Scroll Electric Compressor Passive Pressure Recycling for Lower Noise
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Solution Overview
Problem
Electric compressors in battery-powered vehicles face challenges with high-speed operation leading to noise and reduced battery life due to continuous operation, limited heat pump efficiency by refrigerant saturation temperature, and inefficient refrigerant recycling.
Innovation Solution
A scroll-type electric compressor with a passive pressure system that automatically opens a passage between discharge and intake volumes, allowing compressed refrigerant to be recycled, enhancing efficiency and reducing noise by converting high-pressure refrigerant back into low-pressure refrigerant.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the electric compressor operates at high speed to improve cooling efficiency, then the cooling performance is improved, but noise increases
Solution Approach 1:
The patent implements periodic reciprocating motion of the piston through crankshaft mechanism, converting continuous rotational motor motion into periodic compression cycles. This periodic action allows the compressor to achieve high cooling efficiency through rapid compression cycles while the controlled reciprocating motion reduces noise compared to continuous high-speed rotation
Solution Approach 2:
The patent uses a crankshaft and connecting rod mechanism to convert the continuous rotational motion of the electric motor into dynamic reciprocating motion of the piston. This dynamic conversion allows the system to operate at high effective speeds for cooling while the controlled back-and-forth motion reduces noise generation
2Productivity
If the compressor operates continuously to provide cooling, then cooling availability is improved, but battery life is reduced
Solution Approach 1:
The passive pressure system automatically recycles high-pressure refrigerant from the discharge side back to the suction side without requiring additional energy input. The system uses the inherent pressure differential and elastic deformation of the membrane to create a check valve mechanism that self-regulates refrigerant flow, reducing continuous motor operation and extending battery life
Solution Approach 2:
The patent recovers high-pressure refrigerant that would otherwise be discharged and discarded, redirecting it back to the suction side through the passive pressure system. This recovery mechanism reduces the need for continuous compression operation, thereby conserving battery energy and extending battery life
3Power
If the heat pump operates to move heat, then heating or cooling capacity is improved, but efficiency is limited by refrigerant saturation temperature
Solution Approach 1:
The passive pressure system dynamically changes the pressure parameters of the refrigerant by recycling high-pressure refrigerant back to the suction side. This pressure modulation allows the refrigerant to operate at more favorable temperature-pressure conditions, improving heat pump efficiency and capacity while overcoming saturation temperature limitations
4Productivity
If a passive pressure system is added to recycle refrigerant, then system efficiency is improved, but device complexity increases
Solution Approach 1:
The passive pressure system uses the inherent pressure differential between discharge and suction sides, combined with elastic membrane deformation, to create a self-regulating check valve mechanism. This passive design requires no external power source, control systems, or complex actuation mechanisms, improving efficiency while minimizing added complexity
Solution Approach 2:
The elastic membrane acts as an intermediary element between the high-pressure and low-pressure chambers. It passively transduces pressure differential into mechanical displacement that opens or closes the refrigerant passage, enabling efficient refrigerant recycling through a simple intermediary component rather than a complex control system
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 passive pressure system improves compressor efficiency, reduces noise, and extends battery life by recycling compressed refrigerant, thereby increasing operating time and heat pump capacity.
Implementation Method 1
The passive pressure system is configured to automatically open a passage between the discharge volume and the intake volume allowing compressed refrigerant to be recycled into the intake volume
Implementation Method 2
The passive pressure system includes a spring, a valve, and a passage
Implementation Method 3
The compression device receives the refrigerant from the intake volume and compresses the refrigerant as the drive shaft is rotated by the motor
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 passive pressure system. 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 scroll-type 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 scroll-type electric compressor from the discharge volume. The passive pressure system is located within the compression device and has a first end located adjacent the intake volume and a second end located adjacent the discharge volume. The passive pressure system is configured to automatically open a passage between the discharge volume and the intake volume allowing compressed refrigerant to be recycled into the intake volume.