Patent Application
20060171819
The present invention is directed to a discharge muffler for a compressor used in heating, ventilation, air conditioning and refrigeration systems, and more particularly to a discharge muffler that provides sound attenuation with minimum discharge pressure reduction.
Heating and cooling systems typically maintain temperature control in a structure by circulating a fluid within coiled tubes such that passing another fluid over the tubes effects a transfer of thermal energy between the two fluids. A primary component in such a system is a compressor which receives a cool, low pressure gas and by virtue of a compression device, exhausts a hot, high pressure gas. One type of compressor is a screw compressor, which generally includes two cylindrical rotors mounted on separate shafts inside a hollow, double-barreled casing. The side-walls of the compressor casing typically form two parallel, overlapping cylinders which house the rotors side-by-side, with their shafts parallel to the ground. Screw compressor rotors typically have helically extending lobes and grooves on their outer surfaces forming a large thread on the circumference of the rotor. During operation, the threads of the rotors mesh together, with the lobes on one rotor meshing with the corresponding grooves on the other rotor to form a series of gaps between the rotors. These gaps form a continuous compression chamber that communicates with the compressor inlet opening, or “port,” at one end of the casing and continuously reduces in volume as the rotors turn and compress the gas toward a discharge port at the opposite end of the casing for use in the system.
These rotors rotate at high rates of speed, and multiple sets of rotors (compressors) may be configured to work together to further increase the amount of gas that can be circulated in the system, thereby increasing the operating capacity of a system. While the rotors provide a continuous pumping action, each set of rotors (compressor) produces pressure pulses as the pressurized fluid is discharged at the discharge port. These discharge pressure pulsations act as significant sources of audible sound within the system.
To minimize the undesirable sound, noise attenuation devices or systems can be used. Examples of noise attenuation systems include a dissipative or absorptive muffler system and a restrictive muffler system that subjects the refrigerant to a tortuous path, each typically located at the compressor discharge. Mufflers typically cause a significant pressure drop downstream of the compressor discharge which reduces system efficiency.
What is needed is a muffler that sufficiently attenuates pressure pulsations generated by compressor operations without adversely affecting compressor operating efficiency.
The present invention is directed to a discharge muffler for a compressor in a HVAC&R system. The discharge muffler includes a plate; and a plurality of tubes configured and disposed to extend through the plate substantially perpendicular to the plate, the plurality of tubes disposed in a predetermined spacing arrangement to provide substantially mutual axial alignment of the plurality of plates.
The present invention is further directed to a compressor system in a HVAC&R system. The compressor system includes a compressor having a housing, the housing having an inlet for receiving refrigerant to be compressed by the compressor and an outlet for discharging pressurized compressed refrigerant. A muffler disposed in the outlet includes a plate and a plurality of tubes configured and disposed to extend through the plate substantially perpendicular to the plate. The plurality of tubes are disposed in a predetermined spacing arrangement to provide substantially mutual axial alignment of the plurality of plates.
The present invention is still further directed to a chiller system including a compressor, a condenser arrangement and an evaporator arrangement connected in a closed refrigerant loop. A muffler includes a plate and a plurality of tubes configured and disposed to extend through the plate substantially perpendicular to the plate, the plurality of tubes disposed in a predetermined spacing arrangement to provide substantially mutual axial alignment of the plurality of plates. The muffler is disposed in the closed refrigerant loop between the compressor and the condenser.
An advantage of the present invention is that it can provide sound attenuation with minimal discharge pressure reduction.
A further advantage of the present invention is a muffler that provides improved discharge flow characteristics from the compressor.
A still further advantage of the present invention is improved HVAC&R system efficiency.
Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.
Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
One embodiment of a discharge muffler 20 is depicted in
Plate or reflector 30 is comprised of a material, such as metal, that can withstand pulsating pressurized refrigerant vapor discharged by compressor 10. Additionally, upon installation in the discharge 24, reflector 30 reflects a portion of the sound waves transmitted along discharge 24 while securing the plurality of tubes 34, 38 and 42 that are received in corresponding apertures 32 of the reflector 30. In one embodiment, reflector 30 is circular, but can have any peripheral shape that is received in a preferably substantially fluid tight conformal arrangement in discharge 24, preferably with reflector 30 disposed substantially perpendicular to the direction of refrigerant flow. It is preferred that the proportion of surface area of reflector 30 disposed in fluid communication in discharge 24 remaining after subtracting the surface area of apertures 32 is about ⅓. For example, if the cross sectional area of discharge 24 is 20 square inches, the reflector 30 would cover approximately 7 square inches of discharge 24. However, it is to be understood that this proportion value is merely a guide, and that the proportion can be greater than or less than ⅓.
In addition to being preferably disposed in a substantially fluid tight conformal arrangement in discharge 24, reflector 30 may also be substantially vibrationally isolated from discharge 24. A gasket 54 can be disposed between reflector 30 and discharge 24, the gasket material preferably being a viscoelastic material, such as neoprene or other polymer, to damp vibrations that would other wise propagate from the reflector 30 to the compressor 10. Preferably, the reflector 10 is also sufficiently resilient when compressed to provide a substantially fluid tight seal between the discharge 24 and the reflector 30. In an alternate embodiment, gasket 54 can have a U-shaped cross section (see
In one embodiment of the muffler 20 as shown in
In addition to sizing the tube cross sectional area (diameter for round tubes) it is preferable to also control the tube length, as tube length is used to tune the tube to a particular frequency. For example, in one embodiment, a tube having a length of 1.75 inches, as measured from the surface of the plate 30 (0.50 inch thick) to the end of the tube, is tuned to 714 Hz. Preferably, this tube is 4.00 inches long, so that the remainder of the tube extends past the other side of the plate by the same length. In other words, it is preferable that the plate 30 substantially bisects the tubes 34, 38 and 42. Further, it is preferable that tubes 34, 38 and 42 are in substantially mutual axial alignment, running substantially perpendicular to the plate 30. To secure tubes 34, 38 and 42 in position, adhesive, chemical or mechanical bonding techniques, known in the art, including welding, can be employed. Alternatively, the tubes 34, 38 and 42 and the plate 30 can be of unitary construction.
Preferably extending from each side of the plate 30 between adjacent tubes 34, 38 and 42 are vanes 46, the vanes 46 further preferably extending radially outward from a center tube 34. The vanes 46 attenuate higher sound frequencies than the tubes 34, 38 and 42, which is believed to result, at least in part, to result from the vanes 46 forming additional tuned cavities of smaller cross sectional areas than the tubes. To further secure the vanes 46 extending between adjacent tubes, a joint 50 can be formed to at least one side or to opposite sides of the vane 46. While the vanes 46 can define a profile having any closed geometry, an embodiment shown in
While in one embodiment the tubes 34, 38 and 42 and vanes 46 are symmetric about a center axis 62 (see
Test results were conducted using an embodiment of the muffler 20 as shown in
The compressor 10 compresses a refrigerant vapor and delivers it to the condenser 70 after the flow of the refrigerant vapor has been improved by the muffler 20 as previously discussed. The refrigerant vapor delivered to the condenser 70 enters into a heat exchange relationship with a fluid, e.g., air or water, and undergoes a phase change to a refrigerant liquid as a result of the heat exchange relationship with the fluid. The condensed liquid refrigerant from condenser 70 flows through corresponding expansion devices to an evaporator 72.
The evaporator 72 can include connections for a supply line and a return line of a cooling load 80. A secondary liquid, which is preferably water, but can be any other suitable secondary liquid, e.g., ethylene, calcium chloride brine or sodium chloride brine, travels into the evaporator 72 via return line and exits the evaporator 72 via supply line. The liquid refrigerant in the evaporator 72 enters into a heat exchange relationship with the secondary liquid to chill the temperature of the secondary liquid. The refrigerant liquid in the evaporator 72 undergoes a phase change to a refrigerant vapor as a result of the heat exchange relationship with the secondary liquid. The vapor refrigerant in the evaporator 72 then returns to the compressor 10 to complete the cycle. It is to be understood that any suitable configuration of condenser 70 and evaporator 72 can be used in the system 100, provided that the appropriate phase change of the refrigerant in the condenser 70 and evaporator 72 is obtained.
While the invention has been described with reference to a preferred embodiment, 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 invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
