Electric compressor with integrated vapor injection circuit

1 . An assembly associated with an electric scroll compressor having a compression chamber, comprising:

a housing defining an intake volume, a discharge volume, and a vapor injection cavity, the housing including:

a center housing;

a rear head coupled to the center housing;

a refrigerant inlet port coupled to the rear head and configured to introduce refrigerant to the intake volume;

a refrigerant outlet port coupled to the rear head and configured to allow compressed refrigerant to exit from the discharge volume; and,

a vapor injection port integral with the rear head, the vapor injection port being coupled to the vapor injection cavity;

a valve plate adjacent the rear head and defining at least one plate groove, the at least one plate groove defining a vapor injection channel, a reed receiving portion, and an injection portion, the injection portion being fluidly coupled to the vapor injection cavity, the reed receiving portion positioned between the vapor injection channel and the injection portion, the vapor injection channel having a first end and a second end, the first end of the vapor injection channel being adjacent the reed receiving portion, the vapor injection channel including a vapor plate channel outlet aperture at the second end and being fluidly coupled to the compression chamber; and,

a vapor reed mechanism positioned within the reed receiving portion of the plate groove and being configured to control flow of vapor from the vapor injection cavity through the vapor injection channel and the vapor plate channel outlet aperture to the compression chamber, wherein the rear head includes a rear head cavity, the rear head cavity being divided into the discharge volume and the vapor injection cavity by a series of partitions integral with the rear head.

2 . The assembly, as set forth in claim 1 , the series of partitions having a top surface adjacent the center housing.

3 . The assembly, as set forth in claim 2 , wherein the valve plate is positioned adjacent the top surface of the series of partitions.

4 . The assembly, as set forth in claim 3 , wherein the series of partitions divides the discharge volume into a plurality of sub-chambers including a central sub-chamber, wherein the at least one plate groove includes first and second plate grooves formed within the valve plate on opposite sides of the central sub-charge.

5 . The assembly, as set forth in claim 4 , further including a gasket positioned between the center housing and the rear head and being configured to provide sealing between the sub-chamber and the vapor injection cavity and the vapor injection channel of each of the first and second grooves.

6 . An electric scroll compressor configured to compress a refrigerant for use with a vapor injection system, comprising:

a housing having a center housing and a rear head and defining an intake volume, a discharge volume, and a vapor injection cavity;

a refrigerant inlet port coupled to the housing and configured to introduce the refrigerant to the intake volume;

a refrigerant outlet port coupled to the housing and configured to allow compressed refrigerant to exit the electric scroll compressor from the discharge volume;

a vapor injection port integral with the rear head and being coupled to the vapor injection cavity;

a drive shaft rotatably coupled inside the housing;

a compression device coupled to the drive shaft, configured to receive the refrigerant from the intake volume and to compress as the drive shaft, the compression device including:

a fixed scroll located within the housing and being fixed relative thereto; and,

an orbiting scroll coupled to the drive shaft, the orbiting scroll and the fixed scroll forming a compression chamber for receiving the refrigerant from the intake volume and compressing the refrigerant as the drive shaft is rotated;

a valve plate adjacent the rear head and defining at least one plate groove, the at least one plate groove defining a vapor injection channel, a reed receiving portion, and an injection portion, the injection portion being fluidly coupled to the vapor injection cavity, the reed receiving portion positioned between the vapor injection channel and the injection portion, the vapor injection channel having a first end and a second end, the first end of the vapor injection channel being adjacent the reed receiving portion, the vapor injection channel including a vapor plate channel outlet aperture at the second end and being fluidly coupled to the compression chamber; and,

a vapor reed mechanism positioned within the reed receiving portion of the plate groove and being configured to control flow of vapor from the vapor injection cavity through the vapor injection channel and the vapor plate channel outlet aperture to the compression chamber, wherein the rear head includes a rear head cavity, the rear head cavity being divided into the discharge volume and the vapor injection cavity by a series of partitions integral with the rear head.

7 . The electric scroll compressor, as set forth in claim 6 , wherein the at least one plate groove includes first and second plate grooves formed within the valve plate.

8 . The electric scroll compressor, as set forth in claim 7 , the series of partitions having a top surface adjacent the center housing.

9 . The electric scroll compressor, as set forth in claim 6 , wherein the valve plate is positioned adjacent the top surface of the series of partitions between the rear head and the fixed scroll.

10 . The electric scroll compressor, as set forth in claim 8 , wherein the series of partitions divides the discharge volume into a plurality of sub-chambers including a central sub-chamber, wherein the at least one plate groove includes first and second plate grooves formed within the valve plate on opposite sides of the central sub-chamber.

11 . The electric scroll compressor, as set forth in claim 9 , further including a gasket positioned between the center housing and the rear head and being configured to provide sealing between the discharge volume and the vapor injection cavity and vapor injection channels.

12 . An electric scroll compressor configured to compress a refrigerant for use with a vapor injection system, comprising:

a housing having a center housing and a rear head and defining an intake volume, a discharge volume, and a vapor injection cavity;

a refrigerant inlet port coupled to the housing and configured to introduce the refrigerant to the intake volume;

a refrigerant outlet port coupled to the housing and configured to allow compressed refrigerant to exit the electric scroll compressor from the discharge volume;

a vapor injection port integral with the rear head and being coupled to the vapor injection cavity;

an inverter module mounted inside the housing and adapted to convert direct current electrical power to alternating current electrical power;

a motor mounted inside the housing and being coupled to the inverter module;

a drive shaft coupled to the motor; and,

a compression device coupled to the drive shaft, for receiving the refrigerant from the intake volume and compressing the refrigerant as the drive shaft is rotated by the motor, the compression device including:

a fixed scroll located within the housing and being fixed thereto; and,

an orbiting scroll coupled to the drive shaft, the orbiting scroll and the fixed scroll forming a compression chamber for receiving the refrigerant from the intake volume and compressing the refrigerant as the drive shaft is rotated about the center axis;

a valve plate adjacent the rear head and defining at least one plate groove, the at least one plate groove defining a vapor injection channel, a reed receiving portion, and an injection portion, the injection portion being fluidly coupled to the vapor injection cavity, the reed receiving portion positioned between the vapor injection channel and the injection portion, the vapor injection channel having a first end and a second end, the first end of the vapor injection channel being adjacent the reed receiving portion, the vapor injection channel including a vapor plate channel outlet aperture at the second end and being fluidly coupled to the compression chamber; and,

a vapor reed mechanism positioned within the reed receiving portion of the plate groove and being configured to control flow of vapor from the vapor injection cavity through the vapor injection channel and the vapor plate channel outlet aperture to the compression chamber, wherein the rear head includes a rear head cavity, the rear head cavity being divided into the discharge volume and the vapor injection cavity by a series of partitions integral with the rear head.

13 . The electric scroll compressor, as set forth in claim 12 , wherein the at least one plate groove includes first and second plate grooves.

14 . The electric scroll compressor, as set forth in claim 12 , the series of partitions having a top surface adjacent the center housing.

15 . The electric scroll compressor, as set forth in claim 14 , wherein the valve plate is positioned adjacent the top surface of the series of partitions between the rear head and the fixed scroll.

16 . The electric scroll compressor, as set forth in claim 15 , wherein the series of partitions divides the discharge volume into a plurality of sub-chambers including a central sub-chamber, wherein the at least one plate groove includes first and second plate grooves formed within the valve plate on opposite sides of the central sub-chamber.

17 . The electric scroll compressor, as set forth in claim 16 , further including a gasket positioned between the center housing and the rear head and being configured to provide sealing between the discharge volume and the vapor injection cavity and vapor injection channels.