ELECTRIC COMPRESSOR WITH INTEGRATED SENSOR(S)

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 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 electric compressor includes integral pressure(s) and/or temperatures sensor(s).

FIELD OF THE INVENTION

The invention relates generally to electric compressor, and more particularly to an electric compressor that compresses a refrigerant using a scroll compression device.

BACKGROUND OF THE INVENTION

Compressors have long been used in cooling systems. In particular, scroll-type compressors, in which an orbiting scroll is rotated in a circular motion relative to a fixed scroll to compress a refrigerant, have been used in systems designed to provide cooling in specific areas. For example, such scroll-type compressors have long been used in the HVAC systems of motor vehicles, such as automobiles, to provide air-conditioning. Such compressors may also be used, in reverse, in applications requiring a heat pump. Generally, these compressors are driven using rotary motion derived from the automobile's engine.

With the advent of battery-powered or electric vehicles and/or hybrid vehicles, in which the vehicle may be solely powered by a battery at times, such compressors must be driven or powered by the battery rather than an engine. Such compressors may be referred to as electric compressors.

In addition to cooling a passenger compart of the motor vehicle, electric compressors may be used to provide heating or cooling to other areas or components of the motor vehicle. For instance, it may be desired to heat or cool the electronic systems and the battery or battery compartment, when the battery is being charged, especially during fast charging modes, as such generate heat which may damage or degrade. the battery and/or other system. It may also be used to cool the battery during times when the battery is not being charged or used, as heat may damage or degrade the battery. Since the electric compressor may be run at various times, even when the motor vehicle is not in operation, such use, obviously, requires electrical energy from the battery, thus reducing the operating time of the battery.

In use, it may be necessary or advantageous to utilize the pressure and/or temperature of the refrigerant at an intake side and/or a discharge side of the compressor to control an electrical compressor. In prior design, generally the pressure and temperature at the intake and discharge side are measured by sensors external to the electrical compressor, e.g., within refrigerant lines to and from the electrical compressor. Use of external sensors may present several disadvantages, e.g., use of outdated sensor technology, additional cost in raw materials and labor and the requirement of an additional wire or wire harness to connect the sensors to an engine control unit (ECU).

Therefore, it may be advantageous to integrate pressure and/or temperature sensors within the electric compressor. Such integration may act to decouple pressure and temperature disturbances that occur between the line and compressor for a more direct measurement. It also enables the compressor to use this measured data for optimized decision making (protection modes, speed changes, etc. . . . ).

It is thus desirable to provide an electric compressor having high efficiency, low-noise and maximum operating life. The present invention is aimed at one or more of the problems or advantages identified above.

BRIEF SUMMARY OF THE INVENTION

In a first aspect of the present invention, a scroll-type electric compressor configured to compress a refrigerant, is provided. The scroll-type electric compressor includes a housing, an inverter module, a motor, a compression device, an internal housing partition and a pressure sensor. The housing defines an intake volume, a discharge volume, and an inverter cavity. The housing has a generally cylindrical shape and a central axis. 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. The motor is mounted inside the housing. The compression device is coupled to the motor, receives the refrigerant from the intake volume and compresses the refrigerant as the motor is rotated. The internal housing partition separates the intake volume and the inverter cavity and a passage therethrough for receiving refrigerant from the intake volume. The passage has an intake volume end and an inverter cavity end. The pressure sensor is positioned within the inverter cavity adjacent the inverter cavity end of the passage for sensing a pressure associated with the refrigerant within the passage.

In a second aspect of the present invention, a scroll-type electric compressor configured to compress a refrigerant is provided. The scroll-type electric compressor includes a housing, an inverter module, a motor, a compression device, an internal housing partition, a holder, a pressure sensor, and a temperature sensor. The housing defines an intake volume, a discharge volume and an inverter cavity and has a generally cylindrical shape and a central axis. The housing includes an inverter housing and an inverter back cover. The inverter housing and the inverter back cover define the inverter cavity. The inverter housing includes a holder aperture. 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. The inverter module includes a printed circuit board. The motor is mounted inside the housing. The compression device is coupled to the motor, receives the refrigerant from the intake volume and compresses the refrigerant as the motor is rotated. The internal housing partition separates the intake volume and the inverter cavity and includes a passage therethrough for receiving refrigerant from the intake volume. The passage has an intake volume end and an inverter cavity end. The holder is located within the holder aperture and defines at least a portion of the internal housing partition. The passage is located within the holder. The pressure sensor is mounted to the printed circuit board and is positioned within the inverter cavity adjacent the inverter cavity end of the passage for sensing a pressure associated with the refrigerant within the passage. The temperature sensor is positioned within the intake volume and is coupled to the printed circuit board by a plurality of wires.

In a third aspect of the present invention, a scroll-type electric compressor configured to compress a refrigerant is provided. The scroll-type electric compressor includes a housing, an inverter module, a motor, a compression device, an internal housing partition, a pressure sensor housing partition and a pressure sensor. The housing defines an intake volume, a discharge volume and an inverter cavity and has a generally cylindrical shape and a central axis. The housing includes an inverter housing and an inverter back cover. The inverter housing and the inverter back cover define the inverter cavity. The inverter housing includes a pressure sensor module aperture. The inverter module includes a printed circuit board. 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. The motor is mounted inside the housing. The compression device is coupled to the motor for receiving the refrigerant from the intake volume and for compressing the refrigerant as the motor is rotated. The internal housing partition separates the intake volume and the inverter cavity and includes a passage therethrough for receiving refrigerant from the intake volume. The passage has an intake volume end and an inverter cavity end. The pressure sensor module housing has a pressure sensor cavity and an intake volume side wall and is located within the pressure sensor module aperture. The intake volume side wall defines at least a portion of the internal housing partition. The passage is located within the intake volume side wall. The pressure sensor module includes a pressure sensor module printed circuit board electrically coupled to the printed circuit board. The pressure sensor is positioned within a pressure sensor cavity and adjacent the inverter cavity end of the passage for sensing a pressure associated with the refrigerant within the passage.

DETAILED DESCRIPTION OF THE INVENTION

Referring to theFIGS.1A-26C, wherein like numerals indicate like or corresponding parts throughout the several views, an electric compressor10having an outer housing12is provided. The electric compressor10is particularly suitable in a motor vehicle, such as an automotive vehicle (not shown). The electric compressor10may be used as a cooling device or as a heating pump (in reverse) to heat and/or cool different aspects of the vehicle. For instance, the electric compressor10may be used as part of the heating, ventilation and air conditioning (HVAC) system in electric vehicles (not shown) to cool or heat a passenger compartment. In addition, the electric compressor10may be used to heat or cool the passenger compartment, on-board electronics and/or a battery used for powering the vehicle while the vehicle is not being operated, for instance, during a charging cycle. The electric compressor10may further be used while the vehicle is not being operated and while the battery is not being charged to maintain, or minimize the degradation, of the life of the battery. In the illustrated embodiment, the electric compressor10has a capacity of 36 cubic centimeters (cc). The capacity refers to the initial volume captured within the compression device as the scrolls of the compression device initially close or make contact (see below). It should be noted that the electric compressor10disclosed herein is not limited to any such volume and may be sized or scaled to meet particular required specifications.

In the illustrated embodiment, the electric compressor10is a scroll-type compressor that acts to compress a refrigerant rapidly and efficiently for use in different systems of a motor vehicle, for example, an electric or a hybrid vehicle. The electric compressor includes10an inverter section14, a motor section16, and a compression device (or compression assembly)18contained within the outer housing12. The outer housing12includes an inverter back cover20, an inverter housing22, a center housing24, and a front cover28(which may be referred to as the discharge head). The center housing24houses the motor section16and the compression device18.

In a first aspect of the electric compressor10of the disclosure, an electric compressor10having a compression device with a fixed scroll having a modified scroll floor is provided. In a second aspect of the electric compressor10of the disclosure, an electric compressor10with an isolation and constraint system is provided. In a third aspect of the electric compressor10of the disclosure, an electric compressor10having a head design having a reed mechanism with three reeds is provided.

In one embodiment, the inverter back cover20, the inverter housing22, the center housing24, and the front cover28are composed from machined aluminum. The inverter10may be mounted, for example, within the body of a motor vehicle, via a plurality of mount points120.

General Arrangement, and Operation, of the Electric Compressor10

The inverter back cover20and the inverter housing22form an inverter cavity30. The inverter back cover20is mounted to the inverter housing22by a plurality of bolts32. The inverter back cover20and the inverter housing22are mounted to the center housing24by a plurality of bolts34which extend through apertures36in the inverter back cover20and apertures38in the inverter housing22and are threaded into threaded apertures40in the center housing24. An inverter gasket42, positioned between the inverter back cover20and the inverter housing22keeps moisture, dust, and other contaminants from the internal cavity30. A motor gasket54C is positioned between the inverter housing22and the center housing24to provide and maintain a refrigerant seal to the environment.

With reference toFIG.11, an inverter module44mounted within the inverter cavity30formed by the inverter back cover20and the inverter housing22. The inverter module44includes an inverter or controller circuit46mounted on a printed circuit board48, which is mounted to the inverter housing22. The inverter circuit46converts direct current (DC) electrical power received from outside of the electric compressor10into three-phase alternating current (AC) power to supply/power the motor54(see below). The inverter circuit46also controls the rotational speed of the electric compressor10. High voltage DC current is supplied to the inverter circuit46via a high voltage connector50. Low voltage DC current to drive the inverter circuit46, as well as control signals to control operation of the inverter circuit46, and the motor section16, is supplied via a low voltage connector52.

The center housing24forms a motor cavity56. The motor section16includes a motor54located within the motor cavity56. The motor cavity56is formed by a motor side22A of the inverter housing22and an inside surface24C of the center housing22. With specific reference toFIG.12, the motor54is a three-phase AC motor having a stator56. The stator58has a generally hollow cylindrical shape with six individual coils (two for each phase). The stator58is contained within, and mounted to, the motor housing24and remains stationary relative to the motor housing24.

The motor54includes a rotor60located within, and centered relative to, the stator58. The rotor60has a generally hollow cylindrical shape and is located within the stator58. The rotor60has a number of balancing counterweights60A,60B, affixed thereto. The balancing counterweights balance the motor54as the motor54drives the compression device18and may be machined from brass.

Power is supplied to the motor54via a set of terminals54A which are sealed from the motor cavity56by an O-ring54B.

A drive shaft90is coupled to the rotor60and rotates therewith. In the illustrated embodiment, the draft shaft90is press-fit within a center aperture60C of the rotor60. The drive shaft90has a first end90A and a second end90B. The inverter housing22includes a first drive shaft supporting member22B located on the motor side of the inverter housing22. A first ball bearing62located within an aperture formed by the first drive shaft supporting member22supports and allows the first end of the drive shaft90to rotate. The center housing24includes a second drive shaft supporting member24A. A second ball bearing64located within an aperture formed by the second drive shaft supporting member24A allows the second end90B of the drive shaft90to rotate. In the illustrated embodiment, the first and second ball bearing62,64are press-fit with the apertures formed by the first drive shaft supporting member22of the inverter housing22and the second drive shaft supporting member24A of the center housing24, respectively.

As stated above, the electric compressor10is a scroll-type compressor. The compression device18includes the fixed scroll26and an orbiting scroll66. The orbiting scroll66is fixed to the second end of the rotor60. The rotor60with the drive shaft90rotates to drive the orbiting scroll66motion under control of the inverter module44rotate.

With reference toFIGS.14A,14B,16A and16B, the drive shaft90has a central axis90C around which the rotor60and the drive shaft90are rotated. The orbiting scroll66moves about the central axis90C in an eccentric orbit, i.e., in a circular motion while the orientation of the orbiting scroll66remains constant with respect to the fixed scroll26. The center of the orbiting scroll66is located along an offset axis90D of the drive shaft90defined by an orbiting scroll aperture (or drive pin location)90E (seeFIG.14A) located at the second end90B of the drive shaft90. As the drive shaft90is rotated by the motor54, the orbiting scroll66follows the motion of the orbiting scroll aperture90E through the drive pin126and the drive hub of the swing-link mechanism124and bearing108as the drive shaft90is rotated about the central axis90C.

With specific reference toFIGS.1,2and9, intermixed refrigerant and oil (at low pressure) enters the electric compressor10via a refrigerant inlet port68and exits the electric compressor10(at high pressure) via refrigerant outlet port70after being compressed by the compression device18. As shown in the cross-sectional view ofFIG.9, the refrigerant follows the refrigerant path72through the electric compressor10. As shown, refrigerant enters the refrigerant inlet port68and enters an intake volume74formed between the motor side22A of the inverter housing22and the center housing24adjacent the refrigerant inlet port68. Refrigerant is then drawn through the motor section16and enters a compression intake volume76formed between an internal wall of the fixed scroll26and the orbiting scroll66(demonstrated by arrow92inFIG.14A).

The fixed scroll26is mounted within the center housing24. As shown inFIGS.9and13, the fixed scroll26has a fixed scroll base26A and a fixed scroll lap26B extending away from the fixed scroll base26A towards the orbiting scroll66. As shown inFIGS.16A-16B, the orbiting scroll66has an orbiting scroll base66A and an orbiting scroll lap66B extending from the orbiting scroll base66A towards the fixed scroll26. The laps26B,66B have a tail end26C,66C adjacent an outer edge of the respective scroll26,66and scroll inward towards a respective center end26D,66D.

Respective tip seals94are located within a slot (not shown) located at a top surface of the fixed scroll26and the orbiting scroll66, respectively. The tip seals94are comprised of a flexible material, such as a Polyphenylene Sulfide (PPS) plastic. When assembled, the tip seals94are pressed against the opposite base26A66A to provide a seal therebetween. In one embodiment, the slots, are longer than the length of the tip seals94to provide room for adjustment/movement along the length of the tip seals94.

With reference toFIGS.17A-17I, refrigerant enters the compression device12from the compression intake volume76. InFIGS.17A-17I, a cross-section view of the fixed scroll26and the top of the orbiting scroll66are shown.

As discussed in detail below, the fixed scroll lap26B and the orbiting scroll lap66B form compression chambers80in which low or unpressurized (saturation pressure) refrigerant enters from the compression device12. As the orbiting scroll66moves to enable the compression chambers80to be closed off and the volume of the compression chambers80is reduced to pressurize the refrigerant. At any one time during the cycle, one or more compression chambers80are at different stages in the compression cycle. The below description relates just to one set of compression chambers80during a complete cycle of the electric compressor10.

The refrigerant enters the compression chambers80formed between the orbiting scroll lap66B and the fixed scroll lap26B. During a cycle of the compressor10, the refrigerant is transported towards the center of these chambers. The orbiting scroll66orbits in a circular motion indicated by arrow78formed by the relative position of the orbiting scroll66relative to the fixed scroll26is shown during one cycle of the electric compressor10.

InFIG.17A, the position of the orbiting scroll66at the beginning of a cycle is shown. As shown, in this initial position, the tail ends26C,66C are spaced apart from the other scroll lap66B,26B. At this point, the compression chambers80are open to the compression intake volume76allowing refrigerant under low pressure to fill the compression chambers80from the compression intake volume76. As the orbiting scroll66moves along path78, the space between the tail ends26C,66C and the other scroll66,16decreases until the compression chambers80are closed off from the compression intake volume76(FIGS.17B-17E). As the orbiting scroll66continues to move along78, the volume of the compression chambers80is further reduced, thus pressurizing the refrigerant in both compression chambers80(FIGS.17F-H). As shown inFIGS.17I-18J, as the orbiting scroll66continues to orbit, the two compression chambers80are combined into a single volume. This volume is further reduced until the pressurized refrigerant is expelled from the compression device18(see below)

As discussed below, the refrigerant enters chambers formed between the walls of the orbiting scroll66and the fixed scroll26. During the cycle of the compressor10, the refrigerant is transported towards the center of these chambers. The orbiting scroll66orbits or moves in a circular motion indicated by arrow78formed by the relative position of the orbiting scroll66relative to the fixed scroll26is shown during one cycle of the electric compressor10.

Returning toFIG.1, the front cover28forms a discharge volume82. The discharge volume82is in communication with the refrigerant output port70. As discussed in more detail below, pressurized refrigerant leaves the compression device18through a central orifice84A and two side orifices84B in the fixed scroll26(seeFIGS.18C and18E) The release of pressurized refrigerant is controlled by a reed mechanism86. In the illustrated embodiment, the reed mechanism86includes three reeds: a central reed87A and two side reeds87B corresponding to the central orifice84A and the two side orifices84B (see below).

As shown inFIGS.18D and18E, in the illustrated embodiment, the reed mechanism86includes a discharge reed86A and a reed retainer86B. The discharge reed86A is made from a flexible material, such as steel. The characteristics, such as material and strength, are selected to control the pressure at which the pressurized refrigerant is released from the compression device18. The reed retainer86B is made from a rigid, inflexible material such as stamped steel. The reed retainer86B controls or limits the maximum displacement of the discharge reed86A relative to the fixed scroll26. Generally, oil is directed rearward through the motor section16, providing lubrication and cooling to the rotating components of the electric compressor10, such as the rotor60, the drive shaft90and all bearings62,64,108. Oil is drawn upward towards the top of the motor54by the rotation of the rotor60. From there, oil enters the interior of the motor54to lubricate the second ball bearing64and the oil by the rotational forces within the motor section16may impact against the motor side22A of the inverter housing22. The oil is further directed by the motor side22A into the ball bearing62, as further discussed below.

In the illustrated embodiment, the read mechanism86is held or fixed in place via a separate fastener89. As shown inFIGS.18E and18F, the reed mechanism86includes a plurality of apertures86C which are configured to receive associated posts83A on the fixed scroll26. As shown inFIG.18E, the back surface of the fixed scroll26includes a bezel83B surrounding the orifices84A,84B which assists in tuning the pressure at which refrigerant exits the compression device18. Additionally, a debris collection slot83C collects debris near the orifices84A,84B to prevent interference with the reed mechanism86.

As shown inFIG.9, the path of refrigerant through the electric compressor is indicated by dashed arrow72.

The electric compressor10utilizes oil (not shown) to provide lubrication to the between the components of the compression device18and the motor54, for example, between the orbiting scroll66and the fixed scroll26and within the ball bearings62,64. The oil intermixes with the refrigerant within the compression device18and the motor54and exits the compression device18via the orifice84. As discussed in more detail below, the oil is separated from the compressed refrigerant within the front cover28and is returned to the compression device18.

An oil separator96facilitates the separation of the intermixed oil and refrigerant. In the illustrated embodiment, the oil separator96is integrated within the front cover28. The front cover28further defines an oil reservoir98which collects oil from the oil separator96before the oil is recirculated through the motor54and motor cavity56and the compression device18. In use, the electric compressor10is generally orientated as shown inFIGS.3-5, such that gravity acts as indicated by arrow106and oil collects within the oil reservoir98.

With reference toFIG.9, the general path oil travels from the bottom of the electric compressor10through the compression device18, out the orifice84to the discharge volume82of the front cover28and back to the compression device18is shown by arrow88.

In the illustrated embodiment, the front cover28is mounted to the center housing24by a plurality of bolts122inserted through respective apertures therein and threaded into apertures in the center housing24. A fixed head gasket110and a rear heard gasket112, are located between the center housing24and the fixed scroll26to provide scaling.

An oil separator96facilitates the separation of the intermixed oil and refrigerant. Generally, the oil separator96only removes some of the oil within the intermixed oil and refrigerant. The separator oil is stored in an oil reservoir and cycled back through the compression device18, where the oil is mixed back in with the refrigerant.

In the illustrated embodiment, the oil separator96is integrated within the front cover28. The front cover28further defines an oil reservoir98which collects oil from the oil separator96before the oil is recirculated through the motor54and motor cavity56and the compression device18. In use, the electric compressor10is generally orientated as shown inFIGS.3-5, such that gravity acts as indicated by arrow106and oil collects within the oil reservoir98. With reference toFIG.9, the general path oil travels from the bottom of the electric compressor10through the compression device18, out the orifice84to the discharge volume82of the front cover28and back to the compression device18is shown by arrow88. As shown, the oil is drawn back up into the compression device18where the oil is mixed back into or with the refrigerant.

As stated above, refrigerant, which is actually a mixture of refrigerant and oil enters the electric compressor10via the refrigerant inlet port68. The intermix of oil and refrigerant is drawn into the motor section16, thereby providing lubrication and cooling to the rotating components of the electric compressor10, such as the rotor60, the drive shaft90. Oil and refrigerant enters the interior of the motor54to lubricate the second ball bearing64and the oil by the rotational forces within the motor section16. may impact against the motor side22A of the inverter housing22. The refrigerant and oil is further directed by the motor side22A into the ball bearing62, further discussed below.

Swing-Link Mechanism and Concentric Protrusion of the Drive Shaft

With specific reference toFIGS.13-18B, in a first aspect of the electric compressor10of the disclosure, an electric compressor10includes a swing-link mechanism124and the drive shaft90has a concentric protrusion90F. In one embodiment, the concentric protrusion90F is integrally formed with the drive shaft90. As discussed below, the swing-link mechanism124is used to rotate the orbiting scroll66in an eccentric orbit about the drive shaft90.

In the prior art, the drive shaft is coupled to a swing-link mechanism by a drive pin and a separate eccentric pin, both of which are pressing into the drive shaft. The drive pin is used to rotate the swing-link mechanism124which moves the orbiting scroll66along its eccentric orbit. The drive pin and the eccentric pin are inserted into respective apertures at the end of the drive shaft. The eccentric pin is used to limit articulation of the orbiting scroll66is the orbiting scroll66travels along the eccentric orbit. Neither the drive pin, nor the eccentric pin, are located along the central axis of the drive shaft. As the drive shaft is rotated, the drive pin and the eccentric pin are placed under considerable stress. Thus, both pins are composed from a hardened material, such as SAE52100bearing steel. In addition, the eccentric pin may require an aluminum bushing or other slide bearing to prevent damage to the eccentric pin, as the eccentric pin is used to limit the radial movement of the eccentric orbit of the orbiting scroll66. Also, the prior art eccentric pin requires additional machining on the face of the drive shaft90, including precise apertures for the drive pin, and eccentric pin.

As discussed in more detail below, the eccentric pin of the prior art is replaced with a concentric protrusion90F.

In the illustrated embodiment, the scroll-type electric compressor10includes the housing12, the refrigerant inlet port68, the refrigerant outlet port70, the drive shaft90, the concentric protrusion90F, the motor54, the compression device18, the swing-link mechanism124, a drive pin126and a ball bearing108. The housing12defines the intake volume74and the discharge volume82. The refrigerant inlet port68is coupled to the housing12and is configured to introduce the refrigerant to the intake volume74. The refrigerant outlet port70is coupled to the housing12and is configured to allow compressed refrigerant to exit the scroll-type electric compressor10from the discharge volume82. The drive shaft90is located within the housing12and has first and second ends90A,90B. The drive shaft90defines, and is centered upon, a center axis90C.

The concentric protrusion90F is located at the second end90B of the drive shaft90and is centered on the center axis90C. The concentric protrusion90F and extends away from the drive shaft90along the central axis90C. The concentric protrusion90F includes a drive pin aperture90E. The motor54is located within the housing12and is coupled to the drive shaft90to controllably rotate the drive shaft90about the center axis90C. The drive pin126is located within the drive pin aperture90E and extends away from the drive shaft90. The drive pin126is parallel to the concentric protrusion90F.

The concentric pin90F may further include an undercut90G, and the outer surface may be surface hardened or after treated with a coating or bearing surface. The concentric pin90F may be further machined simultaneously with the drive shaft90.

As explained above, the compression device18includes the fixed scroll26and the orbiting scroll66. The fixed scroll26is located within, and being fixed relative to, the housing12. The orbiting scroll66is coupled to the drive shaft90. The orbiting scroll66and the fixed scroll26form compression chambers80(see above) for receiving the refrigerant from the intake volume74and for compressing the refrigerant as the drive shaft90is rotated about the center axis90C. The orbiting scroll66has an inner circumferential surface66E.

The swing-link mechanism124is coupled to the drive shaft90and has first and second apertures124A,124B for receiving the concentric protrusion90F and the drive pin126. The swing-link mechanism124further includes an outer circumferential surface124C.

The ball bearing108is positioned between, and adjacent to each of, the inner circumferential surface66E of the orbiting scroll66and the outer circumferential surface124C of the swing-link mechanism124. The drive shaft90, drive pin126, orbiting scroll66and swing-link mechanism124are arranged to cause the orbiting scroll66to rotate about the central axis90C in an eccentric orbit.

In one embodiment, the concentric protrusion90F is integrally formed with the drive shaft90. The drive shaft90, concentric protrusion90F, and swing-link mechanism124may be machined from steel. The concentric protrusion90F being formed simultaneously and within the same machining operation with the drive shaft90further increases manufacturing efficiencies.

The expanded view of a portion of the compression device18illustrated inFIG.16G, further illustrates the concentric protrusion90F. The concentric protrusion90F interacts and guides the swing-link mechanism124. The concentric protrusion90F is sized and machined with a controlled tolerance with the first aperture124A to create a controlled gap that limits the radial movement of the eccentric orbit of the orbiting scroll66. Unlike the prior art, the concentric protrusion90F does not require a second pin, or any additional machining operations. The concentric protrusion90F further co-operates with the guidance pins24B and the slots66I on a lower surface66F of the orbiting scroll66, further discussed below.

The scroll-type electric compressor10includes an inverter section14, a motor section16, and the compression device18. The motor section16includes a motor housing24that defines a motor cavity56. The compression section18includes the fixed scroll26. The housing12is formed, at least in part, the fixed scroll26and the center housing24.

With specific reference toFIGS.13,16B, and18A-18Fin the illustrated embodiment, the orbiting scroll66has a lower surface66F. The lower surface66F has a plurality of ring-shaped slots66I. The center housing24includes a plurality of articulating guidance pin apertures155. The guidance pins24B are located within the guidance pin apertures155and extend towards the compression device18and into the ring-shaped slots66I. The guidance pins24B are configured to limit articulation of the orbiting scroll66as the orbiting scroll66orbits about the central axis90C. In one embodiment, each of the ring-shaped slots66I includes a ring sleeve118. A thrust plate142is located between the fixed scroll26and a thrust body144(see below) and provides a wear surface therebetween.

Discharge Head Design Having a Three-Reed Reed Mechanism and an Oil Separator

In the illustrated embodiment, the electric compressor10includes a multicavity pulsation muffler system159and an oil separator96which may be located in the discharge volume82and integrally formed with the discharge head or front cover28. As discussed above, oil is used to provide lubrication between the moving components of the electric compressor10. During operation, the oil and the refrigerant become mixed. The oil separator96is necessary to separate the intermixed oil and refrigerant before the refrigerant leaves the electric compressor10.

Generally, refrigerant is released from the compression device18during each cycle, i.e., revolution (or orbit) of the orbiting scroll66. In the illustrated embodiment, refrigerant leaves the compression device18through the central orifice84A and two side orifices84B in the fixed scroll26. Release of the refrigerant through the orifices,84A,84B is controlled by the central reed87A and two side reeds87B, respectively. The multicavity pulsation muffler system159and the oil separator96are described in more detail below.

Scroll Bearing Oil Orifice

The electric compressor10may include a scroll bearing oil injection orifice138(seeFIGS.16C and16E). As discussed above, the compression device18of the present disclosure includes a ball bearing108. In the illustrated embodiments, the ball bearing108is located between the swing-link mechanism124and the orbiting scroll66. However, as a result of the location of the ball bearing108within the compression device18, there may be limited oil delivery to the ball bearing108resulting in reduced durability. As shown inFIG.9, the oil orifice138allows oil (and refrigerant) to travel from the discharge chamber82to the ball bearing108along the path73(which may be referred to as the “nose bleed” path).

The scroll-type electric compressor10may include a housing12, a refrigerant inlet port68, a refrigerant outlet port70, an inverter module44, a motor54, a drive shaft90and a compression device18. The housing12defines an intake volume74and a discharge volume82. The refrigerant inlet port68is coupled to the housing12and is configured to introduce the refrigerant to the intake volume74. The refrigerant outlet port70is coupled to the housing12and is configured to allow compressed refrigerant to exit the scroll-type electric compressor10from the discharge volume82. The inverter module44is mounted inside the housing12and adapted to convert direct current electrical power to alternating current electrical power. The motor54is mounted inside the housing12. The drive shaft90is coupled to the motor54. The compression device18receives the refrigerant from the intake volume74and compresses the refrigerant as the drive shaft90is rotated by the motor54. The compression device18includes a fixed scroll26, an orbiting scroll66, a swing-link mechanism124, a ball bearing108and a plug136.

The fixed scroll26is located within, and is fixed relative to, the housing12. The orbiting scroll66is coupled to the drive shaft90. The orbiting scroll66and the fixed scroll26form compression chambers80for receiving the refrigerant from the intake volume74and compressing the refrigerant as the drive shaft90is rotated about the center axis90C. The orbiting scroll66has a first side (or the lower surface)66F and a second side (or upper surface)66G. The orbiting scroll66has an oil aperture140through the orbiting scroll66from the first side66F to the second side66G.

The swing-link mechanism124is coupled to the drive shaft90. The ball bearing108is positioned between and adjacent to each of the orbiting scroll66and the swing-link mechanism124. The drive shaft90, orbiting scroll66and swing-link mechanism124are arranged to cause the orbiting scroll66to orbit the central axis90C in an eccentric orbit.

As shown inFIGS.16B-16E, the tip of the orbiting scroll66includes a plug136and has an oil orifice138. The plug136may be press fit within the oil aperture140of the orbiting scroll66. The oil orifice138is configured to allow oil with a controlled flow rate or compressed refrigerant to pass through the orbiting scroll66to the ball bearing108.

The size of the oil orifice138may be tuned to the specifications of the electric compressor10. For example, given the specifications of the electric compressor10, the diameter of the oil orifice138may be chosen such that only oil is allowed to pass through and to limit the equalization of pressure between the first and second sides of the orbiting scroll66. By using a separate plug136, rather than machining the oil orifice138directly in the orbiting scroll66, manufacturing efficiencies may be achieved. And the plug136may have an oil orifice138that is specifically designed and tuned to allow for oil flow and refrigerant flow to increase or decrease depending on the diameter and geometry of the oil orifice138.

As shown inFIGS.16D-16E, in one embodiment, the oil orifice138may have a first bore138A and a second bore138B, wherein a diameter of the first bore138A is less than a diameter of the second bore138B. For example, in one application of this embodiment the first bore138A has an approximate diameter of 0.3 mm. The second bore138B has a diameter greater than the diameter of the first bore138A and is only used to shorten the length of the first bore138A. The flow of the oil and coolant is designed to provide thermal and lubricant to the ball bearing108supporting the radial forces created by the eccentric orbit of the orbiting scroll66.

Further, as discussed above, the orbiting scroll66has an orbiting scroll base66A and an orbiting scroll lap66B. The orbiting scroll lap66B may have an orbiting scroll tail end66C and an orbiting scroll center end66D. As shown, the oil aperture140is located within the orbiting scroll center end66D. The plug136may be secured into the oil aperture140, by press fit or any other method that will secure the plug136.

As shown inFIG.9, the oil orifice138allows oil (and refrigerant) to travel from the discharge chamber82to the ball bearing108along the path73(which may be referred to as the “nose bleed” path).

Bearing Oil Communication Hole

The electric compressor10may include one or more bearing oil communication holes. As discussed above, in the illustrated embodiment, a drive shaft90is rotated by the motor54to controllably actuate the compression device18. The drive shaft90has a first end90A and a second and90B. The housing10of the electric compressor10forms a first drive shaft supporting member22B and a second drive shaft support member24A. In the illustrated embodiment, the first drive shaft supporting member22B is formed in a motor side22of the inverter housing22A and the second drive shaft supporting member24A is formed within the center housing24. First and second ball bearings62,64are located within the first and second drive shaft support members22B,24A.

The location of the first drive shaft supporting members22B is not a flow-through area for refrigerant (and oil). This may result in a low lubricating condition and affect the durability of the electric compressor10.

As shown inFIG.16F, the first drive supporting member22B may include one or more holes22C to allow oil to enter the first drive support member22B and lubricate the first ball bearing62.

In the illustrated embodiment, the scroll-type electric compressor10includes a housing12, a first ball bearing62, a second ball bearing64, a refrigerant inlet port68, a refrigerant outlet port70, an inverter module44, a motor54, a drive shaft90, and a compression device18.

The housing12defines an intake volume74and a discharge volume82and includes first and second drive shaft supporting members22B,24A. The first ball bearing62is located within the first drive shaft supporting member22B. The first drive shaft support member22B of the housing12includes one or more oil communication holes22C for allowing oil to enter the first ball bearing62.

The second ball bearing64is located within the second drive shaft supporting member24A. The refrigerant inlet port68is coupled to the housing12and is configured to introduce the refrigerant to the intake volume74. The refrigerant outlet port70is coupled to the housing12and is configured to allow compressed refrigerant to exit the scroll-type electric compressor10from the discharge volume82. The inverter module44is mounted inside the housing12and is adapted to convert direct current electrical power to alternating current electrical power. The motor54is mounted inside the housing12. The drive shaft90is coupled to the motor54. The drive shaft90has a first end90A and a second end90B. The first end90A of the drive shaft90is positioned within the first bearing62and the second end90B of the drive shaft90is positioned within the second bearing64. The compression device18receives the refrigerant from the intake volume74and compresses the refrigerant as the drive shaft90is rotated by the motor54. As discussed above, in the illustrated embodiment, the first drive shaft support member22may be formed on the motor side22A of the inverter housing22.

The rotational movement within the motor section16of the compression device18creates a flow path and movement to the oil from the oil reservoir98, as shown by arrows88inFIG.9. As shown the oil flows from the oil reservoir98toward the motor section16and continues toward the stator58and rotor60. The rotational motion of the orbiting scroll, rotor and drive shaft pulls the oil upward to mix with the inlet flow of the refrigerant path72. The rotational movement of the rotor60and drive shaft90will further propel the oil against the motor side22A of the inverter housing22. The motor side22A surface further includes a series of ribs22D, shown inFIG.16F. The ribs22D provide the needed rigidity for supporting the first drive shaft support member22and allow for a ridged backing and pocket to secure the first bearing62. The inverter housing22may further defines an oil cavity22E where the oil collected between the ribs22D is directed by gravity downward and into the oil cavity22E. The ribs22D and the sloped surface of the motor side22A cooperate to capture and direct the oil splashed or propelled against the motor side22A by the rotor60or drive shaft90, to assist in increasing the oil flow into the oil cavity22E and first bearing62.FIG.16Fillustrates two communication holes22C, but it is appreciated additional or less than 2 oil communication hole22C may be included above and between the ribs22D on the motor side22A of the inverter housing22. For example, in the illustrated embodiment the hole is 3.5 mm in diameter and the motor side22A includes a sloping wall between the ribs22D. In addition, the motor side22A may include an outer oil collection area.

Domed Inverter Cover

The scroll-type electric compressor10of the present invention may include a domed inverter cover20. The scroll-type electric compressor10includes the housing12, the refrigerant inlet port68, the refrigerant outlet port70, the inverter module44, the motor54, the drive shaft90, the compression device18and the inverter cover20. The housing12defines the intake volume74and the discharge volume82. The housing12has a generally cylindrical shape and the central axis90C. The refrigerant inlet port68is coupled to the housing12and is configured to introduce the refrigerant to the intake volume70. The refrigerant outlet port70is coupled to the housing12and is configured to allow compressed refrigerant to exit the scroll-type electric compressor10from the discharge volume82.

The inverter module44is mounted inside the housing12and adapted to convert direct current electrical power to alternating current electrical power. The motor54is mounted inside the housing12. The drive shaft90is coupled to the motor54. The compression device18is coupled to the drive shaft90and is configured to receive the refrigerant from the intake volume and to compress the refrigerant as the drive shaft90is rotated by the motor54.

As discussed above, the compression device18may rotate at a high speed (>2,000 RPM) which may create undesirable noise, vibration, and harshness (NVH) and low durability conditions. In the prior art, the inverter cover20is generally flat and tends to amplify and/or focus, the vibrations from the compression device18.

To disperse vibrations rather than focus, the vibrations from the compression device18, the inverter back cover20of the electric scroll-like compressor10of the fifth aspect of the disclosure is provided with a generally curved or domed profile.

As shown in the FIGS., specificallyFIGS.1,3and6, the inverter cover20is located at one end of the scroll-type electric compressor10and includes a first portion20A and a second portion20B. The first portion20A includes an apex or apex portion20C and is generally perpendicular to the central axis90C and has an apex20C and an outer perimeter20D. The first portion20A has a relatively domed-shaped such that the inverter cover20has a curved profile from the apex20C towards the outer perimeter20D. The amount and location of the curvature may be dictated or limited by other considerations, such as packaging constraints, i.e., the space in which the electric scroll-type compressor10must fit, and constraints placed by internal components, i.e., location and size). The first portion20A may also have to incorporate other features, e.g., apertures to receive fastening bolts. The second portion20B may include a portion of the inverter cover20that is not domed, i.e., is relatively flat that is located about the perimeter of the inverter cover.

Fixed Scroll Having Modified Scroll Flooring

In a first aspect of the present invention, the scroll-type electric compressor10with a modified fixed scroll flooring is configured to compress a refrigerant. The scroll-type electric compressor10includes the housing12, the refrigerant inlet port68, the refrigerant outlet port70, the inverter module44, the motor54, the drive shaft90, and the compression device18. The housing12defines an intake volume74and a discharge volume82.

The refrigerant inlet port68is coupled to the housing12and is configured to introduce the refrigerant to the intake volume74. The refrigerant outlet port70is coupled to the housing12and is configured to allow compressed refrigerant to exit the scroll-type electric compressor12from the discharge volume82. The inverter module44is mounted inside the housing12and adapted to convert direct current electrical power to alternating current electrical power. The motor54is mounted inside the housing12and the drive shaft90is coupled to the motor54.

In general, and as described above, the compression device18receives the refrigerant from the intake volume74and compresses the refrigerant as the drive shaft90is rotated by the motor54.

The compression device18includes a fixed scroll26and an orbiting scroll66. The compression device18defines antechamber volume134. The antechamber volume134(seeFIGS.18C and18G) feeds refrigerant to the chambers80at the start of a compression cycle. During the compression cycle, when the chambers80close (as the laps26B,66B come into contact, the pressure within the antechamber volume134drops due to suction which can affect the efficiency of the electric compressor10. In one aspect of the present invention, it is desirable to increase the volume of the antechamber (to make additional refrigerant available to the compression device18). This increases the “capacitance” of the compression device18and smooths out the compression cycle.

In the illustrated embodiment, the base26A,66A of one of the fixed scroll26and the orbiting scroll66has a cutout136to increase the antechamber volume134.

In the illustrated embodiment, the cutout136is located in the floor or base26A of the fixed scroll26.

As shown, the fixed scroll26has a first side26F defined by fixed scroll base26A and a second side26G defined by a top surface of the fixed scroll lap26B. The fixed scroll lap26B extends from the fixed scroll base26A towards the second side26G of the fixed scroll26. As shown inFIGS.18C and18G, the cutout136in the floor of the fixed scroll base26A defines a first portion which has a depth, d1, which is greater than a depth, d2, of a second portion138.

The size of the first portion or cutout136may be limited by a couple constraints. First, the depth, d1, must leave sufficient material to maintain the structural integrity of the fixed scroll26. In addition, to ensure that the chamber80is scaled, the geometry of the cutout must remain outside the orbiting lap66B, to allow the chamber80to close and seal as shown in17D. The cutout136may provide additional volume within the antechamber134to allow the volumes within chambers80in17D to be fully filled. The cutout136is limited by the path of the orbiting scroll66, and limitations to the floor and wall thickness needed to the fixed scroll26. In addition, machine tooling and access to the floor of the fixed scroll may provide additional limitations to the size and areas outside the seal area of the orbiting scroll66.

In a second aspect of the present invention, an isolation and constraint system145may be used to isolate the housing12from the oscillations and pulsations caused by the orbiting scroll66.

In a typical, scroll-type electric compressor, the motor and the fixed scroll are directly coupled to the housing. is directly coupled to the housing. As discussed above, guidance pins directly coupled to the housing may cooperate with ring shaped slots on the orbiting scroll to limit articulation of the orbiting scroll as it orbits the drive shaft. With this type of arrangement, oscillations and pumping pulsations from the orbiting scroll may be transmitted to the housing and through the mounts to the, e.g., vehicle structure.

The scroll-type electric compressor10is configured to compress a refrigerant. The scroll-type electric compressor includes the housing12, the refrigerant inlet port68, the refrigerant outlet port70, the inverter module44, the motor54, the drive shaft90and a compression device18. The housing12defines an intake volume74and a discharge volume82and has a generally cylindrical shape. The refrigerant inlet port68is coupled to the housing12and is configured to introduce the refrigerant to the intake volume74. The refrigerant outlet port70is coupled to the housing12and is configured to allow compressed refrigerant to exit the scroll-type electric compressor12from the discharge volume82. The inverter module44is mounted inside the housing12and adapted to convert direct current electrical power to alternating current electrical power. The motor54is mounted inside the housing12. The drive shaft90is coupled to the motor54. The compression device18is coupled to the drive shaft90for receiving the refrigerant from the intake volume74and compressing the refrigerant as the drive shaft90is rotated by the motor54.

As discussed above, the compression device16includes a fixed scroll26and an orbiting scroll66. The fixed scroll26is located within, and is fixed relative to, the housing12. The orbiting scroll66is coupled to the drive shaft90. The orbiting scroll66and the fixed scroll26form compression chambers80for receiving the refrigerant from the intake volume74and for compressing the refrigerant as the drive shaft90is rotated about the center axis90C.

The orbiting scroll66has a lower surface having a plurality of ring-shaped slots66I (see above).

With specific reference toFIG.20A, the scroll-type electric compressor10further includes a thrust body144, the plurality of articulating guidance pins24B, a plurality of mounting pins148and a plurality of isolating sleeves146. The thrust body144has a plurality of guidance pin apertures155. The plurality of mounting pins148extend from the guidance pin apertures155. The guidance pins24B are configured to limit articulation of the orbiting scroll66as the orbiting scroll66orbits about the central axis90.

Each mounting pin148has a housing end148A and a thrust body end148B. The housing end148A is press fit within respective receiving apertures in the housing12. The thrust body end148B is cylindrical with an outer surface. The plurality of isolating sleeves146are composed from a flexible material, such as a chemically resistant synthetic rubber. One such material is ethylene propylene diene monomer (EPDM). The thrust body end148B of each mounting pin148is encapsulated within a respective sleeve146and is received in a respective slot153within the thrust body144. In this way, the only connection between the thrust body144and the housing12is through the mounting pins148which is isolated or insulated by the sleeves146to prevent or minimize vibrations from the orbiting scroll66from being transmitted to the housing12.

As shown inFIG.20A, in one embodiment, the isolating sleeves146are integrally formed with a circular gasket or ring147.

As shown inFIG.20B, in another embodiment, the thrust body end148B of each mounting pin148is fully encapsulated by the flexible material using, for example, an over-molding process. The outer surface of the of the isolating sleeves146may be ribbed to assist with the isolation.

Electric Compressor Head Design

In a third aspect of the electric compressor10of the disclosure, a front cover28design includes an oil separator96and a three-reed reed mechanism86. As discussed below, the design of the front cover28, the fixed scroll26and the reed mechanism86define a multicavity pulsation muffler system159.

In prior art electric compressors, refrigerant is released from the compression device once per revolution (or orbit) of the orbiting scroll. This creates a first order pulsation within the compressed refrigerant released by the electric compressor. The relative strong amplitude and low frequency of the pulsation creating in the refrigerant may excite other components (internal or external to the electric compressor) which may create undesirable noise, vibration and harshness (NVH) and low durability conditions.

With reference toFIGS.18C-18FandFIGS.19A-19B, the multicavity pulsation muffler system159compressed refrigerant is released from the compression device18twice during a compression cycle. As discussed in more detail below, the compression device18includes two smaller secondary discharge ports are placed into (adjacent) two secondary discharge chambers, The secondary discharge chambers are downstream (in the discharge head) of the pressure drop from a central discharge port. As also described further below, the front cover28defines a parallel discharge path for refrigerant exiting the compression device18to the refrigerant outlet port70.

In the illustrated embodiment, the compressor10includes the housing12, the inverter module44, the motor54, and a compression device18. The housing12defines an intake volume74and a discharge volume82. The housing12has a generally cylindrical shape and a central axis90C. The inverter module44is mounted inside the housing12and adapted to convert direct current electrical power to alternating current electrical power. The motor54is mounted inside the housing.

The compression device18is coupled to the motor54for receiving the refrigerant from the intake volume74and compressing the refrigerant as the motor54is rotated.

The compression device18has a central compression device outlet orifice84A and first and second side compression device outlet orifices84B for controllably releasing compressed refrigerant into the discharge volume82during a compression cycle. The compression device18is configured to release compressed refrigerant into the discharge volume82via the first and second side compression device outlet orifices84B earlier in the compression cycle then refrigerant is released via the central discharge orifices84A.

In addition, the oil separator96utilizes two parallel paths between the compression device18and the refrigerant outlet port70to reduce the net pressure drop while maintaining the reduction in this pulsation.

In the illustrated embodiment, the oil separator96may be located in the discharge volume82and integrally formed with the discharge head or front cover28. As discussed above, oil is used to provide lubrication between the moving components of the electric compressor10. During operation, the oil and the refrigerant become mixed. The oil separator96is necessary to separate the intermixed oil and refrigerant before the refrigerant leaves the electric compressor10.

Generally, refrigerant is released from the compression device18during each cycle, i.e., revolution (or orbit) of the orbiting scroll66. In the illustrated embodiment, refrigerant leaves the compression device18through the central orifice84A and two side orifices84B in the fixed scroll26. Release of the refrigerant through the orifices,84A,84B is controlled by the central reed87A and two side reeds87B, respectively (see below).

In the illustrated embodiment, the oil separator96connects the discharge chambers (see below) by relatively small channels to create pressure drops between the chambers. This acts to smooth out the flow of compressed refrigerant out of the electric compressor10. Additionally, the oil separator96utilizes two parallel paths between the compression device18and the refrigerant outlet port70to reduce the net pressure drop while maintaining the reduction in this pulsation.

The oil separator96may include a series of walls98A extending from an inner surface of the front cover28. As shown, the walls98A separate the discharge volume82into a central discharge chamber82A, two side discharge chambers82B, am upper discharge chamber82C and the oil reservoir98. The central discharge chamber82A is adjacent the central reed87A and receives intermixed pressurized refrigerant and oil from the compression device18through the central orifice84A via the reed87A. The side discharge chamber82B is adjacent respective side reed87B and receives intermixed pressurized refrigerant and oil from the compression device18through the side orifices84B via respective reeds87B. Generally, the pressure of the refrigerant in the chambers is: central discharge chamber82A>side discharge chambers82B>upper discharge chamber82C.

The central discharge chamber82A is in fluid communication with the two side discharge chambers82B via respective side channels100which are in fluid communication with the upper discharge chamber82C and the oil reservoir98via upper discharge channels102and lower discharge channels104, respectively. In one embodiment, the side channels100extend at an acute angle through to the side discharge chambers82B. The angle of the channels100further directs the impact of the discharging mixture of refrigerant and oil to further improve the separation and increase the amount of oil separated out by the oil separator96. For example, inFIG.19C, the side channels100extend through and downward into the side discharge chambers82B at approximately a 45-degree angle relative to the inner wall of the central discharge chamber82A. However, the angle may vary depending on the application or surface contours of the side discharge chambers82B, and in some variations may increase to approximately 60 degrees. The angle may vary but is designed to direct the flow to create turbulence and direct the flow impact to create a tortuous path within the side discharge chambers82B to increase the separation of oil into the lower discharge channels104.

As shown, the oil separator96includes the central discharge chamber82A and a lower baffle132. In the illustrated embodiment, the lower baffle132is chevron-shaped (inverted “v”) and is located between the central chamber82and the oil reservoir98. The shape of the lower baffle132creates an area of low pressure directly underneath. Intermixed oil and refrigerant enter the central discharge chamber82A and is drawn downward by the low-pressure area. The oil and refrigerant are separated when the intermixed oil and refrigerant comes into contact with the upper surface of the lower baffle132. The oil drops into the oil reservoir98.

Refrigerant may enter the side discharge chambers82B via the side channels100and/or lower discharge channels104. Refrigerant may then enter the upper discharge chamber82C and then exit via the refrigerant outlet port70.

The oil reservoir98is located below the pair of side chambers and is connected thereto via the respective lower discharge channels104. The oil reservoir is configured to receive oil separated from the compressed refrigerant in the side chambers. Gravity acting on the oil assists in the separation and the oil falls through the lower discharge channels104located in the side discharge chambers82B into the oil reservoir98.

As discussed above, the reed mechanism86includes a discharge reed86A and a reed retainer86B which define the reeds87A,87B. The discharge reed86A is used to tune the pressure at which the refrigerant is allowed to exit the compression device18through the central orifice84A and two side orifices84B, respectively.

Electric Compressor with Integrated Sensor(s)

With reference toFIGS.21and22A-26C, in one aspect of the present invention, an electric scroll-type sensor10may include one or more integrated sensors150. With specific reference toFIG.21, a functional block diagram of the electric compressor10with the integrated sensor(s)150is shown. In one embodiment, the integrated sensor(s)150includes an integrated first pressure sensor150A. In another embodiment, the integrated sensor(s)150may also include an integrated first temperature sensor150B. As shown, the integrated first pressure sensor150A and the integrated first temperature sensor150B are connected to a first filter circuit152for conditioning and filtering the raw sensor data from the integrated sensors150A,150B. The filter circuit152is coupled to an off-board vehicle electronic control unit230and provides filtered/conditioned sensor signals to the off-board vehicle electronic control unit230. The first temperature sensor150B may be connected to the printed circuit board48by a pair of wires (see below) that are routed through the internal housing partition168.

In one embodiment, the integrated first pressure sensor150A and the filter circuit152are integrated into a single integrated circuit156, e.g., a micro-electromechanical system (MEMS). In the illustrated embodiment, the first integrated pressure sensor150A and the first integrated temperature sensor150B are configured to measure or establish a pressure and temperature, respectively, associated with the intake volume74.

The electric compressor10may also include an integrated second pressure sensor150C and an integrated second temperature sensor150D. The integrated second pressure and temperature sensors150C,150D are connected to a second filter circuit158. As shown, the integrated second pressure sensor150C and the second filter circuit158may be integrated into a second integrated circuit160, such as a second MEMS.

As discussed in more depth below, the first pressure sensor150A and the first temperature sensor150B may be configured to sense or establish a pressure and a temperature, respectively, associated with the intake volume74. The second pressure sensor150C and the second temperature sensor150D may be configured to sense or establish a pressure and a temperature, respectively, associated with the discharge volume82.

With reference toFIGS.22A-26C, several embodiments will be discussed below.

In a first embodiment shown inFIGS.22A-22I, the electric scroll-type compressor10includes the integrated first pressure sensor150A and the integrated first temperature sensor150B. As discussed above, the inverter or controller circuit46is mounted to a printed circuit board48. In the embodiment, shown inFIGS.22A-22I, the first pressure sensor150is mounted directly to the printed circuit board48.

In a second embodiment, shown inFIGS.23A-23G, the electric scroll-type compressor10only includes the first pressure sensor150A mounted to the printed circuit board48.

As discussed in more detail below, in the third and fourth embodiments the electric compressor10includes a pressure sensor module162. The pressure sensor module162includes a pressure sensor module housing162A. The pressure sensor module housing162A defines a pressure sensor cavity162C. A pressure sensor module (or second) printed circuit board162B is positioned within the pressure sensor cavity162C and is electrically coupled to the printed circuit board48via an electrical connector166that is used for communications between the sensor(s)150A,150B. The pressure sensor150A is mounted directly to the pressure sensor module printed circuit board162B.

The first temperature sensor150B may be connected or wired to the second printed circuit board162B. The removable pressure module, including the first pressure sensor150A and the first temperature sensor150B, may be preassembled and installed as a preassembled unit into the electric compressor10.

As discussed above, the electric compressor10has an outer housing or housing12. The housing12includes an inverter housing22and an inverter back cover20. The inverter housing and the inverter back cover20define the inverter cavity30. An inverter module44is located/positioned within the inverter cavity30. The inverter module44includes an inverter or controller circuit46mounted at least partially on a printed circuit board48. As discussed in more detail below, each of the embodiments shown inFIGS.22A-22I,FIGS.23A-23G,FIGS.24A-24H, andFIGS.25A-25E, the electric compressor10includes an internal housing partition168separating an intake volume74and the inverter cavity30. The internal housing partition168includes a passage170therethrough for receiving refrigerant from the intake volume74. The passage170has an intake volume end170A and an inverter cavity end170B. The intake volume end170A is open to the intake volume74. As discussed in more detail below, the first pressure sensor150A is positioned within the inverter cavity30adjacent to the inverter cavity end170B of the passage170for sensing a pressure associated with the refrigerant within the passage (and thus, the intake volume74).

With reference toFIGS.26A-26C, the electric scroll-type compressor10includes the integrated second pressure and temperature sensors150C,150D. The embodiment shown in FIGS.26A-26C may be used with, or adapted for use by, any of the first, second, third and fourth embodiments.

First Embodiment of Electric Scroll-Type Compressor with Integrated Sensor(s)

With reference toFIGS.22A-22I, a scroll-type electric compressor10with an integrated first pressure sensor150A and an integrated first temperatures sensor150B according to the first embodiment is shown. With specific reference toFIGS.22A,22B,22C, and22F-22I, in the first embodiment, the scroll-type electric compressor includes a holder180. As best shown inFIG.22E, the inverter housing22includes a holder aperture182for receiving the holder180. In the illustrated embodiment, the holder180includes an outer edge180A located on an outer surface of, extending away from the holder180. The outer edge180A is positioned between, and held in place, by a surface22A of the inverter housing22and a retainer184. Alternatively, or in addition, the holder180may be held in place relative to the inverter housing22by an interference fit. The holder180may be composed from a non-metallic material, for example, a plastic. As shown, the holder180defines at least part of the internal housing partition168.

In the illustrated embodiment, the passage170is positioned or located within the holder180. The holder180may be cylindrical with a generally circular outer circumference. The holder180may include an upper cavity180B defined by an upper ridge180C. As shown, in the illustrated embodiment, the upper ridge180C encircles an outer edge of a top of the holder180.

As shown, the pressure sensor150A and the filter circuit152may be embodied in a MEMS integrated circuit or package156mounted directly on the printed circuit board48. The MEMS package156includes a pressure sensitive plate156A that is located adjacent the inverter cavity end170B of the passage170. The pressure sensitive plate156A measures or senses a pressure associated with the refrigerant in the intake volume74and the passage170. As discussed above, the filter circuit152conditions the signal from the pressure sensor150A which is communicated to the controller circuit46which communicates a filter or conditioned pressure signal to the vehicle electronic control unit230.

The MEMS package156may be scaled against a bottom surface of the upper cavity180B of the holder180using adhesive186. An O-ring188, located between an outer surface of the holder180and an interior surface of the inverter housing22may be provided to seal the upper cavity180B and the inverter cavity30from the intake volume74adjacent a bottom surface of the holder180(opposite the upper cavity180B).

In the illustrated first embodiment, the electric compressor10includes the first temperature150B. However, it should be noted that the first temperature150B is optional.

As shown, the first temperature sensor150B is positioned with the intake volume74near or adjacent the bottom surface of the holder180. The first temperature sensor150B may be a thermistor and may be connected or electrically coupled to the printed circuit board48by a pair of wires150B-1. With reference toFIGS.22G,22H and22I, the pair of wires150B-1may be routed through respective apertures180D. Each aperture180D includes a first end180D-1within the bottom surface of the holder180and a second end180D-2within the upper cavity180B.

The printed circuit board48may include one or more sub-boards. For example, the printed circuit board48may include a sub-board48A. The MEMS package156may be mounted directly to the sub-board48A which, when the electric compressor10is assembled, fits within a complementary recess in the main board48B of the printed circuit board. Suitable electrical contacts on the sub-board48A and the main board48B connect the MEMS package156to the inverter circuit46mounted to the main board48B. It should also be noted that the retainer184may include two or more retainer portions184A,184B.

As mentioned above, the first temperature sensor150B is optional. If a first temperature sensor150B is not utilized, then the holder180does not include the apertures180D.

Second Embodiment of Electric Scroll-Type Compressor with Integrated Sensor(s)

With specific reference toFIGS.23A-23G, an electric compressor10according to a second embodiment is shown. In the second embodiment, the internal housing partition168is composed from, or is part of the, the inverter housing22. In other words, the electric compressor10does not include the separate holder180(of the first embodiment). As with the first embodiment, the MEMS package156is mounted directly to the printed circuit board48. With specific reference toFIGS.23A-23D, the inverter housing22includes a raised housing feature200that rises from the inverter housing22to mate with the MEMS package156. The raised housing feature200is part of, and integrally formed, with the inverter housing22. The passage22is located within the raised housing feature200which extends from a lower surface of the inverter housing22towards the inverter cavity30. The passage170includes an intake volume end170A and an inverter cavity end170B. The raised housing feature200includes an upper surface200A that is adjacent to, and in contact with the MEMS package156. The junction between the MEMS package156and the upper surface200A of the raised housing feature200may be scaled with an O-ring202and/or adhesive (in cavity204).

In the illustrated embodiment, the passage170includes a lower portion170-1, an intermediate portion170-2, and an upper portion170-3. The lower portion170-1extends from lower surface of the inverter housing22and forms the intake volume end170A of the passage. The intermediate portion170-2is located at an opposite end of the lower portion170-1. The upper portion170-3is positioned above the intermediate portion170-2and forms the inverter cavity end170B of the passage170. The lower portion170-1has a diameter that is greater than a diameter of the upper portion170-3. The intermediate portion170-2has a diameter that is equal to the diameter of the lower portion170-1at one end and a diameter equal to the diameter of the upper portion170-3at the opposite end.

As shown, the pressure sensor150A and the filter circuit152may be embodied in a MEMS integrated circuit or package156mounted directly on the printed circuit board48. The MEMS package156includes a pressure sensitive plate156A that is located adjacent the inverter cavity end170B of the passage170. The pressure sensitive plate156A measures or senses a pressure associated with the refrigerant in the intake volume74and the passage170. As discussed above, the filter circuit152conditions the signal from the pressure sensor150A which is communicated to the controller circuit46which communicates a filter or conditioned pressure signal to the vehicle electronic control unit230.

Third Embodiment of Electric Scroll-Type Compressor with Integrated Sensor(s)

With reference toFIGS.24A-24H, an electric compressor10according to the third embodiment is shown. In the third embodiment, the electric compressor10includes the pressure sensor module162. In one aspect of the present invention, the pressure sensor module162may be preassembled and removable from the electric compressor10.

In the illustrated embodiment, the pressure sensor module162of the third embodiment, includes the first pressure sensor150A and the first temperature sensor150B. However, it should be noted that the first temperature sensor150B is optional. In other words, the pressure sensor module162of the third embodiment, may be provided with the first pressure sensor150A only. As discussed above, the pressure sensor module162includes a pressure sensing housing162A that defines a pressure sensor cavity162C. The pressure sensing housing162A may further include an intake volume side wall162D. The passage170may be formed within the intake volume side wall162D.

As shown, in the illustrated embodiment, the pressure sensor module housing162A may include a first portion162A-1and a second portion162A-2. The first and second portions162A-1,162A-2may be composed from a non-metallic material, such as a plastic. The intake volume side wall162D may be formed in the first portion162A-1of the pressure sensor module housing162A.

As shown, the inverter housing22may include a slot22F located around a periphery of the pressure sensor module aperture22G for receiving a retainer164configured to retain the pressure sensor module162within the pressure sensor module aperture22G. The retainer164may be in the form of a C clamp as shown inFIG.24D.

As shown, the pressure sensor module162may also include the first temperature sensor150B. The first temperature sensor150B may be coupled to the pressure module printed circuit board by a plurality of wires210. The temperature sensor150B is located within the intake volume74when the scroll-type electrical compressor10is assembled. As shown, the pressure sensor module162may include one or more aperture212for receiving the plurality of wires210.

Fourth Embodiment of Electric Scroll-Type Compressor with Integrated Sensor(s)

With reference toFIGS.25A-25E, an electric compressor10according to the fourth embodiment is shown. In the fourth embodiment, the electric compressor10includes the pressure sensor module162. In one aspect of the present invention, the pressure sensor module162may be preassembled and removable from the electric compressor10.

In the illustrated embodiment, the pressure sensor module162of the fourth embodiment, includes the first pressure sensor150A. As discussed above, the pressure sensor module162includes the pressure sensing housing162A that defines a pressure sensor cavity162C. The pressure sensor module circuit board162B is positioned within the pressure sensor cavity162C and the first pressure sensor150A is mounted thereon. As shown, in the fourth embodiment, the pressure sensor module housing162A is open at one end (adjacent to the inverter housing22) and the internal housing partition168is formed by the inverter housing22. The passage170is firmed by the internal housing partition168within the inverter housing22. In the illustrated embodiment, the passage170includes a lower portion170-1, an intermediate portion170-2, and an upper portion170-3. The lower portion170-1extends from lower surface of the inverter housing22and forms the intake volume end170A of the passage. The intermediate portion170-2is located at an opposite end of the lower portion170-1. the upper portion170-3is positioned above the intermediate portion170-2and forms the inverter cavity end170B of the passage170. The lower portion170-1has a diameter that is greater than a diameter of the upper portion170-3. The intermediate portion170-2has a diameter that is equal to the diameter of the lower portion170-1at one end and a diameter equal to the diameter of the upper portion170-3at the opposite end.

As discussed above, the passage170includes an intake volume end170A and an inverter cavity end170B. An upper surface of the inverter housing22is adjacent to, and in contact with the MEMS package156. The junction between the MEMS package156and the upper surface of the inverter housing22may be scaled with an O-ring202and/or adhesive (in cavity204).

Electric Scroll-Type Compressor with Integrated Sensor(s) at Discharge Side

In the first, second, third and fourth embodiments, discussed above, the electric compressor10may include a first pressure sensor150A and/or a first temperature sensor150B for measuring a pressure and/or a temperature associated with the intake volume74. In some applications, it may be desirable to establish a pressure and/or a temperature associated with the discharge side of the compressor10, i.e., the discharge volume82.

With specific reference toFIGS.26A-26C, the housing12of the electric compressor10may define a second passage220. The second passage220has a discharge cavity end220A and an inverter cavity end220B. The discharge cavity end220A is located with the discharge cavity82. The inverter cavity end220B is located at/within or adjacent to the inverter housing22. Pressurized refrigerant from the discharge volume82. The second pressure sensor150C may be located within the inverter cavity30and configured to establish a pressure associated with the pressurized refrigerant from the discharge volume82within the second passage220. As shown inFIGS.26A, the second passage220may be embodied in a rib222positioned along an outer surface of the housing12. The second temperature sensor150D, if used/provided, may be positioned within the discharge volume82and coupled to the printed circuit board48by a plurality of wires routed through the second passage220.

The foregoing invention has been described in accordance with the relevant legal standards, thus the description is exemplary rather than limiting in nature. Variations and modifications to the disclosed embodiment may become apparent to those skilled in the art and fall within the scope of the invention.