Balanced rolling piston compressor with central mass reductions for improved compressor stability

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Solution Overview

Problem

Existing rotary compressors in electric vehicles face challenges in achieving high efficiency, low noise, and extended operating life due to unbalanced operation, especially when powered by batteries, which can lead to increased noise, vibration, and reduced battery life from excessive electrical consumption.

Innovation Solution

A rolling piston compressor design with a balanced compression device that includes a cylinder and a rolling piston, eccentrically coupled to a drive shaft, forming variable sub-chambers within a compression chamber, and a vane biased to maintain contact with the piston, allowing efficient refrigerant compression without separate balancing components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If a rolling piston compressor is used in electric vehicles, then cooling functionality is provided, but noise and vibration increase due to unbalanced operation

Engineering Contradiction:

Improvenoise and vibrationVSAvoidcooling efficiency

Core Design Contradiction:

Object-affected harmful factorsVSProductivity

Solution Approach 1:

A counterweight is provided on the compression device that rotates with the rolling piston, positioned to offset the unbalanced mass. This counterweight creates a balancing force that reduces vibration and noise during compressor operation, while maintaining the cooling functionality.

Inventive Principle:

Principle #8Anti-weight (Counterweight)

Solution Approach 2:

The counterweight is integrated into the compression device structure, merging the balancing function with the existing compression mechanism. This eliminates the need for separate balancing components and reduces overall system complexity.

Inventive Principle:

Principle #5Merging (Combining)

2Use of energy by moving object

If compressor operation is optimized for efficiency, then energy consumption is reduced, but complexity increases due to additional balancing components

Engineering Contradiction:

Improveelectrical energy consumptionVSAvoidcompressor structure

Core Design Contradiction:

Use of energy by moving objectVSDevice complexity

Solution Approach 1:

The counterweight is integrated into the existing compression device structure, combining the balancing function with the compression mechanism. This eliminates the need for separate balancing components and reduces overall system complexity while optimizing energy consumption.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The compression device structure serves multiple functions: compression and balancing. The counterweight is part of the rotating assembly, providing both structural support and vibration balancing, making the system more efficient without adding complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Object-affected harmful factors

If separate balancing components are added to reduce vibration, then noise and vibration are reduced, but device complexity increases

Engineering Contradiction:

ImprovevibrationVSAvoidnumber of components

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 design achieves improved efficiency, reduced noise, and extended operating life by minimizing vibration and optimizing energy use, while maintaining compressor stability and reducing battery degradation.

Implementation Method 1

The cylinder is eccentrically coupled to the drive shaft. The rolling piston rotates the cylinder as the drive shaft and the piston device is rotated by the motor.

Methodology Applied

Scientific EffectEccentric rotation: Eccentric

Data Source

PatentUS12523223B1Balanced rolling piston compressor with central mass reductions for improved compressor stability

Publication Date: 2026.01.13 MAHLE INT GMBH

AI summary

An electric compressor includes a housing and a compression device. The housing defines an intake volume and a discharge volume. The compression device is a rotary-type compression device configured to compress refrigerant. The compression device includes a piston device including a cylinder and a rolling piston. The cylinder is eccentrically coupled to a drive shaft. The rolling piston has an outer surface in contact with an inner surface of a compression chamber. The rolling piston rotates about the cylinder as the drive shaft and the piston device are rotated by a motor. A vane moveably coupled to the housing and having an end adjacent the compression chamber is biased such that the end of the vane is in contact with the rolling piston as the piston device is rotated by the drive shaft.