Compression module for vehicle

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Solution Overview

Problem

In heat pump systems for electric and hybrid vehicles, ensuring sufficient superheat of the refrigerant in the condenser and evaporator is challenging, leading to noise and durability issues in the compressor, and complicating the layout and assembly of the compressor and accumulator components.

Innovation Solution

A compression module that integrates the functions of both the compressor and accumulator, allowing for direct heat exchange between the compression unit, accumulator unit, and control unit, thereby optimizing the accumulator capacity and reducing the guaranteed temperature of control unit elements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the compressor and accumulator are configured as separate components connected through a tube, then the system can ensure sufficient superheat of refrigerant, but the mounting space requirement increases and layout becomes complicated

Engineering Contradiction:

Improvesuperheat of refrigerantVSAvoidmounting space

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The patent combines the compressor and accumulator into a single integrated compression module. The accumulator chamber is formed within the housing of the compression module, allowing the accumulator to be mounted directly on the compressor body without requiring external tubes or separate mounting locations. This merging resolves the contradiction by maintaining the functional separation needed for refrigerant superheating while eliminating the space and layout complications of separate component installation.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The compression module housing serves multiple functions: it encloses the compressor mechanism, provides mounting surfaces for the accumulator, and acts as part of the refrigerant flow path. The integrated design allows a single component structure to fulfill multiple system functions, reducing the overall number of parts and mounting requirements while maintaining the necessary thermal and fluid dynamics for proper refrigerant superheating.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If the compressor and accumulator are configured as separate components, then the system can be assembled, but the number of work processes and manufacturing costs increase

Engineering Contradiction:

Improvesystem functionalityVSAvoidnumber of work processes

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

By integrating the accumulator within the compression module housing, the patent reduces the total number of assembly operations. Instead of separately mounting the accumulator and connecting it via tubes, the accumulator is positioned and secured as part of the compression module assembly process. This merging of components directly reduces the number of work processes and associated manufacturing costs while maintaining full system functionality.

Inventive Principle:

Principle #5Merging (Combining)

3Temperature

If the control unit is cooled by refrigerant from the accumulator, then the control unit can operate, but the accumulator capacity must be increased or high temperature elements must be used, causing cost increase

Engineering Contradiction:

Improvecontrol unit operating temperatureVSAvoidaccumulator capacity

Core Design Contradiction:

TemperatureVSQuantity of substance

Solution Approach 1:

The patent introduces a heat exchanger as an intermediary component between the refrigerant and the control unit. This heat exchanger efficiently transfers heat from the control unit to the refrigerant or surrounding environment, providing effective cooling without requiring the accumulator to be oversized. The heat exchanger mediates the thermal management function, allowing the use of standard-capacity accumulators and conventional temperature-rated electronic components, thereby avoiding cost increases.

Inventive Principle:

Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This integrated solution reduces the number of components and assembly processes, improves layout flexibility in tight spaces, optimizes accumulator capacity, decreases the guaranteed temperature of control unit elements, and minimizes the use of tubes, ultimately reducing costs and enhancing efficiency.

Implementation Method 1

a compression unit (110) configured to compress a refrigerant introduced into the compression unit

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

an heat exchange unit (132) formed on one surface of the accumulator unit that is in close contact with the control unit

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Data Source

PatentUS12291082B2Compression module for vehicle

Publication Date: 2025.05.06 HYUNDAI MOTOR CO LTD

AI summary

An embodiment compression module for a vehicle includes a compression unit configured to compress a refrigerant introduced into the compression unit, a control unit having a first surface separably assembled to the compression unit to control the compression unit, and an accumulator unit separably mounted on a second surface of the control unit in a direction opposite to the compression unit, the accumulator unit being configured to supply the refrigerant to the compression unit in a gaseous state.