Electric scroll compressor with motor connector assembly and motor connector assembly for electric scroll compressor
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Solution Overview
Problem
Electric compressors in vehicles face challenges with high noise levels, reduced battery life due to high-speed operation, and current leakage issues when using traditional scroll-type compressors driven by electric motors in HVAC and heat pump systems, especially in electric vehicles where energy efficiency and longevity are critical.
Innovation Solution
The design incorporates a housing with an inverter module, a motor, and a motor connector assembly that converts direct current to alternating current, featuring a motor connector housing with internal walls separating intake and inverter cavities, and a potting material to minimize electrical leakage and noise, while ensuring efficient refrigerant compression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electric motor windings pass through the coolant to connect to the drive circuit, then electrical connection is achieved, but current leakage and energy loss occur
Solution Approach 1:
The patent divides the electrical connection path into separate segments: the motor windings remain isolated within the motor housing, while the drive circuit is positioned externally. Magnetic coupling through the housing wall enables energy transfer without physical wire penetration, thus segmenting the electrical pathway to eliminate leakage points.
Solution Approach 2:
The motor housing wall acts as an intermediary medium that enables magnetic field coupling between the internal motor windings and external drive circuit. This intermediary allows electrical energy transfer without direct wire contact through the coolant, preventing current leakage while maintaining connection reliability.
2Productivity
If the compressor operates at high speed to improve cooling efficiency, then refrigerant compression efficiency increases, but noise levels increase
Solution Approach 1:
The patent utilizes the magnetic field, which is inherently present in motor operation, as a beneficial intermediary for external control and monitoring. Sensors and control circuits externally measure and regulate motor parameters without physical penetration, converting the motor's electromagnetic field into a tool for noise-free monitoring and control.
Solution Approach 2:
The patent replaces mechanical wire penetration through the housing with electromagnetic coupling. This substitution eliminates the need for physical connectors that would create noise and leakage, using magnetic field interaction instead for energy and signal transfer.
3Use of energy by moving object
If the motor windings are connected through the coolant to the drive circuit, then electrical power transmission is achieved, but current leakage occurs
Solution Approach 1:
The electrical system is segmented into isolated zones: the motor windings are contained within the sealed motor housing, while the drive circuit operates externally. Power transmission occurs through magnetic coupling across the housing boundary, creating distinct electrical zones that prevent leakage paths through the coolant.
Solution Approach 2:
The motor housing serves as an intermediary barrier that enables controlled electromagnetic energy transfer while blocking direct electrical contact with the coolant. This intermediary structure maintains electrical isolation, preventing current leakage while allowing power transmission through magnetic field coupling.
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 configuration enhances the efficiency, reduces noise, and extends the operational life of electric compressors by minimizing current leakage and optimizing the motor connection, thereby improving energy usage and reducing wear on vehicle batteries.
Implementation Method 1
The inverter module is mounted inside the inverter cavity of the housing and is adapted to convert direct current electrical power to alternating current electrical power
Implementation Method 2
The motor has a plurality of motor windings and is mounted inside the housing. The compression device is coupled to the motor for receiving the refrigerant from the intake volume and compressing the refrigerant as the motor is rotated
Implementation Method 3
The compression device is coupled to the motor for receiving the refrigerant from the intake volume and compressing the refrigerant as the motor is rotated
Data Source
AI summary
An electric compressor includes a housing, refrigerant inlet port, a refrigerant outlet port, an inverter section, a motor section, a compression device and a front cover. The housing defines an intake volume and a discharge volume. The refrigerant inlet port is coupled to the housing and is configured to introduce the refrigerant to the intake volume. The compression device is a compression device configured to compress the refrigerant. The refrigerant outlet port is coupled to the housing and is configured to allow compressed refrigerant to exit the electric compressor from the discharge volume.