The present disclosure relates to a compressor and to a valve assembly of the compressor.
This section provides background information related to the present disclosure and is not necessarily prior art.
A climate-control system such as, for example, a heat-pump system, a refrigeration system, or an air conditioning system, may include a fluid circuit having an outdoor heat exchanger, an indoor heat exchanger, an expansion device disposed between the indoor and outdoor heat exchangers, and one or more compressors circulating a working fluid (e.g., refrigerant or carbon dioxide) between the indoor and outdoor heat exchangers. Efficient and reliable operation of the compressor is desirable to ensure that the climate-control system in which the compressor is installed is capable of effectively and efficiently providing a cooling and/or heating effect on demand. Sometimes the compressor may be noisy during operation. It is advantageous for an efficient compressor to have reduced sound during operation.
This section provides a general summary of the disclosure and is not a comprehensive disclosure of its full scope or all of its features.
In one form, the present disclosure provides a compressor that includes a scroll and a discharge valve assembly. The scroll includes an end plate and a spiral wrap extending from the end plate. The end plate includes a discharge passage. The discharge valve assembly is mounted to the scroll and is configured to control fluid flow through the discharge passage. The discharge valve assembly includes a backer, a valve member, and a retainer body. The retainer body includes a top wall, an outer wall, and an inner hub. The outer wall is spaced apart from and surrounds the inner hub defining an annular inner passage therebetween in fluid communication with the discharge passage. The backer is disposed between the valve member and the retainer body. The backer defines a range of motion of the valve member. The valve member is deflectable between a closed position in which the valve member restricts fluid flow through the discharge passage and an open position in which the valve member allows fluid flow through the discharge passage.
In some configurations of the compressor of the above paragraph, the valve member is a reed valve having a fixed end and a movable end that deflects relative to the fixed end between the open and closed positions.
In some configurations of the compressor of either of the above paragraphs, the first portion of the discharge valve assembly includes a base fixed relative to the end plate. The valve member is mounted to the base. The valve member is disposed between the base and the backer.
In some configurations of the compressor of any of the above paragraphs, the first portion of the discharge valve assembly further includes a spacer disposed between the base and the valve member.
In some configurations of the compressor of any of the above paragraphs, a first side of the base includes a seat surface. A movable end of the valve member contacts the seat surface when the valve member is in the closed position. The movable end of the valve member is spaced apart from the seat surface when the valve member is in the open position.
In some configurations of the compressor of any of the above paragraphs, an axial end of the retainer body engages a surface of the backer.
In some configurations of the compressor of any of the above paragraphs, the retainer body, the backer, and the valve member are disposed within a recess of the scroll.
In some configurations of the compressor of any of the above paragraphs, when the valve member is in the open position, working fluid flows through the discharge passage and through the retainer body before flowing through an aperture in a partition that separates a suction chamber of the compressor from a discharge chamber of the compressor.
In some configurations of the compressor of any of the above paragraphs, the top wall defines one or more apertures in fluid communication with the inner passage.
In some configurations of the compressor of any of the above paragraphs, the one or more apertures are slots.
In some configurations of the compressor of any of the above paragraphs, each of the slots include a first end and a second end. The slots are curved between the first and second ends.
In some configurations of the compressor of any of the above paragraphs, the one or more apertures are kidney-shaped apertures.
In some configurations of the compressor of any of the above paragraphs, the compressor further includes a shell assembly defining a suction chamber and a discharge chamber. When the valve member is in the open position, working fluid flows through the discharge passage and through the inner passage of the retainer body to the discharge chamber.
In some configurations of the compressor of any of the above paragraphs, the top wall of the retainer body defines one or more apertures in fluid communication with the inner passage and the discharge chamber. When the valve member is in the open position, the one or more apertures allow fluid communication between the discharge passage and the discharge chamber.
In some configurations of the compressor of any of the above paragraphs, the scroll is a non-orbiting scroll.
In another form, the present disclosure provides a compressor that includes a shell assembly, a scroll, and a discharge valve assembly. The scroll is disposed within the shell assembly. The scroll includes a first end plate and a first spiral wrap. The first end plate includes a discharge passage and a discharge recess in fluid communication with the discharge chamber. The discharge valve assembly is mounted to the scroll. The discharge valve assembly is configured to control fluid flow between the discharge passage and the discharge chamber. The discharge valve assembly includes a valve member, a backer, and a retainer body. The discharge valve assembly defines a first passage, a second passage, and a third passage. The backer is disposed between the valve member and the retainer body. The backer defines the first passage. The first passage is in fluid communication with the discharge passage. The second passage is an annular passage defined by the retainer body. The second passage is in fluid communication with the first passage and the third passage. The third passage includes one or more apertures formed in the retainer body. The second passage is disposed between the first and third passages such that when the valve member is in an open position, fluid flows from the first passage to the second passage and subsequently through the third passage.
In some configurations of the compressor of the above paragraph, the backer defines a range of motion of the valve member. The valve member is deflectable relative to the first end plate between a closed position and the open position. When the valve member is in the closed position, the valve member restricts fluid flow through the discharge passage. When the valve member is in the open position, the valve member allows fluid flow through the discharge passage.
In some configurations of the compressor of either of the above paragraphs, the valve member is a reed valve having a fixed end and a movable end that deflects relative to the fixed end between the open and closed positions.
In some configurations of the compressor of any of the above paragraphs, the discharge valve assembly further includes a base fixed relative to the end plate. The valve member is disposed between the base and the backer. The valve member contacts a seat surface of the base when the valve member is in the closed position. The valve member is spaced apart from the seat surface of the base when the valve member is in the open position.
In some configurations of the compressor of any of the above paragraphs, the one or more apertures are slots.
In some configurations of the compressor of any of the above paragraphs, each of the slots includes a first end and a second end. The slots are curved between the first and second ends.
In some configurations of the compressor of any of the above paragraphs, the one or more apertures are kidney-shaped apertures.
In some configurations of the compressor of any of the above paragraphs, the backer includes a pair of arms and a lobe portion. The first passage is defined by the pair of arms and the lobe portion.
In some configurations of the compressor of any of the above paragraphs, an axial end of the retainer body engages a surface of the backer.
In some configurations of the compressor of any of the above paragraphs, the retainer body, the backer, and the valve member are disposed within a recess in the scroll.
In some configurations of the compressor of any of the above paragraphs, when the valve member is in the open position, working fluid flows through the discharge passage, through the first passage, through the second passage, and through the third passage before flowing through an aperture in a partition that separates the suction chamber from the discharge chamber.
Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations and are not intended to limit the scope of the present disclosure.
Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
Example embodiments will now be described more fully with reference to the accompanying drawings.
Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.
The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore 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, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.
When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.
Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
With reference to
The shell assembly 12 may house the motor assembly 18, the bearing housing assembly 20, the compression mechanism 22, the floating seal assembly 26, and the discharge valve assembly 28. The shell assembly 12 may include a generally cylindrical shell 34, an end cap 36, a transversely extending partition 37, and a base 38. The end cap 36 may be fixed to an upper end of the shell 34. The base 38 may be fixed to a lower end of the shell 34. The end cap 36 and the partition 37 may define a discharge chamber 42 therebetween that receives compressed working fluid from the compression mechanism 22. The partition 37 may include an aperture 39 providing communication between the compression mechanism 22 and the discharge chamber 42. The discharge chamber 42 may generally form a discharge muffler for the compressor 10.
The discharge fitting 14 may be attached to the end cap 36 and is in fluid communication with the discharge chamber 42. The suction inlet fitting 16 may be attached to the shell 34 and may be in fluid communication with a suction chamber 43. While the compressor 10 is shown in
The motor assembly 18 may include a motor stator 44, a rotor 46, and a drive shaft 48. The stator 44 may be press fit into the shell 34. The drive shaft 48 may be rotatably driven by the rotor 46 and supported by the bearing housing assembly 20. The drive shaft 48 may include an eccentric crank pin 52 having a flat thereon for driving engagement with the compression mechanism 22. The rotor 46 may be press fit on the drive shaft 48. The bearing housing assembly 20 may include a main bearing housing 54 and a lower bearing housing 56 fixed within the shell 34. The bearing housings 54, 56 may be fixed relative to the shell assembly 12 and may house bearings that rotatably support the drive shaft 48. The main bearing housing 54 may include an annular flat thrust bearing surface 58 that supports the compression mechanism 22 thereon.
The compression mechanism 22 may be driven by the motor assembly 18 and may generally include an orbiting scroll 60 and a non-orbiting scroll 62. The orbiting scroll 60 may include an end plate 64 having a spiral vane or wrap 66 on the upper surface thereof and an annular flat thrust surface 68 on the lower surface. The thrust surface 68 may interface with an annular flat thrust bearing surface 58 on the main bearing housing 54. A cylindrical hub 70 may project downwardly from the thrust surface 68 and may have a drive bushing 72 disposed therein. The drive bushing 72 may include an inner bore in which the crank pin 52 is drivingly disposed. The crank pin 52 may drivingly engage a flat surface in a portion of the inner bore of the drive bushing 72 to provide a radially compliant driving arrangement.
As shown in
As shown in
Returning to
The spiral wrap 80 of the non-orbiting scroll 62 may meshingly engage the spiral wrap 66 of the orbiting scroll 60, thereby creating a series of pockets therebetween. The fluid pockets defined by the spiral wraps 66, 80 may decrease in volume as they move from a radially outer position (at a suction pressure) to a radially intermediate position (at an intermediate pressure) to a radially inner position (at a discharge pressure) throughout a compression cycle of the compression mechanism 22. The discharge passage 94 may be in fluid communication with a fluid pocket 123 at the radially inner position. When the discharge valve assembly 28 is in the open position (
With renewed reference to
The discharge valve assembly 28 may be received in the discharge recess 92 of the non-orbiting scroll 62 and may control fluid flow through the discharge passage 94. As shown in
With reference to
The base 149 may include a seat surface 160 on a first side 162 of the base 149. The spacer 151 may be mounted to the seat surface 160. The first side 162 of the base 149 may be the side adjacent to the reed valve member 150 when the discharge valve assembly 28 is assembled.
The reed valve member 150 may be a thin, resiliently flexible member having a fixed end 170 and a movable end 171. A pair of arms 172 may extend from the fixed end 170 and may each include a bore 173. The reed valve member 150 may be seated against the spacer 151, which in turn, may be seated against the base 149 such that the bores 173 are coaxially aligned with the bores 155 in the base 149. The movable end 171 of the reed valve member 150 is deflectable relative to the fixed end 170 between the closed position (
The reed valve member 150 may be moved to the open position due to a pressure differential on opposing sides of the reed valve member 150, such as when the pressure within the discharge passage 94 (and fluid pocket 123) exceeds the pressure within the discharge chamber 42. An amount of deflection of the movable end 171 of the reed valve member 150 may vary based on a distance from the fixed end 170. For example, the amount of deflection may be larger in portions of the movable end 171 of the reed valve member 150 which are farther away from the fixed end 170. The fixed end 170 may be fixed by the backer 152 being coupled to the base 149 (i.e., the fixed end 170 is sandwiched between the backer 152 and the base 149). A maximum amount of deflection of the movable end 171 may occur at a portion 175 of the movable end 171 of the reed valve member 150 furthest from the fixed end 170.
The movable end 171 of the reed valve member 150 may move to the closed position by moving in a downward direction toward the seat surface 160 due to the pressure in the discharge chamber 42 increasing relative to the pressure within the discharge passage 94 and/or due to pressure within the discharge passage 94 decreasing relative to the pressure in the discharge chamber 42, which allows the spring force of the resiliently flexible reed valve member 150 to force the movable end 171 toward the closed position. In the closed position, the reed valve member 150 restricts or prevents fluid flow between the discharge chamber 42 and the discharge passage 94.
The spacer 151 may include a pair of arms 177 shaped to correspond to the arms 172 of the reed valve member 150. Each of the arms 177 may include a bore 178 coaxially aligned with corresponding ones of the bores 173, 155. The spacer 151 may be disposed between the base 149 and the reed valve member 150 to create a space between the movable end 171 and the discharge opening 154. The movable end 171 of the reed valve member 151 may move into this space when entering the closed position to seal the discharge opening 154.
The backer 152 may include a body 179 having a pair of bores 180 extending therethrough. The bores 180 may be coaxially aligned with corresponding bores 173, 155, 178. The body 179 may include a lobe portion 181 shaped to correspond to the shape of the movable end 171 of the reed valve member 150. The body may include a pair of arms 182 shaped to correspond to the arms 177 of the spacer and/or 172 of the reed valve member 150. The body 179 may include a first or top surface 183. The lobe portion 181 may include an inclined surface 184 that faces the reed valve member 150 and forms a valve stop that defines a maximum amount of deflection of the movable end 171 of the reed valve member 150. The inclined surface 184 may be shaped to allow the reed valve member 150 to open to a greater extent than traditional discharge valve assemblies while limiting stress in the reed valve member 150. Such an expanded opening may allow for increased flow of the working fluid through the discharge passage 94 and through the discharge valve assembly 28. Such increased fluid flow improves the efficiency of the compressor 10, which reduces energy consumption and improves operation of the climate-control system in which the compressor 10 is installed.
When the reed valve member 150 is in the open position (
Fasteners 190 may pass through the bores 116, 155, 173, 178, 180 to secure the discharge valve assembly 28 to the end plate 78. In some embodiments, the fasteners may be threaded. In some embodiments, the fasteners may be spiral pins having resiliently contractable diameters to facilitate insertion into the bores 116, 155, 173, 178, 180. In some embodiments, pins may be press fit in the non-threaded bores 116, 155, 173, 178, 180 to secure the discharge valve assembly 28 to the end plate 78.
As shown in
The inner hub 204 may cooperate with the top wall 201 to define a central aperture or passage 209 extending therethrough. The central aperture 209 may by fluidly connected to the inner passage 206. The inner hub 204 may be generally cylindrical or cup-shaped, although other shapes and configurations are possible. While a central aperture 209 is shown in the embodiment of
The top wall may define a third passage. The third passage may include one or more retainer apertures 210. The one or more retainer apertures 210 may extend through the top wall 201 and may be fluidly connected with the inner passage 206. During normal operation of the compressor 10, fluid may flow from the discharge passage 94, through the recess passage 186 (
Each of the retainer apertures 210 may be elongated between a first end 212 and a second end 214. For example, the retainer apertures 210 may be slots. Each of the slots may be curved between the first end 212 and the second end 214. The retainer apertures 210 may curve along at least a portion of the perimeter of the top wall 201. In the configuration shown in
The first end 212 and the second end 214 may have a round shape. Retainer apertures 210 having rounded first and second ends 212, 214 may decrease the operational noise and/or sound of the compressor 10 as compared to a compressor with retainer apertures having flat or sharp edges.
While three evenly-spaced retainer apertures 210 are shown in the embodiment of
While not shown in the embodiment of
As shown in
With renewed reference to
The movable end 171 of the reed valve member 150 may deflect or contact the inclined surface 184 of the backer 152 when in the open position (
In some discharge valve assemblies, when the reed valve member 150 is in the open position, the fluid flow through the discharge opening 154 is partially obstructed by the lobe portion 181 of the backer 152, causing turbulent fluid vibrations (e.g., vortices) to move around the lobe portion 181 through the recess passage 186 and into the discharge chamber 42. These vibrations from the fluid flow may create acoustic wave pulses that may excite the end cap 36 and/or the partition 37. When the end cap 36 and/or the partition 37 are excited, the compressor may be relatively noisy during operation.
In the discharge valve assembly of the present disclosure, the inner hub 204 may cooperate with the outer wall 202 and retainer apertures 210 to concentrate and direct the fluid flow into the discharge chamber 42 through the recess passage 186, inner passage 206, and retainer apertures 210 thereby reducing or eliminating structural excitation (e.g., the excitation of the end cap 36 and/or partition 37) of the compressor 10. In this way, the configuration of the recess passage 186, inner passage 206, and retainer apertures 210 in the discharge valve assembly 28 cooperate to reduce turbulent fluid vibrations through the discharge valve assembly 28 and into the discharge chamber 42, thus reducing the operating noise of the compressor 10. In other words, the retainer portion 98 of the discharge valve assembly 28 may act as a muffler to decrease acoustic wave pulses in the discharge chamber 42 and resulting noise in the compressor 10. For example, in one particular example embodiments of the compressor 10, the retainer portion 98 and valve member portion 96 of the present discharge valve assembly 28 cooperate to decrease the sound level of the compressor 10 about 3-5 A-weighted decibels (dBA) as compared to a compressor having a conventional discharge valve assembly.
The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.
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