Separating Can Rotor-Stator Layout for Insulated Refrigerant Compressors
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Solution Overview
Problem
Refrigerant compressors in high-voltage systems of vehicles face risks of ignition due to insufficient electrical insulation, particularly in battery-powered electric vehicles or fuel cell vehicles, where refrigerants with flammable components are used in proximity to high-voltage systems.
Innovation Solution
A refrigerant compressor design with a separating can that separates the stator and rotor in a fluid-tight and gas-tight manner, using non-magnetic materials like plastic or carbon fiber, and a direct compressor feed to minimize interaction between electrical components and refrigerant, combined with a cooling device for the motor section.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the refrigerant flows through the motor section to cool the electric motor, then the cooling efficiency is improved, but the electrical insulation is compromised and ignition risk increases
Solution Approach 1:
The motor section is segmented into multiple hermetically sealed chambers (suction chamber, compression chamber, discharge chamber) separated by the separating can. This allows the refrigerant to flow through compression and discharge chambers for cooling while preventing contact with energized components in the suction chamber, thus maintaining both cooling efficiency and electrical insulation.
Solution Approach 2:
The separating can acts as an intermediary barrier between the refrigerant flow path and the energized stator windings. It creates a hermetic seal that allows thermal management while preventing direct contact between the refrigerant and electrical components, eliminating the ignition risk while preserving cooling functionality.
2Power
If the stator and rotor are placed in direct contact to enable magnetic coupling, then the motor efficiency is improved, but the electrical insulation between energized components and refrigerant is compromised
Solution Approach 1:
The separating can functions as a thin-walled hermetic barrier that physically separates the stator and rotor while allowing magnetic field penetration. This maintains the magnetic coupling necessary for motor operation while providing reliable electrical insulation between the refrigerant environment and energized components.
Solution Approach 2:
The separating can creates an inert, hermetically sealed environment around the stator windings, isolating them from the refrigerant. This ensures reliable electrical insulation while allowing the motor to operate efficiently through magnetic coupling across the barrier.
3Reliability
If a separating can is introduced to isolate the stator and rotor, then the electrical insulation is improved, but the device complexity increases
Solution Approach 1:
The separating can serves multiple functions simultaneously: it provides hermetic sealing between chambers, acts as an electrical insulation barrier, supports bearing assemblies, and maintains structural integrity of the motor section. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in device complexity.
Solution Approach 2:
The separating can combines several protective and structural functions into a single integrated component. By merging the insulation barrier, chamber separator, and bearing support into one element, the design achieves improved electrical insulation without proportionally increasing overall device complexity.
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
Enhances electrical insulation, reducing the risk of ignition and ensuring safe operation near high-voltage systems by creating a robust barrier between energized components and refrigerant, while maintaining efficient heat dissipation and hermetic sealing.
Implementation Method 1
the stator and the rotor are separated from each other by a separating can in a fluid-tight and/or gas-tight manner
Implementation Method 2
The refrigerant flows through a gap between the stator and the rotor and absorbs the heat generated in the electric motor
Implementation Method 3
A brushless electric motor is arranged in the motor section, which comprises a stator and a rotor
Data Source
AI summary
The invention relates to a refrigerant compressor for mobile applications, having a compressor section and a motor section, wherein variable compression chambers are formed in the compressor section in order to receive and compress a refrigerant flowing through a working medium circuit, and wherein a brushless electric motor is arranged in the motor section, which comprises a stator and a rotor which is drive-connected to the compressor section. The invention is characterized in that the stator and the rotor are separated from one another in a fluid-tight and/or gas-tight manner by a separating can.