Electric Scroll Compressor With Integrated Vapor Injection for EV Efficiency
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Solution Overview
Problem
Existing electric compressors for vehicles, particularly those in battery-powered or hybrid vehicles, face challenges in efficiency, noise, and operational life due to the complexity and cost of external vapor injection systems, which are not optimized for electric power sources.
Innovation Solution
An integrated vapor injection circuit is incorporated into the electric scroll compressor, with components such as a vapor injection cavity and channels being integral with the housing, allowing for efficient vapor injection without additional external assemblies, enhancing compressor efficiency and reducing noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If an external vapor injection system is added to increase compressor capacity, then compressor efficiency and capacity are improved, but device complexity and cost increase
Solution Approach 1:
The vapor injection system is merged with the compressor housing by integrating the vapor injection cavity and channels directly into the housing structure. This eliminates the need for separate external vapor injection components and their associated connections, thereby maintaining the capacity enhancement benefit while reducing system complexity and cost.
2Adaptability or versatility
If additional external components are used for vapor injection, then vapor injection functionality is achieved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The vapor injection cavity and channels are formed as integral parts of the compressor housing during the housing manufacturing process. This integration eliminates the need for separate manufacturing of external vapor injection components and their subsequent assembly, thereby achieving vapor injection functionality while simplifying manufacturing and reducing costs.
3Ease of operation
If traditional rotary compressors are used in electric vehicles, then cooling function is provided, but energy consumption from battery increases
Solution Approach 1:
The compressor is converted from a rotary design to a scroll compression design, fundamentally changing the compression mechanism. The scroll compressor uses orbital motion of one scroll relative to another to compress refrigerant, which reduces friction and energy losses compared to rotary compressors with pistons and valves. This parameter change in compression mechanism reduces the energy required to operate the cooling system, thereby conserving battery energy in electric vehicles.
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
The integrated vapor injection system improves compressor efficiency and reduces noise while extending operational life, optimizing performance for electric vehicle applications.
Implementation Method 1
scroll-type compressors, in which an orbiting scroll is rotated in a circular motion relative to a fixed scroll to compress a refrigerant
Implementation Method 2
a portion of the compressed refrigerant from the output of the compressor may be controllably diverted through a vapor generator and sent back to the compressor under a higher temperature, pressure and/or vapor content and inserted back into the compression cycle
Data Source
Figure 1A
Figure 1B
Figure 2A~2B
AI summary
An electric scroll compressor configured to compress a refrigerant for use with a vapor injection system, is provided. The compressor includes refrigerant inlet and outlet ports and a vapor injection port. The housing includes a vapor injection cavity and at least one vapor injection channel which are integral therewith. A compression device includes a fixed scroll and an orbiting scroll. The orbiting scroll and the fixed scroll form compression chambers for receiving the refrigerant from the intake volume and compressing the refrigerant as the drive shaft is rotated about the center axis. The fixed scroll includes at least one vapor outlet aperture in communication with the at least one vapor injection channel for allowing vapor to enter a compression chamber formed between the fixed scroll and the orbiting scroll.