Patent Application
20210293457
Exemplary embodiments pertain to the art of compressor and, more specifically, to aluminum alloy compressors.
Compressors are used in various fluid processing operations, including various industrial and residential applications. One common application for compressors is in cooling or other heat pump applications involving compressible fluid refrigerants. Compressors are often subject to corrosion. For example, compressors disposed in marine environments can be subject to external corrosion. Corrosion can degrade the structural integrity of compressor components, and failure of those containing high pressure fluids can lead to unwanted repairs, safety risk, and fluid loss, as well as environmental and clean-up risks from leaked fluids. Elevated temperatures can also pose issues a problem in compressors. Certain components (e.g. compressor heads and discharge shells) can operate at temperatures in excess of 150° C., which can limit the use of organic coatings to provide corrosion protection.
A compressor is disclosed, including an outer casing and a fluid guide around a cavity within the casing. An inlet is in operative fluid communication with the cavity, and an outlet is also in operative fluid communication with the cavity. A prime mover includes an actuator disposed in the cavity. The actuator includes a surface arranged to receive fluid in the cavity from the inlet, impart compression to received fluid in the cavity, and discharge compressed fluid to the outlet. A surface of the compressor includes a cladding over a core, with the core comprising a first aluminum alloy, and the cladding comprising a second aluminum alloy. The second aluminum alloy is less noble than the first aluminum alloy and comprises an alloying element selected from tin, indium, gallium, or combinations thereof.
In some embodiments, the cladding is disposed on a surface of the outer casing.
In any one or combination of the foregoing embodiments, the cladding is disposed on a surface of the fluid guide around the cavity.
In any one or combination of the foregoing embodiments, the cladding is disposed on a surface of the actuator.
In any one or combination of the foregoing embodiments, the cladding is disposed on a surface of the inlet or on a surface of the outlet.
In any one or combination of the foregoing embodiments, the cladding comprises a cast aluminum alloy.
In any one or combination of the foregoing embodiments, the prime mover is disposed within the outer casing.
In any one or combination of the foregoing embodiments, the prime mover is disposed outside of the outer casing, in operative mechanical communication with the actuator within the outer casing.
In any one or combination of the foregoing embodiments, the actuator is selected from a reciprocating piston, a rotary screw, a scroll, a rotary vane, or an impeller.
In any one or combination of the foregoing embodiments, the second alloy further comprises zinc or magnesium.
Also disclosed is a heat transfer system comprising a heat transfer fluid circulation loop includes a compressor, a heat rejection heat exchanger in thermal communication with a heat sink, an expansion device, and a heat absorption heat exchanger in thermal communication with a heat source, connected together in order by conduit, wherein the compressor is according to any one or combination of the foregoing embodiments.
In some embodiments, the heat source is an indoor conditioned air space and the heat sink is an outdoor air space.
In any one or combination of the foregoing heat transfer system embodiments, the compressor is in disposed in the outdoor air space.
In any one or combination of the foregoing heat transfer system embodiments, the compressor is an indoor air space separate from the conditioned air space, and is exposed to an external source of moisture.
In any one or combination of the foregoing heat transfer system embodiments, the heat transfer fluid circulation loop is configured for an operational pressure of less than atmospheric pressure in at least a portion of the heat transfer fluid circulation loop.
The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:
A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.
As mentioned above, a compressor includes an outer casing, a fluid guide around a cavity within the outer casing, an inlet and outlet in operative fluid communication with the cavity, and a prime mover including an actuator in the cavity arranged to compress fluid. The above components are the main components of the compressor, but the compressor can of course include numerous additional components, sub-components, and features not listed above. For example, in some embodiments, the fluid guide includes not only a cavity or cavity within which the actuator is situation, but also one or more sections around flow paths between the inlet and the actuator cavity or between the actuator cavity and the outlet. Also, in some embodiments, the fluid guide (or components thereof) can be distinct components disposed and directly or indirectly attached or mounted to the casing. In some embodiments, the fluid guide can integrated with the outer casing, such as in embodiments where the outer casing (which can be formed from a cast metal) includes a wall having an exterior surface that is the exterior of the compressor and an interior surface that serves as a fluid guide. Additionally, various types of actuators can be utilized, including but not limited to reciprocating pistons, rotary screws, scrolls, rotary vanes, or impellers. Example embodiments of different types of compressors and arrangements of components are shown below in
With reference now to
In the open-drive embodiment of the reciprocating compressor 10 as depicted in
In the closed drive embodiment of the reciprocating compressor 10 as depicted in
To prevent leakage of the higher pressure interior of the main casing 12, it is necessary to seal the respective interfaces between the open ends 22, 24 of the casing main body 12 and the respective first and second casing end covers 16, 18. The reciprocating compressor 10 includes a sealing arrangement 40 at both ends of the casing main body 12 for sealing the interface between the first end cover 16 and the first open end 22 of the casing main body 12 and for sealing the interface between the second end cover 18 and the second open end 24 of the casing main body 12.
The exemplary rotors are supported for rotation about their respective axes by one or more bearings (e.g., rolling element bearings) along shaft portions protruding from opposite ends of each such rotor working portion. In an exemplary embodiment, upstream end bearings 150 and 152, respectively, are mounted in associated compartments in a main casting (main case member) 154 of the case assembly which forms a rotor case and the body of a motor case. The rotor case portion defines respective bores 156 and 158 accommodating the lobed working portions. At an upstream end of the motor case portion, a motor case cover or endplate 160 encloses the motor case and provides the inlet port such as via an integral fitting 162. The exemplary cover 160 is secured to the upstream end of the main case member 154 via a threaded fastener (screw/bolt) 164 circle (e.g., at least 8 fasteners, more specifically, 15 to 40 or 20 to 35) extending through a flange of the cover and into threaded bores of the main case member. A mounting face 161 of a mounting portion 163 of the cover is mated to the inlet/suction end face 155 of the case member 154. 1A web 165 extends inward and outward/upstream from the mounting portion 163 to the fitting 162. A mating plane 520 is shown between the cover and case member 154. There may be a gasket (not shown) along the mating plane. The case opening at the end face 155 is large enough to pass the motor. An inlet filter 169 is also shown, fastened (e.g., screwed) to the inboard face of the cover. A plane 522 is shown of a rim surface or end 166 of the fitting.
At the downstream end of the main case member 154, the case assembly includes a separate bearing case member (discharge end bearing case) 170 which has bearing compartments in which the respective discharge end bearings 172 and 174 of the male rotor and female rotor are mounted. A discharge case (cover or endplate) 180 may cover the bearing case 170 and may provide the discharge port such as via a fitting 182 (
In operation, the exemplary flowpath 510 through the compressor passes from the suction port 124 through the motor case (around and/or through the motor), into a suction plenum 100 (
A first roller 9a fits in the peripheral wall of the first eccentric portion 341 and is housed in the first cylinder chamber 310a of the first cylinder 35a. A second roller 309b fits in the peripheral wall of the second eccentric portion 342 and is housed in the second cylinder 305b. In association with rotation of the rotational axis 304, the first and second rollers 309a and 309b eccentrically rotate while their peripheral walls partially come into contact with the peripheral walls of the first cylinder chamber 310a and the second cylinder chamber 310b, respectively. A pair of discharge mufflers 311 is attached to the main bearing 307, and cover a discharge valve mechanism 312a provided in the main bearing 307. A discharge muffler 313 is attached to the sub-bearing 8, and covers a discharge valve mechanism 312b provided in the sub-bearing 308.
A discharge gas guide path is provided over the sub-bearing 308, the second cylinder 305b, the intermediate partition plate 306, the first cylinder 305a and the main bearing 307. The gaseous refrigerant discharged to discharge muffler 313 is guided into the double discharge mufflers 311 in the upper part through the above discharge gas guide path, is mixed with the gaseous refrigerant discharged through discharge valve mechanism 312a and is discharged into the sealed case.
A first vane unit 351 is provided in the first cylinder 305a, including a first vane 351a and a second vane 351b. The posterior end portions of the first and second vanes 351a and 351b come into contact with an end portion of a coil spring 316a. Coil spring 316a biases the first and second vanes 351a and 351b toward the first roller 339a such that the end portions of the first and second vanes 351a and 351b come into contact with the outer peripheral surface of the first roller 309a. A vane groove 317a which opens in the first cylinder chamber 310a is provided in the first cylinder 305a. The first cylinder 305a also includes a vane back chamber 318a in the posterior end portion of vane groove 317a, which opens in the sealed case 301 so that the posterior ends of the first and second vanes 351a and 351b are influenced by the pressure in the sealed case 301. A spring housing hole 19a is provided on the outer peripheral wall of the first cylinder 5a, to the extent of the first cylinder chamber 310a side via vane back chamber 318.
A second vane unit 352 is provided in the second cylinder 305b. The second vane unit 352 comprises a first vane 352a and a second vane 352b. The first vane 352a and the second vane 352b overlap each other in the height direction of the second cylinder 305b. The posterior portions of the first and second vanes 352a and 352b come into contact with an end portion of a coil spring 316b which biases the first and second vanes 352a and 352b toward the second roller 309b such that the apical end portions of the first and second vanes 352a and 352b come into contact with the outer peripheral surface of the second roller 309b. A vane groove 317b which opens in the second cylinder chamber 310b is provided in the second cylinder 305b, and the second cylinder 305b includes a vane back chamber 318b in the posterior end portion of vane groove 317b. The vane back chamber 318b opens in the sealed case 301 so that the posterior ends of the first and second vanes 352a and 352b are influenced by the pressure in the sealed case 301. A spring housing hole 319b is provided on the outer peripheral wall of the second cylinder 305b, to the extent of the second cylinder chamber 10b side via vane back chamber 18b.
During operation, discharge valve mechanism 312a of the main bearing 307 communicates with the first cylinder chamber 310a. When the pressure in the first cylinder chamber 310a has reached a predetermined pressure after increase in association with a compression influence, discharge valve mechanism 312a opens and discharges the compressed gaseous refrigerant into discharge mufflers 311. Discharge valve mechanism 312b of the sub-bearing 308 communicates with the second cylinder chamber 310b. When the pressure in the second cylinder chamber 310b has reached a predetermined pressure after increase in association with a compression influence, discharge valve mechanism 312b opens and discharges the compressed gaseous refrigerant into discharge muffler 313. If the pressure in the sealed case 301 is low and is not enough to press the first and second vanes 351a and 351b onto the first roller 309a at the time of activation, coil spring 16a biases the first and second vanes 351a and 351b toward the first roller 309a. This mechanism is also applied to coil spring 316b.
During operation, when the rotational axis 304 is rotationally driven in association with power distribution to the electric motor unit 302, the posterior ends of the first and second vanes 351a and 351b are influenced by the pressure in the sealed case 301 and the bias force of coil spring 316a in the first cylinder chamber 310a. By the bias force, the first and second vanes 351a and 351b elastically come into contact with the peripheral wall of the first roller 309a. In this manner, the first roller 309a eccentrically rotates. In a similar manner, in the second cylinder chamber 310b, the posterior ends of the first and second vanes 352a and 352b are influenced by the pressure in the sealed case 301 and the bias force of coil spring 316b. By the bias force, the first and second vanes 532a and 352b elastically come into contact with the peripheral wall of the second roller 309b. In this manner, the second roller 309b eccentrically rotates. In association with the eccentric rotation of the first and second rollers 309a and 309b, a gaseous refrigerant is introduced to the inlet 361 of the first and second cylinder chambers 310a and 310b partitioned by the first and second vane units 351 and 352. Moreover, the gaseous refrigerant is moved to the compression side of the first and second cylinder chambers 310a and 310b partitioned by the first and second vane units 351 and 352 and is compressed. When the pressure of the gaseous refrigerant is increased to a predetermined pressure in association with decrease in the volume on the compression side, the discharge valve mechanism 312 opens, and the gaseous refrigerant is discharged from the discharge hole 326.
The gaseous refrigerant discharged from the first cylinder chamber 310a and the gaseous refrigerant discharged from the second cylinder chamber 310b join in two discharge mufflers 11, and the joined gaseous refrigerant is discharged into the sealed case 301. The gaseous refrigerant discharged into the sealed case 301 fills the upper end portion of the sealed case 301 through the gas guide path provided among the components of the electric motor unit 302, and is discharged from the outlet 362 to the outside of the rotary compressor 300.
From inlet to outlet, a flowpath 438 through the compressor proceeds sequentially through an inlet housing 440 of the housing assembly. The exemplary inlet housing 440 may be based on one that contains an inlet guide vane (IGV) array. At the downstream end of the inlet housing is the inlet 446 to the first stage impeller 432. The inlet 446 is an axial inlet and the first stage impeller 432 has a radial outlet 448. The exemplary impeller 432 has a circumferential array of vanes extending between the inlet 446 and outlet 448 and extending between a hub and a shroud. Alternative impellers can be unshrouded. Flow from the first stage impeller outlet 448 proceeds radially outward through a diffuser 460 and then back radially inward through a return back axially to encounter inlet of the second stage impeller 434. The second stage impeller itself also has a radial outlet, hub, vanes, and an optional shroud. Flow discharged from the second stage impeller passes radially outward through a diffuser 82 into a discharge chamber or collector 484 and therefrom out the discharge port 424. Optionally, an intermediate port may be located along the flowpath. For injecting the swirl, injectors can protrude radially into the flowpath, which can promote efficient distribution of the injected refrigerant. In the
As mentioned above, a surface of the compressor includes a cladding over a core, where the core comprises a first aluminum alloy and the cladding comprises a second aluminum alloy. The core/cladding surface can be on a compressor outer casing, an actuator, a fluid guide disposed around an actuator, a fluid guide not disposed around an actuator, one or more components of the prime mover, or any other external or internal component of any of the example embodiments of compressors described above. An example embodiment of a clad aluminum alloy surface is shown in
The first aluminum alloy for the core 540 can be an aluminum alloy based material. In some embodiments, the aluminum alloy for the core 540 can be cast aluminum and can be made from aluminum alloys from AA200 series and AA300 series. Examples of cast aluminum alloys that can be used as core materials include but are not limited to AA242, AA295, AA355, AA356, AA360. It is noted that some cast alloying designations can also include a decimal and fourth digit that relates to a molded product form (e.g., AA242.x), and this fourth digit is omitted herein for ease of illustration. In some embodiments, the core can be wrought aluminum and can be made from aluminum alloys selected from 2000 series, 3000 series, 5000 series, or 6000 series aluminum alloys Examples of aluminum alloys that can be used as core materials include but are not limited to AA2024, AA3003, AA5052, AA6061. As used herein, all cast and wrought alloy numbers and alloy series numbers and individual alloy numbers are as specified and published by The Aluminum Association/ANSI.
The second aluminum alloy for the cladding 530 can be an aluminum alloy based material and, in some embodiments, may be made from aluminum alloys selected from 1000 series, 3000 series, 5000 series, 6000, or 7000 series aluminum alloys, including but not limited to AA1100, AA1145, AA3003, AA3102, AA5052, AA7072, AA8005, or AA8011. The second aluminum alloy of the outer cladding is less noble, than the first aluminum alloy. By “less noble”, it is meant that the second aluminum alloy is galvanically anodic with respect to the first aluminum alloy, i.e., that the second alloy has a lower galvanic potential or a lower electrode potentials than the first aluminum alloy such that the second aluminum alloy would be anodic with respect to the first aluminum alloy in a galvanic cell. This allows the second aluminum alloy to provide sacrificial corrosion protection to the first aluminum alloy. In some embodiments, the difference in galvanic potential between the second aluminum alloy, and the nearest potential of the first aluminum alloy is in a range having a lower end of >0 V, 50 mV, or 150 mV, and an upper end of 400 mV, 650 mV, or 900 mV. These range endpoints can be independently combined to form a number of ranges, and each possible combination is hereby expressly disclosed. In some embodiments, the second aluminum alloy can be provided with reduced nobility by incorporating alloying elements such as zinc or magnesium.
In some embodiments, the second aluminum alloy can be provided with reduced nobility by incorporating alloying elements such as zinc or magnesium. In some embodiments where zinc is present, the zinc can be present in the second aluminum alloy at a level in a range with a lower end of >0 wt. %, 0.8 wt. %, or 4.0 wt. %, zinc and an upper end of 1.3 wt. %, 5.0 wt. %, or 10.0 wt. %. These range endpoints can be independently combined to form a number of ranges, and each possible combination (i.e., 0-1.3 wt. %, 0-5.0 wt. %, 0-10 wt. %, 0.8-1.3 wt. %, 0.8-5.0 wt. %, 0.8-10 wt. %, 4.0-5.0 wt. %, 4.0-10 wt. %, and excluding impossible combinations where a ‘lower’ endpoint would be greater than an ‘upper’ endpoint) is hereby expressly disclosed. In some embodiments where magnesium is present, the magnesium can be present in the second aluminum alloy at a level in a range with a lower end of >0 wt. %, 0.05 wt. %, 1.0 wt. %, 1.3 wt. % or 2.2 wt. %, and an upper end of 0.4 wt. %, 1.3 wt. %, 2.8 wt. %, or 4.9 wt. %. These range endpoints can be independently combined to form a number of ranges, and each possible combination is hereby expressly disclosed. The second aluminum alloy also includes one or more alloying elements selected from tin, indium, or gallium. In some embodiments, the selected alloying element(s) can be present in the second aluminum alloy at a level in a range with a lower end of 0.010 wt. %, 0.016 wt. %, or 0.020 wt. %, and an upper end of 0.020 wt. %, 0.035 wt. %, 0.050 wt. %, or 0.100 wt. %. These range endpoints can be independently combined to produce different possible ranges, each of which is hereby explicitly disclosed (i.e., 0.010-0.020 wt. %, 0.010-0.035 wt. %, 0.010-0.050 wt. %, 0.010-0.100 wt. %, 0.016-0.020 wt. %, 0.016-0.035 wt. %, 0.016-0.050 wt. %, 0.016-0.100 wt. %, 0.020-0.020 wt. %, 0.020-0.035 wt. %, 0.020-0.050 wt. %, 0.020-0.100 wt. %). The second alloy can also include one or more other alloying elements for aluminum alloys. In some embodiments, the amount of any individual other alloying element can range from 0-1.5 wt. %. In some embodiments, the total content of any such other alloying elements can range from 0-2.5 wt. %. Examples of such alloying elements include Si, Fe, Mn, Cu, Ti, or Cr. In some embodiments, the second aluminum alloy can have a composition consisting of: 4.0-6.0 wt. % zinc or magnesium, 0.01-0.05 wt. % of one or more alloying elements selected from tin, indium, gallium, or combinations thereof, 0-2.5 wt. % other alloying elements, and the balance aluminum.
The cladding 530 can be overlaid on the core 540 by techniques including but not limited to thermal spray (e.g., plasma spray, wire arc spray, high-velocity air fuel (HVAF) spray), electroplating, electroless plating, physical vapor deposition, and other cladding techniques such as roll cladding that can be used with some compressor component fabrication techniques (e.g., techniques involving wrought aluminum alloys). In some embodiments, the cladding can be applied via cold spray. In some embodiments, the cladding can be applied to a cast aluminum alloy surface via cold spray. In a cold spray process, unmelted metal particles are introduced into a high velocity gas stream being projected out of a high velocity (e.g., supersonic) nozzle toward the coating substrate target. The particles' kinetic energy provides sufficient heat on impact with the coating substrate such that the particles plastically deform and fuse with the substrate and surrounding deposited metal material. As the particles impact the substrate, they rapidly cool even as the particles are deforming. The particles change shape dramatically from relatively round to very thin flat splats on the surface. Cold spray can be applied by supplying metal powder from powder feeder to a spray gun that include a nozzle and a heater. Powder particle diameter sizes can range from 1 to 120 microns, more specifically from 5 to 75. Pressurized gas (e.g., helium, nitrogen) is fed from a gas pre-heater to the gun heater. The powder and the gas streams are mixed in the gun and accelerated to supersonic speeds as the gas/powder mixture exits the gun nozzle. The term “cold” in “cold spray deposition” refers to the fact that the gas is maintained at a temperature below the melting point of the metal powder; however, as described above the gas is heated in both the gas pre-heater and the gun heater. In some embodiments, the temperature of the gas used in the process can range from 0° C. to 670° C., and gas pressure can range from 5 bar to 60 bar.
In some embodiments, the compressors disclosed herein are used in a heat transfer system. Referring now to the
The heat transfer system shown in
To the extent used herein, the term “about” is intended to include the degree of error associated with measurement of the particular quantity based upon the equipment available at the time of filing the application. For example, “about” can include a range of ±8% or 5%, or 2% of a given value.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, element components, and/or groups thereof.
While the present disclosure has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the essential scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this present disclosure, but that the present disclosure will include all embodiments falling within the scope of the claims.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2019/067441 | 12/19/2019 | WO | 00 |
| Number | Date | Country | |
|---|---|---|---|
| 62781944 | Dec 2018 | US |
