WO2020050826A1

WO2020050826A1 - Radial compliance in co-rotating scroll compressors

Info

Publication number: WO2020050826A1
Application number: PCT/US2018/049468
Authority: WO
Inventors: Joe Hill; Gregory Hahn; Jianhui PENG; Gene Fields
Original assignee: Hitachi-Johnson Controls Air Conditioning, Inc.
Priority date: 2018-09-05
Filing date: 2018-09-05
Publication date: 2020-03-12
Also published as: CN112654787A; CN112654787B

Abstract

In some examples, a co-rotating scroll compressor includes a driver scroll having an axis aligned with the main axis and having a spiral involute; an idler scroll having an axis offset from the main axis and having a spiral involute intermeshed with the spiral involute of the driver scroll; an Oldham coupling disposed between the driver scroll and idler scroll; an idler scroll shaft hub fixed to the lower cap and having an axis aligned with the idler scroll axis and having a drive flat, a hub of the idler scroll is disposed on the idler scroll shaft hub fixed to the lower cap; and a circular seal plate.

Description

RADIAL COMPLIANCE IN CO-ROTATING SCROLL COMPRESSORS

TECHNICAL FIELD

[0001] This disclosure relates to the technical field of co-rotating scroll compressors.

BACKGROUND

[0002] Scroll compressors are widely used in refrigerant compression applications including variable refrigerant flow (VRF) systems. A co-rotating scroll compressor includes a driver scroll and an idler scroll and both the driver and idler scroll involute sections on one side, but shaft sections on the opposite sides. The center of each involute is on the center of its respective shaft section. The driver scroll may have a long shaft, and the idler scroll may have a shorter shaft or bearing hub for a shaft. In some implementations, the driver scroll is in the center of the compressor, that is, it is aligned with the central axis or centerline of the compressor, and its rotation is powered by motor components including a rotor and a stator. The idler scroll may be positioned in-line, but an orbit radius offset from the driver scroll. An Oldham coupling is disposed directly between the driver scroll land the idler scroll. In general, the driver scroll rotates the Oldham coupling, and the coupling then rotates the idler scroll. While both scrolls rotate, the relative motion between each is an orbiting motion. Therefore, one involute will orbit with respect to the other involute.

SUMMARY

Some implementations include arrangements and techniques for achieving dynamic radial compliance of a co-rotating scroll compressor at variable speeds. For example, a scroll compressor may comprise a cylindrical housing; a lower cap housing engaging with the cylindrical housing; a main shaft disposed along a main axis; a driver scroll having an axis aligned with the main axis and having a spiral involute; an idler scroll having an axis offset from the main axis and having a spiral involute intermeshed with the spiral involute of the driver scroll; an Oldham coupling disposed between the driver scroll and idler scroll; an idler scroll shaft hub fixed to the lower cap having an axis aligned with the idler scroll axis and having a drive flat with a stationary drive angle, a hub of the idler scroll is disposed on the idler scroll shaft hub fixed to the lower cap; and a circular seal plate disposed above the driver scroll and a circular thrust plate disposed below the idler scroll, wherein the seal plate and the thrust plate are maintained in a parallel state. BRIEF DESCRIPTION OF THE DRAWINGS

[0003] The detailed description is set forth with reference to the accompanying figures. The use of the same reference numbers in different figures indicates similar or identical items or features.

[0004] FIG. 1 illustrates an example of a cross-sectional view of a scroll compressor according to some implementations.

[0005] FIG. 2 illustrates an example of a lower portion of a cross-sectional view of a scroll compressor according to some implementations.

[0006] FIG. 3 illustrates an example of a lower portion of a scroll compressor in an isometric view of a cross-section according to some implementations.

[0007] FIG. 4 illustrates an example of an isometric view of a cross-section of the compressor showing the seal plate, bolts, and thrust plate according to some implementations.

[0008] FIG. 5 illustrates an example of a detailed portion of a cross-sectional view of a compressor showing a seal plate and a bolt according to some implementations.

[0009] FIG. 6 illustrates a side view of an example of a driver scroll of a compressor according to some implementations.

[0010] FIG. 7 illustrates a bottom view of an example of a driver scroll according to some implementations .

[0011] FIG. 8 illustrates a top view of an example of an Oldham coupling of a compressor according to some implementations.

[0012] FIG. 9 illustrates a perspective view of an example of an Oldham coupling of a compressor according to some implementations.

[0013] FIG. 10 illustrates a top view of an example of an idler scroll a compressor according to some implementations.

[0014] FIG. 11 illustrates a side view of an example of an idler scroll of a compressor according to some implementations.

[0015] FIG. 12 illustrates a detailed view of an example of a components of a compressor according to some implementations.

[0016] FIG. 13 illustrates an example of a slider block of a compressor according to some implementations .

[0017] FIG. 14 illustrates an example of a chart showing exemplary dimensions and values of the slider block and associated components according to some implementations. [0018] FIG. 15 illustrates an example of a lower portion of a compressor according to some implementations.

[0019] FIG. 16 illustrates an example of a cross-sectional view of a compressor along the line A- A of FIG. 15.

[0020] FIG. 17. Illustrates an example of a cross-sectional view of a compressor along the line B-B of FIG. 15.

[0021] FIG. 18 illustrates an example of a cross-sectional view of a compressor along the line C-C of FIG. 15.

[0022] FIG. 19 is an illustration of an example of a cross-sectional view of components of a compressor according to some implementations.

[0023] FIG. 20 is an illustration of an example of a cross-sectional view of components of a compressor according to some implementations.

[0024] FIG. 21 is an example of a cross-sectional view of components of a compressor according to some implementations.

[0025] FIG. 22 is detailed view of an example of components shown in FIG. 21 according to some implementations.

[0026] FIG. 23 illustrates an example of a detailed view of a cross-sectional view of components of a compressor according to some implementations.

[0027] FIG. 24 illustrates an example of a cross-sectional view of components of a scroll compressor according to some implementations.

[0028] FIG. 25 shows a cross-sectional view of components of a compressor shown in FIG. 24 along line A-A according to some implementations.

[0029] FIG. 26 illustrates an example of a cross-sectional view of components of a scroll compressor according to some implementations.

[0030] FIG. 27 shows a cross-sectional view of components of a compressor shown in Fig. 26 along line A-A according to some implementations.

DESCRIPTION OF THE EMBODIMENTS

[0031] The respective involutes of the driver scroll and idler scroll fit together as an intermeshing pair of spiral involutes that form crescent shaped pockets of refrigerant gas during operation. In general, during operation, suction gas enters the compressor and then enters an outside area of the scroll pair. The pockets reduce in volume as the orbiting motion occurs, and this compresses the gas to a higher pressure. In some implementations, near the center section, the compression pockets reach a discharge port in the driver scroll and the high pressure gas exits through this port. In some implementations, the compressor is a“high side” design, where suction gas enters directly into the compression chamber and most of the volume inside the compressor housing is at discharge pressure.

[0032] Radial compliance in a co-rotating scroll compressor will allow operation consistently from low speeds to very high speeds. The compliant mechanism will also provide journal bearing tolerance from shaft deflections due to the centrifugal and gas pressure forces. The existence of radial compliance could allow the minimization of clearance between the slider block and idler scroll bearing, which would then allow minimizing the oil flow into suction. For example, the radial compliance mechanisms may include the shaft pin with a drive flat at an angle of Q, with respect to the idler scroll coordinate axis, the corresponding slider block, and the idler scroll bearing and hub.

[0033] Under high loads the main shaft of conventional variable speed scroll compressors can experience bending. The load includes both a gas pressure force and, at very high speeds, for example, a centrifugal force of the orbiting scroll mass. The radial compliant mechanisms will also provide journal bearing tolerance from shaft deflections due to the centrifugal and gas pressure forces. During variable speed operation optimum compression is achieved, in part, by maintaining appropriate involute contact between the fixed scroll and orbiting scroll, in conventional designs, and driver scroll and the idler scroll in the following techniques and design. Further, one objective of variable speed compressors may be to normalize the scroll flank force to be more constant at all speeds. In conventional scroll compressor designs, the tangential gas, radial gas, and centrifugal force vectors rotate with respect to the center axis. Conversely, these vectors in a co-rotating scroll compressor have constant direction, with respect to a center axis.

[0034] Additionally, the various techniques and structures described herein may provide lubrication such as oil, to the idler scroll bearing and crown on the slider block drive flat, minimize/optimize the friction force between the bottom of the slider block and the idler shaft hub, where the seal is located, and minimize/optimize the amount of high pressure oil that is expelled into the low side of the compressor. In some implementations, the slider block seal will control the amount of oil that passes into the low side, as well as define the stabilizing load of the slider block against the idler shaft hub. Further, during operation the radial compliance may allow the minimization of clearance between the slider block and idler scroll bearing, which would then allow minimizing the oil flow into suction. [0035] In general, some of the techniques discussed herein provide radial compliance to produce a relatively constant involute wall contact regardless of operating condition and speed. Fig. 1 illustrates an example of a cross-sectional view of a scroll compressor 1 according to some implementations. The body or housing of the compressor may include an upper cap 2, center shell 4, and lower cap or base 6. These components may be press fit together, as shown in portions 12 and 14. The upper cap 2, center shell 4, and lower cap 6 may have generally circular profiles. The lower cap 6 may essentially be bowl-shaped having vertical extending edges or rims that are essentially parallel to the main axis or centerline of driver scroll 96. The lower cap 6 may have an open end or face into which components of the compressor are assembled or disposed. The center shell 4 may essentially be cylindrical having an axis parallel to the main axis 96 and may be concentric to the bore(s) of the one or more bearings on the main shaft or driver scroll shaft 20, such as the main bearing 24 and/or a lower bearing or idler scroll bearing 94. The center shell 4 has open top and bottom ends and may be referred to as a“case.” The upper cap 2 may essentially be a bowl-shaped having vertical edges or rims that are essentially parallel to the main axis 96. The lower cap 6 has an open end or face which houses components of the compressor once pressed in place during assembly that may include, for example, components of the compression mechanism or compression unit, such as the driver scroll 50 and the idler scroll 80 and associated components. The center shell 4 may be sheet metal or steel tubing or the like. The upper cap 2, center shell 4, and lower cap 5 may be made of low carbon steel. Further the scroll compressor 1 may be hermetically sealed from the ambient surroundings, but the techniques described herein may also be applied to a semi-hermetic scroll design, without loss in performance. As shown, a hermetic terminal 40 may be disposed in the center shell 4 or alternatively in the upper cap 2.

[0036] In some implementations, the entire compressor chamber above the main frame 26, such as the high chamber 28, contains high-pressure discharge gas, the motor components (e.g., motor stator 16 and motor rotor 18), and the upper bearing 22 assembly. This chamber may also contain the oil sump or reservoir 42, which may essentially be between the main frame 26 and the motor components. The chamber below the main frame 26 may contain the low pressure suction gas, the compression mechanisms (e.g., driver scroll 50 and idler scroll 80) one or more of the radial compliance features (e.g., the shaft pin with a drive flat at an angle of Q, with respect to the idler scroll coordinate axis, the corresponding slider block 264, and the idler scroll bearing 94 and hub 260 (described below)), and some of the oil in the compressor due to natural leakage through the bearings. In some implementations a seal 44 is disposed around the driver scroll shaft 20 to seal the main frame 26.

[0037] Further, an upper bearing plate 32 may be disposed with a portion around the upper bearing 22 and fanning upward and out toward the upper cap 2. The upper bearing plate 32 may include apertures such as a first set of apertures 38 and a second set of apertures 36. An oil separator dome 34 may also be disposed essentially in the upper cap 2 and above the upper bearing plate 32. In some implementations, the oil separator dome 34 may contact or be connected to the upper bearing plate 32. For example, the discharge gas that exits the driver scroll, contains both gas and entrapped oil. The dome 34 may reverse the discharge flow and the mixture exits through apertures 38, in a downward direction. Since the discharge fitting 10 is the exit for compressed gas from the compressor, the downward flow direction of the fluid is reversed; and flows through the apertures 36 to reach the discharge fitting. Because of the reverse flow direction between apertures 38 and 36, most of the entrapped oil in the fluid is separated from the gas.

[0038] A suction inlet 8 may be disposed in the lower cap 6 to suction a refrigerant gas or or a mixture of liquid and gas and a discharge outlet 10 may be disposed in an upper cap 2. In the example shown in Fig. 1 the refrigerant is suctioned directly into the compression chamber formed by the intermeshing of involutes of the driver scroll 50 and idler scroll 80, and most of the interior of the housing is at a discharge pressure, which may be known as a “high side” compressor.

[0039] A drive scroll shaft or main shaft 20 is aligned with the main axis 96 and as mentioned above may be supported by at least a main bearing 24 and the upper bearing 22, such that the main axis 96 may be rotated up to very high speeds by the rotor 18, operating inside stator 16. The lower bearing or idler scroll bearing 94 may be disposed inside a hub section of the idler scroll 80. Further, the main frame 26 may be press fit inside center shell 4. Since the main bearing 24 is concentric with the main frame pressing diameter, the driver scroll/ main shaft 20 will then be aligned concentrically with the stator 16. Upon operation, the stator 16 imparts a magnetic field such that the rotor 18 will spin and produce high power for compressing the gas in the compression unit, e.g., compression pockets of gas formed by the intermeshing of the spiral involute of the driver scroll 50 and the spiral involute of the idler scroll 80 upon operation. In some implementations, the motor (e.g., rotor 18 and stator 16) may contain a special winding design for the stator 16, as well as a rotor 18 with permanent magnets. [0040] As shown in Fig. 1 and discussed in further detail below, a seal plate 60 may be disposed on top of a first surface of the driver scroll plate 52 in some implementations. An Oldham coupling 70 may be disposed between the driver scroll 50 and the idler scroll 80 and a thrust plate 66 may be disposed below the idler scroll plate 80 in some implementations. Further, in some examples, the seal plate 60 is attached to the thrust plate 66 by one or more bolts 62 (e.g., 4 equally spaced shoulder blots). Additionally, the compressor 1 may include an oil supply tube 92 that supplies discharge pressure oil from the high side above the main frame 26.

[0041] Fig. 2 illustrates an example of a lower portion of a cross-sectional view of a scroll compressor according to some implementations. As shown in Fig. 2, the compression mechanisms, which may include the driver scroll 50 and the idler scroll 80 are disposed below the main frame 26. The driver scroll 50 includes a spiral involute extending downward from a lower surface or bottom surface 53 of the driver scroll plate 52. The spiral involute of the idler scroll 80 extend upwards from an upper surface or top surface 81 of the idler scroll plate 82 to intermesh with the involute of the driver scroll 50. As mentioned, the driver scroll 50 axis is on the main axis 96 of the compressor and in some implementations is aligned with at least the upper bearing 22, stator 16, rotor, 18 and main bearing 24. According to some examples, the idler scroll 80 axis is offset 98 from the main axis 96 (as shown in Fig. 1) and may be disposed at a distance equal to the orbit radius of the two involutes.

[0042] A discharge port or hole 202 may be disposed in the driver scroll 50 for discharging compressed gas. A main bearing 24 may be disposed concentrically on the driver scroll shaft 50 and in between the main frame 26 and the driver scroll shaft 20. In some implementations, the main bearing 24 is disposed below the shaft seal 44 and above a thrust washer 212. In some implementations, the driver scroll 50 load is primarily carried by the main bearing 24. The thrust washer 212 may be disposed between the driver scroll plate 52 and the main frame 26. Further, the main bearing 24 may be pressed into the main frame 26 and the driver scroll shaft 20 rotates within the main bearing 26.

[0043] In some implementations and as shown in Fig. 2, an Oldham coupling 70 may be disposed directly between each scroll member (e.g., the driver scroll 50 and the idler scroll 80) and may rest on the idler scroll plate 82. The axis keys of the Oldham coupling 70 are engaged between the driver scroll 50 and the idler scroll 80. In general, as the driver shaft 20 rotates, the driver scroll 50 rotates the Oldham coupling 70, and the Oldham coupling 70 then rotates the idler scroll 80. The Oldham 70 coupling transfers motion from the driver scroll 50 to the idler scroll 80. Accordingly, during operation, while the driver scroll 50 and the idler scrolls 80 rotate, the relative motion between each is a circular orbiting motion. Therefore, during operation one involute will orbit with respect to the other involute.

[0044] In some implementations, the idler scroll 80 includes an idler scroll hub 256 that extends in a downward direction from a lower surface or bottom surface 83 of the idler scroll plate 82. The idler scroll hub 256 may be disposed around the idler scroll bearing 94. Further, the idler scroll hub 256 and the idler scroll bearing 94 may be aligned with the idler scroll axis offset 98, through the idler scroll shaft 260 and the slider block 264. In some implementations, the idler scroll 80 load is primarily carried by the idler scroll bearing 94 and the idler scroll bearing 94 may be pressed into the idler scroll hub 256 and rotates around the essentially stationary slider block 264. The slider block 264 serves as a compliant shaft journal and has a drive flat (discussed below) that is positioned with respect to an idler axis coordinate, at a drive angle Q, which effectively adds adequate flank contact force from the Ftg (tangential gas) vector to minimize leakage.

[0045] As is discussed in further detail below, the idler scroll bearing 94 and a crown on the slider block 264 drive flat are lubricated with oil. The slider block 264, in some implementations may be a sintered, hardened, and ground component, which forms a journal for the idler scroll bearing 94.

[0046] Fig. 2 further shows that in some examples, an idler shaft hub 260 may be welded, by resistance welding, for example, to the lower cap 6 and may have one or more protrusions extending downward to be welded. The idler scroll hub 256, slider block 26, and idler scroll bearing 94 are each essentially aligned with the idler shaft hub 260. These components“self align,” to the idler scroll axis offset of Fig 1. While the offset is essentially a calculated value, based on the scroll involute geometry, the actual value will be established by the radial compliance mechanism, which will be described in detail.

[0047] A slider block seal 262 may be disposed at a lower portion of the slider block 264 and may form a seal at an upper surface of the base portion of the idler shaft hub 260. The slider block sea 2621 may control an amount of oil that passes into the low side of the compressor as well as define a stabilizing load of the slider block 264 against the idler shaft hub 260.

[0048] Further, in some implementations, a lubricant such as oil may be supplied to the lower portion of the compressor by an oil supply tube 92 that may be sealed 210 into the main frame 26 and/or sealed into the idler shaft hub 260. According to some implementations, discharge pressure oil may be supplied underneath the idler scroll hub 256 or shaft; such that the shaft 256 or hub becomes similar to a rotating piston. This is because the idler shaft hub 260 and the slider block 264 are essentially a non-rotating piston, and the idler scroll bearing 94 and idler scroll hub 256 are essentially a rotating cylinder for the stationary piston. In some implementations, both the driver scroll 50 and the idler scroll 80 have oil pressurized by discharge pressure applied to them, except the driver scroll force will always have discharge pressure gas v. the idler with discharge pressure oil. Therefore, this implementation is to apply the optimum axial gas force to contain the scroll compression, as well as effectively cancel the downward force of the driver scroll. The oil supply tube 92 is one example for conveying the pressurized oil.

[0049] Fig. 2 further shows one or more oil injection paths 274 of idler scroll plate 82, which are explained in more detail below. With respect to axial compliance, because the driver scroll shaft 20 is located in the high side of the compressor, a downward force of discharge pressure (Pd) times the area of the shaft 20 diameter is produced. Therefore, the diameter of the driver scroll shaft 20 is important to the axial compliant force, as well as the strength and deflection considerations. The discharge pressure force component for axial compliance may be accomplished by specifying the diameter of the driver scroll shaft 20. The diameter of the driver scroll shaft is selected for optimum load carrying capability as well as the associated journal bearing, and the adequate hydrodynamic oil film. Therefore, the piston diameter effect of discharge pressure force is essentially a result of the shaft bearing selection. For example, a shaft 20 diameter of 28mm for a compressor capability of lOhp. It should be noted that essentially all axial compliant scroll designs contain a force produced by discharge pressure x area, as well as a force produced by (compressed suction) intermediate pressure x a different area. These two forces are then optimized for all operating conditions. Additionally, in an attempt to maintain axial compliance, some implementations may include a seal plate 60 which will contain compressed suction intermediate gas pressure, disposed above a top surface or upper surface 51 of the driver scroll plate 52, in the low side chamber. The seal plate 60 may have one or more annual grooves 253, 255 in which corresponding inner seal 252 and outer seal 254 may engage with to form a sealed chamber during operation. In some examples, the grooves or channels may be disposed in the top surface 51 of the driver scroll plate 52. Additionally, in some examples, the inner seal 252 and/or the outer seal 254 may be fixed to the surface of the driver scroll plate. In some instances, the seal plate 60 may be attached to a thrust plate 66, by one or more bolts 62 and in some examples four equally-spaced bolts 62 are disposed. The body of a bolt 62 may be a precision ground diameter and length. Further, the bolts 62 may be equally spaced in precise positions, and these are carried downward through the driver scroll plate 52 and rigidly into the thrust plate 66. In some examples, the bolts 62 have a precision slip fit through the seal plate 60, as well as the driver scroll plate 52.

[0050] In some examples, between the seal plate 60 and the top surface or upper surface 51 of the driver scroll base plate 52, there is a specific clearance 280 and this may be accounted for in the overall length of the bolts 62. Additionally, there may be a specific clearance 280 between the top surfaces of the driver scroll plate 51 and the bottom surface of the seal plate 63 and this clearance may depend on the length of the bolts 62. This clearance is required such that the seals 252, 254 can extend upward and make contact between the driver scroll plate 52 and the seal plate 60, and the differential pressure across the respective seals 252, 254 causes this to occur. Further, there may be a clearance or gap between the top surface of the respective seals 252, 254 and the bottom surface of the respective grooves 253, 255 that the top surface of the seals 252, 254 face. Depending on the type of seals, the clearance could be from 120 - 200 micron. In some examples, the seal application is static, because there is no spinning or orbiting motion between the driver scroll plate 52 and the seal plate 60. In some implementations, the pressure between the inner seal 252 and outer seal 254 is less than the discharge pressure. In some implementations, the inner seal 252 and outer seal 254 may be a spring loaded face-type. Further, during operation, a back chamber force may be produced between the inner seal 252 and outer seal 254 of the seal plate 60 and the gas pressure inside the back chamber is higher than outside of an area between the inner seal 252 and outer seal 254, which is suction pressure Ps.

[0051] In some implementations, a thrust plate 66 may be disposed concentric with the driver scroll axis 96. The thrust plate 66 may be disposed underneath the lower surface or bottom surface 83 of the idler scroll plate 82. Further, corresponding holes for the one or more bolts 62 are disposed in the thrust plate 66, which are described in more detail below. In general, the thrust plate 66 may rotate around the driver scroll axis 20, and the idler scroll 80 on its own axis. Also, as is explained in more detail below, the driver scroll plate 52 may further include one or more radial and horizontal passages (e.g., passages 220, 222, 224) for compressed suction gas, for example. Additionally, the idler scroll 80 may be loaded against and orbit directly between the top of the thrust plate 66 and the involute floor surface of the driver scroll 50.

[0052] Fig. 3 illustrates an example of a lower portion of a scroll compressor in an isometric view of a cross-section according to some implementations. As mentioned, one or more passages (e.g., passages 220, 222, 224 for compressed suction gas passages may be disposed in the driver scroll base plate 52 and these passages may be a hole or other cavity drilled or otherwise created in the driver scroll plate 52. The passages may open to each other or otherwise intersect to create a flow of gas under pressure through the driver scroll plate 52. Fig. 3 also shows an exit passage or hole 21 in the driver scroll 50. In some implementations, a hole 320 may be drilled or otherwise created radially in the idler scroll plate 82 to balance the idler scroll 80. This hole may be plugged. Additionally, as shown in Fig. 3, a mounting portion or base 330 may be attached to the lower cap 6.

[0053] For example, the passages in the driver scroll base plate 52 may include a first radial passage 222, a first axial passage 220, and a second axial passage 224. The first radial passage 222 may have a radius greater than the respective radii of the axial passages 220, 224 in the driver scroll plate 52. Also, the outer radial extent of the first radial passage 222 may be plugged with a plug 221.

[0054] A first axial passage 220 may intersect with the first radial passage 222 at one opening and may be disposed between the inner seal 252 and outer seal 254. That is, the other opening of the first axial passage 220 may open between the inner seal 252 and outer seal 254.

[0055] Further, a second axial passage 224 that intersects with the first radial passage 222 may be disposed inward of the first radial passage 222 in the radial direction. That is, one opening of the second axial passage 224 may open and intersect with the first radial passage 222 and the other opening of the second axial passage 224 may open into the floor between involute walls of the driver scroll 50 involute. During operation, this opening allows compressed suction gas source to be supplied and the position of this opening should be precise within the involute geometry to obtain the required pressure. During operation, the corresponding involute of the idler scroll 50 passes back and forth over this hole or opening, opening to different pressures in each pocket. For this reason, the diameter of this hole is small (small compared to the other opening of this passage. In some implementations, the first radial passage 222 may be 3mm, the second axial passage 224 may be .7mm, and the first axial passage 220 into seal chamber may be 2mm. The hole or opening of the first axial passage 222 that is between the inner seal 252 and outer seal 254 is may be less than the opening to the compression pocket of the second axial passage 224, to minimize the transient back flow.

[0056] For example, the source of compressed suction gas enters second axial passage 224. This gas cycles from low to high pressure, as the compression involute pockets actually orbit. The second axial passage 224 starts out at the lowest pressure in a pocket, then increases to the highest pressure, before the adjacent involute wall of the driver scroll 50 passes over the second axial passage 224. Then a new low pressure enters the second axial passage 224. The diameter of first axial passage 220 is essentially very small, and this greatly limits the sinusoidal pressure variation inside the compressed suction gas chamber. It essentially averages the high and low pressure variation.

[0057] In some implementations, the driver scroll plate 52 includes two Oldham key support extensions 302 spaced equally apart around the driver scroll plate 52 and extending downward from the bottom surface or lower surface 83 of the driver scroll plate 52. The Oldham key support extensions 302 enable the Oldham coupling 70 to fit between the scrolls, and directly engage each scroll base plate to rotate in near perfect alignment. The Oldham key support extensions 302 may not extend downward from the second lower surface or bottom surface 83 of the driver scroll base plate as much as the involute extends downward. Further, the outer face of the Oldham key support extension 302 may be flush with an outer surface of the driver scroll plate 52. Disposed within each key support extension 302 is a slot 310 for engaging with a driver scroll key (described below) of the Oldham coupling 70 having a corresponding shape to the slot 310. Additionally, there is adequate clearance between the inner face of the key support extension 302 and the outer wall of the involute.

[0058] As shown in Fig. 3, the seal plate 66 has an outer annular groove or channel 255 and inner annular groove or channel 253 disposed in a bottom or lower surface of the seal plate 66. The outer groove 255 and inner groove 253 correspond with the outer seal 254 and inner seal 252, respectively. According to some examples, the outer seal 254 and inner seal 252 are annular protrusions, extensions, or ridges protruding from the top surface or upper surface 51 of the driver scroll plate 52.

[0059] Fig. 4 illustrates an example of an isometric view of a cross-section of the compressor showing the seal plate, bolts, and thrust plate according to some implementations. In some implementations, the seal plate 66 may be essentially disk shaped having a bore 422 of an inner diameter that is concentric with respect to the driver scroll shaft 20 and an axial portion of the main frame 26. The first surface or top surface 61 and lower or bottom surface 63 of the seal plate 66 may be flat and parallel. Further, one or more holes 410 may be disposed through the seal plate to accommodate a bolt 62, as shown. The holes 410 (and bolts 62) may be equally spaced apart.

[0060] In some implementations, each bolt 62 penetrates through the seal plate 60 and each bolt 62 may have a head or shoulder 64 that remains above the top surface 61 and may contact the top surface 61. Further the bolts 62 may have a precision slip fit through the hole 410 of the seal plate 66.

[0061] As mentioned above, the seal plate 60 may have one or more annual grooves, such as the inner seal groove 253 and outer seal groove 255, which in some implementations, are both between the one or more bolts 62 and the bore 422 in the radial dimension. A back chamber force may be produced from gas supplied from one or more gas passages 220, 222, 224 in driver scroll plate 52. The seal plate 60 provides an annular area between the inner seal 252 and outer seal 254. Compressed suction gas enters the chamber defined by these two seals 252, 254, and the lower surface of the seal plate 63 and the upper surface of the driver scroll plate 51. This in turn produces a force from pressure x area. Additionally, the nature of the seals 252, 254 between the driver scroll plate 52 and the seal plate 60 may allow some deflection due to bending forces on the driver scroll 50 produced by the gas compression.

[0062] In some examples, the thrust plate 66 may be disk shaped having a bore 430 of an inner diameter that may be the same diameter as the bore 422 of the seal plate, may be greater or may be less than the diameter of the bore of the seal plate 422 as long as the bore 430 is concentric with respect to the idler scroll hub 256.

[0063] The first surface or top surface 406 and lower or bottom surface 408 of the thrust plate may be flat and parallel. The top surface 406 may have a ground finish, since there may be a high thrust load against the lower surface of the idler scroll plate 83. Further, one or more holes 434 may be disposed through the thrust plate to accommodate a bolt, as shown. The holes 434 (and bolts 62) may be equally spaced apart.

[0064] In some implementations, each bolt 62 penetrates through the thrust plate 66 such that an end of each bolt is below the bottom surface. Further the bolts 62 may have a precision slip fit through the holes 410 of seal plate 60. In some examples, the bolts 62 may be threaded into the thrust plate 66. Additionally, in some examples, the bolts 62 may be threaded into the seal plate 60 and a head 64 of the bolt 62 may protrude below the thrust plate 66.

[0065] Additionally, in some implementations, the seal plate 60 and the thrust plate 66 are parallel to one another and the thrust plate 66 maintains parallelism with the lower surface or bottom surface 83 of the idler scroll, in order to support the oil film pressure.

[0066] When the one or more bolts 62 are tightened, there may be a specific length from each bolt head 64 to the upper surface 406 of the thrust plate 66. One aspect of the parallelism between the seal plate 60 and the thrust plate 66 is to avoid idler scroll thrust lubrication issues due to deflection. In some examples, the idler scroll 80 must maintain face to face contact with the driver scroll while 50 compressing gas; therefore the pull force of the seal plate 60 must transmit into an upward force from the thrust plate 66, which is parallel to the scroll set tip-to-floor contact axis. For example, when any type of axially compliant scroll compressor is in operation, an external gas pressure force is applied to one of the scrolls, and the other is fixed from moving in some way. In our case, the idler scroll 80 is pushed into the driver scroll 50, by the thrust plate 66 below the idler scroll 80. The design objective is for the planes of respective involute tips 54, 84 and floors (i.e., bottom or lower surface of driver scroll plate 53 and top or upper surface of idler scroll plate 81) to make complete contact. For example, the tip of the driver scroll involute 54 will make contact with the floor of the idler scroll involute 81. The tip of the idler scroll involute 84 will make contact with the floor of the driver scroll 53. This thrust force of tip and floor is significant and must be adequate at all operating conditions; but not enough to damage the surfaces 53, 81.

[0067] Fig. 5 illustrates an example of a detailed portion of a cross-sectional view of a compressor showing a seal plate and a bolt according to some implementations. As shown in Fig. 5, the one or more holes or bores 410 through the seal plate 60 for the respective bolts 62 may have an arched, crown, or“hour glass” shape 440 such that the openings of the hole 410 have a greater inner diameter than a center of the hole 440, according to some implementations. The change in diameter may be gradual and may be symmetrical such that the top of the hole 410 has the same inner diameter as the bottom of the hole 410, for example. Further, this hour-glass shaped bore or hole 410 may also be the shape of the one or more holes or bores through the driver scroll plate. This feature may provide some compliance in the parallelism of the seal plate 60 and thrust plate 66, due to inherent deflections of the scroll components under load. [0068] Fig. 6 illustrates a side view of an example of a driver scroll of a compressor according to some implementations. Fig. 7 illustrates a bottom view of an example of a driver scroll according to some implementations. As shown in Fig. 6, the driver scroll shaft 20 extends from the first or top surface 51 of the driver scroll plate 52 and near a top end of the driver scroll shaft 20 an upper bearing journal 602 which may have a lubrication flat 604 is disposed. In some implementations, one or more balance holes 610 may be bored or drilled into the outer diameter 603 of the driver scroll plate 52. Additionally, in some examples, two Oldham key support extensions 302 may extend from the bottom or lower surface 53 of the driver scroll plate 52, which as mentioned above, may include an Oldham key slot 310, which may have a floor section or surface.

[0069] In some implementations, extending downward in the axial direction from the outer diameter 603 of the driver scroll plate 52 and flush with the outer diameter 603 of the driver scroll plate 52 may be one or more arc structures 620, 624 which wrap as arc-shape structures around portions of the outer circumference 603 of the driver scroll 50. In some implementations, the arc structures 620, 624 may have a radial depth that is less than a radial depth of the one or more Oldham key support extensions 302. Additionally, as shown, one or more of the arc structures 620,624 may extend downward in the axial direction further than one or more of the Oldham key support extensions 302.

[0070] As mentioned above, the driver scroll plate 52 has a spiral involute 650 extending downward from the bottom surface 53 of the plate. The bottom surface or tip 54 of the involute may be in the same plane as the bottom surface 621 of the respective arc sections 620, 624. That is, the bottom surface or tip 54 of the involute may not extend lower than respective bottom surfaces 621 of the arc structures 620, 624, in some implementations. In some implementations, the bottom surface 54 of the involute and the bottom surface 621 of the one or more arc structures are machined at the same time.

[0071] The arc structures 620, 624 may have different arc lengths and sizes. Further, between one arc structure 620 and another arc structure 624 a gap 622 may exist which may be a space for a bolt hole 640 and the bolt 62, upon assembly. Another gap 626 may exist between adjacent arc structures 620 and this gap 626 may have a greater arc length than the previously mentioned gap 622. An Oldham key support extension 302 may also be disposed in a gap between two arc structures 302. Additionally, the lower bottom facing surface 621 of each of the arc structures may be in the same plane. [0072] Further, the arc structures 620, 624 on the outer edge 603 of the driver scroll plate 52 may counter the tipping moment produced by tangential gas forces Ftg. In some implementations, the arc sections provide a 13-23% gain in stability and this can be utilized for power reduction and high compressor performance. As further shown in Fig. 7, one or more holes 640 may be disposed in the driver scroll plate between respective gaps 622 of respective arc structures (e.g., 620, 624).

[0073] Fig. 8 illustrates a top view of an example of an Oldham coupling of a compressor according to some implementations. Fig. 9 illustrates a perspective view of an example of an Oldham coupling of a compressor according to some implementations.

[0074] In some implementations, the Oldham coupling 70 includes one or more driver scroll keys 802 each having a portion 806 extending upward from a top surface of a base portion extending outward 808 from the outer surface of the Oldham coupling 70. As shown, the portions 806, 808 may have a shape corresponding to the Oldham key slot 310 in an Oldham key support extension 302 of the driver scroll plate 52.

[0075] Additionally, in some implementations, one or more idler scroll keys 804 may be disposed each having a portion 810 extending downward from a bottom surface portion 804 extending outward from the outer surface thereof. The portions 804, 810 may have a shape corresponding to the idler scroll Oldham key slots of the idler scroll plate 82 (discussed below).

[0076] The Oldham coupling 70 may be produced as die cast aluminum, followed by machining the necessary surfaces for operation. As mentioned above, the Oldham coupling 70 essentially maintains the involute coordinate axis between the orbiting and fixed scroll involutes. Upon operation, for example, the driver scroll 50 rotates and this motion is then transferred to the respective Oldham keys, which in turn rotates the Oldham coupling 70. While it rotates with the driver scroll 50, there is an orbiting motion of the Oldham coupling 70, the same as with the involute orbit motion. From this point, the idler scroll keys then rotate the idler scroll 80 in harmony with the driver scroll 50.

[0077] Fig. 10 illustrates a top view of an example of an idler scroll a compressor according to some implementations. Fig. 11 illustrates a side view of an example of an idler scroll of a compressor according to some implementations. As discussed above, an involute extends upward from a top surface 81 of the idler scroll base plate 82. Further, in some implementations, one or more indentations, cut-outs, grooves, or clearances 1020 are disposed in the outer edge or diameter 1004 of the idler scroll plate 82. The clearances 1020 are spaces for the bolts 62 to extend past the outer diameter or edge 1004 of the idler scroll plate to the thrust plate 66. Accordingly, during operation of gas compression, the idler scroll plate 82 does not contact the bolts 62. The one or more clearances 1020 are shown as curved surfaces, but some implementations may include other shapes, such as corners or straight edges.

[0078] Additionally, according to some implementations, one or more idler scroll Oldham key slots 1006 may be disposed in the outer edge or diameter 1004 of the idler scroll plate. The Oldham key slots 1006 may essentially be grooves, cut-outs or indentations and may essentially be U-shaped or have another shape corresponding to the idler scroll key portions 804, 810. Further, the Oldham key slots 1006 have floor sections or structures 1008 such that the key slot does not penetrate the entire way through the idler scroll plate and the bottom surface 1003 of the idler scroll plate is uninterrupted to ensure lubrication against the thrust plate.

[0079] As shown in Fig. 11, one or more balance holes or bores 320 extending inwardly in the radial direction may be drilled or otherwise created in the idler scroll plate. Fig. 11 also shows the idler scroll involute 1030 extending upwardly from the top surface 81 and the idler scroll hub 256 extending downward in the axial direction from the bottom surface 83 of the idler scroll plate 82.

[0080] Fig. 12 illustrates a detailed view of an example of components of a compressor according to some implementations. As mentioned above, the idler scroll hub 256 extends from a bottom surface 83 of the idler scroll plate 82 essentially perpendicularly. As also mentioned, between the slider block 264 and the idler shaft hub 260 is an idler scroll bearing 94. Additionally, in some implementations, there is a clearance 1205 between a portion of the bottom surface 1203 of the idler scroll plate 52 and the top surface 1204 of the slider block. Further, in some implementations a seal 262 for the slider block 264 is disposed within and around a bottom surface 1206 of the slider block 264. As mentioned, in some implementations, discharge pressure oil is applied below the idler scroll shaft 50 to create a piston effect which offsets the essentially equal downward force produced by the driver scroll. Because of the weight of the driver scroll 50 and motor rotor 18, the downward force exerted by the driver scroll 50 will be higher than simply the Pd pressure x shaft area. Therefore, the diameter of the idler hub 256, bearing 94, and slider block 264 would be designed slightly larger than the equivalent driver scroll parameters. Discharge pressure oil leakage into the suction side must be minimized and injection into the scroll inlet 8 can be achieved more precisely. Therefore, the seal 262 may be disposed on the lower skirt of the slider block 264. Further, while an effect of disposing the seal 262 around the lower skirt of the slider block 264 may be to produce a high piston force upward, there is a low friction force downward, on the base. This enhances the self-adjustment agility of radial compliance.

[0081] Additionally, in some examples, a clearance 1208 exists between the outer surfaces of the idler shaft hub 260, including the hub portion 1212, and the slider block. Further, a base portion 1210 of the shaft hub 260 may be welded or otherwise anchored to the bottom shell 6 and in some implementations the base portion 1210 may include protrusions for resistance welding. Extending from the base portion is the hub portion 1212, which has an axis offset from the axis of the drive shaft 20.

[0082] As discussed earlier, an oil supply tube 92 may supply discharge gas pressurized oil to an oil supply tube inlet 270 and is sealed at the inlet 270 by a seal 271. Drilled and otherwise created in the idler shaft hub mass may be an oil passage 272, which may include a radial extending oil passage 1220 and an axially extending oil passage 1222 that intersect each other in the base portion 1210. As shown, one end of the radial extending oil passage 1220 connects with the oil supply tube 92. The axial oil passage 1222 extends upward through a top surface 1224 of the hub portion 1212 and opens to the clearance 1208 between the hub portion 1212 and the slider block 264.

[0083] In some examples, an axially extending oil metering passage 1230 may be drilled or otherwise created in a top surface 1204 of the slider block 264. A lower end of the passage 1230 is open to and intersects with the clearance 1208. A top end of the passage 1230 is open to and intersects with a clearance 1205 between a top surface 1204 of the slider block 264 and a portion of the lower or bottom surface 1203 of the idler scroll plate 82.

[0084] Further, in some implementations a bump or protrusion 1234 is disposed or extends from the top surface 1204 of the slider block 264. The bump 1234 may be rounded, for example. Also, in some examples, the bump 1234 is aligned with the axis of the hub portion 1212 of the idler scroll hub 260.

[0085] In some implementations, one or more oil passages 1236, 1238, 1240 are drilled or otherwise created in the idler scroll base plate 82. For example, a first axially extending passage 1236 may have a lower end open to and intersecting with the clearance 1205. A top opening or end of the passage 1236 may open to and intersect with a radially extending passage 1238 (274). The radial extending passage 1238 may open to and intersect with a lower end or opening of a second axially extending passage 1240. The outer extent of radially extending passage 1238 is sealed with a press fit plug. The top end or opening 1241 of the second axially extending passage 1240 may open to a space between respective involutes of the driver scroll 50 and idler scroll 80, as shown. Further, the diameter of the radial extending passage 1238 may be greater than the first and second axially extending passages 1236, 1240. Passage 1240 will be a smaller diameter, which is designed to meter a small amount of oil into the compression chamber.

[0086] In some examples, when the compressor is not operating, and with no residual pressure, the weight of some or all of the rotating parts in the scroll assembly are contained by the bump or protrusion 1234 that may be pre-machined into the hardened and ground slider block 264. One purpose of the bump 1234 is to minimize thrust loss and particle debris during startup. Over time the bump 1234 may form a mating surface into the cast iron idler scroll, the contact area will increase, and soon reach stability.

[0087] In some implementations, a spring of a leaf-type, for example, may be inserted into small slots, produced in the slider block 264. The spring is compressed as it is inserted, and provides a force Fsp, which is parallel with the slider block drive flat. This contributes an opposite force to the radial gas vector Frg, and is essentially constant throughout the operating conditions as well as speeds. One purpose of this spring force is to ensure that the involute flanks are in contact during the start-up of the compressor. For example, without this force, the Frg radial gas force could prevent this contact and impede start-up.

[0088] Fig. 13 illustrates an example of a slider block of a compressor according to some implementations. Fig. 14 illustrates an example of a chart showing exemplary dimensions and values of the slider block and associated components according to some implementations. For example, in Fig. 14, OD represents an outer diameter and ID represents an inner diameter.

[0089] When discharge pressure starts to build, oil may flow from a an oil reservoir 42 and into the 260 idler shaft hub. The oil metering passage 1230 may be beneficial during the transient conditions. Once discharge pressure oil covers the surface area Al of the block, the mechanism can be described with the example analysis in Fig. 14. In some implementations, during operation, the idler scroll 80 will lift up and off of the slider block bump 1234, and oil pressure may push oil upward. The upper surface inside the idler scroll hub 256 could be machined to a smooth finish, to minimize viscous power loss.

[0090] For example, the pressure gradient across area A5 and the seal 262 is shown in the example. An operating differential pressure of 350psi may be assumed, along with the exemplary dimensions of Fig. 14. The upward piston force against the idler scroll could be 508.2lbf with an almost static thrust force load of the slider block 264 to idler scroll hub 256 of 78.7lbf. These dimensions are examples and other dimensions may be used to optimize the entire mechanism.

[0091] Fig. 15 illustrates an example of a lower portion of a compressor according to some implementations. Fig. 16 illustrates an example of a cross-sectional view of a compressor along the line A-A of Fig. 15. Fig. 15 shows, for example, the outer diameter of main frame bearing hub 1602, an exit passage/hole in driver scroll 21 diameter of the driver scroll shaft journal 1606, and outer diameter of the main bearing 1610. The inside diameter of the seal plate 1612 has a radial clearance 1614 from the outside diameter of the main frame bearing hub 1602. Fig. 15 further shows the holes for the bolts 640 disposed in the driver scroll plate 52.

[0092] Fig. 17. Illustrates an example of a cross-sectional view of a compressor along the line B-B of Fig. 15. In Fig. 17, the rotation of the driver scroll and idler scroll are clockwise in this view. These X-Y coordinates establish the true position and 1700 represents the driver scroll axis coordinates and 1702 represents the idler scroll axis coordinates. In some implementations, the angular alignment of the involutes is important for total flank contact, as shown on both sides of the Y axis. As mentioned above, the driver scroll axis 96 is on the centerline of the compressor; aligned with the upper bearing 22, motor components (e.g., rotor 18 and stator 16), and main bearing 24. The idler scroll axis 98 may be aligned at a distance equal to the orbit radius of the two involutes.

[0093] In Fig. 17, the Oldham coupling 70, shown to its full movement extent in the X axis direction, is controlled by the involute geometry; and also orbits with respect to the centerline between each scroll coordinate axis. As further shown, the one or more bolts 62 clear the perimeter or outer surface 1004 of the idler scroll plate 82 and the Oldham coupling keys for the idler scroll are within key slots 1006. Further, although the oil supply tube 92 is shown to be located on the X axis, this location is exemplary. The Oldham coupling 70 rotates at or nearly the same speed, but also orbits between each scroll - one rotation produces one orbit.

[0094] In Fig. 17, the tangential gas force vector (Ftg) and radial gas force vector (Frg) are shown, relative to the axis coordinates. Not shown in this view is the axial gas force, which is also very large and contributes much to the requirement of the applied forces to maintain stability at all operating conditions. One major challenge in scroll compressors is to accomplish this stability, and ensure constant compression, without consuming excessive power or causing wear failure. Fs is the force generated by the motor to compress the gas, and transmitted into the slider block 264 drive flat.

[0095] Fig. 18 further indicates the eccentric shaft drive flat Q with respect to the scroll coordinate axis. A positive angle applies a portion of the Ftg force into the radial direction, to ensure scroll flank contact to maintain compression. In this view, components inside the lower cap 6 except the oil supply tube 92 and lower cap 6 rotate. The thrust plate 66 rotates around the driver scroll axis 96, and the idler scroll on its own axis 98

[0096] Simple radial compliance is possible because of the characteristics of tangential and radial gas forces in co-rotating scroll configurations. As described earlier, in ah orbiting scrolls these forces rotate with the orbit. Because of this, it is not practical to apply common radial compliance in orbiting scroll variable speed designs; because the flank contact force varies with the speed. In these orbiting scroll designs, the drive angle Q must be set high to maintain contact at low speeds, but this creates very high contact forces at higher speeds. It is a significant limitation, and the reason that virtually all existing VRF scrolls are fixed eccentric. As stated above, these forces remain fixed with respect to the offset of the driver 50 and idler scrolls 80. Therefore, in some implementations of the co-rotating invention, a drive angle Q essentially produces the same flank force, regardless of the speed.

[0097] Fig. 18 illustrates an example of a cross-sectional view of a compressor along the line C-C of Fig. 15. In some implementations, the eccentric pin 1804 with a drive flat at the angle of Q, with respect to the idler scroll coordinate axis, the corresponding slider block profile, and the idler bearing 94 and hub 256. Fig. 18 also shows the axial oil passage 1222 through the idler scroll shaft hub 260.

[0098] As previously described, the idler shaft hub contains a circular weld projection on the lower end 258, suitable for resistance welding. The upper end is similar to an eccentric drive with a crowned flat 1802. In some implementations, the idler scroll has a bearing insert in its bore, and is machined concentric to the involute axis center. The diameter of this bearing and machined section in the casting/insert may have adequate area to offset the driver scroll area; for force cancellation to minimize rotating thrust loss.

[0099] Fig. 19 is an illustration of an example of a cross-sectional view of components of a compressor according to some implementations. Fig. 20 is an illustration of an example of a cross-sectional view of components of a compressor according to some implementations. As shown in Figs. 19 and 20, a seal plate 1902 is disposed below an idler scroll plate 82. The seal plate 1902 may be essentially disk shaped. In some implementations, extending off the lower or bottom surface 83 of the idler scroll plate 82 may be one or more seals, such as an inner seal 1906 and an outer seal 1904 that may be annular seals. Further, one or more grooves or channels 1940, 1942 may be disposed in the top surface of the seal plate in a shape corresponding to respective one or more seals (e.g., inner seal 1906 and/or outer seal 1904). Additionally, in some examples, one or more grooves or channels may be disposed in idler scroll plate in a shape corresponding to the respective one or more seals (e.g., inner seal 1906 and/or outer seal 1904).

[00100] In some examples, there may be a clearance between a lower surface of each seal 1904, 1906 extending off the idler scroll plate 82 and a bottom surface of each respective groove 1940, 1942 in the seal plate 1902. Additionally, there may be a clearance 1910 between the top surface 1960 of the seal plate and the bottom surface 83 of the idler scroll plate 82.

[00101] Additionally, in some implementations, a first radial gas passage 1952 may be drilled or otherwise disposed in the idler scroll plate 82. This first radial gas passage 1952 may intersect with a first axial gas passage 1950, which is open to a compression pocket and a second axial gas passage 1954 which opens to a portion between the inner seal groove 1940 and outer seal groove 1942. These passages 1950, 1952, 1954 are for delivering compressed gas to the seal plate 1902 (between inner and outer seal grooves 1940, 1942, for example). Further, a plug 1930 may be disposed in the radial gas passage 1952.

[00102] As shown better in Fig. 20, one or more bolts 62 may be disposed through the driver scroll plate 52 and the seal plate 1902. The bolts 62 may slip through one or more bores 2002 for each respective bolt in the driver scroll plate 52 and one or more bores 2004 in the seal plate 1902. The one or more bolts 62 may suspend the seal plate 1902 directly from the driver scroll plate 52. The bolt 62 length may provide a clearance of 120-200 micron, for example, between the seal plate 1902 and the bottom surface of the idler scroll 83. In some implementations, under a normal operation, there is no metal-to-metal contact between the seal plate 1902 and the bottom surface 83 of the idler scroll base plate 82.

[00103] With respect to axial compliance, the one or more seals 1904, 1906 experience an orbiting motion against the lower or bottom surface 83 of the idler scroll plate 82, and this circular path has the same orbit radius as the two involutes. As mentioned above, an area between the inner seal 1906 and the outer seal 1904 may be known as a back chamber, and may be supplied compressed suction gas. For example, the pressure outside the two seals 1904, 1906 may now be suction pressure Ps. Additionally, a pair of dynamic face seals including a spring to preload the sealing may be implemented.

[00104] In some implementations, the seal plate 1902 and bolts 62 do not move, but the seals 1904, 1906 must extend upward by the differential pressure. Further, the seal plate 1902 doesn’t have to be exactly parallel to the driver scroll plate 52 because the dynamic seals 1904,1906 actually adapt to the differences.

[00105] Fig. 21 is an example of a cross-sectional view of components of a compressor according to some implementations. In some examples one or more by-pass valves 2102 may be disposed in the driver scroll plate 52 and having a port 2108 disposed at least partially within a compression chamber 2160 of respective involute walls so that, for example, if the compression chamber pressure exceeds the open point of the by-pass valve 2102, the gas is expelled earlier than the design ratio of the involute.

[00106] This may greatly minimize the over-compression loss that would occur. Because the scroll has two generally equal compression pockets, the compressor may contain two by-pass valves 2102. For example, a radial passage or hole 2106 may be drilled or otherwise created in the driver scroll plate 52. One end of the passage 2106 may be plugged with a plug 2104, for example, and the other end 2110 of the passage 2106 may be open to and intersect with the discharge port 202 in the driver scroll 50. In some implementations, the by-pass valve 2102 may be disposed between the inner seal 252 and outer seal 254 of the seal plate 60.

[00107] Further, the bypass valve 2102 may be applied in a driver scroll plate 50 in a configuration in which the seal plate 60 is disposed above the driver scroll plate, as in Fig. 21, and in a configuration in which a seal plate 1902 is disposed below the idler scroll plate 82, as in Fig. 19.

[00108] Fig. 22 is detailed view of an example of components shown in Fig. 21 according to some implementations. In the detailed view of Fig. 22, a clearance 2202 between the top or upper surface 53 of the driver scroll plate 52 and the lower surface or bottom surface 63 of the seal plate 60. As shown, a clearance may also exist between the top of a respective seal (e.g., seal 252) and bottom of groove or channel 253. There also may be a clearance 2260 between a lower surface of the poppet valve 2208 and the lower or bottom surface 53 of the driver scroll plate 52 when the valve is closed (as shown in Fig. 22).

[00109] In some implementations, the by-pass valve 2108 is disposed within a valve bore 2204, which may be drilled or otherwise created in an axial dimension perpendicular to the passage 2106. The bore 2204 may be significantly larger than the valve port 2212. Further, in some examples, the by-pass valve 2108 includes a valve cap 2206 near the top of the bore 2204, a compression spring 2230 connected to and/or around a valve stem 2205. The valve stem 2205 may include the poppet valve 2208, which may have a conical head portion to seal against a conical surface 2210 at the end of the opening of the bore 2204. In the closed position, for example, the poppet valve 2208 creates a seal against the conical surface 2210 of the driver scroll plate 52. The seal may be a leak-proof seal made at the outer end of the bore 2204 and could be press fit or threaded. Further, the valve sealing member or poppet, may be produced from an engineered plastic material.

[00110] In some instances, the opening of the valve port 2212 may be disposed and aligned near a wall 2251 of the involute of the driver scroll 50 to open at the correct crank angle of compression. Further, the valve port 2212 may be partially open to the compression pocket 2160 such that a portion of the opening overlaps with the involute floor. For example, the involute by-pass port 2212 may be located mathematically in a position, such that it is aligned with the desired pressure that the by-pass valve 2108 should open.

[00111] Fig. 22 further shows that in some implementations, the valve bore 2204 is greater than the valve port 2212, and is located partially over the adjacent driver scroll involute wall. This technique can provide much large flow area for the by-pass gas, and not interfere with normal compression. Further, when the conical valve2208 surfaces seal, that the valve to involute floor volume can be greatly reduced. This can be very important, because as the mating idler involute passes over the valve to involute floor clearance, it can greatly minimize the pocket of gas that becomes“re-expansion” into the following compression pocket.

[00112] With respect to assembly, after assembly of the valve2l08 is inserted into the valve bore 2204, a valve cap is placed over the assembly and may be press fit into the top (back side) of the driver scroll. The valve cap aligns the spring in the center of the valve bore.

[00113] In general, the top side of the valve 2108 will always have the discharge pressure force and a compression spring, holding it closed over the involute by-pass port 2212. For valve 2108 operation, when the compression chamber exceeds the discharge pressure in the driver scroll 50 (and spring force), the poppet will open and expel the gas into this chamber 2160 and out through the driver scroll shaft. Multiple by-pass port-valve assemblies can expel gas into this common exit passage. [00114] Fig. 23 illustrates an example of a detailed view of a cross-sectional view of components of a compressor according to some implementations. In some implementations, a radial passage 2304 may be drilled or otherwise created in the driver scroll plate 52. A bore 2302 for the valve 2301 may be drilled or otherwise created in the driver scroll plate 52 that intersects with the passage 2304.

[00115] For example, the valve 2301 may include a valve cap 2306 and a spring 2308. At an opposite end of the valve cap 2306 may be a disc valve structure 2310 that creates a seal against the flat surface 2312 of the end of the bore of the driver scroll plate when the valve is closed. For example, the valve 2301 may be a round, and flat disc, which fits together with the valve bore to provide adequate clearance for the up/down movement.

[00116] An opening of the bore opens to a passage 2314 that opens to a compression pocket 2360 between respective involutes. For example, the passage 2314 may be located partially over the adjacent driver scroll involute wall. Accordingly, when the valve is open compressed gas enters the passage 2314, flows into the radial passage 2304 and ultimately to the driver scroll discharge port 202.

[00117] In some implementations, there also may be a clearance 2365 between the disc valve structure 2310 and the lower or bottom surface 53 of the driver scroll plate 52 when the valve is closed.

[00118] Fig. 24 illustrates an example of a cross-sectional view of components of a scroll compressor according to some implementations. Fig. 25 shows a cross-sectional view of components of a compressor shown in Fig. 24 along line A-A according to some implementations .

[00119] In some implementations, a driver scroll 2402 includes a driver scroll plate 2404 having an upper or top main surface 2430 and a lower or bottom surface 2431. Extending from the bottom surface 2431 is an involute 2406. Further, extending upwards from the top surface 2430 may be a flange section 2420 that may essentially be cylindrical. Further, the driver scroll shaft 2410 may be connected to the driver scroll flange section 2420 and may be produced or otherwise manufactured as a separate part from the driver scroll plate 2404. Further, a discharge port 2408 is shown in communication with a discharge chamber 2409.

[00120] Further, a seal 2422 may be disposed between the driver scroll flange section 2420 and driver scroll plate 2404 due to the difference of pressure (e.g., suction pressure). A by pass valve cavity 2421 may be disposed above the top surface 2430 and partially enclosed by the driver scroll flange section structure 2420 and may be partially enclosed by the driver scroll shaft. Additionally, in some implementations, one or more reed valves 2416 having a bolt or fastener 2414 and a valve backer 2412 may be disposed within the by-pass valve cavity 2421 with the reed portions covering a by-pass port, passage or hole 2418 when closed.

[00121] For example, one or more by-pass ports may be drilled or otherwise created through the driver scroll plate with one end open to the cavity and another end open to a compression pocket. In some implementations, the reed valves are placed partially over the driver scroll involute.

[00122] Fig. 24 also shows a distance 2481 between the plane 2480 including the bottom surface 2431 and the bottom of the by-pass valve cavity 2421. Further, as shown, the driver scroll flange section may be concentric with respect to the driver scroll and main axis. Further, one or more mounting bolts 2502 may be disposed in the driver scroll flange section. In addition, dowels or other technique could be used to ensure alignment between the driver scroll flange and shaft section, as well as ensure adequate rotational torque strength.

[00123] With respect to the structure shown in Figs. 24 and 25, the discharge pulsations and potential flow loss could be lower than the single piece Driver scroll, because there is a large by-pass valve 2108 cavity.

[00124] Fig. 26 illustrates an example of a cross-sectional view of components of a scroll compressor according to some implementations. Fig. 27 shows a cross-sectional view of components of a compressor shown in Fig. 26 along line A-A according to some implementations .

[00125] In some implementations, a driver scroll 2602 includes a driver scroll plate 2604 having an upper or top main surface 2630 and a lower or bottom surface 2631. Extending from the bottom surface 2631 is an involute 2606. Further, extending upwards from the top surface 2630 may be a flange section 2620 that may essentially be cylindrical. Further, the driver scroll shaft 2610 may be connected to the driver scroll flange section 2620 and may be produced or otherwise manufactured as a separate part from the driver scroll plate 2604. Further, a discharge port 2608 is shown in communication with a discharge chamber 2609.

[00126] Further, a seal 2622 may be disposed between the driver scroll flange section 2620 and driver scroll plate 2604 due to the difference of pressure (e.g., suction pressure). A by pass valve cavity 2621 may be disposed above the top surface 2630 and partially enclosed by the driver scroll flange section structure 2620 and may be partially enclosed by the driver scroll shaft. Additionally, in some implementations, one or more reed valves 2616 having a bolt or fastener 2614 and a valve backer 2612 may be disposed within the by-pass valve cavity 2621 with the reed portions covering a by-pass port, passage or hole 2618 when closed.

[00127] For example, one or more by-pass ports 2618 may be drilled or otherwise created through the driver scroll plate 2618 with one end open to the cavity and another end open to a compression pocket. In some implementations, the reed valves are placed partially over the driver scroll involute.

[00128] Fig. 26 also shows that in some implementations a discharge reed valve 2690 and a fastener or bolt may be disposed within the bypass valve cavity 2621. The discharge reed valve 2690 may cover the discharge port 2609. The discharge reed valve 2690 may provide a benefit whenever the compressor is operating at a higher pressure ratio than is designed into the scroll involute section. The scroll involutes compress the suction gas as one of the scrolls orbits about the other. For example, after about 2.4 revolutions about the orbit circle, the compressed gas is discharged through the discharge port 2609. Normally the compressed gas is higher than the pressure above the discharge port 2609, and the process is normal. However, if the HVAC system is cooling in a very high ambient temperature, or heating in a very low ambient temperature, a problem can occur. In these conditions, the discharge pressure in the system as well as inside the exit inside the shaft 20, will be higher than the gas that is compressed and released from the scroll involutes. Therefore, the existing higher pressure will back flow into the discharge port 2609, and this can be a serious loss in performance.

[00129] Fig. 26 also shows a distance 2681 between the plane 2680 including the bottom surface 2631 and the bottom of the by-pass valve cavity 2621. Further, as shown, the driver scroll flange section may be concentric with respect to the driver scroll and main axis. Further, one or more mounting bolts 2702 may be disposed in the driver scroll flange section, as shown in Fig. 27. In addition, dowels or other technique could be used to ensure alignment between the driver scroll flange and shaft section, as well as ensure adequate rotational torque strength.

[00130] The processes described herein are only examples for discussion purposes. Numerous other variations will be apparent to those of skill in the art in light of the disclosure herein. Further, while the disclosure herein sets forth several examples of suitable frameworks, architectures and environments for executing the processes, the implementations herein are not limited to the particular examples shown and discussed. Furthermore, this disclosure provides various example implementations, as described and as illustrated in the drawings. However, this disclosure is not limited to the implementations described and illustrated herein, but can extend to other implementations, as would be known or as would become known to those skilled in the art.

[00131] Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described. Rather, the specific features and acts are disclosed as example forms of implementing the claims.

Claims

1. A compressor, comprising:

a cylindrical housing;

a lower cap housing engaging with the cylindrical housing;

a main shaft disposed along a main axis;

a driver scroll having an axis aligned with the main axis and having a spiral involute; an idler scroll having an axis offset from the main axis and having a spiral involute intermeshed with the spiral involute of the driver scroll;

an Oldham coupling disposed between the driver scroll and idler scroll;

an idler scroll shaft hub fixed to the lower cap having an axis aligned with the idler scroll axis and having a drive flat with a stationary drive angle, a hub of the idler scroll is disposed on the idler scroll shaft hub fixed to the lower cap; and

a circular seal plate disposed above the driver scroll and a circular thrust plate disposed below the idler scroll, wherein the seal plate and the thrust plate are maintained in a parallel state.

2. The compressor according to claim 1, further comprising:

two or more fasteners each having a predetermined length and equally spaced apart around the seal plate.

3. The compressor according to claim 2,

wherein each of the two or more bolts are disposed through respective bores in the seal plate and each bore has a crowned shape having a diameter at the center of the bore greater than a diameter at a top of the bore.

4. The compressor according to claim 1,

wherein one or more annular grooves are disposed in a bottom surface of the seal plate that faces a top surface of a driver scroll plate of the driver scroll, and

wherein respective one or more annular seals are disposed within each of the respective one or more annular grooves.

5. The compressor according to claim 1, wherein one or more annular grooves are disposed in a top surface of a driver scroll plate of the driver scroll that faces a bottom surface of the seal plate, and

6. The compressor according to claim 1,

further comprising a plurality of downward extending arc-shaped extensions extending from a side surface of a driver scroll plate of the driver scroll,

wherein a bottom surface of each of the plurality of downward extending arc-shaped extensions and a bottom facing surface of the spiral involute are in a same plane.

7. The compressor according to claim 1,

wherein the idler scroll shaft hub extends from a base portion that is fixed to the lower cap,

wherein a slider block is disposed on the idler scroll shaft hub and a seal is disposed around the idler scroll shaft hub and engages with the bottom surface of the slider block and a top surface of the base portion of the idler scroll shaft hub, and

wherein the slider block includes a protrusion protruding from a top surface of the slider block in center portion thereof and wherein the protrusion contacts a bottom surface of an idler scroll plate of the idler scroll that faces downward toward the slider block.

8. The compressor according to 7,

wherein an oil supply tube supplies oil pressurized by a discharge pressure to a first oil passage disposed in the base portion,

wherein the first oil passage is in communication with an upward extending second oil passage disposed at least partially in the base portion and disposed in the idler scroll shaft hub,

wherein the second oil passage is in communication with a third oil passage disposed through the top surface of the slider block, and

wherein the idler scroll plate includes a fourth oil passage in communication with the third oil passage that is open to a top surface of the idler scroll plate within the involute spiral.

9. The compressor according to claim 1,

wherein a passage compressed gas may be disposed within a driver scroll plate of the driver scroll having a first opening in a bottom surface of the driver scroll plate within the spiral involute and a second opening a top surface of the driver scroll plate between two annularly disposed seals.

10. A compressor, comprising:

a cylindrical housing;

a lower cap housing engaging with the cylindrical housing;

a main shaft disposed along a main axis;

an Oldham coupling disposed between the driver scroll and idler scroll;

an idler scroll shaft hub fixed to the lower cap having an axis aligned with the idler scroll axis and a drive flat with a stationary drive angle, a hub of the idler scroll is disposed on the idler scroll shaft hub fixed to the lower cap; and

a circular seal plate disposed below the idler scroll.

11. The compressor according to claim 10,

wherein one or more annular grooves are disposed in a top surface of the seal plate that faces a bottom surface of an idler scroll plate of the idler scroll, and

12. The compressor according to claim 10

wherein one or more annular grooves are disposed in a bottom surface of an idler scroll plate of the idler scroll that a top surface of the seal plate, and

13. The compressor according to claim 11, wherein a gas passage is disposed in the idler scroll plate having a first opening in a top surface of the idler scroll plate within the spiral involute and having a second opening in the bottom surface of the idler scroll plate between two annular seals.

14. The compressor according to claim 1,

wherein a bypass valve is disposed in a driver scroll plate of the driver scroll to allow compressed gas to pass from between compression pockets of the intermeshed driver scroll involute and idler scroll involute to a discharge port disposed within the driver scroll plate via a passage disposed in the driver scroll plate,

wherein the valve portion of the bypass valve has one of a conical shape and a flat disc shape, and

wherein the bypass valve includes a compression spring biasing the valve portion to the bottom surface of the driver scroll plate.

15. The compressor according to claim 10,

wherein a bypass valve is disposed in a driver scroll plate of the driver scroll to allow compressed gas to pass from between compression pockets of the intermeshed driver scroll involute and idler scroll involute to a discharge port disposed within the driver scroll plate via a passage disposed in the driver scroll plate, and

wherein the valve portion of the bypass valve has one of a conical shape and a flat disc shape and the bypass valve includes a compression spring biasing the valve portion to the bottom surface of the driver scroll plate.

16. The compressor according to claim 1,

wherein a discharge port of the driver scroll is in communication with a cavity in which a bypass valve is disposed,

wherein the cavity is above the discharge port of the driver scroll and is open to a discharge chamber on a top side and enclosed around a circumference of the cavity, and

wherein the bypass valve includes a reed valve that, when closed, covers a bypass port extending through the driver scroll plate.

17. The compressor according to claim 10, wherein a discharge port of the driver scroll is in communication with a cavity in which a bypass valve is disposed,

18. The compressor according to claim 1, further comprising a reed valve disposed within the cavity and having a reed that, when closed, covers the discharge port.

19. The compressor according to claim 10, further comprising a reed valve disposed within the cavity and having a reed that, when closed, covers the discharge port.