor flowpath 151 may be provided by bearing cooling system 200 to cool bearing 121. Bearing cooling system 200 may also include a second bearing injection passage 251 fluidly connecting power region 230 to thrust and / or journal components of bearing 121. For example, the second bearing injection passage 251 may include a hole extending axially toward the motor 134 to fluidly connect the output region 230 of the flow portion 210 to the gap between the motor case 139 and the motor housing 150. (There may be an annular sealing member 255 that seals the coolant in the first axial end 188 and separates it from the air provided by the second bearing injection passage 251.) There may also be an axial passage 253 defined between the shaft 140 and an inner radial lip 254 of the motor housing 150 that supplies air from the second bearing injection passage 251 to the other axial side of the thrust disk 178. Air in this region may similarly flow to the journal elements of the bearing 121. Additionally, the bearing cooling system 200 may include features that define further downstream flow paths.

[0036]

[0042] Thus, during operation, inlet 202 of bearing cooling system 200 may receive air from compressor flowpath 151. This air may flow downstream through holes 206 ( FIG. 2 ) and to input region 228 of flow portion 210. The flow may continue radially inward along flow path 226 of flow portion 210 and to bearing 121 via first and second bearing injection paths 250, 251. The air may eventually flow to outlet 204.

[0037]

[0043] The outlet 204 is represented schematically in FIGS. 1 and 2 . As shown, the outlet 204 may be an elongated passage defined through one or more portions of the housing 119 and extending back to fluidly connect to the inlet 153 of the compressor flowpath 151. In some embodiments, the outlet 204 may extend from a region proximate the second end 144 of the shaft 140 through the motor housing 150 and / or the compressor housing 152 to fluidly connect to the inlet 153. A first end outlet branch 260 ( FIG. 2 ) may also be present. The branch 260 may be a radially extending bore. The branch 260 may extend through the motor housing 150 to an axial location between the motor 134 and the axial face 156. The branch 260 may intersect with the portion of the outlet 204 extending from the second end 144. As such, flow from the branch 260 may return to the inlet 153. Also, in some embodiments, at least a portion of outlet 204 may extend along the outside of housing 119. Thus, outlet 204 may return the second fluid of bearing cooling system 200 to inlet 153 of compressor flowpath 151 upstream of compressor wheel 130.

[0038]

[0044] The bearing cooling system 200 and the motor cooling system 180 may be arranged together in a heat exchanger configuration such that heat is transferred therebetween. For example, the flow portion 210 of the bearing cooling system 200 and the axial end 188 of the motor cooling system 180 may be arranged at different axial positions along the axis 120, and heat may be exchanged between the fluids axially (i.e., generally along the axis 120) through an intervening portion 270 of the motor housing 150. The flow portion 210 and the radial flow portion 192 of the motor cooling system 180 may also be arranged at different axial positions along the axis 120, and heat may be exchanged between the fluids axially through an intervening portion 272 of the thrust cover 158. For example, in some embodiments and / or under some operating conditions, the air in the flow portion 210 of the bearing cooling system 200 flows at a higher temperature than the coolant in the radial flow portion 192 and the axial end 188 of the motor cooling system 180. The cooling fluid may therefore be a heat sink and may accept heat from the air within the flow section 210 during such operation.

[0039]

[0045] Thus, the heat exchanger configuration of the bearing and motor cooling systems 180, 200 may provide effective cooling for the bearing 121, which may ultimately increase the operating efficiency of the compressor device 102. These features may also make the compressor device 102 robust for a long operational life of the compressor device 102. Furthermore, the compressor device 102 may be compact and lightweight due to the features discussed above. In addition, the compressor device 102 of the present disclosure is highly manufacturable due to a relatively low part count and a simple assembly process.

[0040]

[0046] While at least one exemplary embodiment has been presented in the foregoing detailed description, it should be understood that numerous variations exist. It should also be understood that the exemplary embodiment is merely an example and is not intended to limit the scope, applicability, or configuration of the present disclosure in any way. Rather, the foregoing detailed description is intended to provide those skilled in the art with a convenient road map for implementing exemplary embodiments of the present disclosure. It should be understood that various changes can be made in the function and arrangement of elements described in the exemplary embodiment without departing from the scope of the present disclosure as set forth in the appended claims. [Explanation of symbols]

[0041] 100 Fuel Cell System 102 Compressor Device 104 Fuel Cell Stack 105 Electric Motor 106 Tank 110 Compressor part 112 Motor part 118 Rotation Group 119 Housing 120 Rotational Axis 121 Bearings 122 Inlet airflow 124 Compressed Airflow 128 Intercooler 130 Compressor wheel 132 Exhaust gas flow 134 Electric Motor 136 Rotor 138 Stator 139 Motor Case 140 shaft 142 First Edge 144 Second Edge 146 Front 147 Blade 148 Backside 150 motor housing 151 Compressor flow path 152 Compressor housing 153 Entrance 154 Spiral Passage 156 Axial surface 158 Intermediate housing member / thrust cover 160 First axial surface 162 Second Axis Surface 163 first outer radial edge portion 164 second outer radial edge portion 170 Diffusion section 172 Diffusion Region 174 Thrust bearing part 176 Compressor Color 178 Thrust Disc 180 Motor Cooling System 181 Entrance 182 Exit 184 Coolant jacket 186 Outer diameter part 188 first shaft end 189 Second shaft end 190 First Axial Channel 192 Radial flow section 194 Groove 196 Second Axial Channel 200 Bearing Cooling System 202 Entrance 204 Exit 206 holes 210 Flow section 212 recess 214 Wall 222 Second recess 220 First recess 224 areas 226 Channel 228 Input Area 230 Output Area 232 First Arcuate Area 234 Second Arcuate Area 236 Third Arc Section 238 First circumferential gap 240 Second circumferential gap 242 Arcuate area 244 Longitudinal straight area 250 First bearing injection path 251 Second bearing injection path 253 Axial path 254 Inner Radial Lip 255 Sealing member 260 First End Exit Branch 270 Interposition part 272 Interposition part

Claims

1. Housing and a rotating group having a compressor wheel; a bearing that supports rotation of the rotating group within the housing about a rotation axis; a motor that drives the rotation of the rotating group around the rotation axis; providing a first flow of a first fluid through the housing to cool the motor; 1. A motor cooling system, the motor cooling system providing a first fluid flow at a first axial location. the first fluid flow portion extending radially downstream relative to the axis of rotation; a motor cooling system; a shaft providing a second flow of a second fluid through said housing to cool said bearing; a bearing cooling system, the bearing cooling system being axially spaced from the first axial location; a second fluid flow portion at a second axial location where the second fluid flow portion is rotating; a bearing cooling system extending radially downstream relative to the rolling axis; The first fluid flow portion and the second fluid flow portion are a compressor device disposed in a heat exchanger arrangement configured to transfer heat between the compressor device and the fluid; vinegar.

2. The second fluid flow portion extends radially through the second fluid flow portion in the downstream direction.

2. The compressor device of claim 1, wherein the compressor device extends to and about the axis of rotation.

3. The second fluid flow portion includes at least one arcuately extending portion about the axis of rotation. The compressor device of claim 2 including an arcuate section.

4. The at least one arcuate section is configured to rotate both radially and circumferentially relative to the axis of rotation. The compressor device of claim 3 , wherein the compressor device extends from

5. 3. The at least one arcuate section extends at a constant radius relative to the axis of rotation.

2. The compressor device according to claim 1 .

6. The second fluid flow portion includes a plurality of longitudinally straight sections, the plurality of straight sections being arranged end to end so as to extend from one side of the axis of rotation to an opposite side of the axis of rotation.

3. The compressor device of claim 2, wherein the compressor device is connected by

7. The second fluid flow portion extends from one side of the rotation axis to an opposite side of the rotation axis.

2. The compressor device of claim 1 .

8. The housing includes a compressor housing having a spiral passage, and the compressor wheel the coil is configured to compress the flow of the second fluid as the second fluid flows into the spiral passage; the bearing cooling system includes an inlet in communication with the spiral passage; The compressor device of claim 1 , wherein a fluid flow portion is downstream of the inlet.

9. The compressor housing includes a compressor inlet, and the compressor wheel is and receiving the second fluid through the The bearing cooling system directs the second fluid to the compressor inlet upstream of the compressor wheel.

9. The compressor device of claim 8, including an outlet returning to the mouth.

10. a one-piece housing having a diffusion section and a thrust bearing section for compressing the second fluid; Further comprising a member, 2. The method of claim 1, wherein the first fluid flow portion is defined within the unitary housing member. Posted Compressor device.

11. The housing includes a motor housing that houses the motor, the ring has a first axial surface; the one-piece housing member includes a second axial surface opposite the first axial surface; The first axial surface and the second axial surface define at least a portion of the second fluid flow portion. The compressor device of claim 10 , wherein the compressor device cooperatively defines:

12. The first axial surface includes at least one first recess, and the second axial surface includes at least a second recess; The at least one first recess and the at least one second recess are 12. The compressor device of claim 11, wherein the first and second fluid flow portions cooperate to define at least a portion of the fluid flow portion of the compressor. vinegar.

13. The motor cooling system is a second motor that is axially spaced from the first and second axial positions. a third fluid flow portion at a third axial location; The second fluid flow portion is between the first fluid flow portion and the third fluid flow portion. The compressor device of claim 12 , wherein the compressor device is axially disposed in the

14. The second fluid flow portion extends radially inward relative to the axis of rotation in the downstream direction. The compressor device of claim 1 .

15. The compressor device of claim 1 , wherein the bearing is an air bearing.

16. 1. A method of manufacturing a compressor device, comprising: accommodating the rotating group of the compressor device within a housing of the compressor device; wherein the rotating group includes a compressor wheel; housing a motor of the compressor device in the housing, the motor configured to drive rotation of the rotating group about an axis of rotation; The bearings of the compressor device allow the compressor device to rotate within the housing about the axis of rotation. supporting rotations of a rotation group; providing a first flow of a first fluid through the housing to cool the motor; Providing a motor cooling system, the motor cooling system comprising: a first fluid flow portion at a position radially outwardly of the axis of rotation; a step extending downstream in the direction a shaft providing a second flow of a second fluid through said housing to cool said bearing; providing a bearing cooling system, the bearing cooling system being adapted to a second fluid flow portion at a second axial location axially spaced from said second fluid flow portion; a flow portion extending radially downstream relative to the axis of rotation; The first fluid flow portion and the second fluid flow portion are separated by a second fluid and a first fluid. and disposing the fluid in a heat exchanger arrangement configured to transfer heat between the fluid and the heat exchanger arrangement. A method comprising:

17. A housing including a compressor housing, a motor housing, and an inner member, the compressor housing having an inlet, a diffusion region, and a volute passage, the inner member comprising: a housing having a diffusion portion adjacent to the diffusion region and a thrust bearing portion; a rotating group having a compressor wheel; a bearing that supports rotation of the rotating group within the housing about a rotation axis; The compressor wheel passes from the inlet through the diffusion region into the spiral passage. a motor that drives rotation of the rotating group about the rotation axis so as to compress flowing air; through the motor housing to cool the motor, 1. A motor cooling system for providing a first flow of coolant partially through a member, the motor cooling system including a first fluid flow portion at a first axial location, the first fluid flow portion a motor cooling system having a cooling fan extending radially downstream relative to the rotary shaft; A volume of air is received from the spiral passage and directed through the housing for cooling the bearing. a bearing cooling system for providing a second flow of air through said bearing, said bearing cooling system a second fluid flow portion at a second axial location axially spaced from the first axial location; wherein the second fluid flow portion extends radially downstream relative to the rotational axis; The first fluid flow portion and the second fluid flow portion are transferred from the air to the cooling liquid. The compressor device is arranged in a heat exchanger arrangement configured to transfer heat.

18. The first fluid flow portion extends through the inner member of the housing, and the second fluid flow portion extends through the inner member of the housing. is defined by a front surface of the inner member of the housing.

8. The compressor device according to claim 7.

19. The motor cooling system is a second motor that is axially spaced from the first and second axial positions. a third fluid flow portion within the motor housing at a third axial location; The second fluid flow portion is between the first fluid flow portion and the third fluid flow portion.

20. The compressor device of claim 18, wherein the compressor device is axially disposed in the

20. The second fluid flow portion extends radially inward relative to the axis of rotation in the downstream direction.

18. The compressor device of claim 17.

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