WO2024005869A1

WO2024005869A1 - Rolling piston rotary compressor

Info

Publication number: WO2024005869A1
Application number: PCT/US2023/000024
Authority: WO
Inventors: Cassio Ricardo Naidhig MAULE; Mario Luis BOTEGA; Regis SCAPINI MARQUES; Celso Kenzo TAKEMORI; Robert Terry; Hiroshi Saito; Marcelo A. REAL; Edu De Moraes MACHADO; Edmar Baars; Diego Willlian DA SILVA
Original assignee: Tecumseh Products Company Llc
Priority date: 2022-06-26
Filing date: 2023-06-26
Publication date: 2024-01-04
Also published as: WO2024005869A4

Abstract

An apparatus includes a semi-hermetic compressor housing, an electrically- powerable dual-cylinder rolling piston rotary compressor assembly housed in the housing, electric motor driver electronics, and an auxiliary housing. The auxiliary housing defines a semi-hermetic refrigerant inlet compartment having a wall. The auxiliary housing also defines an electronics compartment sharing the wall with the inlet compartment but semi- hermetically separated from the inlet compartment. The compressor housing is semi- hermetically coupled to the inlet compartment and in fluid communication therewith. The electronics compartment houses the electronics..

Description

ROLLING PISTON ROTARY COMPRESSOR

CROSS REFERENCE TO RELATED APPLICATION(S)

[0001] This application claims the benefit of priority to United States Provisional Patent Application No. 63/438,769, filed on January, 12, 2023, and claims the benefit of priority to United States Provisional Patent Application No. 63/355,611, filed on June 26, 2022, each of which is incorporated herein by reference.

FIELD OF THE INVENTION

[0002] Various embodiments herein relate to positive-displacement compressors and, more particularly, to semi-hermetic, electrically-powerable, rolling piston rotary compressors for compressing refrigerants in air conditioning, refrigeration, heat pump, and/or other cooling and/or heating systems for electric vehicles, internal combustion engine vehicles, aircraft, marine vehicles, buildings, manufacturing systems, and/or other suitable applications.

BACKGROUND

[0003] Mitigating climate change will require rethinking historical paradigms. While a rotary scroll refrigerant compressor can typically outperform a comparably sized rolling piston rotary compressor within a narrow range of fairly constant load conditions, a growing number of cooling and heating applications will present relatively broad ranging and dynamic load conditions which could benefit from a more suitable rolling piston rotary compressor. For example, internal combustion engine (“ICE”) vehicles have typically used scroll compressors in their driver/passenger-cabin heating, ventilation, and air conditioning (“HVAC”) systems. But a conventional ICE vehicle typically has an abundance of power to burn for operating an HVAC system (which presents a fairly narrow and constant compressor load). Moreover, an ICE vehicle typically does not have significant additional refrigeration needs. Electric vehicles, on the other hand, are increasingly requiring battery cooling, brake cooling, and presenting other demands for thermal management of various drivetrain-related air and/or liquid heat exchanging systems - in addition to traditional driver/passenger-cabin HVAC. Such additional loads can be significantly more dynamic than traditional HVAC systems.

[0004] Suitable rolling piston rotary compressors are needed to reduce overall HVAC power consumptions and to meet various battery cooling, brake cooling, and/or other electric vehicle cooling demands, and, in turn, to produce higher efficiency (longer range) electric vehicles. Moreover, in addition to supporting a cooling system, a rolling piston compressor can typically operate as a heat pump that more efficiently provides heat than traditional, resistive heaters. As electric vehicle technology continues to develop and the number of electric vehicles on the roads increases, needs for (and potential advantages of) efficient rolling piston rotary compressors will continue to grow.

SUMMARY OF THE INVENTION

[0005] In some embodiments, an apparatus includes a semi-hermetic compressor housing, an electrically-powerable dual-cylinder rolling piston rotary compressor assembly housed in the housing, electric motor driver electronics, and an auxiliary housing. The auxiliary housing defines a semi-hermetic refrigerant inlet compartment having a wall. The auxiliary housing also defines an electronics compartment sharing the wall with the inlet compartment but semi-hermetically separated from the inlet compartment. The compressor housing is semi-hermetically coupled to the inlet compartment and in fluid communication therewith. The electronics compartment houses the electronics.

[0006] In some embodiments, an apparatus includes a first rolling piston rotary compressor roller, a second rolling piston rotary compressor roller, a substantially hollow camshaft arranged to cooperate with the first roller and the second roller, an Archimedes screw, and a flexible coupling mechanically coupled to the camshaft therein. The flexible coupling has a first end portion extending from the camshaft in a first direction, has a second end portion extending in a second direction into engagement with the Archimedes screw, and has an intermediate portion extending between the first end portion and the second end portion and bending from the first direction to the second direction.

[0007] In some embodiments, an apparatus includes a first rolling piston rotary compressor roller, a second rolling piston rotary compressor roller, a camshaft arranged to cooperate with the first roller and the second roller, and an electric motor including a rotor. The rotor is mechanically coupled to the camshaft and includes a first end and a second end. The rotor is generally cylindrical between the first end and the second end. A first generally discoidal counterweight is attached to the first end of the rotor. The first counterweight has a first generally C-shaped portion extending therefrom. A second generally discoidal counterweight is attached to the second end of the rotor. The second counterweight has a second generally C-shaped portion extending therefrom. The second generally C-shaped portion is positioned on the second end of the rotor at about 180 degrees rotational displacement relative to the first generally C-shaped portion. A first generally discoidal cap is attached to first counterweight. The first cap has a third generally C-shaped portion extending therefrom. The third generally C-shaped portion faces toward the first counterweight at about 180 degrees rotational displacement relative to the first generally C-shaped portion. A second generally discoidal cap is attached to second counterweight. The second cap has a fourth generally C-shaped portion extending therefrom. The fourth generally C-shaped portion faces toward the second counterweight at about 180 degrees rotational displacement relative to the second generally C-shaped portion.

[0008] In some embodiments, an apparatus includes a semi-hermetic compressor housing and a pair of rolling piston rotary compressor cylinders housed in the housing, including a first rolling piston rotary compressor cylinder and including a second rolling piston rotary compressor cylinder. A pair of compressor cylinder discharge valves includes a first valve mechanically coupled to the first cylinder and includes a second valve mechanically coupled to the second cylinder. A pair of plates is interposed between the first cylinder and the second cylinder. The plates include a first plate. The first plate defines a first recess. The plates include a second plate. The second plate faces toward the first plate and defines a second recess. The first recess and the second recess together define a first acoustic muffler chamber. The valves are arranged to control refrigerant flows from the first cylinder and the second cylinder to the first chamber.

[0009] In some embodiments, an apparatus includes a semi-hermetic compressor housing and a pair of rolling piston rotary compressor cylinders housed in the housing, including a first rolling piston rotary compressor cylinder and including a second rolling piston rotary compressor cylinder. A pair of compressor cylinder discharge valves includes a first valve mechanically coupled to the first cylinder and includes a second valve mechanically coupled to the second cylinder. A camshaft extends through the cylinders. The camshaft has an inboard portion and an outboard portion. An inboard bearing supports the inboard portion of the camshaft. A first inboard plate is positioned inboard of the bearing and defines a first acoustic muffler chamber having a pair of refrigerant flow holes therein. The holes include a first hole extending about a first respective axial line and include a second hole extending about a second respective axial line. A second inboard plate is positioned inboard of the first plate and defines a second acoustic muffler chamber having a first refrigerant discharge port therein. The first discharge port extends about a third respective axial line. The valves are arranged to control refrigerant flows from the first cylinder and the second cylinder to the first chamber. The second chamber is in fluid communication with the first chamber, but neither the first axial line nor the second axial line is aligned with the third axial line.

[0010] It will be appreciated that the various embodiments described in this summary section, as well as elsewhere in this application, can be expressed as a large number of different combinations and subcombinations. All such useful, novel, and inventive combinations and subcombinations are contemplated herein, it being recognized that the explicit expression of each of these combinations is unnecessary.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Some of the figures shown herein may include dimensions. Further, the figures shown herein may have been created from scaled drawings, scaled models, or from photographs that are scalable. It is understood that such dimensions, or the relative scaling within a figure, are by way of example, and not to be construed as limiting unless so stated in a claim. Persons of ordinary skill will also recognize that computer-aided design (“CAD”) renderings may include lines that pertain to changes in surface geometry, and not necessarily to component features.

[0012] Fig. 40 illustrates a top front left perspective view of a semi-hermetic compressor in accordance with aspects of the present disclosure.

[0013] Fig. A illustrates a top front left perspective partially exploded view of the semi- hermetic compressor of Fig. 40.

[0014] Fig. B illustrates a top front left perspective partially exploded view of the electrically-powerable dual-cylinder rolling piston rotary compressor assembly of Fig. A.

[0015] Fig. C illustrates a top front left perspective exploded view of the dual-cylinder rolling piston rotary compressor assembly of Fig. B.

[0016] Fig. D illustrates a top rear right perspective exploded view of the dual-cylinder rolling piston rotary compressor assembly of Fig. C.

[0017] Fig. 59 illustrates a vertical cross-sectional view of semi-hermetic compressor of Fig. 40, in the direction of line(s) 59-59 of Fig. 40.

[0018] Fig. 61 illustrates a vertical cross-sectional view of the semi-hermetic compressor of Fig. 40, in the direction of line(s) 61 -61 of Fig. 40.

[0019] Fig. 62 illustrates an enlarged vertical cross-sectional isolation view of the semi- hermetic coupling of the semi-hermetic compressor housing to the auxiliary housing, taken from Fig. 61. [0020] Fig. 63 illustrates a perspective view of the chamfered shim of the of the semi- hermetic coupling of Fig. 62.

[0021] Fig. F illustrates a vertical cross-sectional view of an alternative semi-hermetic compressor in accordance with aspects of the present disclosure, in a direction analogous to line(s) 61-61 of Fig. 40.

[0022] Fig. 48 illustrates a top front right perspective view of an outboard portion of the electrically-powerable dual-cylinder rolling piston rotary compressor assembly of Fig. A.

[0023] Fig. 47 illustrates a vertical cross-sectional view of the semi-hermetic compressor of Fig. 40, in the direction of line(s) 47-47 of Fig. 40.

[0024] Fig. 57 illustrates an enlarged vertical cross-sectional isolation view of the helical oil pump assembly of the semi-hermetic compressor of Fig. 40, taken from Fig. 47.

[0025] Fig. 56 illustrates an exploded perspective view of the helical oil pump assembly of the semi-hermetic compressor of Fig. 40.

[0026] Fig. 54 illustrates an enlarged vertical cross-sectional isolation view of the refrigerant discharge tube of the semi-hermetic compressor of Fig. 40, taken from Fig. 47. [0027] Fig. 53 illustrates a perspective view of the refrigerant discharge tube of the semi-hermetic compressor of Fig. 40.

[0028] Fig. 51 illustrates an enlarged vertical cross-sectional isolation view of the aft oil spigot installed in the aft end of the camshaft of the semi-hermetic compressor of Fig. 40, taken from Fig. 47.

[0029] Fig. 50 illustrates an enlarged vertical cross-sectional isolation view of the aft oil spigot of the semi-hermetic compressor of Fig. 40, taken from Fig. 51 . [0030] Fig. 49 illustrates a perspective view of the aft oil spigot of the semi-hermetic compressor of Fig. 40.

[0031] Fig. 45 illustrates a top front left perspective view of the counterweighted motor rotor assembly of the electrically-powerable dual-cylinder rolling piston rotary compressor of Fig. B.

[0032] Fig. 44 illustrates a top front left perspective partially exploded view of the counterweighted motor rotor assembly.

[0033] Fig. 68 illustrates a truncated oblique cross-sectional view of an acoustic muffler system of the electrically-powerable dual-cylinder rolling piston rotary compressor assembly of Fig. B, in the direction of line(s) 68-68 of Fig. 40.

[0034] Fig. 65 illustrates an complementary perspective exploded view of the intermediate acoustic muffler plates of the semi-hermetic compressor of Fig. 40.

[0035] Fig. 69 illustrates an isolated cross-sectional view of an inboard end of an alternative acoustic muffler system of an alternative semi-hermetic compressor in accordance with aspects of the present disclosure, in a direction analogous to Fig. 68.

DETAILED DESCRIPTION OF ONE OR MORE EMBODIMENTS

[0036] For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates. At least one embodiment of the present invention will be described and shown, and this application may show and/or describe other embodiments of the present invention, and further permits the reasonable and logical inference of still other embodiments as would be understood by persons of ordinary skill in the art. Unless expressly claimed herein as particularly limited to one or more specific materials, any component of the invention may be made from any one or more suitable metals, plastics, woods, fabrics, fibers, and/or combination(s) thereof (and/or any other suitable material(s) or combination(s) thereof) as would be understood by one of ordinary skill in the art.

[0037] It is understood that any reference to “the invention” is a reference to an embodiment of a family of inventions, with no single embodiment including an apparatus, process, or composition that should be included in all embodiments, unless otherwise stated. Further, although there may be discussion with regards to “advantages” provided by some embodiments of the present invention, it is understood that yet other embodiments may not include those same advantages, or may include yet different advantages. Any advantages described herein are not to be construed as limiting to any of the claims. The usage of words indicating preference, such as “various embodiments” or “preferably,” refers to features and aspects that are present in at least one embodiment, but which are optional for some embodiments, it therefore being understood that use of the word “preferably” implies the term “optional.”

[0038] Like reference numerals refer to like parts throughout the description and the drawings. Additionally, the use of an N-series prefix for an element number (NXX.XX) refers to an element that is the same as the non-prefixed element (XX.XX), except as shown and described. As an example, an element 1020.1 would be the same as element 20.1 , except for those different features of element 1020.1 shown and described. Further, common elements and common features of related elements may be drawn in the same manner in different figures, and/or use the same symbology in different figures. As such, it is not necessary to describe the features of 1020.1 and 20.1 that are the same, since these common features are apparent to a person of ordinary skill in the related field of technology. Further, it is understood that some features 1020.1 and 20.1 may be backward compatible, such that a feature of a later discussed embodiment (NXX.XX) may include features compatible with other various embodiments that were discussed earlier (MXX.XX), as would be understood by those of ordinary skill in the art. This description convention also applies to the use of prime (‘), double prime (“), triple prime ('”) and star or asterisk (*) suffixed element numbers. Therefore, it is not necessary to describe the features of 20.1 , 20.1 ’, 20.1”, 20. T” and 20* that are the same, since these common features are apparent to persons of ordinary skill in the related field of technology.

[0039] What follows are paragraphs that express particular embodiments of the present invention. In those paragraphs that follow, some element numbers are prefixed with an “X” indicating that the words pertain to any of the similar features shown in the drawings or described in the text. However, those of ordinary skill in the art will recognize various other non-X prefixed element numbers that discuss features applicable to other embodiments.

[0040] This document may use different words to describe the same element number, or to refer to an element number in a specific family of features (NXX.XX). It is understood that such multiple, different words are not intended to provide a redefinition of any language herein. It is understood that such words demonstrate that the particular feature can be considered in various linguistical ways, such ways not necessarily being additive or exclusive.

[0041] Fig. 40 illustrates a top front left perspective view of a semi-hermetic compressor 100 in accordance with aspects of the present disclosure. The compressor 100 includes a semi-hermetic compressor housing 120. The compressor housing 120 is configured to semi-hermetically house an electrically-powerable dual-cylinder rolling piston rotary compressor assembly 140 (not visible in Fig. 40, but see Fig. A) and is made primarily of suitably gasketed and bolted aluminum castings. The compressor housing 120 includes a plenary refrigerant discharge port 160 configured to suitably semi-hermetically couple to a hose, tube, or the like (not shown) for supplying compressed refrigerant gas thereinto. The compressor 100 also includes an auxiliary housing 180 bolted to the compressor housing 120. The auxiliary housing 180 is also made primarily of suitably gasketed and bolted aluminum castings, and includes a plenary refrigerant inlet port 200 configured to suitably semi-hermetically couple to a hose, tube, or the like (not shown) for receiving relatively low pressure refrigerant gas therefrom. The auxiliary housing 180 also includes an electric power receptacle or socket 220 suitably configured to electrically couple to a mating plug (not shown) for receiving electrical power (for powering the compressor assembly 140) from an electric vehicle power system or other suitable external power supply (not shown). And the auxiliary housing 180 includes an electric signal port 240 suitably configured to electrically couple to a mating port (not shown) for receiving electrical signals (for controlling operations of the compressor assembly 140) from an electric vehicle power management system or other suitable external control system (not shown).

[0042] Fig. A illustrates a top front left perspective partially exploded view of the semi- hermetic compressor assembly 100. The semi-hermetic compressor housing 120 includes a chamber body 260 and an aft or back cover plate 280. The electrically- powerable dual-cylinder rolling piston rotary compressor assembly 140 fits into the chamber body 260. Bolts 300 extend through the cover plate 280 and into the chamber body 260. And the cover plate 280 semi-hermetically seals against compressor assembly 140 and the chamber body 260 under the urging of the bolts 300. Further, the chamber body 260 defines a mating slot 320 and an intermediate refrigerant reception port 340. The auxiliary housing 180 includes a protrusion 360 fitting into the mating slot 320, and includes an intermediate refrigerant delivery port 380 that semi-hermetically couples to the reception port 340 via a suction tube assembly 500 (which is not shown in Fig. A, but see Fig. B). Bolts 400 secure the auxiliary housing 180 to the chamber body 260. The compressor assembly 100 also includes a plenary refrigerant discharge tube 404 extending upwardly though the discharge port 160. [0043] Fig. B illustrates a top front left perspective partially exploded view of the electrically-powerable dual-cylinder rolling piston rotary compressor assembly 140. The compressor assembly 140 includes a core compressor assembly 420, a helical oil pump assembly 440, a gas flow deflector or baffle 460, bolts 480, a suction tube assembly 500, an electric motor 540, and a hollow camshaft 560. The camshaft 560 extends through the compressor assembly 420 along an axial line 580 and includes a front end portion 600 and a rear portion 620. The front end portion 600 protrudes forwardly from the assembly 420. The rear end portion 620 protrudes rearwardly from the assembly 420. The oil pump assembly 440 includes a cup-like fitting 640. As discussed further in connection with Fig. 57 and Fig. 56, the fitting 640 couples the assembly 440 to the front end portion 600 of the camshaft 560. The baffle 460 arches above the oil pump assembly 440 and is positioned between discharge tube 404 (not shown in Fig. B, but see Fig. A) and the oil pump assembly 440 (generally above the oil pump assembly 440 and below the discharge tube 404). The bolts 480 secure the baffle 460 to the compressor assembly 420. The baffle 460 is designed to inhibit refrigerant turbulence (and in turn, inhibit oil agitation) proximal to the oil pump assembly 440, which the inventors believe may improve oil pump inlet conditions, and which the inventors believe may in turn improve the efficiency/performance of the oil pump assembly 440. The suction tube assembly 500 is semi-hermetically coupled to the compressor assembly 420, and extends generally laterally and downwardly therefrom. The electric motor 520 may be any suitable direct- current (“DC”) motor (brushed or brushless) or an alternating-current (“AC”) motor. The motor 520 includes a counterweighted motor rotor assembly 660 mechanically coupled to the rear portion 620 of the camshaft 560. It should be appreciated that the motor 520 is operable to turn the counterweighted motor rotor assembly 660. It should also be appreciated that the core compressor assembly 420 is operable to suck refrigerant thereinto through the suction tube assembly 500 and compress the refrigerant in response to the rotation of the camshaft 560.

[0044] Fig. C and Fig. D illustrate a top front left perspective exploded view and a top rear right perspective exploded view, respectively, of electrically-powerable dual-cylinder rolling piston rotary compressor assembly 140. The compressor assembly 140 includes a front end cap 680, leaf or reed valves 700, a first or forward cylinder cover plate 720, vanes 740, a first or forward compression cylinder 760, the suction tube assembly 500, the hollow camshaft 560, an axial flow impeller 780 fastened to the camshaft 560 therein, an aft oil spigot 800 substantially inserted into the rear portion 620 of the camshaft 560 but nevertheless protruding therefrom, a first or forward compression roller 820, a first or forward intermediate cylinder cover plate 840, a second or aft intermediate cylinder cover plate 860, a second or aft compression roller 880, a second or aft compression cylinder 900, a plug or stopper 920, a second or aft cylinder cover plate 940, a first or intermediate inboard end cap 960, and a second or aft or back inboard end cap 980.

[0045] Fig. 59 illustrates a vertical cross-sectional view of the semi-hermetic compressor 100, in the direction of line(s) 59-59 of Fig. 40. The auxiliary housing 180 defines a semi-hermetic refrigerant inlet compartment 1000 having a wall 1020. The auxiliary housing 180 also includes a sieve 1040 spanning obliquely across inlet compartment 1000. Further, the auxiliary housing 180 defines an electronics compartment 1060. The electronics compartment 1060 shares the wall 1020 with the inlet compartment 1000. But when the auxiliary housing 180 is fully assembled, the electronics compartment 1060 is not in fluid communication with the inlet compartment 1000. When the auxiliary housing 180 is fully assembled, the electronics compartment 1060 is semi-hermetically separated (or semi-hermetically sealed away) from the inlet compartment 1000. Meanwhile, via the suction tube assembly 500, the semi-hermetic compressor housing 120 is both semi-hermetically coupled to the inlet compartment 1000 and in fluid communication with inlet compartment 1000.

[0046] The compressor 100 includes electric motor driver electronics 1080 housed in the electronics compartment 1060. The electric motor driver electronics 1080 may be one or more capacitors, inductor coils, transformers, resistors, transistors or other semiconductor devices, integrated circuits, inverter circuits, combinations thereof, or other electrical or electronic components or circuits for suitably conveying power and/or control signals to the motor 520. In operation of the semi-hermetic compressor assembly 100, the compressor assembly 140 sucks refrigerant (not shown) through the refrigerant inlet port 200 and into the inlet compartment 1000. As the refrigerant flows (generally downwardly) though the inlet compartment 1000, the refrigerant may effectively cool the electric motor driver electronics 1080 (by absorbing heat, generated by the electronics 1080 and transferred through the wall 1020), which may desirably extend the life of the electronics 1080, and which may to some extent evaporate any undesirable liquid from the refrigerant. Additionally, the sieve 1040 may filter undesirable impurities from the refrigerant. Although in other embodiments the sieve 1040 may be oriented generally perpendicularly to the wall 1020, it should be appreciated that the oblique orientation of the sieve 1040 provides for the sieve 1040 having an increased surface area as compared to a perpendicularly oriented sieve. [0047] Fig. 61 illustrates a vertical cross-sectional view of the semi-hermetic compressor 100, in the direction of line(s) 61-61 of Fig. 40. The semi-hermetic compressor housing 120 includes a first exterior wall portion 1100 having a generally convex cross section. The auxiliary housing 180 includes a second exterior wall portion 1120 having a generally concave cross section. The second exterior wall portion 1120 faces the first exterior wall portion 1100 and is radially spaced away from the first exterior wall portion 1100. The generally concave cross section generally arcuately mirrors the generally convex cross section, and the second exterior wall portion 1120 is radially spaced away from the first exterior wall portion 100 by at least 10 mm. In other embodiments, the second exterior wall portion 1120 is radially spaced away from the first exterior wall portion 1100 by about 0.1 mm to 15 mm.

[0048] Fig. 62 illustrates an enlarged vertical cross-sectional isolation view of the semi- hermetic coupling (provided by the suction tube assembly 500) of the semi-hermetic compressor housing 120 to the auxiliary housing 180, taken from Fig. 61. The suction tube assembly 500 includes a straight tube 1140 having a radial flange 1160. It should be appreciated that the flange 1160 facilitates insertion and sealing of the tube 1140 into the reception port 340 of the chamber body 260 of the compressor housing 120. The suction tube assembly 500 also includes a chamfered shim 1180. The shim 1180 distributes pressure exerted by the suction volume over the whole area of the suction tube flange 1160. The suction tube assembly 500 also includes a pair of radial sealing O-rings 1200, a first axial sealing O-ring 1220, and a second axial sealing O-ring 1240. Fig. 63 illustrates a perspective view of the shim 1180. [0049] Fig. F illustrates a vertical cross-sectional view of an alternative semi-hermetic compressor 1260 in accordance with aspects of the present disclosure, in a direction analogous to line(s) 61-61 of Fig. 40. Comparing Fig. F to Fig. 62, it should be appreciated that relative to the compressor 100, the compressor 1260 has replaced the straight tube 1140 with a J-tube suction accumulator tube 1280. It should be appreciated that the suction accumulator tube 1280 has a hole 1300 therein and has a generally J- shaped cross section.

[0050] Fig. 48 illustrates a top front right perspective view of an outboard portion of the electrically-powerable dual-cylinder rolling piston rotary compressor assembly 140.

[0051] Fig. 47 illustrates a vertical cross-sectional view of the semi-hermetic compressor 100, in the direction of line(s) 47-47 of Fig. 40. Referring to Fig. 47, it can be appreciated that the axial flow impeller 780 (which is fixedly coupled to the hollow camshaft 560 therein) is arranged to urge oil flow from the helical oil pump assembly 440 through the camshaft 560 towards and out from the spigot 800 as the camshaft 560, impeller 780, and spigot 800 together rotate during operation of the semi-hermetic compressor 100. It can also bee seen that the camshaft 560 also has intermediate side bores 1320 positioned forward of the spigot 800. It should be appreciated that the side bores distribute oil as well.

[0052] Fig. 57 illustrates an enlarged vertical cross-sectional isolation view of the helical oil pump assembly 440 of the semi-hermetic compressor 100, taken from Fig. 47. The oil pump assembly 440 is an Archimedes screw type pump including a coiled spring 1340, a screw 1360 made of plastic or any other suitable material, an outer sleeve or tube 1380, and a cup-like fitting 640 made of metal or any other suitable material. The tube 1380 is mechanically coupled to the cup-like fitting 640. The screw extends along an axial line 1420. The line 1420 is preferably angled (not co-axial or parallel) in relation to the axial line 580 (of extension of the camshaft 560). The spring 1340 is fixedly coupled to the camshaft 560 at one end and transmits/redirects rotational movement of the camshaft 560 to the screw 1360. Accordingly, an opposing portion or end 1440 of the spring 1340 extends into the screw 1360 and is fixedly coupled thereto. The screw 1360 rotates within the tube 1380 so as to pump a fluid (in this case oil) in an Archimedes-screw-principle fashion. The tube 1380 (which does not rotate) is fixedly coupled to a bearing 1460 via the fitting 640. Within the fitting 640, the bearing 1460 abuts the camshaft 560 at a camshaft lubricating hole or inlet 1480. Oil pumped by the screw 1360 flows into the spring 1340 (proximal to the camshaft 560) through gaps between the coils of the spring 1340 (it should be appreciated that such gaps are exaggerated where the spring 1340 bends from the axial line 1420 (of the screw 1360) towards the camshaft lubricating inlet 1480) and then flows from inside the spring 1320 into camshaft lubricating inlet 1480. The distal end 1500 of the spring (i.e., the end relatively farther away from the crankshaft lubricating inlet 1480) is closed by a metallic plug 1520, which may also fixedly couple the spring 1340 to the screw 1360. Fig. 56 illustrates an exploded perspective view of the helical oil pump assembly 440. In alternative embodiments, the coiled spring 1340 may be replaced with a suitably flexible rod.

[0053] Fig. 54 illustrates an enlarged vertical cross-sectional isolation view of the discharge tube 404, taken from Fig. 47, and Fig. 53 illustrates a perspective view of the discharge tube 404. The discharge tube 404 is designed to inhibit lubrication oil (circulated within the compressor housing 120 during operation of the compressor 100) from being swept by the refrigerant flow through the discharge port 160. The discharge tube 404 includes a sidewall 1540. The sidewall 1540 defines an inlet hole 1560 therethrough. The inlet hole 1560 receives refrigerant and/or oil laden refrigerant flow into the discharge tube 404. The discharge tube 404 also includes a bottom end 1580 defining a drip hole 1600. It should be appreciated that the drip hole 1620 permits oil to drip or fall back down into the compressor housing 120 for recirculation by cooperations of the oil pump assembly 440, the impeller 780, and the camshaft 560. The discharge tube 404 also has a top, upward facing, outlet opening or orifice 1580 coupled to the discharge port 160. It should be appreciated that the outlet opening 1580 permits compressed refrigerant and/or relatively less oil laden compressed refrigerant to be supplied from the compressor housing 120 through the discharge port 160.

[0054] Fig. 51 illustrates an enlarged vertical cross-sectional isolation view of the aft oil spigot 800, taken from Fig. 47. Fig. 50 illustrates an enlarged vertical cross-sectional isolation view of the aft oil spigot 800, taken from Fig. 51. And Fig. 49 illustrates a perspective view of the aft oil spigot 800. As can be seen in Fig. 51 (and as discussed above), the oil spigot 800 is inserted into the rear portion 620 of the camshaft 560 and protrudes therefrom. Further, as can be seen in Fig. 51 and even more easily in Fig. 50 and Fig. 49, the spigot 800 is generally cup-like, tapered to facilitate insertion into the camshaft 560, and has a sidewall 1640. The sidewall 1640 defines an oil release orifice or hole 1660 therein. It should be appreciated that although a the spigot 800 is substantially inserted into the camshaft 560, the spigot 800 does protrude enough from the camshaft 560 that the camshaft 560 does not block or seal off the hole 1660, thus, allowing the spigot 800 to release oil through the orifice 1160 as the camshaft 560 rotates during operation of the compressor 100.

[0055] Fig. 45 illustrates a top front left perspective view of the counterweighted motor rotor assembly 660. And Fig. 44 illustrates a top front left perspective partially exploded view of the counterweighted motor rotor assembly 660. The rotor assembly 660 is generally cylindrical, has a first end 1680, has a second end 1700, and a generally cylindrical core 1720 axially extending between the first end 1680 and the second end 1700. The core 1720 is suitably configured with conventional electrical wiring/windings, magnetic materials, and/or other conventional electric motor rotor materials and features that cause the rotor assembly 660 to be operable to suitably rotate in response to magnetic/electromagnetic fields. The rotor assembly 660 includes a first generally discoidal counterweight plate 1740 attached to the first end 1680 of the core 1720 and generally axially aligned with the core 1720, and the rotor assembly 660 includes a second generally discoidal counterweight plate 1760 attached to the second end 1700 of the core 1720 and generally axially aligned with the core 1720. The first plate 1740 has a first generally C-shaped portion 1780 extending therefrom. The second plate 1760 has a second generally C-shaped portion 1800 extending therefrom. The second portion 1800 is positioned at about 180 degrees rotational displacement relative to the first portion 1780.

[0056] The assembly 660 also includes a first generally discoidal cap 1820 attached to first plate 1740. The first cap 1820 has a third generally C-shaped portion 1840 extending therefrom. The third portion 1840 faces toward the first plate 1740 at about 180 degrees rotational displacement relative to the first portion 1780. The assembly 660 further includes a second generally discoidal cap 1860 attached to second plate 1760. The second cap 1860 has a fourth generally C-shaped portion 1880 extending therefrom. The fourth portion 1880 faces toward the second plate 1760 at about 180 degrees rotational displacement relative to the second portion 1800.

[0057] The rotor cap 1820 and the rotor cap 1860 may be made of plastic (or any other suitable material(s)) in order to hold down their weights (and thus hold down their impact on counterweight dimensioning for balancing. In some embodiments, the mass of the third portion 1840 is at least 5 times less than the mass of the first portion 1780, and the mass of the fourth portion 1880 is at least 5 times less than the mass of the second portion 1800.

[0058] Fig. 68 illustrates a truncated oblique cross-sectional view of an acoustic muffler system 1900 of the electrically-powerable dual-cylinder rolling piston rotary compressor assembly 140.

[0059] As can be seen in Fig. 68, the muffler system 1900 includes:

1.) an outboard or forward camshaft bearing 1920;

2.) the front end cap 680 (see also FIG. C);

3.) the first intermediate plate 840 (see also FIG. C);

4.) the second intermediate plate 860 (see also FIG. C);

5.) an inboard or relatively rearward camshaft bearing 1940;

6.) the first inboard end cap 960 (see also FIG. C); and

7.) the second inboard end cap 980 (see also FIG. C).

[0060] The outboard bearing 1920 and the front end cap 680 together form a first acoustic muffler chamber or volume 1960. The first intermediate plate 840 and the second intermediate plate 860 together form a second acoustic muffler chamber or volume 1980. The inboard bearing 1940 and the first inboard end cap 960 form a third acoustic muffler chamber or volume 2000. And the first inboard end cap 960 and the second inboard end cap 980 form a fourth acoustic muffler chamber or volume 2020. The first acoustic muffler chamber 1960, the second acoustic muffler chamber 1980, the third acoustic muffler chamber 2000, and the fourth acoustic muffler chamber 2020 remain in uninterrupted fluid communication with each other via holes 2040 extending through the outboard bearing 1920, holes 2060 extending through the first intermediate plate 840, respective channels 2080 extending between the holes 2040 and the holes 2060, holes 2100 extending through the second intermediate plate 860, holes 2120 extending through the inboard bearing 1940, respective channels 2140 extending between the holes 2100 and the holes 2120, and holes 2160 in the first inboard end cap 960.

[0061] The outboard bearing 1920 and the front end cap 680 are semi-hermetically coupled together. The second inboard end cap 980 includes an inboard collar portion 2180. The collar portion 2180 encircles a respective inboard portion 2200 of the inboard bearing 1940 but is radially spaced apart therefrom, such that the collar portion 2180 and the inboard portion 2200 together provide an annular refrigerant discharge orifice 2220.

[0062] In operation of the compressor assembly 140, compressed refrigerant is alternatively released into the muffler system 1900 by the first cylinder 760 and the second cylinder 900. The refrigerant is acoustically dampened by the muffler system 1900, and circulates in and flows though the muffler system 1900, and is discharged through the annular orifice 2220 into the semi-hermetic compressor housing 120. [0063] Fig. 65 illustrates an complementary perspective exploded view of the first intermediate acoustic muffler plate 840 and the second intermediate acoustic muffler plate 860. The intermediate plates 840, 860 are undercut to form an acoustic cavity 2240 that reduces undesirable sound/noise emissions. It should be appreciated that in some embodiments the exact shape of the cavity 2240 may differ from the shape illustrated herein, provided that the overall geometry yields suitable acoustical muffling.

[0064] Fig. 69 illustrates an isolated cross-sectional view of an inboard end of an alternative acoustic muffler system 2260 of an alternative semi-hermetic compressor in accordance with aspects of the present disclosure, in a direction analogous to Fig. 68. The muffler system 2260 includes an outer cap 2280 having two side-by-side holes 2300 (only one of which is visible in Fig. 69) to discharge the refrigerant, the holes are misaligned with holes 2320 of a less inboard cap 2340 and are positioned on the lower part of the alternative compressor to help wash its lubricating oil.

[0065] It should be appreciated that aspects of the present disclosure may be incorporated into air and/or liquid heat exchanging air conditioning, refrigeration, heat pump, and/or other cooling and/or heating systems for electric vehicles, internal combustion engine vehicles, aircraft, marine vehicles, buildings, manufacturing systems, and/or any other suitable application(s).

[0066] While the inventions have been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only certain embodiments have been shown and described and that all changes and modifications that come within the spirit of the inventions are desired to be protected.

Claims

CLAIMS What is claimed is:

1. An apparatus, comprising: a semi-hermetic compressor housing; an electrically-powerable dual-cylinder rolling piston rotary compressor assembly housed in the housing; electric motor driver electronics; and an auxiliary housing defining a semi-hermetic refrigerant inlet compartment having a wall, and defining an electronics compartment sharing the wall with the inlet compartment but semi-hermetically separated from the inlet compartment; wherein the compressor housing is semi-hermetically coupled to the inlet compartment and in fluid communication therewith, and the electronics compartment houses the electronics.

2. The apparatus of claim 1 , wherein the compressor housing includes a first exterior wall portion having a first convex cross section, the auxiliary housing includes a second exterior wall portion having a generally concave cross section, the second exterior wall portion faces the first exterior wall portion, the second exterior wall portion is radially spaced away from the first exterior wall portion, and the generally concave cross section generally arcuately mirrors the generally convex cross section.

125992.000514:GWR/pb2_125992.000514

3. The apparatus of claim 1 , wherein the second exterior wall portion is radially spaced away from the first exterior wall portion by about 0.1 mm to 15 mm.

4. The apparatus of claim 3, wherein the second exterior wall portion is radially spaced away from the first exterior wall portion by at least 10 mm.

5. The apparatus of claim 4, comprising: a suction accumulator extending into the inlet compartment, wherein the compressor housing is semi-hermetically coupled to the inlet compartment through the suction accumulator.

6. The apparatus of claim 5, wherein the suction accumulator includes a tube having a generally J-shaped cross section.

7. The apparatus of claim 3, wherein the compressor housing is substantially aluminum.

8. The apparatus of claim 5, wherein the compressor housing is substantially aluminum.

9. An apparatus, comprising: a first rolling piston rotary compressor roller; a second rolling piston rotary compressor roller; a substantially hollow camshaft arranged to cooperate with the first roller and the second roller; an Archimedes screw; and a flexible coupling mechanically coupled to the camshaft therein, having a first end portion extending from the camshaft in a first direction, having a second end portion extending in a second direction into engagement with the Archimedes screw, and having an intermediate portion extending between the first end portion and the second end portion and bending from the first direction to the second direction.

10. The apparatus of claim 9, wherein the flexible coupling includes a flexible rod.

11 . The apparatus of claim 9, wherein the flexible coupling includes a flexible coil.

12. The apparatus of claim 11 , comprising an oil flow tube covering the intermediate portion of the coil.

13. The apparatus of claim 12, wherein the first direction is generally vertical and the second direction is generally downward.

14. The apparatus of claim 13, comprising: an axial flow impeller fastened to the camshaft therein, wherein the first end portion of the coil is fastened to the axial flow impeller.

15. The apparatus of claim 13, comprising: a semi-hermetic compressor housing; a baffle positioned generally above the oil flow tube, the baffle including a bottom surface and a top surface; a refrigerant discharge tube positioned generally above the top surface of the baffle, opening inside the compressor housing, extending through the compressor housing, and opening outside the compressor housing as well, wherein the oil flow tube and the baffle are housed in the compressor housing, and the bottom surface of the baffle is in fluid communication with the top surface of the baffle within the compressor housing.

16. The apparatus of clam 15, wherein the baffle generally arches above the oil flow tube.

17. The apparatus of claim 16, wherein the compressor housing includes a first portion having an interior diameter, the baffle is positioned generally within the first portion of the compressor housing, and the baffle laterally spans a substantial portion of the inner diameter.

18. The apparatus of claim 17, wherein the baffle includes a notched left portion and a notched right portion.

19. The apparatus of claim 18, wherein the baffle is substantially laterally symmetrical.

20. The apparatus of claim 16, wherein the refrigerant discharge tube includes a bottom portion defining a refrigerant drip hole, includes a top portion defining a refrigerant discharge port, and includes a generally longitudinal portion extending between the bottom portion and the top portion and defining a refrigerant receiving hole, and wherein the drip hole is smaller than the discharge port, and the drip hole is smaller than the receiving hole.

21. An apparatus, comprising: a first rolling piston rotary compressor roller; a second rolling piston rotary compressor roller; a camshaft arranged to cooperate with the first roller and the second roller; an electric motor including a rotor, the rotor mechanically coupled to the camshaft, the rotor including a first end, including a second end, and being generally cylindrical between the first end and the second end; a first generally discoidal counterweight attached to the first end of the rotor, the first counterweight having a first generally C-shaped portion extending therefrom; a second generally discoidal counterweight attached to the second end of the rotor, the second counterweight having a second generally C-shaped portion extending therefrom, the second generally C-shaped portion positioned on the second end of the rotor at about 180 degrees rotational displacement relative to the first generally C-shaped portion; a first generally discoidal cap attached to first counterweight, the first cap having a third generally C-shaped portion extending therefrom, the third generally C-shaped portion facing toward the first counterweight at about 180 degrees rotational displacement relative to the first generally C-shaped portion; and a second generally discoidal cap attached to second counterweight, the second cap having a fourth generally C-shaped portion extending therefrom, the fourth generally C-shaped portion facing toward the second counterweight at about 180 degrees rotational displacement relative to the second generally C-shaped portion.

22. The apparatus of claim 21 , wherein the first generally C-shaped portion has a first mass, the second generally C-shaped portion has a second mass, the third generally C- shaped portion has a third mass, the fourth generally C-shaped portion has a fourth mass, and the first mass is at least 5 times the third mass.

23. An apparatus, comprising: a semi-hermetic compressor housing; a pair of rolling piston rotary compressor cylinders housed in the housing, including a first rolling piston rotary compressor cylinder and including a second rolling piston rotary compressor cylinder; a pair of compressor cylinder discharge valves, including a first valve mechanically coupled to the first cylinder and including a second valve mechanically coupled to the second cylinder; and a pair of plates interposed between the first cylinder and the second cylinder, the plates including a first plate defining a first recess, the plates including a second plate facing toward the first plate and defining a second recess, the first recess and the second recess together defining a first acoustic muffler chamber, wherein the valves are arranged to control refrigerant flows from the first cylinder and the second cylinder to the first chamber.

24. The apparatus of claim 23, wherein the second recess generally mirrors the first recess.

25. The apparatus of claim 24, wherein each of the plates is discoidal.

26. The apparatus of claim 25, wherein the valves are arranged to alternate refrigerant flows from the first cylinder and the second cylinder, respectively, to the first chamber.

27. The apparatus of claim 26, comprising: a camshaft extending through the cylinders, the camshaft having an inboard portion and an outboard portion; an outboard bearing supporting the outboard portion of the camshaft; and an outboard plate positioned outboard of the bearing and defining a second acoustic muffler chamber, wherein the second chamber is in fluid communication with the first chamber.

28. An apparatus, comprising: a semi-hermetic compressor housing; a pair of rolling piston rotary compressor cylinders housed in the housing, including a first rolling piston rotary compressor cylinder and including a second rolling piston rotary compressor cylinder; a pair of compressor cylinder discharge valves, including a first valve mechanically coupled to the first cylinder and including a second valve mechanically coupled to the second cylinder, a camshaft extending through the cylinders, the camshaft having an inboard portion and an outboard portion; an inboard bearing supporting the inboard portion of the camshaft; a first inboard plate positioned inboard of the bearing and defining a first acoustic muffler chamber having a pair of refrigerant flow holes therein, the holes including a first hole extending about a first respective axial line, the holes including a second hole extending about a second respective axial line; and a second inboard plate positioned inboard of the first plate and defining a second acoustic muffler chamber having a first refrigerant discharge port therein, the first discharge port extending about a third respective axial line, wherein the valves are arranged to control refrigerant flows from the first cylinder and the second cylinder to the first chamber, and the second chamber is in fluid communication with the first chamber, but neither the first axial line nor the second axial line is aligned with the third axial line.

29. The apparatus of claim 28, wherein the camshaft longitudinally extends about a fourth axial line and the third axial line is aligned with the fourth axial line.

30. The apparatus of claim 29, wherein the first discharge port has an inner diameter, the inboard bearing includes a bearing portion having an outer diameter and extending into the first discharge port, and the outer diameter of the bearing portion is less than the inner diameter of the first discharge port.

31. The apparatus of claim 30, wherein the second inboard plate defines a second discharge port in the second chamber, the first discharge port is positioned relatively lower than the camshaft, and the second discharge port is positioned relatively lower than the camshaft.

32. The apparatus of claim 28, comprising: a pair of intermediate plates interposed between the first cylinder and the second cylinder, the intermediate plates including a first intermediate plate defining a first recess, the intermediate plates including a second intermediate plate facing toward the first intermediate plate and defining a second recess, the first recess and the second recess together defining a third acoustic muffler chamber, wherein the valves are arranged to control refrigerant flows from the first cylinder and the second cylinder to the third chamber, and the third chamber is in fluid communication with the first chamber.

33. The apparatus of claim 32, comprising: an outboard bearing supporting the outboard portion of the camshaft; and an outboard plate positioned outboard of the bearing and defining a fourth acoustic muffler chamber, wherein the fourth chamber is in fluid communication with the third chamber.