Compressor module

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Solution Overview

Problem

Existing refrigerant circuits for motor vehicle air-conditioning systems using R744 refrigerant face challenges in achieving cost-efficiency, space-saving design, and stability due to the limited integration of components like collectors and compressors, leading to complex assemblies and increased component counts.

Innovation Solution

A modular compressor module with integrated components such as an inner heat exchanger, refrigerant collector, and refrigerant sensors, housed within a unified pressure-tight housing, reducing the number of individual components and simplifying assembly by leveraging existing compressor housing structures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If components like collectors and heat exchangers are integrated into the compressor housing, then the number of individual components is reduced and space is saved, but the complexity of the integrated modular components increases

Engineering Contradiction:

Improvenumber of individual componentsVSAvoidcomplexity of integrated modular components

Core Design Contradiction:

Device complexityVSDevice complexity

Solution Approach 1:

The patent merges the compressor, collectors, and inner heat exchanger into a single integrated compressor module with a unified pressure-tight housing. This combining of previously separate components reduces the overall number of parts while managing the integration complexity through modular design principles.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The compressor housing is designed to serve multiple functions: it houses the compressor mechanism, contains the collectors for refrigerant distribution, and encloses the inner heat exchanger. This multi-functionality reduces the need for separate housings and components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of manufacture

If the inner heat exchanger is integrated into the compressor module, then separate housings are eliminated, but the manufacturing complexity of the integrated component increases

Engineering Contradiction:

Improvenumber of separate housingsVSAvoidmanufacturing complexity of integrated component

Core Design Contradiction:

Ease of manufactureVSEase of manufacture

Solution Approach 1:

The inner heat exchanger is nested within the compressor module housing, which itself is contained within the outer housing. This nested arrangement eliminates the need for separate external housings for the heat exchanger while organizing the integration complexity in a structured manner.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The housing is divided into an outer housing and an inner housing structure that contains the heat exchanger. This segmentation allows for modular assembly and manufacturing while achieving the goal of eliminating separate external housings.

Inventive Principle:

Principle #1Segmentation

3Device complexity

If refrigerant sensors are integrated into the compressor housing, then the number of connection elements is reduced, but the integration complexity increases

Engineering Contradiction:

Improvenumber of connection elementsVSAvoidintegration complexity

Core Design Contradiction:

Device complexityVSDevice complexity

Solution Approach 1:

The refrigerant sensors are integrated directly into the compressor housing structure, merging the sensing function with the housing. This eliminates the need for separate connection elements and mounting structures for the sensors.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The housing structure itself provides the mounting and connection functionality for the refrigerant sensors, making the housing self-sufficient for multiple functions including sensor integration, thereby reducing external connection requirements.

Inventive Principle:

Principle #25Self-service

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 integration results in reduced complexity, lower installation costs, and improved efficiency by eliminating the need for separate housings and refrigerant lines, enhancing lubrication through oil viscosity management and improving inverter and motor performance due to better cooling.

Implementation Method 1

an inner heat exchanger of the refrigerant circuit is produced such that it is integrated into the compressor module

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Implementation Method 2

one refrigerant compressor

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS12460637B2Compressor module

Publication Date: 2025.11.04 HANON SYST CO LTD

AI summary

A compressor module for a refrigerant circuit of a motor vehicle air-conditioning system, exhibiting a modular multi-part housing with a low-pressure refrigerant inlet, a high-pressure refrigerant outlet and a compressor, characterized in that an inner heat exchanger of the refrigerant circuit is produced such that it is integrated into the compressor module, wherein the housing of the compressor module fully encloses the inner heat exchanger.