Scroll compressor with discharge valve

Abstract: A scroll machine (10) includes a normally open discharge valve assembly (130) for controlling compressed refrigerant flow from the discharge chamber through the compression members. This controlling of flow results in an increased performance for the compressor by reducing recompression volume and the elimination of reverse rotation at shut down. The discharge valve assembly includes a valve seat (132), a valve plate (134) and a valve stop (136) secured within a recess (78) formed within the compressor. The valve stop and the valve seat include a contoured surface (172) which is engaged by the valve plate when it opens and closes. The contoured surface controls the movement of the valve plate.

Description: Field of the Invention The present invention relates to rotary compressors. More particularly the present invention relates to a unique direct discharge valve incorporating a curved stop plate which is utilized in both a scroll compressor and a rotarycompressor. Background of the Invention Scroll machines are becoming more and more popular for use as compressors in both refrigeration as well as air conditioning and heat pump applications due primarily to their capability for extremely efficient operation. Generally, these machines incorporate a pair of intermeshed spiral wraps, one of which is caused to orbit relative to the other so as to define one or more moving chambers which progressively decrease in size as they travel from an outer suction port towards a center discharge port. An electric motor is normally provided which operates to drive the orbiting scroll member via a suitable drive shaft. Because scroll compressors depend upon successive chambers for suction, compression, and discharge processes, suction and discharge valves in general are not required. However, the performance of the compressor can be increased with the incorporation of a discharge valve. One of the factors which will determine the level of increased performance is the reduction of what is called recompression volume. The recompression volume is the volume of the discharge chamber and discharge port of the compressor when the discharge chamber is at its smallest volume. The minimization of this recompression volume will result in a maximizing of the performance of the compressor. In addition, when such compressors are shut down, either intentionally as a result of the demand being satisfied, or unintentionally as a result of a power interruption, there is a strong tendency for the backflow of compressed gas from the discharge chamber and to a lesser degree for the gas in the pressurized chambers to effect a reverse orbital movement of the orbiting scroll member and its associated drive shaft. This reverse movement often generates noise or rumble which may be considered objectionable and undesirable. Further, in machines employing a single phase drive motor, it is possible for the compressor to begin running in the reverse direction should a momentary power interruption be experienced. This reverse operation may result in overheating of the compressor and/or other inconveniences to the utilization of the system. Additionally, in some situations, such as a blocked condenser fan, it is possible for the discharge pressure to increase sufficiently to stall the drive motor and effect a reverse rotation thereof. As the orbiting scroll orbits in the reverse direction, the discharge pressure will decrease to a point where the motor again is able to overcome this pressure head and orbit the scroll member in the forward direction. However, the discharge pressure will again increase to a point where the drive motor is stalled and the cycle is repeated. Such cycling is undesirable in that it is self-perpetuating. The incorporation of a discharge valve can reduce or eliminate these reverse rotation problems. FR-A-0667882 in the name Charles Willi discloses a reed valve for use in conjunction with pumps and compressors. US-A-5035050 and EP-A-0589667 disclose reed valves used in the context of rotary vane compressors for controlling the flow of pumped medium from a pressure chamber into a discharge chamber. US-A-3191618 discloses a reed valve having a curved seat, and intended for use in a kart engine. A primary object of the present invention resides in the provision of a very simple and unique discharge valve which is associated with the non-orbiting scroll and which can easily be assembled into a conventional gas compressor of the scroll type without significant modification of the overall compressor design. The discharge valve operates to minimize the recompression volume and at compressor shut down operates to prohibit backflow of the discharge gas through the compressor and thus driving the compressor in the reverse direction. Prohibiting the reverse operation of the compressor eliminates the normal shut down noise and other problems associated with such reverse rotation. The discharge valve is normally open due to the configuration of the valve plate and the valve seat. The normally open configuration for the valve eliminates the force to open the valve as well as eliminating any mechanical device to close the valve. The valve relies on pressure differentials for closing. The stop plate for the discharge valve includes a curved backing surface which guides and supports the movement of the valve plate significantly reducing stresses for the valve plate. This invention provides a scroll machine as defined in claim 1. These and other features of the present invention will become apparent from the following description and the appended claims, taken in conjunction with the accompanying drawings. Brief Description of the Drawings I n the drawings which illustrate the best mode presently contemplated for carrying out the present invention: Figure 1 is a vertical sectional view through the center of a scroll compressor which incorporates a discharge valve assembly in accordance with the present invention; Figure 2 is a top elevational view of the compressor shown in Figure 1 with the cap and a portion of the partition removed; Figure 3 is an enlarged view of the floating seal assembly and discharge valve assembly illustrated in Figure 1; Figure 4A is an enlarged view of the discharge valve assembly illustrated in Figures 1 and 3 having a generally planar valve seat; Figure 4B is an enlarged view of the discharge valve assembly illustrated in Figures 1 and 3 having a curved valve seat; and Figure 5 is an exploded perspective view of the discharge valve assembly shown in Figures 1, 3 and 4B. Detailed Description of the Preferred Embodiment Referring now to the drawings in which like reference numerals designate like or corresponding parts throughout the several views, there is shown in Figure 1 a scroll compressor which incorporates a discharge valving system in accordance with the present invention which is designated generally by reference numeral 10. Compressor 10 comprises a generally cylindrical hermetic shell 12 having welded at the upper end thereof a cap 14 and at the lower end thereof a base 16 having a plurality of mounting feet (not shown) integrally formed therewith. Cap 14 is provided with a refrigerant discharge fitting 18. Other major elements affixed to the shell include a transversely extending partition 22 which is welded about its periphery at the same point that cap 14 is welded to shell 12, a main bearing housing 24 which is suitably secured to shell 12 and a two piece upper bearing housing 26 suitably secured to main bearing housing 24. A drive shaft or crankshaft 28 having an eccentric crank pin 30 at the upper end thereof is rotatablyjournaled in a bearing 32 in main bearing housing 24 and a second bearing 34 in upper bearing housing 26. Crankshaft 28 has at the lower end a relatively large diameter concentric bore 36 which communicates with a radially outwardly inclined smaller diameter bore 38 extending upwardly therefrom to the top of crankshaft 28. The lower portion of the interior shell 12 defines an oil sump 40 which is filled with lubricating oil to a level slightly above the lower end of a rotor 42, and bore 36 acts as a pump to pump lubricating fluid up the crankshaft 28 and into bore 38 and ultimatelyto all of the various portions of the compressor which require lubrication. Crankshaft 28 is rotatively driven by an electric motor including a stator 46, windings 48 passing therethrough and rotor 42 press fitted on the crankshaft 28 and having upper and lower counterweights 50 and 52, respectively. The upper surface of upper bearing housing 26 is provided with a flat thrust bearing surface 54 on which is disposed an orbiting scroll member 56 having the usual spiral vane or wrap 58 extending upward from an end plate 60. Projecting downwardly from the lower surface of end plate 60 of orbiting scroll member 56 is a cylindrical hub having a journal bearing 62 therein and in which is rotatively disposed a drive bushing 64 having an inner bore 66 in which crank pin 30 is drivingly disposed. Crank pin 30 has a flat on one surface which drivingly engages a flat surface (not shown) formed in a portion of bore 66 to provide a radially compliant driving arrangement, such as shown in assignee's U.S. Letters Patent 4,877,382. An Oldham coupling 68 is also provided positioned between orbiting scroll member 56 and bearing housing 24 and keyed to orbiting scroll member 56 and a non-orbiting scroll member 70 to prevent rotational movement of orbiting scroll member 56. Oldham coupling 68 is preferably of the type disclosed in assignee's co-pending U.S. Letters Patent 5,320,506. Non-orbiting scroll member 70 is also provided having a wrap 72 extending downwardly from an end plate 74 which is positioned in meshing engagement with wrap 58 of orbiting scroll member 56. Non-orbiting scroll member 70 has a centrally disposed discharge passage 76 which communicates with an upwardly open recess 78 which in turn is in fluid communication with a discharge muffler chamber 80 defined by cap 14 and partition 22. An annular recess 82 is also formed in non-orbiting scroll member 70 within which is disposed a floating seal assembly 84. Recesses 78 and 82 and seal assembly 84 cooperate to define axial pressure biasing chambers which receive pressurized fluid being compressed by wraps 58 and 72 so as to exert an axial biasing force on non-orbiting scroll member 70 to thereby urge the tips of respective wraps 58, 72 into sealing engagement with the opposed end plate surfaces of end plates 74 and 60, respectively. Seal assembly 84 is preferably of the type described in greater detail in U.S. Patent No. 5,156,539. Non-orbiting scroll member 70 is designed to be mounted to bearing housing 26 in a suitable manner such as disclosed in the aforementioned U.S. Patent No. 4,877,382 or U.S. Patent No. 5,102,316. Referring now to Figures 2 and 3, floating seal assembly 84 is of a coaxial sandwiched construction and comprises an annular base plate 102 having a plurality of equally spaced upstanding integral projections 104 each having an enlarged base portion 106. Disposed on plate 102 is an annular gasket assembly 108 having a plurality of equally spaced holes which mate with and receive base portions 106. On top of gasket assembly 108 is disposed an annular spacer plate 110 having a plurality of equally spaces holes which also mate with and receive base portions 106. On top of plate 110 is an annular gasket assembly 112 having a plurality of equally spaced holes which mate with and receive projections 104. The assembly of seal assembly 84 is maintained by an annular upper seal plate 114 which has a plurality of equally spaced holes mating with and receiving projections 104. Seal plate 114 includes a plurality of annular projections 116 which mate with and extend into the plurality of holes in annular gasket assembly 112 and spacer plate 110 to provide stability to seal assembly 84. Seal plate 114 also includes an annular upwardly projecting planar sealing lip 118. Seal assembly 84 is secured together by swaging the ends of projections 104 as indicated at 120. Referring now to Figure 3, seal assembly 84 therefore provides three distinct seals. First, an inside diameter seal at two interfaces 122, second an outside diameter seal at two interfaces 124 and a top seal at 126. Seals 122 isolate fluid under intermediate pressure in the bottom of recess 82 from fluid in recess 78. Seals 124 isolate fluid under intermediate pressure in the bottom of recess 82 from fluid within shell 12. Seal 126 is between sealing lip 118 and an annular seat portion on partition 22. Seal 126 isolates fluid at suction pressure from fluid at discharge pressure across the top of seal assembly 84. The diameter and width of seal 126 are chosen so that the unit pressure between sealing lip 118 and the seat portion on partition 22 is greater than normally encountered discharge pressure, thus ensuring consistent sealing under normal operating conditions of compressor 10, i.e., at normal operating pressure ratios. Therefore, when undesirable pressure conditions are encountered, seal assembly 84 will be forced downward breaking seal 126, thereby permitting fluid flow from the discharge pressure zone of compressor 10 to the suction pressure zone of compressor 10. If this flow is great enough, the resultant loss of flow of motor-cooling suction gas (aggravated by the excessive temperature of the leaking discharge gas) will cause a motor protector to trip thereby de-energizing motor 28. The width of seal 126 is chose so that the unit pressure between sealing lip 118 and the seat portion of partition 22 is greater than normally encountered discharge pressure, thus ensuring consistent sealing. The scroll compressor as thus far broadly described is either now known in the art or is the subject of other pending applications for patent or patents of applicant's assignee. The present invention is directed towards a normally open mechanical valve assembly 230 which is disposed within recess 78 which is formed in non-orbiting scroll member 70. Valve assembly 230 moves between a fully closed and a fully open condition during steady state operation of compressor 10. Valve assembly 230 will close during the shut down of compressor 10. When valve assembly 230 is fully closed, the recompression volume is minimized and the reverse flow of discharge gas through scroll members 56 and 70 is prohibited. Valve assembly 230 is normally open as shown in Figures 3, 4A and 4B. The normally open configuration for valve assembly 230 eliminates the force required to open valve assembly 230 as well as eliminating any mechanical device to close valve assembly 230. Valve assembly 230 relies on pressure differential for closing. Referring now to Figures 3-4B, discharge valve assembly 230 is disposed within recess 78 and it comprises a valve seat 132, a valve plate 234, a valve stop 236 and a retainer 138. Valve seat 132 is a flat metal disc shaped member defining a discharge passage 140, a pair of alignment apertures 142 and a cavity 144. Non-orbiting scroll member 70 defines a pair of alignment bores 146. When apertures 142 are in registry with bores 146, discharge passage 140 is aligned with discharge passage 76. The shape of discharge passage 140 is the same as discharge passage 76. The thickness of valve seat 132, particularly in the area of cavity 144 is minimized to minimize the recompression volume for compressor 10 to increase the performance of compressor 10. The bottom surface of cavity 144 adjacent to valve plate 234 includes a contoured surface 148. The flat horizontal surface of valve seat 132 is used to secure valve plate 234 around its entire circumference. Contoured surface 148 of cavity 144 provides for the normally open characteristic of valve assembly 230. Contoured surface 148 may be a generally planar surface a shown in Figure 4A or contoured surface 148 may be a curved surface as shown in Figure 4B while cavity 144 and contoured surface 148 are shown as a pocket within valve seat 132, it is within the scope of the present invention to have cavity 144 and thus surface 148 extend through the edge of valve seat 132 as shown in phantom in Figure 4A. Also, it is within the scope of the present invention to eliminate valve seat 132 and incorporate cavity 144 and surface 148 directly into and onto non-orbiting scroll 70 if desired. Referring now to Figure 5, a discharge valve assembly 230 is illustrated. Discharge valve assembly 230 includes valve seat 132, a valve plate 234, a valve stop 236 and retainer 138. Valve plate 234 is a flat thin metal disc shaped member which includes an annular ring 250, a pair of radially inwardly extending legs 252 astride an aperture, and a central portion 254 attached to the radial inner end of legs 252. As a result of the aperture between them, legs 252 together are designed to be smaller in width than central portion 254. This reduced section is therefore weaker in bending than portion 254 which results in a faster opening and closing of valve assembly 230. This reduced section of legs 252 is acceptable from a durability standpoint since contoured surface 148 reduces the stress loading on this weaker section. The size and shape of portion 254 is designed to completely cover discharge passage 140 of valve seat 132. The outer peripheral shape of portion 254 is circular and this circular shape eliminates valve breakage which is associated with rectangular valve plates. Valve plate 234 includes the pair of alignment apertures 158, one being located in each leg 252. When apertures 158 are in registry with apertures 142 of valve seat 132, legs 252 position portion 254 in alignment with discharge passage 140. The thickness of valve plate 234 is determined by the stresses developed in legs 252 as valve plate 234 deflects from its normally open position to its closed position and from its normally open position to its fully open position. Valve stop 236 is a thick metal disc shaped member which provides support and bearing for valve plate 234 and valve seat 132. Valve stop 236 includes an annular ring 260, a pair of legs 262 extending radially inward from ring 260, a central portion 264 attached to the radially inner end of legs 262 and a support section 266 extending between central portion 264 and ring 260 on the side of portion 264 opposing to legs 262. Valve stop 236 also defines the pair of alignment apertures 170. When apertures 170 are in registry with apertures 158 in valve plate 234, legs 262 are aligned with legs 252 of valve plate 234 and central portion 264 is in alignment with central portion 254 of valve plate 234. Legs 262 and central portion 264 cooperate to define a curved contour surface 272. Discharge valve assembly 230 is assembled to non-orbiting scroll member 70 by first placing valve seat 132 within recess 78 with contoured surface 148 facing upward while aligning apertures 142 with bores 146 which aligns passage 140 with passage 76. Next, valve plate 234 is placed on top of valve seat 132 within recess 78 while aligning apertures 158 with apertures 142 which aligns circular portion 254 with passage 140. Next, valve stop 236 is placed on top of valve plate 234 within recess 78 while aligning apertures 170 within apertures 158 which aligns portions 262 and 264 with portions 252 and 254, respectively. A roll pin 176 is inserted through each aligned set of apertures 170, 158 and 142 and press fit into each bore 146 to maintain the alignment of these components. Finally, retainer 138 is installed within recess 78 to maintain the assembly of valve assembly 230 with non-orbiting scroll member 70. Retainer 138 can be connected to non-orbiting scroll member 70 by being press fit within recess 78, retainer 138 and recess 78 can be threaded to provide the connection or other means known in the art can be used to secure retainer 138 within recess 78. The assembly of retainer 138 sandwiches the entire circumferential ring 250 of valve plate 234 between the upper flat surface of valve seat 132 and ring 160 of valve stop 236 to secure and retain valve plate 134. Discharge valve assembly 230 is normally in position with valve plate 234 abutting the upper flat surface on valve seat 132. Contoured surface 148 spaces valve plate 234 from valve seat 132 to provide for the normally open characteristic of valve assembly 230. This allows limited fluid flow from discharge muffler chamber 80 into the compression pockets formed by scroll members 36 and 70. In order to close valve assembly 230, fluid pressure within muffler chamber 80 biases valve plate 234 against contoured surface 148 of valve seat 132 when the fluid pressure in chamber 80 is greater than the fluid pressure within the central most fluid pocket formed by scroll members 56 and 70. During operation of compressor 10, the fluid pressure differential between fluid in discharge chamber 80 and fluid within the central most fluid pocket formed by scroll members 56 and 70 will move valve plate 234 between abutment with contoured surface 148 of valve seat 132 and abutment with valve stop 236 or between a closed position and an open position. The normally open position of valve assembly 230 eliminates the force which is required to open a typical discharge valve. The elimination of this force lowers the pressure differential for operating the valve which in turn lowers power losses. In addition the normally open feature reduces the sound generated during the closing of the valve due to the gradual closing of the valve rather than the sudden closure of a normally closed valve. Contoured surface 148 provides for this gradual closing feature. The valve of the present invention operates solely on pressure differentials. Finally, the unique design for valve assembly 230 provides a large flow area to improve the flow characteristics of the system. Valve plate 234 is sandwiched between valve seat 132 and valve stop 136 with annular ring 160 of valve stop 136 abutting annular ring 250 of valve plate 234 which in turn abuts the upper flat surface of valve seat 132. The deflection of valve plate 234 occurs in legs 252 and circular portion 254. To fully close, portions 252 and 254 deflect toward valve seat 132 and to fully open portions 252 and 254 deflect in the opposite direction toward valve stop 236. The stresses encountered by valve plate 234 are stresses that are both plus and minus in direction from the neutral normally open position. Thus, when comparing the stresses of valve plate 234 with those encountered by the flap valve of a normally closed discharge valve the stresses are significantly reduced. The normally closed flap valve begins in a position adjacent a valve seat when the flap valve is unstressed. As the valve begins to open the stresses begin at the unstressed condition and continue to grow as the flap valve opens. Thus they are undirectional from the unstressed condition. The present invention, by centering the stressed conditions of valve plate 234 on both sides of the unstressed condition significantly reduces the stress loading experienced by valve plate 234. In order to further reduce the stress loading and thus the life of valve plate 234, the shape of contoured surface 148 of valve seat 132 and contoured surface 172 of valve stop 136 are chosen to ensure a gradual loading and minimizing of the stresses by distributing the loads over a broader area. Finally, the rounded contours and transitions between ring 250, legs 252 and circular portion 254 are designed to eliminate stress risers. This elimination of stress risers, the equal distribution of the load and the reduction in the maximum stresses encountered significantly improves the life and performance for discharge valve assembly 230. While the above detailed description describes the preferred embodiment of the present invention, it should be understood that the present invention is susceptible to modification, variation and alteration without deviating from the scope and fair meaning of the subjoined claims.

Claims: A scroll machine (10) comprising: a shell (14, 22) defining a discharge chamber (80); a first scroll member (56) disposed in said shell, said first member having a first spiral wrap (58) projecting outwardly from an end plate (60); a second scroll member (70) disposed in said shell, said second scroll member having a second spiral wrap (72) projecting outwardly from an end plate (74), said second spiral wrap (72) being intermeshed with said first spiral wrap (58); a drive member (28) for causing said scroll members to orbit relative to one another whereby said spiral wraps will create pockets of progressively changing volume between a suction pressure zone and a discharge pressure zone, said discharge pressure zone being in fluid communication with said discharge chamber (80); and a discharge valve (230) disposed between said discharge pressure zone and said discharge chamber, said discharge valve being movable between an open position where fluid flow between said discharge pressure zone and said discharge chamber is permitted and a closed position where fluid flow between said discharge chamber and said discharge pressure zone is prohibited, said discharge valve comprising: a valve seat (132) disposed within a recess (78) defined by one (70) of said first and second scroll members; a valve plate (234) disposed within said recess (78) adjacent said valve seat (132), said valve plate including a movable portion (152, 154) movable between a position adjacent said valve seat to place said discharge valve in said closed position and a position spaced from said valve seat to place said discharge valve in said open position; and a valve stop (236) disposed within said recess (78) adjacent said valve plate (234), said valve stop defining a contoured surface (272) for controlling said movement of said movable portion of said valve plate; characterised in that said valve plate (234) includes a stationary portion (250) adjacent said valve seat, and wherein said movable portion defines a first section (252) attached to said stationary portion and a second section (254) attached to said first section, said movable portion defining an aperture in the valve plate (234) such that said first section has a smaller cross-sectional area than said second section. The scroll machine according to claim 1, wherein said movable portion (252, 254) of said valve plate has a curved exterior edge. The scroll machine according to claim 1 or claim 2, wherein said stationary portion of said valve plate (234) is an annular ring (250). The scroll machine according to claim 3, wherein said first section of said movable portion of said valve plate is a generally rectangular portion (252) extending radially inward from said annular ring. The scroll machine according to claim 4, wherein said second section of said movable portion of said valve plate is a generally circular portion (254) attached to said generally rectangular portion (252). The scroll machine according to claim 5, wherein said valve stop (236) includes a second annular ring (260) and said contoured surface of said valve stop is defined by a second generally rectangular portion (262) extending radially inward from said second annular ring and a second generally circular portion (264) attached to said second generally rectangular section. The scroll machine according to claim 6, wherein said valve stop (236) includes a support section (266) attached between said second generally circular portion (264) and said annular ring (260). The scroll machine according to claim 5, wherein said one of said first (56) and second (70) scroll members defines a first discharge passage (76) opening into said recess (78) and said valve seat (132) defines a second discharge passage (140) extending through said valve seat, said discharge valve further comprising means for aligning said second discharge passage (140) with said first discharge passage (76) and for aligning said generally circular portion (254) with said second generally circular portion (264). The scroll machine according to claim 6, wherein said one of said first (56) and second (70) scroll members defines a first discharge passage (76) opening into said recess (78) and said valve seat (132) defines a second discharge passage (140) extending through said valve seat, said discharge valve further comprising means for aligning said second discharge passage (140) with said first discharge passage (76) for aligning said further generally circular portion (264) with said second discharge passage (140) and for aligning said generally circular portion (264) with said further circular portion (254). The scroll machine according to claim 6, wherein said one of said first (56) and second (70) scroll members defines a first discharge passage (76) opening into said recess (78) and said valve seat (132) defines a second discharge passage (140) extending through said valve seat, said discharge valve further comprising means for aligning said second discharge passage (140) with said first discharge passage (76) and for aligning said generally circular portion (254) with said second discharge passage (140). The scroll machine according to any one of the preceding claims, wherein said discharge valve is normally open. The scroll machine according to any one of the preceding claims, wherein said valve seat (132) includes a flat surface and a contoured surface, (148) said contoured surface normally being spaced from said valve plate (234). The scroll machine according to claim 12 wherein said contoured surface (148) is flat. The scroll machine according to claim 12, wherein said contoured surface (148) is curved.

Inventors: PEREVOZCHIKOV MICHAEL MIKHAYLO, PEREVOZCHIKOV, MICHAEL MIKHAYLOVICH
Applicants: COPELAND CORP, COPELAND CORPORATION
Application year: 1999
Main classification: F04C18
IPC codes: F04C29, F04C18