Patent Application
20240384721
The present disclosure relates to a compressor, and more particularly to a compressor including a fluid separator having a retention feature.
Known scroll compressors include a housing, and the housing includes a front housing, a shell, and a rear housing. A conventional scroll compressor is shown and described in U.S. Pat. No. 8,202,071, hereby incorporated herein by reference in its entirety.
Such known compressors also include a fixed scroll-including a first spiral element, and an orbiting scroll including a second spiral element. The spiral elements interfit with one another to form a sealed-off fluid pocket. Such known compressors further include a driving mechanism which drives the orbiting scroll in an orbiting motion, and a rotation preventing mechanism which prevents the orbiting a scroll from rotating. The orbiting scroll, the fixed scroll, the driving mechanism, and the rotation preventing mechanism are positioned inside the housing. Further, such known compressors also include a suction chamber and a discharge chamber, and the fixed scroll separates the suction chamber from the discharge chamber. The driving mechanism and the rotation preventing mechanism are positioned inside the suction chamber.
In the known compressor, a refrigerant gas is introduced into the suction chamber via an external refrigerant circuit. To achieve high reliability and long life of the compressor, a fluid suspended in the refrigerant gas lubricates the driving mechanism, the rotation preventing mechanism, and sliding portions located between the fixed scroll and the orbiting scroll. In addition to lubricating the compressor, the fluid also carries away heat and performs a sealing function, particularly between mating surfaces of the fixed scroll and the orbiting scroll. Specifically, during operation, the fluid separates from the refrigerant gas, and accumulates in a reservoir located in a lower portion of the compressor. It is desirable that the fluid contained in the refrigerant gas be separated before leaving a housing of the compressor, so that the fluid may flow back into the reservoir.
Prior art oil separators, such as cyclone separators, which include filtering means and spaces to reduce the velocity of flow, are known in the art.
U.S. Pat. No. 6,511,530 entitled COMPRESSOR WITH OIL SEPARATOR, hereby incorporated herein by reference in its entirety, discloses an oil separating unit or separator pipe. The separator pipe is a funnel-shaped member adapted to cause a swirling movement of a refrigerant gas. Such swirling movement applies a centrifugal force to a lubricating oil contained in the refrigerant gas, thereby separating the lubricating oil from the refrigerant gas. The separator pipe is coaxially press fitted into a separation chamber of the compressor so that an outer periphery of the funnel-shaped member contacts an inner circumferential wall of the oil separation chamber and is affixed thereto.
U.S. Pat. No. 7,736,136 entitled COMPRESSOR INCLUDING SEPARATION TUBE ENGAGEMENT MECHANISM, hereby incorporated herein by reference in its entirety, discloses a separation tube for separating a lubricating oil from a high pressure refrigerant gas. The separation tube is a hollow member having a passageway formed therethrough. The passageway facilitates the flow of the high pressure refrigerant gas to a discharge port. The separation tube is disposed in a separation chamber of a compressor. An upper end of the separation tube is pressed in the separation chamber and in contact with an inner wall of the separation chamber. A movement of the separation tube in an anti-insertion direction is regulated by either engaging a regulating ring with an engagement groove formed in the separation chamber or threading a seal bolt with an inner surface of an opening at an upper end of the separation chamber.
U.S. Pat. App. Pub. No. 2021/0180595 entitled COMPRESSOR MODULE AND ELECTRIC-POWERED REFRIGERANT COMPRESSOR, hereby incorporated herein by reference in its entirety, discloses a separator device for separating a lubricating mixed in with a high pressure refrigerant gas. The separator device has a hollow-cylindrical chamber wall, which forms a separation chamber. A separator is disposed in the separation chamber of the separator device to form an annular space between the separator and the hollow-cylindrical chamber wall of the separator device.
Although the aforementioned structures operate effectively, the structures involve higher manufacturing costs. Additionally, the structures are complex and/or require tight machining tolerances and/or additional components to prevent back-out.
Accordingly, it would be desirable to produce a compressor with a fluid separator, wherein a cost, complexity, and manufacturing requirements of the fluid separator are minimized.
In concordance and agreement with an embodiment of the present disclosure, an improved a fluid separator which is easy to install and may be used in a variety of compressor designs is surprisingly discovered.
In one embodiment, a fluid separator for a compressor, comprises: a main body including at least one retention feature configured to permit the fluid separator to be fixedly positioned in the compressor at a desired location, wherein a fluid separation chamber of the compressor includes a receiving feature configured to receive the at least one retention feature so that movement of the fluid separator is prevented as the fluid separator is axially constrained by shoulders of the compressor formed on each side of the receiving feature.
In another embodiment, a compressor, comprises: a housing including a discharge chamber and a fluid separation chamber, wherein the fluid separation chamber is in communication with the discharge chamber to receive a first fluid having a second fluid suspended therein; and a fluid separator disposed in the fluid separation chamber, wherein the fluid separator includes: a main body including at least one retention feature configured to permit the fluid separator to be fixedly positioned at a desired location within the fluid separation chamber, wherein the fluid separation chamber of the compressor includes a receiving feature configured to receive the at least one retention feature so that movement of the fluid separator is prevented as the fluid separator is axially constrained by shoulders of the compressor formed on each side of the receiving feature.
In yet another embodiment, a compressor, comprises: a housing including a discharge chamber and a fluid separation chamber, wherein the fluid separation chamber is in communication with the discharge chamber to receive a first fluid having a second fluid suspended therein, and wherein the fluid separation chamber includes a channel portion; and a fluid separator disposed in the fluid separation chamber and configured to separate the second fluid from the first fluid, wherein the fluid separator includes at least one retention feature configured to be received in the channel portion of the fluid separation chamber, and wherein movement of the fluid separator is prevented as the at least one retention feature is axially constrained by shoulders formed on opposite sides of the channel portion.
As aspects of some embodiments, the main body further includes at least one aperture formed therein.
As aspects of some embodiments, the at least one retention feature is configured to cooperate with a surface of the compressor to form a substantially fluid-tight seal therebetween.
As aspects of some embodiments, the at least one retention feature is at least one radially outwardly extending protuberance.
As aspects of some embodiments, the at least one retention feature is at least one radially outwardly extending surface element.
As aspects of some embodiments, the at least one retention feature is an annular array of spaced apart surface elements.
As aspects of some embodiments, the at least one retention feature is formed continuously around an outer surface of the main body.
As aspects of some embodiments, the at least one retention feature includes a sloped portion to facilitate installation of the fluid separator in the compressor.
As aspects of some embodiments, the receiving feature is a radially extending channel portion formed in the fluid separation chamber.
As aspects of some embodiments, the fluid separator further includes a tube portion extending outwardly from the main body.
As aspects of some embodiments, the fluid separation chamber includes a cylindrical portion, a frustoconical portion, and a channel portion.
Further details, features and advantages of configurations of the present disclosure emerge from the following description of exemplary embodiments with reference to the associated figures:
The following detailed description and appended drawings describe and illustrate various embodiments of the present disclosure. The description and drawings serve to enable one skilled in the art to make and use the present disclosure, and are not intended to limit the scope of the present disclosure in any manner. In respect of the methods disclosed, the steps presented are exemplary in nature, and thus, the order of the steps is not necessary or critical.
A″ and “an” as used herein indicate “at least one” of the item is present; a plurality of such items may be present, when possible. Spatially relative terms, such as “front,” “back,” “inner,” “outer,” “bottom,” “top,” “horizontal,” “vertical,” “upper,” “lower,” “side,” “above,” “below,” “beneath,” 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.
As used herein, substantially is defined as “to a considerable degree” or “proximate” or as otherwise understood by one ordinarily skilled in the art or as otherwise noted. Except where otherwise expressly indicated, all numerical quantities in this description are to be understood as modified by the word “about” and all geometric and spatial descriptors are to be understood as modified by the word “substantially” in describing the broadest scope of the technology. “About” when applied to numerical values indicates that the calculation or the measurement allows some slight imprecision in the value (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If, for some reason, the imprecision provided by “about” and/or “substantially” is not otherwise understood in the art with this ordinary meaning, then “about” and/or “substantially” as used herein indicates at least variations that may arise from ordinary methods of measuring or using such parameters.
Where any conflict or ambiguity may exist between a document incorporated by reference and this detailed description, the present detailed description controls. 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.
The first housing 11 may have a cylindrical boss 14 protruding from the center of wall 11A of the first housing 11. The shaft support portion 15 typically has an inner cylindrical portion 17 and an outer cylindrical portion 18 connected by a web portion 19. The inner cylindrical portion 17 has a central bore 20 for receiving a rotary shaft 24 therethrough. The compressor 1 has a rotation prevention pin (not depicted) for preventing a movable scroll member 22 from being rotated on its own axis.
The shaft support portion 15 and the boss 14 rotatably support the rotary shaft 24 at the opposite ends 24A, 24B thereof through radial bearings 25, 26, respectively. The bearing 25 has an outer ring 27, an inner ring 28, and a plurality of rollers 29 arranged between the rings 27, 28. The bearing 25 is fitted in the boss 14, rotatably supporting the end 24A of the rotary shaft 24. On the other hand, the bearing 26 is fitted in the shaft support portion 15. The bearing 26 has an outer ring 30, an inner ring 35, and a plurality of rollers 36 arranged between the rings 30, 35. The rotary shaft 24 inserted through the central bore 20 is fitted in the inner ring 35 of the bearing 26, as shown in
As depicted, the second housing 12 may be configured to accommodate therein a fixed scroll member 16. The fixed scroll member 16 has a base wall 16A, a cylindrical peripheral wall 16B, and a fixed scroll wall 16C formed inside the peripheral wall 16B and extending axially outward from the base wall 16A along a central axis of the compressor 1.
On the other hand, the movable scroll member 22 is provided between the shaft support portion 15 and the fixed scroll member 16 and supported by a radial bearing 34. The movable scroll member 22 has a disk-shaped movable base wall 22A and a movable scroll wall 22B extending axially outward from the movable base wall 22A along the central axis of the compressor 1.
The fixed scroll member 16 and the movable scroll member 22 are moveably engaged with each other through the fixed scroll wall 16C and the movable scroll wall 22B. The distal ends of the fixed scroll wall 16C and the movable scroll wall 22B are slidable on the movable base wall 22A and the fixed base wall 16A, respectively.
Compression chambers 38 are formed between the fixed base wall 16A with the fixed scroll wall 16C of the fixed scroll member 16 and the movable base wall 22A with the movable scroll wall 22B of the movable scroll member 22. A backpressure chamber 39 faces to the end 24B of the rotary shaft 24 between the front side of the movable base wall 22A (or the opposite side of the movable base wall 22A from the compression chamber 38) and the shaft support portion 15. Furthermore, the shaft support portion 15, the peripheral wall 16B and the outermost peripheral portion of the movable scroll wall, 22B cooperate to define therebetween a suction chamber 41.
The first housing 11 has formed therein a suction region 42 formed adjacent the shaft support portion 15. The suction region 42 communicates with the suction chamber 41 through a suction passage (not depicted) formed in the shaft support portion 15. In the suction region 42, a stator 44 of an electric motor 40 is fixed on the inner peripheral surface of the first housing 11 and a rotor 45 is located inward of the stator 44 and fixed on the rotary shaft 24. The rotor 45, the stator 44 and the rotary shaft 24 cooperatively form the electric motor 40 and the rotor 45 is rotated integrally with the rotary shaft 24 when electric current is supplied to the stator 44 (when the stator 40 is energized).
The first housing 11 has formed therethrough at a position adjacent to the front end thereof an inlet (not depicted). In certain instances when the compressor 1 is part of a heating, ventilating, and air conditioning (HVAC) system (not depicted), the suction region 42, via the inlet, communicates with an evaporator (not shown) of the HVAC system. The evaporator may further communicate with an expansion valve and a condenser of the HVAC system. A first fluid (i.e., a low-pressure and low-temperature refrigerant gas) in the HVAC system is supplied into the suction chamber 41 through the inlet, the suction region 42 and the suction passage.
A discharge chamber 47 is formed between the fixed base wall 16A and an inner surface of the second housing 12. The fixed base wall 16A has a discharge outlet 48 through which the compression chamber 38 is in fluid communication with the discharge chamber 47. The fixed base wall 16A has a discharge valve (not shown) for opening and closing the discharge outlet 48 and a retainer 49 for regulating an opening degree of the discharge valve.
As shown in
The fluid separation chamber 51 communicates with the backpressure chamber 39 through a fluid passage 57 so that a backpressure flow (i.e., the fluid under a discharge pressure) is supplied to the backpressure chamber 39 through the fluid passage 57. A fluid filter 62 may be fixedly mounted in the fluid passage 57 for removing foreign matters from the second fluid.
The following will describe the operation of the above-described scroll type compressor. When the rotary shaft 24 of the motor 40 is driven to rotate by the operation of a vehicle operator, a pin 31 turns around the axis of the fixed scroll member 16. In this case, the rotation prevention pin is in sliding and rolling contact with the inner surface of the movable scroll member 22 and, accordingly, the rotation of the movable scroll member 22 on its own axis is prevented and the movable scroll member 22 makes an orbital motion around the axis of the rotary shaft 24. Thus, the compression chambers 38 are moved radially inwardly from the outer peripheral side of the fixed and movable scroll members 16, 22 toward their center by the orbital motion of the movable scroll member 22, thereby progressively reducing volume thereof. Therefore, the first fluid introduced into the suction chamber 41 and then the compression chamber 38 from the evaporator through the inlet, the suction region 42 and the suction passage is compressed in the compression chamber 38. The first fluid compressed to a discharge-pressure is discharged through the discharge outlet 48 into the discharge chamber 47 and then flows into the fluid separation chamber 51 through the discharge passage 53. After the second fluid is separated from first fluid by the fluid separator 55 in the fluid separation chamber 51, the first fluid flows from the fluid separation chamber 51 through the discharge port 56 to be discharged from the compressor 1 to the condenser. Thus, the air conditioning for the vehicle is performed.
The second fluid separated from the first fluid falls from the fluid separator 55 to be reserved in the fluid separation chamber 51. The second fluid reserved in the fluid separation chamber 51 is supplied to the backpressure chamber 39 through the fluid passage 57 together with a small amount of the first fluid. While the second fluid passes through the fluid passage 57, foreign matters contained in the second fluid are removed therefrom by the fluid filter 62 so that foreign matters are prevented from being accumulated in a throttle (not depicted) located downstream of the fluid filter 62. A pressure in the backpressure chamber 39 is restricted to a determined pressure by the throttle in the fluid passage 57. The second fluid supplied to the backpressure chamber 39 serves to lubricate any friction-generating components such as the bearing 26, the bearing 34, and the eccentric pin 31, for example, as a part of the drive for the movable scroll member 22. The pressure in the backpressure chamber 39 functions to oppose the pressure in the compression chambers 38 so as to urge the movable scroll member 22 toward the fixed scroll member 16 thereby to reduce sliding resistance between the movable base wall 22A and the shaft support portion 15 and also to secure the airtightness of the compression chambers 38.
As depicted, the fluid separator 155 may be disposed in a fluid separation chamber 151 of the housing 112 of the compressor 100. The fluid separator 155 includes a main body 160. As shown, the main body 160 is substantially cylindrical in shape with at least one aperture 162 formed therethrough. It is understood that the fluid separator 155 may have other shapes as desired. The main body 160 may be produced from a plastic material, although other materials can be used as desired. If formed from a plastic material, advantageously, a weight thereof is minimized.
In some embodiments shown in
In the embodiment of the fluid separator 155 shown in
It is understood that the at least one retention feature 164 may take various other forms such as a plurality of radially outwardly extending and circumferentially continuous rings, an annular array of spaced apart outwardly extending bumps or semi-circular protrusions, an annular array of spaced apart outwardly extending ribs, at least one radially outwardly extending collar formed continuously around the outer surface, or other protuberances, as shown in
The main body 260 includes at least one retention feature 264 formed on an outer peripheral surface 266 thereof. The at least one retention feature 264 cooperates with an inner surface 168 of the separation chamber 151 to form a substantially fluid-tight seal therebetween and militate against blow by or leakage past the fluid separator 255, thereby causing separation of the second fluid and the first fluid to flow through at least one aperture 262 of the fluid separator 255.
As illustrated, the at least one retention feature 264 may be in the form of an annular array of spaced apart outwardly extending surface elements (e.g., protuberances, tabs, and the like). In the embodiment of the fluid separator 255 shown in
The tube portion 280 may also include at least one aperture 282 formed therethrough. The at least one aperture 282 may be axially aligned with at least one aperture 262 of the main body 260. The tube portion 280 may be integrally formed with the main body 260 as a unitary structure as depicted in
In some embodiments, the separation chamber 151 may be formed by a boring operation. In certain embodiments, the boring operation may be accomplished in phases. However, other machining or forming operations or methods may be used as desired. Adjacent the discharge port 156, the separation chamber 151 may be formed by a substantially right circular cylindrical portion 190 having a substantially constant diameter. Adjacent the right circular cylinder portion 190 in a direction away from the discharge port 156, a substantially frustoconical portion 192 may be formed. Adjacent the frustoconical portion 192 in a direction away from the discharge port 156 may be an annular contraction portion 194 and then adjacent thereto in a direction away from the discharge port 156, a receiving feature (i.e., a radially extending channel portion 196). Adjacent the channel portion 196 in a direction away from the discharge port 156 may be a remainder portion 198 of the separation chamber 151. As discussed hereinabove, each of these portions 190, 192, 194, 196, 198 may be formed by the boring operation or other operations or methods. For example, the channel portion 196 may be formed with a T-tool, similar to that used for forming channels for use with snap rings. The channel portion 196 cooperates with the at least one retention feature 164, 264 of the fluid separators 155, 255, respectively, to properly position the fluid separators 155, 255, hold the fluid separators 155, 255 in place, and militate against blow by or leakage of the second fluid past the fluid separators 155, 255. As best seen in
In some embodiments, an inner diameter of each of the discharge port 156 and the cylindrical portion 190 may substantially equal to or slightly larger than an outer diameter of the at least one retention feature 164 to facilitate insertion of the fluid separator 155 into the separation chamber 151. The fluid separator 155 may be inserted manually, automatically or semi-automatically and by hand or with a tool. An inner diameter of the frustoconical portion 192 gradually decreases from the inner diameter of the cylindrical portion 190 to an inner diameter of the contraction portion 194, which has a slightly smaller inner diameter than the outer diameter of the at least one retention feature 164 of the fluid separator 155. An inner diameter of the channel portion 196 may be substantially equal to or slightly larger than the outer diameter of the at least one retention feature 164. An inner diameter of the remainder portion 198 of the separation chamber 151 adjacent the channel portion 196 may be substantially the same as or slightly larger than an outer diameter of the main body 160 of the fluid separator 155, but smaller than the inner diameter of the channel portion 196. Thus, based upon the differences in the inner diameters of the portions 194, 198 of the separation chamber 151 adjacent both sides of the channel portion 196, the at least one retention feature 164 is axially constrained by the shoulders 197, 199 formed on each side of the channel portion 196, thereby effectively locking the fluid separator 155 in place when fully installed. It should be noted that adjusting a location of the channel portion 196 axially one way or the other in the separation chamber 151 to adjust and provide a desired position of the fluid separator 155 relative to the discharge passage 153 and/or the discharge port 156 and/or the fluid passage 57.
An installation of the fluid separation 255 is similar to that described hereinabove for the fluid separator 155.
The compressors 100 having one of the fluid separators 155, 255 with a simplified structure is easy to manufacture, thereby reducing machining tolerances and minimizing production costs. Press fitting, staking, clipping, screwing, and other methods used during assembly and installation in the prior art are not required, reducing part count and overall assembly complexity. The novel fluid separators 155, 255 of the instant patent application can be used in multiple compressors, thereby eliminating the need for a special design for each compressor, thereby further minimizing overall part cost. The retention features 164, 264 of the respective fluid separators 155, 255 in the compressor 100 also provide sealing and prevent bypass of the second fluid within the first fluid to ensure that a sufficient amount of second fluid is supplied from the fluid separation chamber 151 to the various other moving components of the compressor 100, thereby improving a durability of the compressor 100.
From the foregoing description, one ordinarily skilled in the art can easily ascertain the essential characteristics of this present disclosure and, without departing from the spirit and scope thereof, can make various changes and modifications to the present disclosure to adapt it to various usages and conditions.
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 63/502,541, filed May 16, 2023, the entirety of which is herein incorporated by reference.
| Number | Date | Country | |
|---|---|---|---|
| 63502541 | May 2023 | US |
