Scroll compressor having a separate stationary wrap element secured to a frame

BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a scroll compressor generally utilizable in air conditioning equipment for industrial use and home use.
2. Description of Related Art
The motor-driven compressor now in use in refrigerating systems is available in two types; that in which reciprocating pistons are employed and that in which rotary pistons are employed. Both are generally employed in air conditioning systems for industrial and home use and the use thereof is increasing as they have their own advantages and satisfactory performances. Recently, a new version of compressor known as a scroll compressor has gained a wide application because of its low-noise and low-vibration features.
FIG. 5 is a vertical sectional view showing an example of a conventional scroll compressor. As shown therein, a closed container 1 accommodates, in an upper portion thereof, a compression mechanism 2 comprising a stationary scroll 2a and an orbiting scroll 2b which is to undergo circular translation with a variable circular orbiting radius; a thrust bearing 3 for supporting the orbiting scroll 2b; and a bearing member 4 for supporting the thrust bearing 3. The orbiting scroll 2b has a shaft 2c inserted into an eccentric bearing 6 received in a hole 5b, that is defined at an end 5a of a crankshaft 5, so that the crankshaft 5 can drive the orbiting scroll 2b in one direction. An electric motor 7 includes a rotor 7a mounted on the crankshaft 5 for rotation together therewith, and a stator 7b fixed to the closed container 1 by means of shrinkage fit. The rotor 7a and the stator 7b are disposed below the bearing member 4 within the closed container 1. The crankshaft 5 is supported by a main bearing 8 of the bearing member 4 and an auxiliary bearing 23 thereof.
An oil reservoir 10 for accommodating a quantity of lubricating oil 9 is defined at the bottom of the closed container 1. A gas-sucking pipe 11 is provided on a side of the closed container 1. A gas pressure on the suction side acts on a lower portion of the closed container 1 below a spacer 22, whereas a gas pressure on the compression side acts on an upper portion of the closed container 1 above the spacer 22. The bearing member 4 has an oil exhaust port 12 defined therein for exhausting the lubricating oil 9 which has lubricated and cooled the main bearing 8, the auxiliary bearing 23, the eccentric bearing 6, and the thrust bearing 3. The crankshaft 5 has a through-hole 13 defined therein for supplying the lubricating oil 9 to each bearing, namely, the main bearing 8, the auxiliary bearing 23, the eccentric bearing 6, and the thrust bearing 3.
An oil guide 14 is fixed to the lower end of the crankshaft 5 by means of interference fit or by shrinkage fit so as to suck up the lubricating oil 9 from the oil reservoir 10. The closed container 1 further comprises an exhaust chamber 15 defined therein above the stationary scroll 2a and an exhaust pipe 16 for discharging compressed gas to the outside of the closed container 1. The stationary scroll 2a and the bearing member 4 are fastened to each other by bolts with the spacer 22 sandwiched therebetween. The stationary scroll 2a is of one-piece construction having a frame for fixing the stationary scroll 2a to the bearing member 4, and a wrap element integrally formed with the frame. The orbiting scroll 2b also has a wrap element integrally formed therewith. Each of the wrap elements has a spiral or involute shape required to compress gas.
The spacer 22 has its outer periphery fixed to the closed container 1 by welding, thus partitioning the interior of the closed container 1 into a lower portion on which a gas pressure on the suction side acts and an upper portion on which a gas pressure on the compression side acts.
The closed container 1 further comprises a check valve 19 for preventing a reverse rotation of the orbiting scroll 2b when the scroll compressor is stopped; a check valve guide 24 for restricting an axial movement of the check valve 19; an Oldham ring 20 for preventing the orbiting scroll 2b from rotating about its own axis but allowing it to undergo circular translation with respect to the stationary scroll 2a; and a suction port 21, defined in the bearing member 4, for supplying the compression mechanism 2 with low-pressure gas.
The operation of the compression mechanism 2 having the above-described construction will now be described below. The low-pressure gas is returned into the closed container 1 from the gas-sucking pipe 11 and draw into the compression mechanism 2. The orbiting scroll 2b undergoes circular translation with respect to the stationary scroll 2a, thus allowing the compression mechanism 2 to compress the gas drawn thereinto. Consequently, the pressure of the gas rises and enters the exhaust chamber 15. Then, the gas is discharged to the outside of the closed container 1 from the exhaust pipe 16. Low-pressure gas is introduced into the closed container 1 again and circulated therein, thereby completing a single cycle of compression well known to those skilled in the art.
On the other hand, the lubricating oil 9 sucked up by the oil guide 14 moves upward through the through-hole 13 in the crankshaft 5 to lubricate and cool the auxiliary bearing 23, the eccentric bearing 6, the thrust bearing 3, and the main bearing 8. Thereafter, the lubricating oil 9 is exhausted from the oil exhaust port 12 to an upper portion of the stator 7b and, then, returns to the oil reservoir 10 via a cut-out portion 18 of the stator 7b, thereby completing a lubricating cycle.
In order to manufacture a scroll compressor that is highly reliable, highly efficient, and inexpensive, it is important not only to use light component parts, but also select configurations of the component parts appropriate to forces which would act thereon during the use of the scroll compressor. Also, in order to manufacture the scroll compressor having a high efficiency, it is important to configure the wrap elements with high precision. In this respect, the number of processes required to manufacture a desired involute configuration affects the cost of the scroll compressor. Thus, it is necessary to process the wrap elements having a highly precise involute configuration with a high efficiency. In processing the wrap elements, particularly the wrap element of the stationary scroll 2a, the material thereof has a great influence on the process efficiency and process precision of the scroll compressor. Thus, it can be safely said that whether or not a scroll compressor which is inexpensive and highly efficient can be manufactured depends on the selection of the material of the wrap element of the stationary scroll 2a. A material which can be readily processed into the wrap element is costly. Also, in applications where readily processable eutectic graphite cast iron is used for the wrap element, it is difficult to configure the raw material into a desired configuration and, hence, a quantity of raw material more than necessary is required. Thus, the manufacture of an inexpensive scroll compressor cannot be expected.
In the case of the conventional scroll compressor, the stationary scroll comprises the frame for fixing the stationary scroll to the bearing member and to the spacer; and the wrap element having an involute shape required to compress gas. It is to be noted that the frame and the wrap element are integrally formed with each other. Mostly, the stationary scroll is made of cast iron. Formation of the stationary scroll having a complicated configuration causes the cost of the scroll compressor to be high. The selection of an inexpensive casting method necessitates preparation of a thick material, which leads to the formation of a thick stationary scroll. Consequently, the manufacturing cost becomes high due to the weight increase of the stationary scroll, the rise of a material cost, and the increase in machining allowance.
In the case of the conventional scroll compressor, the bearing member supporting the orbiting scroll via the thrust bearing, the spacer, and the stationary scroll are fastened to each other by means of bolts. During the operation of the compressor, force is applied to the stationary scroll and the orbiting scroll in the direction in which both scrolls move away from each other, due to the influence of compressed gas. Consequently, the compressed gas leaks, lowering the efficiency of the scroll compressor. In order to prevent this, a tip seal is provided at the leading end of each scroll. As a result, the manufacturing cost rises owing to the rise of material cost caused by the increase of the number of parts or owing to the increase of portions to be processed and assembled. Thus, the conventional art is incapable of manufacturing an inexpensive scroll compressor.
In addition, the compressed gas having a high temperature and pressure is exhausted to the periphery of the stationary scroll. Thus, the stationary scroll conducts heat from the compressed high-temperature gas, thus heating low-temperature gas introduced into the closed container and gas being compressed by the compression mechanism. Consequently, the efficiency of the scroll compressor is lowered, resulting in a reduction in volumetric efficiency.
The compressed gas having a high pressure flows backward toward the compressed gas having a low pressure when the compressor is stopped. Therefore, a check valve is required to minimize the period of time in which the orbiting scroll and the crankshaft rotate in reverse. It is important to shorten the period of time in which the orbiting scroll and the crankshaft rotate in reverse, so that the scroll compressor is reliable. To this end, it is necessary to dispose the check valve close to the compression mechanism so as to reduce the volume of high-pressure gas flowing backward. In the conventional compressor, the check valve is disposed immediately above the exhaust port of the stationary scroll. Thus, the check valve guide is required to prevent the check valve from being dislocated.
SUMMARY OF THE INVENTION
The present invention has been developed with a view to substantially solving the above described disadvantages and has for its essential objective to provide an inexpensive and reliable scroll compressor having a stationary scroll that is comprised of a frame and a separate wrap element made of a readily machinable material.
In accomplishing the above and other objectives, the scroll compressor according to the present invention comprises a closed container and a compression mechanism accommodated in the closed container and comprising a stationary scroll and an orbiting scroll. The stationary scroll comprises a frame and a separate wrap element secured to the frame. The orbiting scroll has a wrap element allowed to undergo circular translation with respect to the wrap element of the stationary scroll.
The scroll compressor also comprises a thrust bearing for supporting the orbiting scroll; a crankshaft having an eccentric bearing in engagement with a shaft of the orbiting scroll to drive the orbiting scroll; an electric motor comprising a rotor mounted on the crankshaft and a stator mounted inside the closed container; and an oil reservoir for reserving lubricating oil inside the closed container.
The wrap element of the stationary scroll has a spiral or involute shape and is preferably made of a readily machinable material.
The frame and the wrap element of the stationary scroll may be fixed to each other by means of bolts, shrinkage fit or the like.
Advantageously, the material of the frame differs from that of the wrap element of the stationary scroll. The frame may be made of steel, while the wrap element of the stationary scroll may be made of cast iron.
Preferably, the wrap element of the stationary scroll is made of eutectic graphite cast iron, while the frame is made of grey cast iron.
Advantageously, an insulation material is interposed between the frame and the wrap element of the stationary scroll.
Conveniently, a check valve is interposed between the frame and the wrap element of the stationary scroll so as to stop reverse rotation of the orbiting scroll and the crankshaft which occurs immediately after the compressor is stopped. This construction reduces the quantity of high pressure gas flowing backward. The provision of the check valve reduces the number of parts to be installed in the periphery of a check valve guide, thus reducing the manufacturing cost.
Alternatively, the wrap element of the stationary scroll may be axially slidably movable relative to the frame. In this case, the wrap element of the stationary scroll is pressed against the orbiting scroll by making use of high-pressure gas applied to the upper surface of the wrap element.
According to the technical means of the present invention, it is possible to select different materials suitable for the functional characteristics of the wrap element and the frame of the stationary scroll. That is, the wrap element of the stationary scroll may be made of eutectic graphite cast iron which can be processed with high precision, while the frame may be made of steel or grey cast iron having a high strength. Thus, an inexpensive scroll compressor can be provided.
Further, the separated structure of the frame and the wrap element prevents the stationary scroll from conducting heat of compressed gas, having a high pressure and temperature, present in the periphery of the stationary scroll, thus increasing the efficiency of the scroll compressor.
The heat insulation material interposed between the frame and the wrap element prevents the compressed gas from being heated, thus further increasing the efficiency of the scroll compressor.
In addition, the structure in which the wrap element of the stationary scroll is axially slidably movable relative to the frame also contributes to the efficient scroll compressor.

BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objectives and features of the present invention will become more apparent from the following description of a preferred embodiment thereof with reference to the accompanying drawings, throughout which like parts are designated by like reference numerals, and wherein:
FIGS. 1A and 1B are longitudinal sectional views of a scroll compressor according to a first embodiment of the present invention;
FIG. 2 is a longitudinal sectional view of a stationary scroll and elements disposed in the vicinity thereof according to a second embodiment of the present invention;
FIGS. 3A and 3B are views similar to FIG. 2, but according to a third embodiment of the present invention;
FIG. 4 is a view similar to FIG. 2, but according to a fourth embodiment of the present invention; and
FIG. 5 is a longitudinal sectional view of a conventional scroll compressor.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Before the description of the present invention proceeds, it is to be noted that a scroll compressor according to a first embodiment of the present invention is almost the same as that of the conventional scroll compressor shown in FIG. 5 except for the details of a stationary scroll.
Referring now to FIG. 1A, a closed container 1 accommodates, in an upper portion thereof, a compression mechanism 2 comprising a stationary scroll 25a and an orbiting scroll 2b which is to undergo circular translation with a variable circular orbiting radius; a thrust bearing 3 for supporting the orbiting scroll 2b; and a bearing member 4 for supporting the thrust bearing 3. The orbiting scroll 2b has a shaft 2c inserted into an eccentric bearing 6 within a hole 5b defined at an end 5a of a crankshaft 5 so that the orbiting scroll 2b can be driven in one direction by the crankshaft 5.
An electric motor 7 has a rotor 7a mounted on the crankshaft 5 for rotation together therewith and a stator 7b fixed to the closed container 1 by means of shrinkage fit, both of the rotor 7a and the stator 7b being disposed below the bearing member 4. The crankshaft 5 is supported by a main bearing 8 of the bearing member 4 and an auxiliary bearing 23 thereof. An oil reservoir 10 for reserving lubricating oil 9 is defined in the bottom of the closed container 1. A gas-sucking pipe 11 is provided on a side of the closed container 1. A gas pressure on the suction side acts on the portion of the closed container 1 below a spacer 22, whereas a gas pressure on the compression side acts on the portion of the closed container 1 above the spacer 22.
The bearing member 4 has an oil exhaust port 12 defined therein for exhausting the lubricating oil 9 which has been used to lubricate and cool the main bearing 8, the auxiliary bearing 23, the eccentric bearing 6, and the thrust bearing 3. The crankshaft 5 has a through-hole 13 defined therein for supplying the lubricating oil 9 to each bearing, namely, the main bearing 8, the auxiliary bearing 23, the eccentric bearing 6, and the thrust bearing 3. An oil guide 14 is fixed to the lower end of the crankshaft 5 by means of interference fit or by shrinkage fit so as to suck up the lubricating oil 9 from the oil reservoir 10.
The closed container 1 further comprises an exhaust chamber 15 defined therein above the stationary scroll 25a and an exhaust pipe 16 for discharging compressed gas to the outside of the closed container 1. The stationary scroll 25a and the bearing member 4 are fastened to each other by bolts with the spacer 22 sandwiched therebetween.
The stationary scroll 25a comprises a frame 25d for fixing the stationary scroll 25a to the bearing member 4, and a wrap element 25e having a spiral or involute shape required to compress gas. The wrap element 25e is separate from the frame 25d, but is rigidly secured thereto, unlike the conventional scroll compressor.
The orbiting scroll 2b has a wrap element having a spiral or involute shape similar to that of the wrap element 25e of the stationary scroll 25a.
The spacer 22 has its outer periphery fixed to the closed container 1 by welding, thus partitioning from each other a lower portion on which a gas pressure on the suction side acts and an upper portion on which a gas pressure on the compression side acts.
The closed container 1 further comprises a check valve 19 for preventing reverse rotation of the orbiting scroll 2b when the scroll compressor is stopped; a check valve guide 24 for restricting an axial movement of the check valve 19; an Oldham ring 20 for restricting the movement of the orbiting scroll 2b with respect to the stationary scroll 25a; and a suction port 21, defined in the bearing member 4, for supplying the compression mechanism 2 with low-pressure gas. The wrap element of the orbiting scroll 2b and the wrap element 25e of the stationary scroll 25a are maintained in fixed angular relationship to each other by the Oldham ring 20, which however allows the former to undergo circular translation with respect to the latter.
The operation of the compression mechanism 2 having the above-described construction will now be described below. The low-pressure gas is returned into the closed container 1 from the gas-sucking pipe 11 and drawn into the compression mechanism 2. The orbiting scroll 2b undergoes circular translation with respect to the stationary scroll 2a, thus allowing the compression mechanism 2 to compress the gas drawn thereinto. Consequently, the pressure of the gas rises and enters the exhaust chamber 15. Then, the gas is discharged to the outside of the closed container 1 from the exhaust pipe 16. Low-pressure gas is introduced into the closed container 1 again and circulated therein, thereby completing a known single compression cycle.
The frame 25d and the wrap element 25e of the stationary scroll 25a are fixed to each other by shrinkage or expansion fit or fastened to each other by means of bolts via a sealing member such as an O-ring. The wrap element 25e is made of a readily machinable abrasion-resistant material such as eutectic graphite cast iron, aluminum alloy or the like.
Such a material can be readily processed and configured into the wrap element 25e with high precision at a low cost. Because the wrap element 25e is separate from the frame 25d, a small quantity of light-weight material is sufficient for the wrap element 25e. Thus, although the material of the wrap element 25e is expensive, the rise of the material cost is slight. The frame 25d can readily be formed into a desired configuration if steel or the like is employed and, therefore, a strong, light-weight and inexpensive stationary scroll can be manufactured.
As discussed hereinabove, the light and inexpensive stationary scroll can be easily manufactured by employing a material suitable for the functional characteristic of each of the wrap element 25e and the frame 25d separate from the wrap element 25e. Also, a light-weight, inexpensive and reliable frame 25d having a required configuration can be made upon selection of an appropriate manufacturing method. A material such as eutectic graphite cast iron, aluminum alloy or the like can be readily and precisely processed into the efficient and inexpensive wrap element 25e having an involute shape.
In general, not only is any easily machinable material more expensive for a given quantity than any other material, but also the method that can be used to machine the easily machinable material is limited. In addition, if easily machinable eutectic graphite cast iron is used for the wrap element 25e, the freedom of shaping it is very limited, requiring much machining allowance. Because of this, the method required to complete manufacture requires an increased number of process steps. However, the easily machinable material, namely, an expensive material, is used only for the small-sized wrap element 25e. As such, although the easily machinable material is selected to make the wrap element 25e, the total cost for manufacturing the wrap element 25e is lower than that required to make it with the use of an inexpensive material in view of the machinability.
The frame 25d made of steel or grey cast iron and the wrap element 25e made of cast iron or eutectic graphite cast iron have the above-described advantage. As shown in FIG. 1B, a heat insulation material 31 sandwiched between the frame 25d and the wrap element 25e prevents the stationary scroll 25a from conducting heat of compressed gas, having a high pressure and temperature, present in the periphery of the stationary scroll 25a. That is, the heat insulation material 31 prevents the gas introduced into the closed container 1 and the gas being compressed by the compression mechanism 2 from being heated, thus preventing the efficiency of the scroll compressor from being lowered.
A scroll compressor according to a second embodiment of the present invention will now be described below with reference to FIG. 2. The scroll compressor according to the second embodiment is substantially similar to that according to the first embodiment in construction and hence in operation. Thus, the description of the entire construction of the scroll compressor according to the second embodiment is omitted herein and only the construction thereof that differs from that according to the first embodiment will be described below.
A stationary scroll 30a comprises a frame 30d for fixing a stationary scroll 30a to the bearing member 4a, and a wrap element 30e having a spiral or involute shape required to compress gas. The wrap element 30e and the frame 30d are fastened to each other by means of bolts, with a heat insulation material 31 interposed therebetween.
The heat insulation material 31 prevents the gas introduced into the closed container and gas being compressed by the compression mechanism from being heated, thus contributing to the efficient scroll compressor.
A scroll compressor according to a third embodiment of the present invention will now be described below with reference to FIGS. 3A and 3B. The scroll compressor according to the third embodiment is substantially similar to that according to the first embodiment in construction and hence in operation except for the stationary scroll and other elements disposed in the periphery thereof. Thus, the description of the entire construction of the scroll compressor according to the third embodiment is omitted herein, and only the construction thereof that differs from that according to the first embodiment will be described below.
A stationary scroll 26a comprises a frame 26d and a wrap element 26e freely movable relative to the frame 26d in a direction axially thereof. To this end, the wrap element 26e has an insert 26f slidably inserted into an opening 26g defined in the frame 26d.
In operation, the wrap element 26e is pressed against an orbiting scroll 2b by making use of high-pressure gas applied to the upper surface of the wrap element 26e or by the resiliency of a spring (not shown) exceeding the pressure of the compressed gas.
This construction eliminates a gap between the orbiting scroll 2b and the stationary scroll 26a in the axial direction thereof, thus preventing gas leakage. Because of this, the scroll compressor according to the third embodiment of the present invention is highly efficient.
As is the case with the first embodiment of the present invention, the light and inexpensive stationary scroll can be easily manufactured by employing a material suitable for the functional characteristic of each of the wrap element 26e and the frame 26d separate from the wrap element 26e. As shown in FIG. 3B, heat insulation material 31 may be sandwiched between the frame 26d and the wrap element 26e to prevent the stationary scroll 26a from conducting heat of the compressed gas, having a high pressure and temperature, present in the periphery of the stationary scroll 26a. That is, the use of the heat insulation material 31 can effectively prevent the gas introduced into the closed container and the gas being compressed by the compression mechanism from being heated, thus contributing to the efficient scroll compressor.
A scroll compressor according to a fourth embodiment of the present invention will now be described below with reference to FIG. 4. The scroll compressor according to the fourth embodiment is substantially similar to that according to the first embodiment in construction and hence in operation except for a stationary scroll and other elements disposed in the periphery thereof. Thus, the description of the entire construction of the scroll compressor according to the fourth embodiment is omitted herein, and only the construction thereof that differs from that according to the first embodiment will be described below.
A stationary scroll 28a comprises a frame 28d for fixing the stationary scroll 28a to the bearing member 4 and a wrap element 28e rigidly secured to the frame 28d and having a spiral or involute shape required to compress gas. The wrap element 28e has an insert 28f inserted into an opening defined in the frame 28d. A sealing member such as an O-ring is interposed between the frame 28d and the wrap element 28e. A check valve 19 is operatively inserted in a recess 28g defined in the frame 28d at the center thereof, and the movement of the check valve 19 in a direction axially of the stationary scroll 28a is restricted by the frame 28d and the insert 28f of the wrap element 28e. The check valve 19 stops reverse rotation of the orbiting scroll 2b and the crankshaft which occurs immediately after the compressor is stopped.
The above construction minimizes the period of time in which the orbiting scroll 2b and the crankshaft rotate in reverse due to the backward flow of the compressed gas which occurs immediately after the compressor is stopped, thus improving the reliability of the compressor. Further, this construction eliminates the necessity of the check valve guide for restricting the movement of the check valve and check valve-fixing bolts, thus reducing the material cost and manufacturing cost and providing a highly reliable and inexpensive scroll compressor.
As is apparent from the foregoing description, the stationary scroll which is the main component of the compression mechanism comprises the frame for fixing the stationary scroll to the other elements, and the separate wrap element for compressing gas. The wrap element is made of a machinable material. Thus, the efficient high-accuracy scroll compressor of the present invention can be manufactured at a low cost without wasting the raw material.
Further, because the wrap element and the frame are separate from each other, heat transfer therebetween is small. In addition, the heat insulation material sandwiched between the frame and the wrap element prevents the stationary scroll from conducting heat of compressed gas, thus increasing the efficiency of the scroll compressor.
Although the present invention has been fully described by way of examples with reference to the accompanying drawings, it is to be noted here that various changes and modifications will be apparent to those skilled in the art. Therefore, unless such changes and modifications otherwise depart from the spirit and scope of the present invention, they should be construed as being included therein.

Number	Name	Date
3924977	McCullough	Dec 1975
4995789	Fujio	Feb 1991
5044904	Richardson, Jr.	Sep 1991
5106279	Richardson, Jr.	Apr 1992
5277562	Fukuhara et al.	Jan 1994

Number	Date	Country
59-34494	Feb 1984	JPX
59-79089	May 1984	JPX
63-272981	Nov 1988	JPX
2157487	Jun 1990	JPX

Scroll compressor having a separate stationary wrap element secured to a frame

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