Abstract:
A thermal-valve assembly for a compressor including a partition plate having a first bore formed therethrough is provided. The thermal-valve assembly may include a body having a wall extending from and surrounding a bottom wall. The bottom wall may include a first surface defining a valve seat, a second surface formed on an opposite side of the bottom wall than the first surface and facing the partition plate, and a second bore extending through the bottom wall between the first surface and the second surface and aligned with the first bore. A projection may extend from the second surface and may be attached to the partition plate. A valve element may be received by the body and may be supported on the valve seat between an open state permitting communication through the second bore and a closed state preventing communication through the second bore.

Description:
FIELD 
       [0001]    The present disclosure relates generally to compressors, and more particularly to a compressor having an improved valve assembly. 
       BACKGROUND 
       [0002]    The statements in this section merely provide background information related to the present disclosure and may not constitute prior art. 
         [0003]    A scroll compressor generally includes a hermetic shell defining a chamber and a partition plate dividing the chamber into a discharge-pressure zone and a suction-pressure zone. A scroll assembly may be located within the chamber for compressing a working fluid disposed within the chamber. As the working fluid is compressed in the scroll assembly, the compressed fluid exits the center discharge port of the scroll assembly and enters the discharge-pressure zone. The compressed working fluid may then be discharged to a fluid circuit such as a refrigeration circuit through a discharge port formed in the hermetic shell. 
         [0004]    Compression of the fluid within the chamber of the scroll compressor may cause a temperature within the discharge-pressure zone to rise. A thermal-valve may be provided between the discharge-pressure zone and the suction-pressure zone to allow fluid to leak from the discharge-pressure zone to the suction-pressure zone when a temperature within the discharge-pressure zone exceeds a threshold value. Allowing the fluid to leak from the discharge-pressure zone to the suction-pressure zone when a temperature within the discharge-pressure zone exceeds a predetermined value reduces the temperature within the discharge-pressure zone. 
       SUMMARY 
       [0005]    A thermal-valve assembly for a compressor including a partition plate having a first bore formed therethrough is provided. The thermal-valve assembly may include a body having a wall extending from and surrounding a bottom wall. The bottom wall may include a first surface defining a valve seat, a second surface formed on an opposite side of the bottom wall than the first surface and facing the partition plate, and a second bore extending through the bottom wall between the first surface and the second surface and aligned with the first bore. A projection may extend from the second surface and may be attached to the partition plate. A valve element may be received by the body and may be supported on the valve seat between an open state permitting communication through the second bore and a closed state preventing communication through the second bore. 
         [0006]    In another configuration, a compressor is provided and may include a partition plate, a first bore formed through the partition plate, and a thermal-valve assembly. The thermal-valve assembly may include a body having a wall extending from and surrounding a bottom wall. The bottom wall may include a first surface defining a valve seat, a second surface formed on an opposite side of the bottom wall than the first surface and facing the partition plate, and a second bore extending through the bottom wall between the first surface and the second surface and aligned with the first bore. A projection may extend from the second surface and may be attached to the partition plate. A valve element may be received by the body and may be supported on the valve seat between an open state permitting communication through the second bore and a closed state preventing communication through the second bore. 
         [0007]    Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
     
    
     
       DRAWINGS 
         [0008]    The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. 
           [0009]      FIG. 1  is a cross-sectional view of a compressor in accordance with the teachings of the present disclosure; 
           [0010]      FIG. 2  is a top perspective view of a thermal-valve assembly in accordance with the teachings of the present disclosure; 
           [0011]      FIG. 3  is a bottom perspective view of a thermal-valve assembly in accordance with the teachings of the present disclosure; 
           [0012]      FIG. 4  is a top view of a thermal-valve assembly in accordance with the teachings of the present disclosure; 
           [0013]      FIG. 5  is a cross-sectional view of a thermal-valve assembly taken along line  5 - 5  of  FIG. 4 ; 
           [0014]      FIG. 6  is a cut-away view of a thermal-valve assembly in accordance with the teachings of the present disclosure; 
           [0015]      FIG. 7  is a partial perspective view of a partition plate on which a thermal-valve assembly is mounted; 
           [0016]      FIG. 8  is a partial cut-away view of a thermal-valve assembly and a partition plate; 
           [0017]      FIG. 9  is a cross-sectional view of a thermal-valve assembly mounted to a partition plate, detailing an engagement between the thermal-valve assembly and the partition plate; 
           [0018]      FIG. 10  is a cross-sectional view of a thermal-valve assembly mounted to a partition plate; 
           [0019]      FIG. 11  is a cross-sectional view of a thermal-valve assembly mounted to a partition plate having a relocated discharge hole; 
           [0020]      FIG. 12  a cross-sectional view of a thermal-valve assembly in accordance with the teachings of the present disclosure mounted to a partition plate; 
           [0021]      FIG. 13  is a cross-sectional view of a thermal-valve assembly in accordance with the teachings of the present disclosure mounted to a partition plate; and 
           [0022]      FIG. 14  is a perspective view of the thermal-valve assembly of  FIG. 13 , with a valve element of the thermal-value assembly removed for clarity. 
       
    
    
       [0023]    Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings. 
       DETAILED DESCRIPTION 
       [0024]    The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. 
         [0025]    Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. 
         [0026]    The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed. 
         [0027]    When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. 
         [0028]    Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments. 
         [0029]    Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature&#39;s relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. 
         [0030]    Referring to  FIG. 1 , a compressor  10  is provided and includes a generally cylindrical hermetic shell  12 , a cap  14  welded at an upper end of the shell  12 , and a partition plate  16  (or a muffler plate) dividing the shell  12  into a suction-pressure zone  17  and a discharge-pressure zone  19  (or a muffler chamber). 
         [0031]    A main-bearing housing  18  may be affixed to the shell  12  at a plurality of points adjacent to the partition plate  16  and may include an annular flat thrust bearing surface  48  and a bearing  30 . A second bearing housing  34  may be provided adjacent to a lower portion of the shell  12  and may include a bearing  32 . 
         [0032]    A motor  22  may be disposed below the main-bearing housing  18  and may include a stator  24  and a rotor  42 . The stator  24  may be generally square in cross-section with the corners rounded off and may be press-fit into the shell  12 . Flat portions (not shown) of the stator  24 —located between the rounded corners of the stator  24 —cooperate with the shell  12  to define passageways therebetween to facilitate the flow of lubricant from the top of the shell  12  to the bottom of the shell  12 . 
         [0033]    A motor protector  46  may be disposed proximate to motor windings  40  to prevent the motor  22  from exceeding a predetermined temperature. When the compressor reaches a threshold temperature, the motor protector  46  may de-energize the motor  22  to stop operation of the compressor  10 . 
         [0034]    A crankshaft  26  may be press-fitted into the rotor  42  and may be rotatably driven by the rotor  42  with one or more counterweights  44  mounted thereon. The crankshaft  26  may include an upper end provided with an eccentric crank pin  28  and a lower end formed with an oil-pumping concentric bore  36 . The eccentric crank pin  28  may be rotatably journaled in and supported by the bearings  30  and  32  at both ends. The oil-pumping concentric bore  36  may communicate with a radially outwardly inclined smaller-diameter bore  38  extending upwardly therefrom to the top of the crankshaft  26 . The lower portion of the shell  12  may be filled with lubricating oil. The concentric bore  36  disposed at the bottom of the crankshaft  26  may be the primary pump acting in conjunction with the bore  38 , which acts as a secondary pump, to pump lubricating fluid to various portions of the compressor  10  that require lubrication. 
         [0035]    A scroll assembly  49  may be supported on the main-bearing housing  18  and may comprise an orbiting-scroll member  50  and a non-orbiting scroll member  66 . The orbiting-scroll member  50  may include an end plate  52  contacting the flat thrust bearing surface  48  of the main-bearing housing  18 , a spiral vane or wrap  54  extending upwardly from the end plate  52 , and a cylindrical hub  58  extending downwardly from the end plate  52 . 
         [0036]    The cylindrical hub  58  may include a journal bearing  60  that rotatably receives a drive bushing  62 . The drive bushing  62  may include an inner bore that drivingly receives the crank pin  28 . The engagement between the crank pin  28  and the cylindrical hub  58  may be of the type disclosed in Assignee&#39;s commonly owned U.S. Pat. No. 4,877,382, the disclosure which is incorporated herein by reference. 
         [0037]    The non-orbiting scroll member  66  may be mounted to the main-bearing housing  18  such that the non-orbiting scroll member  66  may be axially moved towards and away from the main-bearing housing  18 . The non-orbiting scroll member  66  may be mounted to the main-bearing housing  18  in the manner disclosed in Assignee&#39;s commonly owned U.S. Pat. Nos. 4,877,382 and 5,102,316, the disclosures of which are incorporated herein by reference. 
         [0038]    The non-orbiting scroll member  66  includes a wrap  64  positioned in meshing engagement with the wrap  54  of the orbiting-scroll member  50  and a centrally disposed discharge passage  72 . The discharge passage  72  communicates with the discharge-pressure zone  19  defined between the end cap  14  and the partition plate  16  through an opening  74 . 
         [0039]    A suction gas inlet fitting  20  may be disposed outside the shell  12  and a gas deflector  23  may be disposed inside the shell  12  adjacent to the suction gas inlet fitting  20 . The cap  14  may include a refrigerant discharge fitting  21 , which may include a discharge valve therein (not shown). A thermal-valve assembly  90  may be mounted on the partition plate  16  covering a leakage hole  92  of the partition plate  16 . The leakage hole  92  may communicate the suction-pressure zone  17  and the discharge-pressure zone  19 . 
         [0040]    Referring to  FIGS. 2-5 , the thermal-valve assembly  90  includes a substantially cylindrical body having a cylindrical wall  94 , a valve seat  93  surrounded by the cylindrical wall  94 , and an annular flange  98 . The annular flange  98  may extend from an end of the cylindrical wall  94  and perpendicularly and downwardly from the valve seat  93 . An annular shoulder  100  may be formed between the cylindrical wall  94  and the annular flange  98 . The bottom wall  96  of the valve seat  93  and the annular flange  98  may cooperate to form a cup shape. 
         [0041]    As shown in  FIGS. 4 through 6 , the cylindrical wall  94  may define an inner space  102 . The valve seat  93  may be provided in the inner space  102  and may include the bottom wall  96  and an annular step  104  extending radially and inwardly from an inner surface  95  of the cylindrical wall  94 . A central opening  108  may be formed through the bottom wall  96 . 
         [0042]    The thermal-valve assembly  90  may further include a valve element  110  and a retainer  112  received in the inner space  102 . The valve element  110  may be a bimetallic disc having a central concaved portion  114  and a plurality of apertures  116 . The central concaved portion  114  may be concave relative to the retainer  112 . It will also be appreciated that the central concaved portion  114  may be convex relative to the central opening  108  and the leakage hole  92 . Accordingly, when the thermal-valve assembly  90  is in a closed position, the valve element  110  may be supported on the annular step  104 , and the central concaved portion  114  may contact the valve seat  93  generally around the central opening  108  and extend into the central opening  108 . When the thermal-valve assembly  90  is in the closed position ( FIGS. 9 and 10 ), the valve element  110  blocks the central opening  108  and prevents discharge-pressure gas from the discharge-pressure zone  19  from entering the suction-pressure zone  17 . When the thermal-valve assembly  90  is in an open position, the central concaved portion  114  of the valve element  110  is separated from the valve seat  93  to permit flow between the discharge-pressure zone  19  and the suction-pressure zone  17 . 
         [0043]    The retainer  112  may be snapped into an inner annular groove  106  formed on the inner surface  95  of the cylindrical wall  94  and may have a ring configuration including a central opening  118 . After the valve element  110  is assembled to the cylindrical wall  94 , the retainer  112  may be snapped into the annular groove  106  to retain the valve element  110  in the inner space  102  when the valve element  110  is in an open position. 
         [0044]    Referring to  FIGS. 7-9 , the thermal-valve assembly  90  is shown mounted on a planar surface  124  of the partition plate  16 . The planar surface  124  is formed adjacent to a leakage hole  92  ( FIG. 8 ) and within the discharge-pressure zone  19 . An annular groove  126  ( FIG. 9 ) may be formed in the planar surface  124  adjacent to the leakage hole  92 . When the thermal-valve assembly  90  is mounted to the partition plate  16 , the annular flange  98  of the thermal-valve assembly  90  may be received within the annular groove  126  such that the central opening  108  of the bottom wall  96  is aligned with the leakage hole  92 . For example, the bottom wall  96  of the valve seat  93  may abut the planar surface  124 . The thermal-valve assembly  90  may be joined to the partition plate  16  by resistance welding through application of heat and pressure at the interface between the thermal-valve assembly  90  and the partition plate  16 . 
         [0045]    The annular groove  126  may be eliminated to simplify machining of the partition plate  16 . As shown in  FIG. 10 , the annular flange  98  may be in contact with the planar surface  124 . By applying heat and pressure at the annular flange  98 , a welded joint  127  around the annular flange  98  may be formed to join the thermal-valve assembly  90  and partition plate  16 . Because the sealing of the thermal-valve assembly  90  is achieved through engagement between the valve element  110  and the valve seat  93 , the disengagement between the valve seat  93  and the planar surface  124  of the partition plate  16  does not affect the sealing of the thermal-valve assembly  90 . 
         [0046]    Referring to  FIG. 11 , when the leakage hole  92  of the partition plate  16  is relocated due to a machining error, for example, the thermal-valve assembly  90  may control opening of a relocated leakage hole  128  while concurrently blocking the originally formed leakage hole  92 . Because the bottom wall  96  of the thermal-valve assembly  90  is substantially planar, when the thermal-valve assembly  90  is mounted to the partition plate  16 , the bottom wall  96  of the valve seat  93  abuts against the planar surface  124  and blocks the originally formed leakage hole  92 , which is no longer needed. Therefore, the thermal-valve assembly  90  allows for reuse of the partition plate  16  when a leakage hole is improperly formed, thereby reducing the number of partition plates that are scrapped during manufacture of the compressor  10 . The cylindrical wall  94  may include a diameter that is at least twice a diameter of the leakage hole  92  or  128  to accommodate multiple leakage holes  92 ,  128  within the cylindrical wall  94 . 
         [0047]    Referring to  FIG. 12 , a thermal-valve assembly  150  is provided and may include a cylindrical wall  152  and a valve seat  153  connected to the cylindrical wall  152 . The valve seat  153  may include a cylindrical end  154  and a tapered portion  156  with a central opening  158  extending along an axis of the valve seat  153 . Like the thermal-valve assembly  90 , the thermal-valve assembly  150  may include an annular step  104  extending radially and inwardly from the cylindrical wall  152 . An annular shoulder  160  may be formed between the cylindrical wall  152  and the tapered portion  156 . When the thermal-valve assembly  150  is mounted to the partition plate  16 , the annular shoulder  160  may abut against the planar surface  124  of the partition plate  16  with the tapered portion  156  and the cylindrical end  154  received in a counterbore  162  of the partition plate  16 . The thermal-valve assembly  150  may be joined to the partition plate  16  by any conventional joining methods such as, for example, welding or brazing. The other element of the thermal-valve assembly  150  are identical to those of the thermal-valve assembly  90 . Accordingly, like reference numerals are used to identify these components. 
         [0048]    Referring to  FIGS. 13 and 14 , a thermal-valve assembly  170  is provided. Rather than being mounted in the discharge-pressure zone  19 , the thermal-valve assembly  170  is mounted in the suction-pressure zone  17 . The thermal-valve assembly  170  may include a cylindrical wall  172 , a valve seat  174  provided at a lower end of the cylindrical wall  172 , and an annular flange  176  provided at an upper end of the cylindrical wall  172 . As with the thermal-valve assembly  150 , the other elements of the thermal-valve assembly  170  are identical to those of the thermal-valve assembly  90 . Accordingly, like reference numerals are used to identify these components. 
         [0049]    The annular flange  176  may extend from the upper end of the cylindrical wall  172 . The valve seat  174  may include an annular step  178  extending radially and inwardly from the cylindrical wall  172  and a bottom surface  180 . An opening  182  may be formed at the bottom surface  180  for communicating to the leakage hole  92  of the partition plate  16 . A valve element  110  may be supported on the annular step  178  and may be disposed adjacent to the bottom surface  180  with the central concaved portion  114  extending into the opening  182 . The thermal-valve assembly  170  may be joined to the partition plate  16  by resistance-welding the annular flange  176 . 
         [0050]    The valve element  110  is spaced from the partition plate  16  such that when the valve element  110  is in the open state (i.e., the valve element  110  is deflected and the central concaved portion  114  is moved away from the opening  182 ), the valve element  110  contacts the partition plate  16  and is restrained by the partition plate  16 . Because the partition plate  16  helps retain the valve element  110  inside the cylindrical wall  172  in the open state, a retainer for retaining the valve element  110  may be eliminated. The leakage hole  92  of the partition plate  16  and the opening  182  of the valve seat  174  may include different diameters. 
         [0051]    An easily machinable material may be used to form the valve seats  93 ,  153 , or  174  because the valve seats  93 ,  153 , or  174  are not provided in the partition plate  16 , which is generally made of a material of poor machinability. Therefore, manufacturing costs associated with the thermal-valve assemblies  90 ,  150 ,  170  can be reduced. Furthermore, testing of the sealing of the thermal-valve assemblies  90 ,  150 ,  170  can be independently conducted without the partition plate  16 , thereby facilitating the assembly process. 
         [0052]    While the leakage hole  92  and the central opening  108  of the valve seats  93 ,  153  have been shown to have the same diameter, they can be made to have different diameters without affecting the sealing of the thermal-valve assemblies  90 ,  150 , as sealing of the thermal-valve assemblies  90 ,  150  is achieved through the engagement between the valve elements and valve seats of the respective assemblies  90 ,  150 . Accordingly, any burrs formed around the leakage hole  92  will not affect the sealing of any of the thermal-valve assemblies  90 ,  150 ,  170 . 
         [0053]    It should be understood and appreciated that the thermal-valve assembly can have a configuration different from those described in the present disclosure. Further, it should be understood and appreciated that the retainer and the corresponding annular groove can be eliminated. Instead, a cover or any retaining device can be provided in the thermal-valve assembly to achieve the purpose of retaining the valve element in the inner space of the cylindrical wall. 
         [0054]    The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.