US20050123418A1 - Compact compressors and refrigeration systems - Google Patents
Compact compressors and refrigeration systems Download PDFInfo
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- US20050123418A1 US20050123418A1 US10/988,399 US98839904A US2005123418A1 US 20050123418 A1 US20050123418 A1 US 20050123418A1 US 98839904 A US98839904 A US 98839904A US 2005123418 A1 US2005123418 A1 US 2005123418A1
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- housing
- compact
- refrigeration system
- compressor
- heat exchanger
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
- F04C18/00—Rotary-piston pumps specially adapted for elastic fluids
- F04C18/30—Rotary-piston pumps specially adapted for elastic fluids having the characteristics covered by two or more of groups F04C18/02, F04C18/08, F04C18/22, F04C18/24, F04C18/48, or having the characteristics covered by one of these groups together with some other type of movement between co-operating members
- F04C18/34—Rotary-piston pumps specially adapted for elastic fluids having the characteristics covered by two or more of groups F04C18/02, F04C18/08, F04C18/22, F04C18/24, F04C18/48, or having the characteristics covered by one of these groups together with some other type of movement between co-operating members having the movement defined in group F04C18/08 or F04C18/22 and relative reciprocation between the co-operating members
- F04C18/344—Rotary-piston pumps specially adapted for elastic fluids having the characteristics covered by two or more of groups F04C18/02, F04C18/08, F04C18/22, F04C18/24, F04C18/48, or having the characteristics covered by one of these groups together with some other type of movement between co-operating members having the movement defined in group F04C18/08 or F04C18/22 and relative reciprocation between the co-operating members with vanes reciprocating with respect to the inner member
- F04C18/3441—Rotary-piston pumps specially adapted for elastic fluids having the characteristics covered by two or more of groups F04C18/02, F04C18/08, F04C18/22, F04C18/24, F04C18/48, or having the characteristics covered by one of these groups together with some other type of movement between co-operating members having the movement defined in group F04C18/08 or F04C18/22 and relative reciprocation between the co-operating members with vanes reciprocating with respect to the inner member the inner and outer member being in contact along one line or continuous surface substantially parallel to the axis of rotation
- F04C18/3442—Rotary-piston pumps specially adapted for elastic fluids having the characteristics covered by two or more of groups F04C18/02, F04C18/08, F04C18/22, F04C18/24, F04C18/48, or having the characteristics covered by one of these groups together with some other type of movement between co-operating members having the movement defined in group F04C18/08 or F04C18/22 and relative reciprocation between the co-operating members with vanes reciprocating with respect to the inner member the inner and outer member being in contact along one line or continuous surface substantially parallel to the axis of rotation the surfaces of the inner and outer member, forming the inlet and outlet opening
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
- F04C23/00—Combinations of two or more pumps, each being of rotary-piston or oscillating-piston type, specially adapted for elastic fluids; Pumping installations specially adapted for elastic fluids; Multi-stage pumps specially adapted for elastic fluids
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25B1/00—Compression machines, plants or systems with non-reversible cycle
-
- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F1/00—Details not covered by groups G06F3/00 - G06F13/00 and G06F21/00
- G06F1/16—Constructional details or arrangements
- G06F1/20—Cooling means
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
- F04C2210/00—Fluid
- F04C2210/26—Refrigerants with particular properties, e.g. HFC-134a
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25B2500/00—Problems to be solved
- F25B2500/01—Geometry problems, e.g. for reducing size
Definitions
- the present invention relates to compact, modular cooling systems, and in particular, to compact compressors and refrigeration systems for electronic equipment cooling.
- the present invention provides compact compressors and refrigeration systems that can be used to cool computers, servers, and other electronic equipment.
- Each compact compressor or refrigeration system includes a compact, substantially enclosed hermitic housing having a simple geometry profile, such as a rectilinear profile, which enables the compact compressor or refrigeration system to be easily inserted within a slot, for example, of an electronic component such as a computer server.
- a compact compressor is provided, which includes a motor-compressor unit within the housing, including a stator, a rotor disposed interiorly of the stator, and a compressor mechanism disposed interiorly of the rotor to provide a compact profile.
- the housing includes the foregoing compact motor-compressor unit, and further includes a condenser formed within one of the walls of the housing and an evaporator formed within another wall of the housing such that the housing defines a completely contained, compact refrigeration system.
- the housing may include only one of the condenser and evaporator, with the other of the condenser and evaporator configured as a modular component which is attached to the housing.
- One embodiment of the invention provides a compact refrigeration system that may be fit within a standard sized slot of a computer server.
- the system includes enclosure walls that define at least one heat exchanger, such as a condenser or evaporator, and each heat exchanger may define a temperature gradient that has a localized maximum or minimum at the center of the heat exchanger, and wherein the heat exchanger defines substantially similar temperatures at locations that are at substantially similar radial distances from the center and local maximum, minimum temperature of the heat exchanger.
- the present invention provides a compact compressor unit, including a substantially enclosed housing including an inlet and an outlet; and a motor-compressor unit disposed within the housing, including a stator; a rotor disposed substantially interiorly of the stator; and a compressor mechanism driven by the rotor and disposed substantially interiorly of the rotor, the compressor mechanism in fluid communication with the inlet and the outlet, whereby the compressor mechanism receives fluid from the inlet at suction pressure, compresses the fluid to discharge pressure, and discharges the fluid at discharge pressure through the outlet.
- the present invention provides a compact refrigeration system, including a substantially enclosed housing having a simple geometry profile including at least first and second sides; a motor-compressor unit disposed within the housing, including a stator; a rotor disposed substantially interiorly of the stator; and a compressor mechanism driven by the rotor, the compressor mechanism having an inlet and an outlet; a condenser formed at least partially within the first side of the housing, the condenser in fluid communication with the compressor mechanism outlet; an evaporator formed at least partially within the second side of the housing, the evaporator in fluid communication with the compressor mechanism inlet; and an expansion device in fluid communication with the condenser and with the evaporator.
- the present invention provides a compact refrigeration system, including a substantially enclosed housing having a simple geometry profile, including an inlet and an outlet and at least a first side; a motor-compressor unit disposed within the housing, including a stator; a rotor disposed substantially interiorly of the stator; and a compressor mechanism driven by the rotor; and a first heat exchanger formed substantially within the first side of the housing, the first heat exchanger in fluid communication with the compressor mechanism.
- the present invention provides a compact refrigeration system, including a housing, including a first housing component including at least a first pair of opposite sides of the housing; and a second housing component including at least another side of the housing, the first and second housing components insertable one into the other; and a compressor mechanism disposed within the housing.
- the present invention provides a compact refrigeration system, including a housing, including a first housing component including at least a first pair of opposite sides of the housing; and a second housing component including at least another side of the housing, the first and second housing components insertable one into the other; and a heat exchanger at least partially integrated into one of the sides of the housing, the heat exchanger including a passage extending from proximate a central portion of the housing side toward a peripheral portion of the housing side.
- the present invention provides a compact refrigeration system, including a housing including an inlet and an outlet; a compressor unit disposed within the housing, the compressor unit including a stator; a rotor disposed substantially interiorly of the stator; and a compressor mechanism driven by the rotor and disposed interiorly of the stator; and a first heat exchanger configured as a modular unit attached to a wall of the housing, the heat exchanger in fluid communication with the inlet and with the outlet.
- the present invention provides a compact refrigeration system, including a first housing component having a simple geometry profile including an exterior wall, and a groove formed within the exterior wall; a second housing component into which the first housing component is received, the second housing component having a wall in abutment with the exterior wall of the first housing component and enclosing the groove to define a heat exchanger passage; and a compressor mechanism disposed within the first housing component and in fluid communication with the heat exchanger passage.
- FIG. 1 is a perspective view of a compact compressor according to a first embodiment of the present invention, showing the components of the compressor housing;
- FIG. 2 is a sectional view taken along line 2 - 2 of FIG. 1 , showing an exemplary manner in which a fluid line or fluid fitting may be attached to the inlet or outlet of the compact compressor;
- FIG. 3 is a perspective cutaway view of the compact compressor
- FIG. 4 is a further perspective cutaway view of the compact compressor, showing components of the compressor mechanism
- FIG. 5 is a further perspective cutaway view of a portion of the compact compressor, showing components of the compressor mechanism
- FIG. 6 is a perspective view of a portion of the compressor mechanism of FIG. 5 ;
- FIG. 7 is a first exploded view of a compact refrigeration system according to a second embodiment, viewed from a first direction;
- FIG. 8 is a second exploded view of the compact refrigeration system, viewed from a second direction;
- FIG. 9 is a perspective view of the compact refrigeration system, showing the components of the refrigeration system housing
- FIG. 10 is a perspective view of a first side of the inner housing component of the compact refrigeration system, showing the condenser;
- FIG. 11 is a perspective view of a second side of the inner housing component of the compact refrigeration system, showing the evaporator;
- FIG. 12 is a perspective view similar to FIG. 10 , showing exemplary weld lines for securing the outer housing component to the inner housing component of the compact refrigeration system;
- FIG. 13 is a perspective view similar to FIG. 11 , showing exemplary weld lines for securing the outer housing component to the inner housing component of the compact refrigeration system;
- FIG. 14 is a perspective view of one compact refrigeration system according to a third embodiment, showing the housing of the compact refrigeration system including a condenser and a modular heat exchanger configured as an evaporator, wherein a portion of the housing of the compact refrigeration system is broken away to show the terminal assembly; and
- FIG. 15 is a perspective view of another compact refrigeration system according to the third embodiment, showing the housing of the compact refrigeration system including an evaporator and a modular heat exchanger configured as a condenser, wherein a portion of the housing of the compact refrigeration system is broken away to show the terminal assembly.
- FIGS. 1-8 A compact compressor 20 according to a first embodiment of the present invention is shown in FIGS. 1-8 .
- compressor 20 generally includes a hermetic enclosure or housing 22 and a motor-compressor unit 24 disposed within hermetic housing 22 .
- housing 22 generally includes a first or inner housing component 26 and a second or outer housing component 28 .
- first housing component 26 is insertable within second housing component 28 , and the foregoing are secured to one another such as by welding in the manner described below.
- compressor housing 22 has a simple geometry profile, shown herein as a rectilinear profile.
- compact compressor 20 may be inserted into a slot in an electronics device in a cartridge-type manner, and be easily removed therefrom for repair or replacement, for example.
- First housing component 26 is shown in FIGS. 1 and 3 , and has a box-type, rectilinear profile generally including three pairs of opposing side walls, including front wall 30 , rear wall 32 , left side wall 34 , right side wall 36 , top wall 38 , and bottom wall 40 ( FIG. 4 ).
- Front side wall 30 includes inlet 42 and outlet 44 , and an electrical terminal assembly 46 is recessed into a cavity defined between left side wall 34 and rear side wall 32 , which is surrounded by shoulder 48 .
- First housing component 26 contains motor-compressor unit 24 therein, as described below.
- Compact compressor 20 is a removable compressor that can be slid into a electronic component using a suitable slot and latch-type mechanism to allow non-destructive replacement of compressor 20 .
- the electrical terminal assembly 46 as shown in FIGS. 1, 3 , and 4 , is embedded within the walls of compressor 20 and, when compressor 20 is properly installed, the terminals of electrical terminal assembly 46 mate with corresponding terminals of the electronic component.
- second housing component 28 includes top wall 50 , bottom wall 52 , left side wall 54 and right side wall 56 .
- first or inner housing component 26 is inserted within second or outer housing component 28 as shown in FIG. 1 in a “matchbox”-type manner, wherein cutout portions of top wall 50 and left side wall 54 of second housing component 28 abut shoulder 48 of first housing component 26 . Thereafter, first and second housing components 26 and 28 are secured to one another in the manner described below.
- each component 26 and 28 has walls or outer surface regions that are exposed to ambient pressure and, during operation, are exposed to internal pressure forces, as described below.
- the side walls of each component 26 and 28 are configured such that the internal and external pressure forces acting upon one wall are balanced by an opposed pressure force acting upon an opposite wall. In the illustrated embodiments, this is accomplished by having the exposed surfaces or outer walls of housing 22 parallel and of substantially equal surface area.
- the front and rear side walls 30 and 32 of housing 22 are both defined by first housing component 26
- the top and bottom walls 50 and 52 and the left and right side walls 54 and 56 are both defined by second housing component 28 .
- the pressure forces acting on the front and back walls 30 and 32 are balanced by first component 26 without having to transmit these forces through a joint or other interface between first and second housing components 26 and 28 .
- the pressure forces acting on the top and bottom walls 50 and 52 and the left and right side walls 54 and 56 are balanced by second housing component 28 without having to transmit these forces through a joint or other interface between first and second components 26 and 28 .
- a significant advantage of this design is that it reduces the forces acting at the interface or seal between first and second housing components 26 and 28 . Because the pressure forces acting upon each individual housing component 26 and 28 are balanced, the pressure forces do not tend to pull apart the housing components 26 and 28 as is typical in a conventional hermetically sealed compressor housing. This balancing of the forces on the individual components 26 and 28 allows the joint between the housing components 26 and 28 to be welded or otherwise sealed in a manner that ensures the seal between the two components without having to compensate for stress due to pressure forces. The forces acting on the joints between the two components 26 and 28 will be mostly mechanical, such as shock, vibration, handling, and securing forces.
- compact compressor 20 and the compact refrigeration systems described below have a rectilinear configuration
- alternative embodiments may employ enclosure walls that balance the pressure forces acting on each individual housing component without the use of enclosure walls that are parallel or flat.
- the exposed walls of the enclosure merely have to be configured such that the overall effective pressure forces acting on individual component walls are substantially balanced to thereby minimize the forces transmitted through the interface between the individual components.
- first housing component 26 includes motor-compressor unit 24 , which generally includes a motor and a compressor mechanism 60 , as described below.
- Motor-compressor unit 24 shown in FIGS. 7 and 8 is shown as a portion of CRS 120 described below, however, motor-compressor unit 24 of compact compressor 20 an CRS 120 are substantially identical.
- bottom wall 40 of first housing component 26 includes a pair of concentric, annular outer and inner stator flanges 62 and 64 extending therefrom.
- An annular stator 66 is mounted within the space between annular stator flanges 62 and 64 , and is secured thereto in a suitable manner, such as via an interference fit.
- Stator 66 generally includes a stator body with windings.
- electrical leads 68 extend from electrical terminal assembly 46 to the windings of stator 66 for providing electrical power to the windings of stator 66 .
- An annular rotor 70 is disposed within stator 66 , and generally includes an annular body having a plurality of magnets 72 attached to the body of rotor 70 around the outer periphery thereof. As shown, magnets 72 are received within complementary shaped, dovetail-shaped recesses around the body of rotor 70 in a press-fit manner, by suitable fasteners, or in another suitable manner.
- First housing component 26 additionally includes a pair of body portions 74 and 76 , one body portion 74 including electrical terminal assembly 46 , and the other body portion 76 including inlet 42 and outlet 44 of compact compressor 20 ( FIG. 1 ).
- Annular needle bearing race 78 is fixed within interior stator flange 62 , and includes a plurality of needle bearings.
- An eccentric 80 is fitted within rotor 70 and fixed thereto, and is bearingly supported by bearing race 78 .
- Eccentric 80 includes a central opening 82 , a portion of which has an axis which is offset from the rotational axis A 1 -A 1 of rotor 66 , as may be seen in FIG. 8 .
- Roller 84 is fitted within the portion of central opening 82 of eccentric 80 which is offset from the rotational axis A 1 -A 1 of rotor 66 .
- a circular discharge valve plate 86 is also received within a portion of central opening 82 of eccentric 80 which is coaxial with rotational axis A 1 -A 1 of rotor 66 , and includes a discharge port 88 .
- a flapper-type discharge check valve 90 is secured to discharge valve plate 86 , and the movement thereof is limited by valve stop plate 92 also secured to discharge valve plate 86 .
- Discharge housing 94 is disposed over discharge valve plate 86 , and includes an arcuate-shaped recess 96 ( FIG. 8 ) therein which defines a discharge muffler chamber.
- Discharge housing may include a boss (not shown) which fits within an opening in wall 38 of first housing component 26 with an O-ring seal therebetween.
- Hub 98 is disposed within the inner annular space of roller 84 and is captured between top wall 38 of first housing component 26 and discharge valve plate 86 .
- Hub 98 includes slot 100 therein in which vane 102 is fitted, with vane 102 biased outwardly of slot 100 by a spring (not shown), such that the tip of vane 102 is in sliding contact with the interior surface of roller 84 .
- stator 66 In operation, electrical power supplied to the windings of stator 66 generates a magnetic field therein which rotates rotor 70 within stator 66 about rotational axis A 1 -A 1 .
- Eccentric 80 is rotated concurrently with rotor 70 , and causes roller 84 to orbit about the rotational axis A 1 -A 1 of rotor 70 .
- the orbital movement of roller 84 about hub 98 causes vane 102 to reciprocate within slot 98 to define a pair of crescent-shaped, variable-volume working pockets between roller 84 , hub 98 , and vane 102 for compressing refrigerant within compression mechanism 60 .
- compact compressor 20 is connected to other components of a refrigeration system which are disposed externally of compressor 20 , such as condenser, an expansion device, and an evaporator (not shown).
- Refrigerant at suction pressure enters compressor housing 22 through inlet 42 , and passes through passages 104 and 106 ( FIG. 5 ) in body portion 76 and bottom wall 40 of housing component 26 , respectively, to the inlet of compressor mechanism 60 .
- the refrigerant is compressed by compressor mechanism 60 in the manner described above, and is discharged through discharge port 88 and check valve 90 into discharge muffler chamber 96 . Thereafter, the compressed refrigerant passes through discharge passages 108 and 110 ( FIG.
- the interior volume 112 of housing 22 defines an oil sump which is in fluid communication with the refrigerant, and may be at either suction pressure or discharge pressure. Oil within the oil sump may be entrained within the refrigerant for lubricating the moving parts of compressor mechanism 60 .
- body portion 76 of first housing component 26 may include an oil hole 101 , such that refrigerant passing through inlet 42 at suction pressure may entrain oil from the oil sump within interior volume 112 of housing 22 through oil hole 101 into the refrigerant stream to lubricate the moving parts of compressor mechanism 60 .
- inlet and outlet 42 and 44 are recessed into front wall 30 of housing 22 .
- the recessed nature of inlet 42 and outlet 44 avoids having inlet and outlet tubes projecting outwardly from housing 22 and thereby facilitates the installation of the compact compressor 20 or CRS 120 .
- the recessed nature of inlet 42 and outlet 44 allow external conduits, or the fittings of an external heat exchanger such as that shown in FIG. 14 , to be easily mounted to inlet 42 and outlet 44 .
- conduits or fittings 114 are located in a cylindrical recess 116 that surrounds the outer radial surface of inlet 42 and outlet 44 with O-rings 118 providing a seal therebetween.
- This allows the external conduit or fitting 114 to be inserted over inlet 42 or outlet 44 with one O-ring 118 being positioned between the internal surface of external conduit or fitting 114 and the external surface of inlet 42 or outlet 44 and a second O-ring 118 positioned between the outer surface of external conduit or fitting 114 and the inner surface of recess 116 without requiring brazing or other similar means of sealing and securing the foregoing components together.
- CRS 120 A compact refrigeration system (“CRS”) 120 according to a second embodiment of the present invention is shown in FIGS. 7-13 . Except as described below, CRS 120 includes a housing 22 with a compact motor-compressor unit 24 which is substantially identical to that of compact compressor 20 described above, and the same reference numerals will be used below to designate identical or substantially identical features between compact compressor 20 and CRS 120 . Housing 22 of CRS 120 , similar to that of compact compressor 20 , is both compact and modular to facilitate its use in changing environments and smaller spaces associated with electronic equipment.
- housing 22 of CRS 120 includes a compact compressor mechanism 60 substantially identical to that described above with respect to compact compressor 20 , and additionally includes other refrigeration system components, including a condenser, expansion device, and evaporator, which are located within housing 22 to hermetically seal CRS 120 from the outside environment and reduce the potential for leaks from the system.
- other refrigeration system components including a condenser, expansion device, and evaporator, which are located within housing 22 to hermetically seal CRS 120 from the outside environment and reduce the potential for leaks from the system.
- the outer surfaces of CRS 120 include high-density heat flux surfaces to provide heat transfer between CRS 120 and components of the electronic equipment being cooled, and also between CRS 120 and a suitable heat sink or the ambient environment.
- CRS 120 may advantageously be formed of stamped parts to thereby reduce the time and cost of manufacture.
- the outer configuration of CRS 120 may altered to adapt it to its intended application, for example, CRS 120 may be shaped as a parallelepiped, cylinder or other shape, and may define hot and/or cold surfaces on various locations on the exterior of its enclosure.
- CRS 120 includes a condenser 122 ( FIGS. 7 and 10 ) defined within top walls 38 and 50 of first and second housing components 26 and 28 , respectively, and an evaporator 124 ( FIGS. 8, 9 , and 11 ) defined within bottom walls 40 and 52 of first and second housing components 26 and 28 , respectively.
- Bottom walls 40 and 52 of first and second housing components 26 and 28 , respectively, including evaporator 124 define a cold face or “cold plate” of CRS 120 which may be placed in thermal communication with the surfaces of electrical components, such as computer chips or other electrical circuitry which require cooling, to facilitate transfer of heat from the electrical component to a suitable refrigerant via evaporator 124 of CRS 120 .
- condenser 122 includes an inlet 126 disposed in a central portion of top wall 38 of first housing component 26 , which is in fluid communication with discharge muffler chamber 96 of compressor mechanism 60 ( FIG. 7 ).
- a spiral condenser passage 128 is shown as a groove which is cast or milled within top wall 38 of first housing component 26 , and is enclosed by top wall 50 of second housing component 28 .
- Outlet 130 of condenser passage 128 is in fluid communication with passage 132 in body portion 74 of first housing component 26 , which leads to evaporator 124 .
- evaporator 124 includes a restrictor passage 134 , shown as a thin groove which is cast or milled within bottom wall 40 of first housing component 26 , and is enclosed by bottom wall 52 of second housing component 28 .
- Restrictor passage 134 is in fluid communication with passage 132 in body portion 74 of first housing component 26 .
- Restrictor passage 134 extends around the outer periphery of first housing component 26 , and terminates in expansion device 136 , which is configured as the entrance to a relatively wide evaporator passage 138 , shown as a relatively wide groove which is cast or milled within bottom wall 40 of first housing component 26 , and is enclosed by bottom wall 52 of second housing component 28 , as shown in FIG. 9 .
- Evaporator passage 138 extends from the central portion of bottom wall 40 of first housing component 26 in an arcuate, alternating manner as shown in FIG. 11 toward the outer periphery of first housing component 26 .
- the outlet 140 of evaporator passage communicates with a deep, substantially annular recess 142 formed within outer stator flange 64 such that, in operation, refrigerant passing through deep recess 142 around outer stator flange 64 cools stator 66 .
- Recess 142 communicates with the inlet of compressor mechanism 60 via a shallow, wide suction line passage 144 .
- the bottom of recess 142 may include openings therein in communication with internal volume 112 of housing 22 , such that recess 142 may function as an oil separator.
- compressed refrigerant discharged from compressor mechanism 60 passes through inlet 126 of condenser passage 128 and thence through condenser passage 128 to allow heat from the refrigerant to diffuse through top wall 50 of second housing component 28 to a suitable heat sink or the ambient atmosphere.
- inlet 126 of condenser passage 128 is disposed near the central portion of top wall 38 of first housing component 26 , and condenser passage 128 extends in a spiral manner outwardly from the central portion of top wall 38 of first housing component 26 , passage of high pressure refrigerant from inlet 126 through condenser passage 128 will generate a heat gradient in top wall 50 of second housing component 28 . In this manner, top wall 50 of second housing component 28 will be relatively hotter near the center thereof, and progressively less hot toward the outer periphery thereof.
- CRS 120 may employ heat exchangers, such as condenser 122 and evaporator 124 , which are formed in or proximate a wall or face of housing 22 and where the hottest or coolest point (depending upon whether the refrigerant is losing or absorbing thermal energy) of the heat exchanger is in the middle of the wall or face. Because potential heat transfer losses may be due to conduction in the enclosure walls, keeping the temperature gradients in the enclosure walls forming parts of the heat exchangers as low as possible will optimize the performance of the heat exchangers.
- heat exchangers such as condenser 122 and evaporator 124 , which are formed in or proximate a wall or face of housing 22 and where the hottest or coolest point (depending upon whether the refrigerant is losing or absorbing thermal energy) of the heat exchanger is in the middle of the wall or face. Because potential heat transfer losses may be due to conduction in the enclosure walls, keeping the temperature gradients in the enclosure walls forming parts of the heat exchangers as low as
- the hottest point of the heat exchanger would be near or at the middle of the wall or face of housing 22 , and the refrigerant would travel radially outward, such as in the spiral shaped condenser passage 128 , as it cools.
- the refrigerant when the refrigerant has reached the outer radial edges of the heat exchanger face and enclosure wall, it will have been cooled and will not increase, or will minimally increase, the temperature gradient within the enclosure walls.
- the high pressure refrigerant then passes through outlet 130 of condenser passage 128 and through passage 132 in body portion 74 of first housing component 26 into narrow restrictor passage 134 in bottom wall 40 of first housing component 26 .
- expansion device 136 Upon encountering expansion device 136 , the pressure of the refrigerant rapidly decreases, and the low pressure refrigerant then passes through evaporator groove 138 of evaporator 124 allowing the low pressure refrigerant to take up heat from an electronics component to be cooled which is disposed adjacent bottom wall 40 of second housing component 28 . As shown in FIG.
- stator 66 itself may include a passage therein, through which some or a portion of the refrigerant is directed to cool stator 66 .
- high pressure refrigerant from condenser 122 can be expanded, such as by passage through a capillary tube, and then directed directly to stator 66 for cooling purposes without first passing through evaporator 124 .
- This arrangement may be used to provide additional cooling capacity for motor-compressor unit 24 . If the pressure of refrigerant which is used to cool stator 66 of motor-compressor unit 24 is higher than the compression suction pressure, an additional expansion device may be used to further reduce the pressure of the refrigerant to the desired suction pressure after it has cooled motor-compressor unit 24 .
- evaporator 124 which defines a “cold plate” of CRS 120
- the heat is conveyed to a suitable heat sink or to the ambient environment via condenser 122 , which functions as a “hot plate” of CRS 120 .
- the foregoing refrigeration cycle can be a conventional cycle with the refrigerant undergoing a phase change in both condenser 122 and evaporator 124 , a transcritical system wherein the refrigerant, such as carbon dioxide, is compressed to a supercritical pressure, or a system wherein the refrigerant remains a gas and does not undergo a phase change.
- first housing component 26 and second housing component 28 may be secured together.
- welding such as laser welding, may be performed along the dashed lines 146 around the outer periphery of condenser passage 128 and optionally, between each of the concentric portions of condenser passage 128 to secure top wall 50 of second housing component 28 to top wall 38 of first housing component 26 , while concurrently isolating the high pressure condenser passage 128 from communication with other portions of CRS 120 .
- welding such as laser welding
- welding such as laser welding, may be performed along the dashed lines 148 around restrictor passage 134 , evaporator passage 138 , and passage 144 as shown to thereby secure bottom wall 52 of second housing component 28 to bottom wall 40 of first housing component 26 while concurrently isolating restrictor passage 134 , evaporator passage 138 , and passage 144 from fluid communication with other portions of CRS 120 .
- a similar laser welding technique may be used to secure first and second housing components 26 and 28 of compact compressor 20 of FIGS. 1-6 , described above. Further characteristics of CRS 120 are discussed below.
- condenser passage 128 of condenser 122 is described above as a groove formed within top wall 38 of first housing component 26 , which is enclosed by top wall 50 of second housing component 28
- restrictor passage 134 and expansion groove 138 are described above as grooves in bottom wall 40 of first housing component 26 which are enclosed by bottom wall 52 of second housing component 28
- the foregoing passages may be constructed in alternative configurations.
- one or more of the foregoing passages may be formed completely within either top wall 38 of first housing component 26 , top wall 50 of second housing component 28 , or in bottom wall 40 of first housing component 26 or bottom wall 52 of second housing component 28 .
- the foregoing passages may be formed in top and bottom walls 50 and 52 of second housing component 28 , and enclosed by top and bottom walls 38 and 40 of first housing component 26 , respectively.
- housing 22 of CRS 120 may have an outer surface or envelope that defines simple geometric shape or profile.
- the use of a simple geometric shape or profile for the outer envelope facilitates the assembly and interchangeability of the system.
- the purpose of the simple geometry envelope is to ensure positioning and alignment of the enclosure to other surfaces in the environment.
- computer servers have slots with predefined dimensions in which electronic components can be inserted.
- compact compressor 20 and CRS 120 By reducing the height of compact compressor 20 and CRS 120 to less than 1U, i.e., less than about 1.75 inches (4.45 cm), by positioning compression mechanism 60 inside rotor 70 as best seen in FIG. 4 , compact compressor 20 and CRS 120 , such as those shown in FIGS. 1-9 , may have dimensions that allow same to be slid into such a server slot, for example, to provide cooling to the server.
- CRS 120 is configured to locate the low pressure regions thereof in the corners of housing 22 between first and second housing components 26 and 28 . This location for the low-pressure regions will help to keep housing 22 free of leaks by lowering the volume of the high pressure regions and thus the effective surface areas of the high-pressure regions.
- the low pressure in these regions may be maintained by sealing these areas off from the high pressure regions and providing fluid communication between the low pressure regions and a volume of the system that is at suction pressure during operation of the compressor, such as a suction line or evaporator 124 .
- the limits on power consumption may be relatively restrictive. In such situations, it may be desirable to trade refrigeration system efficiency for reduced power consumption. For example, it may be desirable to cool the refrigerant as it is being compressed so that the compression process approaches an isothermal process to reduce power consumption at the expense of refrigeration system efficiency.
- the refrigerant may be cooled by convection with refrigerant in internal volume 112 of housing 22 , by suction gas diverted to cool compression mechanism 60 before compression of the suction gas, by conduction that vents thermal energy to the ambient environment, evaporator 124 or other heat sink, by thermoelectric devices, or other suitable means.
- the refrigerant used with CRS 120 may also be selected to reduce the power consumption of CRS 120 .
- R245fa may be used as the refrigerant.
- This freon is conventionally used in heat pump applications or as an insulation blowing agent, not as a refrigerant for a refrigeration system. It has a Global Warming Potential less than R134a.
- the normal boiling temperature of R245fa is relatively high (15° C.) and it also has a relatively low density in comparison to conventional refrigerants commonly used in refrigeration systems.
- the lower density of R245fa requires that this refrigerant be used with a compressor having a relatively large volumetric displacement and thus negatively impacts its performance as a refrigerant in common refrigeration cycles.
- CRS 120 of the present invention a reduction in power consumption by the compressor is highly desirable and although a motor-compressor unit 24 which is designed for use with R245fa will require a large volumetric displacement due to the lower density of the refrigerant, this lower density will also result in a motor that has relatively reduced power requirements. Furthermore, the operating pressures employed when using R245fa are relatively low and the pressure difference across the system is also relatively low in comparison to refrigerants conventionally employed in common refrigeration cycles and the reduced operating pressures and pressure differences facilitate the manufacture of a lightweight and compact CRS 120 .
- CRS 150 Modified versions of CRS 120 , namely, CRS 150 , are shown in FIGS. 14 and 15 which include only condenser 122 ( FIG. 14 ) or evaporator 124 ( FIG. 15 ).
- a modular heat exchanger 152 which may be either a condenser or an evaporator, is attached to housing 22 of CRS 150 .
- CRS 150 of FIGS. 14 and 15 each include a motor-compressor unit 24 therein which is substantially identical to that of compact compressor 20 and CRS 120 described above, and further, except as described below, CRS 150 functions in the same manner as CRS 120 described above, and identical reference numerals are used in FIGS. 14 and 15 to designate identical or substantially identical components therebetween.
- housing 22 of CRS 150 includes inlet 42 and outlet 44 similar to those of compact compressor 20 .
- Modular heat exchanger 152 which may be configured as a condenser or evaporator, is secured to housing 22 via a suitable latching mechanism, for example, and includes an inlet fitting 154 and an outlet fitting 156 in fluid communication with outlet 44 and inlet 42 of housing 22 , such as in the manner described above with respect to FIG. 2 .
- Modular heat exchanger 152 generally includes a refrigerant passage therethrough, and a plurality of heat spreading means such as fins 158 to facilitate thermal exchange between the refrigerant within modular heat exchanger 152 and the ambient environment surrounding modular heat exchanger 152 .
- modular heat exchanger 152 is an evaporator.
- CRS 150 includes motor-compressor unit 24 and condenser 122 .
- compressed refrigerant passes from motor-compressor unit 24 through condenser 122 as described above to transfer heat from the refrigerant to a suitable heat sink or the ambient environment.
- the refrigerant passes through outlet 44 of housing 22 of CRS 150 and into inlet 154 of modular heat exchanger 152 .
- Modular heat exchanger 152 may include an expansion device therein to allow expansion of refrigerant before the refrigerant passes through the internal passages of modular heat exchanger 152 to take up heat from the area surrounding modular heat exchanger 152 .
- the refrigerant passes through outlet 156 of modular heat exchanger 152 , into inlet 42 of housing 22 of CRS 150 and into the inlet of motor-compressor unit 24 to repeat the foregoing refrigeration cycle.
- modular heat exchanger 152 is a condenser.
- CRS 150 includes motor-compressor unit 24 and evaporator 124 and, in operation, refrigerant compressed by motor-compressor unit 24 passes through outlet 44 of housing 22 of CRS 150 and into inlet 154 of modular heat exchanger 152 .
- the heat from the refrigerant diffuses into the ambient atmosphere.
- the refrigerant flows through outlet 156 of modular heat exchanger 152 and into inlet 42 of CRS 150 , and passes through restrictor passage 134 , expansion device 136 , evaporator passage 138 , and suction line passage 144 and into the inlet of motor-compressor unit 24 as described above, wherein evaporator 124 of CRS 150 functions as a “cold plate” in the manner described above.
- CRS 150 may be configured with both condenser 122 and evaporator 124 as described above with respect to CRS 120 , and may additionally include modular heat exchanger 152 to provide a supplemental condenser or evaporator to the system.
- modular heat exchanger 152 may be configured as a suction line heat exchanger (“SLHX”) to allow both further cooling of the refrigerant after same passes through condenser 122 , and further warming of the refrigerant after same passes through evaporator 124 to thereby increase the efficiency of CRS 150 .
- SSHX suction line heat exchanger
Abstract
Description
- This application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application Ser. No. 60/527,798, entitled COMPACT REFRIGERATION SYSTEMS AND HEAT EXCHANGERS, filed on Dec. 8, 2003, assigned to the assignee of the present patent application, the disclosure of which is expressly incorporated herein by reference.
- 1. Field of the Invention
- The present invention relates to compact, modular cooling systems, and in particular, to compact compressors and refrigeration systems for electronic equipment cooling.
- 2. Description of the Related Art
- Conventional refrigeration systems are typically semi-permanent or permanent systems. For example, in a typical refrigerator, it is not necessary to be able to independently move the refrigeration components with respect to the rest of the refrigerator and the components of such refrigeration systems are permanently installed in the refrigerator. In the quickly changing electronics industry, however, it would be useful to have a compact modular cooling unit mounted in thermal communication with a piece of electronic equipment that the user can independently install and remove.
- Also, as electronic equipment has become increasingly smaller, the heat dissipation requirements of such equipment is exceeding the capacity of cooling systems which employ only forced air to convectively cool the equipment.
- What is needed is an improved compact compressor and/or compact cooling system that can be employed to cool electronic equipment.
- The present invention provides compact compressors and refrigeration systems that can be used to cool computers, servers, and other electronic equipment. Each compact compressor or refrigeration system includes a compact, substantially enclosed hermitic housing having a simple geometry profile, such as a rectilinear profile, which enables the compact compressor or refrigeration system to be easily inserted within a slot, for example, of an electronic component such as a computer server. In one embodiment, a compact compressor is provided, which includes a motor-compressor unit within the housing, including a stator, a rotor disposed interiorly of the stator, and a compressor mechanism disposed interiorly of the rotor to provide a compact profile. In another embodiment, the housing includes the foregoing compact motor-compressor unit, and further includes a condenser formed within one of the walls of the housing and an evaporator formed within another wall of the housing such that the housing defines a completely contained, compact refrigeration system. Alternatively, in another embodiment, the housing may include only one of the condenser and evaporator, with the other of the condenser and evaporator configured as a modular component which is attached to the housing.
- One embodiment of the invention provides a compact refrigeration system that may be fit within a standard sized slot of a computer server. The system includes enclosure walls that define at least one heat exchanger, such as a condenser or evaporator, and each heat exchanger may define a temperature gradient that has a localized maximum or minimum at the center of the heat exchanger, and wherein the heat exchanger defines substantially similar temperatures at locations that are at substantially similar radial distances from the center and local maximum, minimum temperature of the heat exchanger.
- In one form thereof, the present invention provides a compact compressor unit, including a substantially enclosed housing including an inlet and an outlet; and a motor-compressor unit disposed within the housing, including a stator; a rotor disposed substantially interiorly of the stator; and a compressor mechanism driven by the rotor and disposed substantially interiorly of the rotor, the compressor mechanism in fluid communication with the inlet and the outlet, whereby the compressor mechanism receives fluid from the inlet at suction pressure, compresses the fluid to discharge pressure, and discharges the fluid at discharge pressure through the outlet.
- In another form thereof, the present invention provides a compact refrigeration system, including a substantially enclosed housing having a simple geometry profile including at least first and second sides; a motor-compressor unit disposed within the housing, including a stator; a rotor disposed substantially interiorly of the stator; and a compressor mechanism driven by the rotor, the compressor mechanism having an inlet and an outlet; a condenser formed at least partially within the first side of the housing, the condenser in fluid communication with the compressor mechanism outlet; an evaporator formed at least partially within the second side of the housing, the evaporator in fluid communication with the compressor mechanism inlet; and an expansion device in fluid communication with the condenser and with the evaporator.
- In a further form thereof, the present invention provides a compact refrigeration system, including a substantially enclosed housing having a simple geometry profile, including an inlet and an outlet and at least a first side; a motor-compressor unit disposed within the housing, including a stator; a rotor disposed substantially interiorly of the stator; and a compressor mechanism driven by the rotor; and a first heat exchanger formed substantially within the first side of the housing, the first heat exchanger in fluid communication with the compressor mechanism.
- In a further form thereof, the present invention provides a compact refrigeration system, including a housing, including a first housing component including at least a first pair of opposite sides of the housing; and a second housing component including at least another side of the housing, the first and second housing components insertable one into the other; and a compressor mechanism disposed within the housing.
- In a further form thereof, the present invention provides a compact refrigeration system, including a housing, including a first housing component including at least a first pair of opposite sides of the housing; and a second housing component including at least another side of the housing, the first and second housing components insertable one into the other; and a heat exchanger at least partially integrated into one of the sides of the housing, the heat exchanger including a passage extending from proximate a central portion of the housing side toward a peripheral portion of the housing side.
- In a further form thereof, the present invention provides a compact refrigeration system, including a housing including an inlet and an outlet; a compressor unit disposed within the housing, the compressor unit including a stator; a rotor disposed substantially interiorly of the stator; and a compressor mechanism driven by the rotor and disposed interiorly of the stator; and a first heat exchanger configured as a modular unit attached to a wall of the housing, the heat exchanger in fluid communication with the inlet and with the outlet.
- In a further form thereof, the present invention provides a compact refrigeration system, including a first housing component having a simple geometry profile including an exterior wall, and a groove formed within the exterior wall; a second housing component into which the first housing component is received, the second housing component having a wall in abutment with the exterior wall of the first housing component and enclosing the groove to define a heat exchanger passage; and a compressor mechanism disposed within the first housing component and in fluid communication with the heat exchanger passage.
- The above mentioned and other features and objects of this invention, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:
-
FIG. 1 is a perspective view of a compact compressor according to a first embodiment of the present invention, showing the components of the compressor housing; -
FIG. 2 is a sectional view taken along line 2-2 ofFIG. 1 , showing an exemplary manner in which a fluid line or fluid fitting may be attached to the inlet or outlet of the compact compressor; -
FIG. 3 is a perspective cutaway view of the compact compressor; -
FIG. 4 is a further perspective cutaway view of the compact compressor, showing components of the compressor mechanism; -
FIG. 5 is a further perspective cutaway view of a portion of the compact compressor, showing components of the compressor mechanism; -
FIG. 6 is a perspective view of a portion of the compressor mechanism ofFIG. 5 ; -
FIG. 7 is a first exploded view of a compact refrigeration system according to a second embodiment, viewed from a first direction; -
FIG. 8 is a second exploded view of the compact refrigeration system, viewed from a second direction; -
FIG. 9 is a perspective view of the compact refrigeration system, showing the components of the refrigeration system housing; -
FIG. 10 is a perspective view of a first side of the inner housing component of the compact refrigeration system, showing the condenser; -
FIG. 11 is a perspective view of a second side of the inner housing component of the compact refrigeration system, showing the evaporator; -
FIG. 12 is a perspective view similar toFIG. 10 , showing exemplary weld lines for securing the outer housing component to the inner housing component of the compact refrigeration system; -
FIG. 13 is a perspective view similar toFIG. 11 , showing exemplary weld lines for securing the outer housing component to the inner housing component of the compact refrigeration system; -
FIG. 14 is a perspective view of one compact refrigeration system according to a third embodiment, showing the housing of the compact refrigeration system including a condenser and a modular heat exchanger configured as an evaporator, wherein a portion of the housing of the compact refrigeration system is broken away to show the terminal assembly; and -
FIG. 15 is a perspective view of another compact refrigeration system according to the third embodiment, showing the housing of the compact refrigeration system including an evaporator and a modular heat exchanger configured as a condenser, wherein a portion of the housing of the compact refrigeration system is broken away to show the terminal assembly. - Although the exemplification set out herein illustrates embodiments of the invention, in several forms, the embodiments disclosed below are not intended to be exhaustive or to be construed as limiting the scope of the invention to the precise forms disclosed.
- The present invention provides both compact compressors and compact refrigeration systems which, in the exemplary application described below, may be used to provide cooling to electronic equipment. A
compact compressor 20 according to a first embodiment of the present invention is shown inFIGS. 1-8 . With initial reference toFIGS. 1-4 ,compressor 20 generally includes a hermetic enclosure orhousing 22 and a motor-compressor unit 24 disposed withinhermetic housing 22. Referring toFIG. 1 ,housing 22 generally includes a first orinner housing component 26 and a second orouter housing component 28. To assemblecompact compressor 20,first housing component 26 is insertable withinsecond housing component 28, and the foregoing are secured to one another such as by welding in the manner described below. - As shown in
FIGS. 1 and 3 ,compressor housing 22 has a simple geometry profile, shown herein as a rectilinear profile. In this manner,compact compressor 20 may be inserted into a slot in an electronics device in a cartridge-type manner, and be easily removed therefrom for repair or replacement, for example.First housing component 26 is shown inFIGS. 1 and 3 , and has a box-type, rectilinear profile generally including three pairs of opposing side walls, includingfront wall 30,rear wall 32,left side wall 34,right side wall 36,top wall 38, and bottom wall 40 (FIG. 4 ). Although the words “front”, “back”, “left”, etc., are used herein to designate sides and/or walls of the compact compressors and refrigeration systems of the present invention, same are necessarily arbitrary designations, and the present invention is not limited orientationally to such terms.Front side wall 30 includesinlet 42 andoutlet 44, and anelectrical terminal assembly 46 is recessed into a cavity defined betweenleft side wall 34 andrear side wall 32, which is surrounded byshoulder 48.First housing component 26 contains motor-compressor unit 24 therein, as described below. -
Compact compressor 20 is a removable compressor that can be slid into a electronic component using a suitable slot and latch-type mechanism to allow non-destructive replacement ofcompressor 20. Theelectrical terminal assembly 46, as shown inFIGS. 1, 3 , and 4, is embedded within the walls ofcompressor 20 and, whencompressor 20 is properly installed, the terminals ofelectrical terminal assembly 46 mate with corresponding terminals of the electronic component. - As shown in
FIG. 1 ,second housing component 28 includestop wall 50,bottom wall 52,left side wall 54 andright side wall 56. In assemblingcompact compressor 20, first orinner housing component 26 is inserted within second orouter housing component 28 as shown inFIG. 1 in a “matchbox”-type manner, wherein cutout portions oftop wall 50 andleft side wall 54 ofsecond housing component 28abut shoulder 48 offirst housing component 26. Thereafter, first andsecond housing components - In the compact compressors and refrigeration systems disclosed herein, after first and
second housing components component component housing 22 parallel and of substantially equal surface area. For example, the front andrear side walls housing 22 are both defined byfirst housing component 26, while the top andbottom walls right side walls second housing component 28. By configuring the enclosure in this manner, the pressure forces acting on the front andback walls first component 26 without having to transmit these forces through a joint or other interface between first andsecond housing components bottom walls right side walls second housing component 28 without having to transmit these forces through a joint or other interface between first andsecond components - A significant advantage of this design is that it reduces the forces acting at the interface or seal between first and
second housing components individual housing component housing components individual components housing components components - Although
compact compressor 20 and the compact refrigeration systems described below have a rectilinear configuration, alternative embodiments may employ enclosure walls that balance the pressure forces acting on each individual housing component without the use of enclosure walls that are parallel or flat. The exposed walls of the enclosure merely have to be configured such that the overall effective pressure forces acting on individual component walls are substantially balanced to thereby minimize the forces transmitted through the interface between the individual components. - Referring to
FIGS. 3-8 first housing component 26 includes motor-compressor unit 24, which generally includes a motor and acompressor mechanism 60, as described below. Motor-compressor unit 24 shown inFIGS. 7 and 8 is shown as a portion ofCRS 120 described below, however, motor-compressor unit 24 ofcompact compressor 20 anCRS 120 are substantially identical. Referring primarily toFIGS. 7 and 8 ,bottom wall 40 offirst housing component 26 includes a pair of concentric, annular outer andinner stator flanges annular stator 66 is mounted within the space betweenannular stator flanges Stator 66 generally includes a stator body with windings. Referring toFIG. 4 , electrical leads 68 extend from electricalterminal assembly 46 to the windings ofstator 66 for providing electrical power to the windings ofstator 66. Anannular rotor 70 is disposed withinstator 66, and generally includes an annular body having a plurality ofmagnets 72 attached to the body ofrotor 70 around the outer periphery thereof. As shown,magnets 72 are received within complementary shaped, dovetail-shaped recesses around the body ofrotor 70 in a press-fit manner, by suitable fasteners, or in another suitable manner. -
First housing component 26 additionally includes a pair ofbody portions body portion 74 including electricalterminal assembly 46, and theother body portion 76 includinginlet 42 andoutlet 44 of compact compressor 20 (FIG. 1 ). Annularneedle bearing race 78 is fixed withininterior stator flange 62, and includes a plurality of needle bearings. An eccentric 80 is fitted withinrotor 70 and fixed thereto, and is bearingly supported by bearingrace 78.Eccentric 80 includes acentral opening 82, a portion of which has an axis which is offset from the rotational axis A1-A1 ofrotor 66, as may be seen inFIG. 8 .Roller 84 is fitted within the portion ofcentral opening 82 of eccentric 80 which is offset from the rotational axis A1-A1 ofrotor 66. A circulardischarge valve plate 86 is also received within a portion ofcentral opening 82 of eccentric 80 which is coaxial with rotational axis A1-A1 ofrotor 66, and includes adischarge port 88. A flapper-typedischarge check valve 90 is secured to dischargevalve plate 86, and the movement thereof is limited byvalve stop plate 92 also secured to dischargevalve plate 86.Discharge housing 94 is disposed overdischarge valve plate 86, and includes an arcuate-shaped recess 96 (FIG. 8 ) therein which defines a discharge muffler chamber. Discharge housing may include a boss (not shown) which fits within an opening inwall 38 offirst housing component 26 with an O-ring seal therebetween. -
Hub 98 is disposed within the inner annular space ofroller 84 and is captured betweentop wall 38 offirst housing component 26 anddischarge valve plate 86.Hub 98 includesslot 100 therein in which vane 102 is fitted, withvane 102 biased outwardly ofslot 100 by a spring (not shown), such that the tip ofvane 102 is in sliding contact with the interior surface ofroller 84. - In operation, electrical power supplied to the windings of
stator 66 generates a magnetic field therein which rotatesrotor 70 withinstator 66 about rotational axis A1-A1.Eccentric 80 is rotated concurrently withrotor 70, and causesroller 84 to orbit about the rotational axis A1-A1 ofrotor 70. The orbital movement ofroller 84 abouthub 98 causes vane 102 to reciprocate withinslot 98 to define a pair of crescent-shaped, variable-volume working pockets betweenroller 84,hub 98, andvane 102 for compressing refrigerant withincompression mechanism 60. - Referring to
FIGS. 1, 5 , 7, and 8,compact compressor 20 is connected to other components of a refrigeration system which are disposed externally ofcompressor 20, such as condenser, an expansion device, and an evaporator (not shown). Refrigerant at suction pressure enterscompressor housing 22 throughinlet 42, and passes throughpassages 104 and 106 (FIG. 5 ) inbody portion 76 andbottom wall 40 ofhousing component 26, respectively, to the inlet ofcompressor mechanism 60. The refrigerant is compressed bycompressor mechanism 60 in the manner described above, and is discharged throughdischarge port 88 andcheck valve 90 intodischarge muffler chamber 96. Thereafter, the compressed refrigerant passes throughdischarge passages 108 and 110 (FIG. 5 ) intop wall 38 andbody portion 76, respectively, andoutlet 44 ofcompressor housing 22. The compressed refrigerant then passes through the condenser, expansion device, and evaporator of the refrigeration system before being drawn intoinlet 42 ofhousing 22 to repeat the foregoing cycle. - The
interior volume 112 ofhousing 22 defines an oil sump which is in fluid communication with the refrigerant, and may be at either suction pressure or discharge pressure. Oil within the oil sump may be entrained within the refrigerant for lubricating the moving parts ofcompressor mechanism 60. For example, referring toFIG. 4 ,body portion 76 offirst housing component 26 may include anoil hole 101, such that refrigerant passing throughinlet 42 at suction pressure may entrain oil from the oil sump withininterior volume 112 ofhousing 22 throughoil hole 101 into the refrigerant stream to lubricate the moving parts ofcompressor mechanism 60. - Referring to
FIGS. 1 and 2 , inlet andoutlet front wall 30 ofhousing 22. In thecompact compressor 20 ofFIGS. 1-6 and the modular refrigeration system orCRS 120 ofFIGS. 7-14 , the recessed nature ofinlet 42 andoutlet 44 avoids having inlet and outlet tubes projecting outwardly fromhousing 22 and thereby facilitates the installation of thecompact compressor 20 orCRS 120. Moreover, as best seen inFIG. 2 , the recessed nature ofinlet 42 andoutlet 44 allow external conduits, or the fittings of an external heat exchanger such as that shown inFIG. 14 , to be easily mounted toinlet 42 andoutlet 44. In the illustrated embodiment, such conduits or fittings 114 are located in acylindrical recess 116 that surrounds the outer radial surface ofinlet 42 andoutlet 44 with O-rings 118 providing a seal therebetween. This allows the external conduit or fitting 114 to be inserted overinlet 42 oroutlet 44 with one O-ring 118 being positioned between the internal surface of external conduit or fitting 114 and the external surface ofinlet 42 oroutlet 44 and a second O-ring 118 positioned between the outer surface of external conduit or fitting 114 and the inner surface ofrecess 116 without requiring brazing or other similar means of sealing and securing the foregoing components together. - A compact refrigeration system (“CRS”) 120 according to a second embodiment of the present invention is shown in
FIGS. 7-13 . Except as described below,CRS 120 includes ahousing 22 with a compact motor-compressor unit 24 which is substantially identical to that ofcompact compressor 20 described above, and the same reference numerals will be used below to designate identical or substantially identical features betweencompact compressor 20 andCRS 120.Housing 22 ofCRS 120, similar to that ofcompact compressor 20, is both compact and modular to facilitate its use in changing environments and smaller spaces associated with electronic equipment. As described below,housing 22 ofCRS 120 includes acompact compressor mechanism 60 substantially identical to that described above with respect tocompact compressor 20, and additionally includes other refrigeration system components, including a condenser, expansion device, and evaporator, which are located withinhousing 22 to hermetically sealCRS 120 from the outside environment and reduce the potential for leaks from the system. - Further, as described below, the outer surfaces of
CRS 120 include high-density heat flux surfaces to provide heat transfer betweenCRS 120 and components of the electronic equipment being cooled, and also betweenCRS 120 and a suitable heat sink or the ambient environment. By locating all of the refrigeration components ofCRS 120 within a single enclosure, the potential for leaks is reduced, andCRS 120 may advantageously be formed of stamped parts to thereby reduce the time and cost of manufacture. Similar tocompact compressor 20, the outer configuration ofCRS 120 may altered to adapt it to its intended application, for example,CRS 120 may be shaped as a parallelepiped, cylinder or other shape, and may define hot and/or cold surfaces on various locations on the exterior of its enclosure. - Referring to
FIGS. 7-11 ,CRS 120 includes a condenser 122 (FIGS. 7 and 10 ) defined withintop walls second housing components FIGS. 8, 9 , and 11) defined withinbottom walls second housing components Bottom walls second housing components evaporator 124, define a cold face or “cold plate” ofCRS 120 which may be placed in thermal communication with the surfaces of electrical components, such as computer chips or other electrical circuitry which require cooling, to facilitate transfer of heat from the electrical component to a suitable refrigerant viaevaporator 124 ofCRS 120.Top walls second housing components condenser 122, define a hot face or “hot plate” ofCRS 120 which may be placed in thermal communication with a suitable heat sink or with the ambient atmosphere to facilitate transfer of heat from the refrigerant to the heat sink or ambient atmosphere viacondenser 122. - Referring to
FIG. 10 ,condenser 122 includes aninlet 126 disposed in a central portion oftop wall 38 offirst housing component 26, which is in fluid communication withdischarge muffler chamber 96 of compressor mechanism 60 (FIG. 7 ). Aspiral condenser passage 128 is shown as a groove which is cast or milled withintop wall 38 offirst housing component 26, and is enclosed bytop wall 50 ofsecond housing component 28.Outlet 130 ofcondenser passage 128 is in fluid communication withpassage 132 inbody portion 74 offirst housing component 26, which leads toevaporator 124. - Referring to
FIG. 11 ,evaporator 124 includes arestrictor passage 134, shown as a thin groove which is cast or milled withinbottom wall 40 offirst housing component 26, and is enclosed bybottom wall 52 ofsecond housing component 28.Restrictor passage 134 is in fluid communication withpassage 132 inbody portion 74 offirst housing component 26.Restrictor passage 134 extends around the outer periphery offirst housing component 26, and terminates inexpansion device 136, which is configured as the entrance to a relatively wideevaporator passage 138, shown as a relatively wide groove which is cast or milled withinbottom wall 40 offirst housing component 26, and is enclosed bybottom wall 52 ofsecond housing component 28, as shown inFIG. 9 .Evaporator passage 138 extends from the central portion ofbottom wall 40 offirst housing component 26 in an arcuate, alternating manner as shown inFIG. 11 toward the outer periphery offirst housing component 26. Theoutlet 140 of evaporator passage communicates with a deep, substantiallyannular recess 142 formed withinouter stator flange 64 such that, in operation, refrigerant passing throughdeep recess 142 aroundouter stator flange 64 coolsstator 66.Recess 142 communicates with the inlet ofcompressor mechanism 60 via a shallow, widesuction line passage 144. Optionally, the bottom ofrecess 142 may include openings therein in communication withinternal volume 112 ofhousing 22, such thatrecess 142 may function as an oil separator. - In operation, compressed refrigerant discharged from
compressor mechanism 60 passes throughinlet 126 ofcondenser passage 128 and thence throughcondenser passage 128 to allow heat from the refrigerant to diffuse throughtop wall 50 ofsecond housing component 28 to a suitable heat sink or the ambient atmosphere. As shown inFIG. 10 , becauseinlet 126 ofcondenser passage 128 is disposed near the central portion oftop wall 38 offirst housing component 26, andcondenser passage 128 extends in a spiral manner outwardly from the central portion oftop wall 38 offirst housing component 26, passage of high pressure refrigerant frominlet 126 throughcondenser passage 128 will generate a heat gradient intop wall 50 ofsecond housing component 28. In this manner,top wall 50 ofsecond housing component 28 will be relatively hotter near the center thereof, and progressively less hot toward the outer periphery thereof. - In other words,
CRS 120 may employ heat exchangers, such ascondenser 122 andevaporator 124, which are formed in or proximate a wall or face ofhousing 22 and where the hottest or coolest point (depending upon whether the refrigerant is losing or absorbing thermal energy) of the heat exchanger is in the middle of the wall or face. Because potential heat transfer losses may be due to conduction in the enclosure walls, keeping the temperature gradients in the enclosure walls forming parts of the heat exchangers as low as possible will optimize the performance of the heat exchangers. As described above, for the heat exchanger functioning ascondenser 122 or gas cooler, the hottest point of the heat exchanger would be near or at the middle of the wall or face ofhousing 22, and the refrigerant would travel radially outward, such as in the spiral shapedcondenser passage 128, as it cools. Thus, when the refrigerant has reached the outer radial edges of the heat exchanger face and enclosure wall, it will have been cooled and will not increase, or will minimally increase, the temperature gradient within the enclosure walls. - The high pressure refrigerant then passes through
outlet 130 ofcondenser passage 128 and throughpassage 132 inbody portion 74 offirst housing component 26 into narrowrestrictor passage 134 inbottom wall 40 offirst housing component 26. Upon encounteringexpansion device 136, the pressure of the refrigerant rapidly decreases, and the low pressure refrigerant then passes throughevaporator groove 138 ofevaporator 124 allowing the low pressure refrigerant to take up heat from an electronics component to be cooled which is disposed adjacentbottom wall 40 ofsecond housing component 28. As shown inFIG. 11 , becauseexpansion device 136 is disposed near the central portion ofbottom wall 40 offirst housing component 26, andevaporator passage 138 extends in an arcuate, alternating manner outwardly from the central portion ofbottom wall 40 offirst housing component 26, passage of low pressure refrigerant throughevaporator passage 138 will generate a cooling gradient inbottom plate 52 ofsecond housing component 28. In this manner,bottom plate 52 ofsecond housing component 28 will be relatively cooler near its center, and progressively less cool toward its outer periphery. - Thereafter, the low pressure refrigerant passes into
deep recess 142 withinstator flange 64 to coolstator 66, and thence throughsuction line passage 144 into the inlet ofcompressor mechanism 60 where the refrigerant is compressed to repeat the foregoing cycle. Alternatively,stator 66 itself may include a passage therein, through which some or a portion of the refrigerant is directed to coolstator 66. Also, instead of directing refrigerant from the outlet ofevaporator 124 to recess 142 or a passage in thestator 66, high pressure refrigerant fromcondenser 122 can be expanded, such as by passage through a capillary tube, and then directed directly tostator 66 for cooling purposes without first passing throughevaporator 124. This arrangement may be used to provide additional cooling capacity for motor-compressor unit 24. If the pressure of refrigerant which is used to coolstator 66 of motor-compressor unit 24 is higher than the compression suction pressure, an additional expansion device may be used to further reduce the pressure of the refrigerant to the desired suction pressure after it has cooled motor-compressor unit 24. - In the manner described above, heat from an electronics component to be cooled is absorbed by
evaporator 124, which defines a “cold plate” ofCRS 120, and the heat is conveyed to a suitable heat sink or to the ambient environment viacondenser 122, which functions as a “hot plate” ofCRS 120. The foregoing refrigeration cycle can be a conventional cycle with the refrigerant undergoing a phase change in bothcondenser 122 andevaporator 124, a transcritical system wherein the refrigerant, such as carbon dioxide, is compressed to a supercritical pressure, or a system wherein the refrigerant remains a gas and does not undergo a phase change. - Referring to
FIGS. 12 and 13 , an exemplary manner in whichfirst housing component 26 andsecond housing component 28 may be secured together is shown. Referring toFIG. 12 , welding, such as laser welding, may be performed along the dashedlines 146 around the outer periphery ofcondenser passage 128 and optionally, between each of the concentric portions ofcondenser passage 128 to securetop wall 50 ofsecond housing component 28 totop wall 38 offirst housing component 26, while concurrently isolating the highpressure condenser passage 128 from communication with other portions ofCRS 120. In a similar manner, referring toFIG. 13 , welding, such as laser welding, may be performed along the dashedlines 148 aroundrestrictor passage 134,evaporator passage 138, andpassage 144 as shown to thereby securebottom wall 52 ofsecond housing component 28 tobottom wall 40 offirst housing component 26 while concurrently isolatingrestrictor passage 134,evaporator passage 138, andpassage 144 from fluid communication with other portions ofCRS 120. A similar laser welding technique may be used to secure first andsecond housing components compact compressor 20 ofFIGS. 1-6 , described above. Further characteristics ofCRS 120 are discussed below. - Although
condenser passage 128 ofcondenser 122 is described above as a groove formed withintop wall 38 offirst housing component 26, which is enclosed bytop wall 50 ofsecond housing component 28, and similarly,restrictor passage 134 andexpansion groove 138 are described above as grooves inbottom wall 40 offirst housing component 26 which are enclosed bybottom wall 52 ofsecond housing component 28, the foregoing passages may be constructed in alternative configurations. For example, one or more of the foregoing passages may be formed completely within eithertop wall 38 offirst housing component 26,top wall 50 ofsecond housing component 28, or inbottom wall 40 offirst housing component 26 orbottom wall 52 ofsecond housing component 28. Still further, the foregoing passages may be formed in top andbottom walls second housing component 28, and enclosed by top andbottom walls first housing component 26, respectively. - Similar to
compact compressor 20 described above,housing 22 ofCRS 120 may have an outer surface or envelope that defines simple geometric shape or profile. The use of a simple geometric shape or profile for the outer envelope facilitates the assembly and interchangeability of the system. The purpose of the simple geometry envelope is to ensure positioning and alignment of the enclosure to other surfaces in the environment. For example, computer servers have slots with predefined dimensions in which electronic components can be inserted. By reducing the height ofcompact compressor 20 andCRS 120 to less than 1U, i.e., less than about 1.75 inches (4.45 cm), by positioningcompression mechanism 60 insiderotor 70 as best seen inFIG. 4 ,compact compressor 20 andCRS 120, such as those shown inFIGS. 1-9 , may have dimensions that allow same to be slid into such a server slot, for example, to provide cooling to the server. - As described above,
CRS 120 is configured to locate the low pressure regions thereof in the corners ofhousing 22 between first andsecond housing components housing 22 free of leaks by lowering the volume of the high pressure regions and thus the effective surface areas of the high-pressure regions. By locating the low pressure regions in the corners ofhousing 22, the overall force exerted by the high pressure refrigerant biasing first andsecond housing components evaporator 124. - When the object to be cooled by
CRS 120 is a computer, the limits on power consumption may be relatively restrictive. In such situations, it may be desirable to trade refrigeration system efficiency for reduced power consumption. For example, it may be desirable to cool the refrigerant as it is being compressed so that the compression process approaches an isothermal process to reduce power consumption at the expense of refrigeration system efficiency. The refrigerant may be cooled by convection with refrigerant ininternal volume 112 ofhousing 22, by suction gas diverted tocool compression mechanism 60 before compression of the suction gas, by conduction that vents thermal energy to the ambient environment,evaporator 124 or other heat sink, by thermoelectric devices, or other suitable means. - The refrigerant used with
CRS 120 may also be selected to reduce the power consumption ofCRS 120. For example, R245fa may be used as the refrigerant. This freon is conventionally used in heat pump applications or as an insulation blowing agent, not as a refrigerant for a refrigeration system. It has a Global Warming Potential less than R134a. The normal boiling temperature of R245fa is relatively high (15° C.) and it also has a relatively low density in comparison to conventional refrigerants commonly used in refrigeration systems. The lower density of R245fa requires that this refrigerant be used with a compressor having a relatively large volumetric displacement and thus negatively impacts its performance as a refrigerant in common refrigeration cycles. ForCRS 120 of the present invention, however, a reduction in power consumption by the compressor is highly desirable and although a motor-compressor unit 24 which is designed for use with R245fa will require a large volumetric displacement due to the lower density of the refrigerant, this lower density will also result in a motor that has relatively reduced power requirements. Furthermore, the operating pressures employed when using R245fa are relatively low and the pressure difference across the system is also relatively low in comparison to refrigerants conventionally employed in common refrigeration cycles and the reduced operating pressures and pressure differences facilitate the manufacture of a lightweight andcompact CRS 120. - Modified versions of
CRS 120, namely,CRS 150, are shown inFIGS. 14 and 15 which include only condenser 122 (FIG. 14 ) or evaporator 124 (FIG. 15 ). Amodular heat exchanger 152, which may be either a condenser or an evaporator, is attached tohousing 22 ofCRS 150. Except as described below,CRS 150 ofFIGS. 14 and 15 each include a motor-compressor unit 24 therein which is substantially identical to that ofcompact compressor 20 andCRS 120 described above, and further, except as described below,CRS 150 functions in the same manner asCRS 120 described above, and identical reference numerals are used inFIGS. 14 and 15 to designate identical or substantially identical components therebetween. - As shown in
FIGS. 14 and 15 ,housing 22 ofCRS 150 includesinlet 42 andoutlet 44 similar to those ofcompact compressor 20.Modular heat exchanger 152, which may be configured as a condenser or evaporator, is secured tohousing 22 via a suitable latching mechanism, for example, and includes an inlet fitting 154 and an outlet fitting 156 in fluid communication withoutlet 44 andinlet 42 ofhousing 22, such as in the manner described above with respect toFIG. 2 .Modular heat exchanger 152 generally includes a refrigerant passage therethrough, and a plurality of heat spreading means such asfins 158 to facilitate thermal exchange between the refrigerant withinmodular heat exchanger 152 and the ambient environment surroundingmodular heat exchanger 152. - In one embodiment, shown in
FIG. 14 ,modular heat exchanger 152 is an evaporator. In this embodiment,CRS 150 includes motor-compressor unit 24 andcondenser 122. In operation, compressed refrigerant passes from motor-compressor unit 24 throughcondenser 122 as described above to transfer heat from the refrigerant to a suitable heat sink or the ambient environment. Thereafter, the refrigerant passes throughoutlet 44 ofhousing 22 ofCRS 150 and intoinlet 154 ofmodular heat exchanger 152.Modular heat exchanger 152 may include an expansion device therein to allow expansion of refrigerant before the refrigerant passes through the internal passages ofmodular heat exchanger 152 to take up heat from the area surroundingmodular heat exchanger 152. Thereafter, the refrigerant passes throughoutlet 156 ofmodular heat exchanger 152, intoinlet 42 ofhousing 22 ofCRS 150 and into the inlet of motor-compressor unit 24 to repeat the foregoing refrigeration cycle. - In one embodiment, shown in
FIG. 15 ,modular heat exchanger 152 is a condenser. In this embodiment,CRS 150 includes motor-compressor unit 24 andevaporator 124 and, in operation, refrigerant compressed by motor-compressor unit 24 passes throughoutlet 44 ofhousing 22 ofCRS 150 and intoinlet 154 ofmodular heat exchanger 152. Inmodular heat exchanger 152, the heat from the refrigerant diffuses into the ambient atmosphere. Thereafter, the refrigerant flows throughoutlet 156 ofmodular heat exchanger 152 and intoinlet 42 ofCRS 150, and passes throughrestrictor passage 134,expansion device 136,evaporator passage 138, andsuction line passage 144 and into the inlet of motor-compressor unit 24 as described above, whereinevaporator 124 ofCRS 150 functions as a “cold plate” in the manner described above. - In a still further embodiment,
CRS 150 may be configured with bothcondenser 122 andevaporator 124 as described above with respect toCRS 120, and may additionally includemodular heat exchanger 152 to provide a supplemental condenser or evaporator to the system. In a further alternative,modular heat exchanger 152 may be configured as a suction line heat exchanger (“SLHX”) to allow both further cooling of the refrigerant after same passes throughcondenser 122, and further warming of the refrigerant after same passes throughevaporator 124 to thereby increase the efficiency ofCRS 150. - While this invention has been described as having an exemplary design, the present invention may be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles.
Claims (47)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/988,399 US20050123418A1 (en) | 2003-12-08 | 2004-11-12 | Compact compressors and refrigeration systems |
Applications Claiming Priority (2)
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US52779803P | 2003-12-08 | 2003-12-08 | |
US10/988,399 US20050123418A1 (en) | 2003-12-08 | 2004-11-12 | Compact compressors and refrigeration systems |
Publications (1)
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US20050123418A1 true US20050123418A1 (en) | 2005-06-09 |
Family
ID=34633002
Family Applications (1)
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US10/988,399 Abandoned US20050123418A1 (en) | 2003-12-08 | 2004-11-12 | Compact compressors and refrigeration systems |
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CA (1) | CA2488985A1 (en) |
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US20090294097A1 (en) * | 2008-05-27 | 2009-12-03 | Rini Technologies, Inc. | Method and Apparatus for Heating or Cooling |
US20140268561A1 (en) * | 2013-03-18 | 2014-09-18 | Fujitsu Limited | Electronic equipment and heat receiving device |
WO2018050621A1 (en) * | 2016-09-15 | 2018-03-22 | Nestec Sa | Compressor arrangement with integrated motor |
CN109690086A (en) * | 2016-09-15 | 2019-04-26 | 雀巢产品技术援助有限公司 | Compressor set with integrated motor |
JP2019530823A (en) * | 2016-09-15 | 2019-10-24 | ソシエテ・デ・プロデュイ・ネスレ・エス・アー | Compressor mechanism with integrated motor |
TWI743157B (en) * | 2016-09-15 | 2021-10-21 | 瑞士商雀巢製品股份有限公司 | Compressor arrangement with integrated motor |
JP7159153B2 (en) | 2016-09-15 | 2022-10-24 | ソシエテ・デ・プロデュイ・ネスレ・エス・アー | Compressor mechanism with integrated motor |
US20190187763A1 (en) * | 2017-12-15 | 2019-06-20 | Auras Technology Co., Ltd. | Pump module |
US10895262B2 (en) * | 2017-12-15 | 2021-01-19 | Auras Technology Co., Ltd. | Pump module having two impellers in series and a multiple plate housing |
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