Abstract:
Suction gas feed assemblies to provide gas to a hermetic compressor are provided. The feed assemblies have capacity for reducing suction noise resulting from suction conduit vibration, valving operation, suction gas pulsing, or the like. The suction gas feed assemblies include a suction plenum in the form of a substantially cylindrical end cap or motor cap having substantially straight side wall, a contoured top wall, and a gas inlet aperture and suction conduit aperture which are configured to provide strong suction and motor cooling, with reduced superheat, suction pulsation, and noise attenuation. The motor cap has excellent structural stiffness and low sound radiation.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    This invention concerns refrigeration or air conditioning compressor units of the hermetically sealed type wherein the compressor housing or “shell” encloses the compressor, its drive motor and accessories. In particular, the invention concerns suction gas feed systems utilizing a motor cap as a suction intake to provide gas to the compressor.  
           [0002]    Hermetically sealed compressors of the reciprocating type typically incorporate a compressor assembly which encloses the pistons, cylinders, and related compressor parts. A piston crankshaft typically extends from one end of the assembly, and is attached to a motor rotor of an electric motor. One or more stators are provided in proximity to the rotor, with an air gap formed between the rotor and the stator. Setting of this air gap is important to provide proper motor performance for suction and compressor operation in most compressors. In addition, suction gas feed systems often employ a suction gas intake plenum from which conduits convey the gas to the intake mechanism of the compressor assembly such as suction valving for the cylinders. Some examples of such systems are shown in U.S. Pat. Nos. 4,105,374; 4,174,189; 4,236,092; 4,239,461; 4,412,791; 4,503,347; 4,591,318, and 5,538,404.  
           [0003]    The suction gas intake plenum may be provided by a number of assemblies and methods. In hermetic compressors, the intake plenum is often provided by a motor cap or shroud (hereinafter “motor cap”) covering the end of the driving motor opposite the shaft. Where a motor cap is provided, it is necessary to provide an inlet or opening in the motor cap to facilitate gas intake for suction by the compressor. Use of a motor cap provides several advantages, such as cooling the motor by directing suction gas across the motor, as well as attenuating suction noise such as from pressure pulses produced by the compressor. For additional sound attenuation, it is well known that suction mufflers or other noise attenuators can be mounted in-line in the suction conduit systems, as shown in U.S. Pat. Nos. 3,101,891; 3,645,358; 3,864,064; 4,239,461; and 5,538,404. The utility disclosures of the above-listed patents are incorporated herein by reference.  
           [0004]    However, the prior constructions of suction gas feed assemblies do not provide a high degree of noise attenuation and efficient performance. For example, where motor caps are provided, they are primarily cylindrical in shape, which shape produces the undesirable result of providing excess volume in undesirable areas of gas flow that results in increased superheat and poor motor cooling. Superheat occurs when the suction gas temperature is elevated above the desired temperature, and can be caused by the gas absorbing too much heat from the motor before returning to the compressor. Superheat results in inefficiency in compression since more energy must be expended to lower the elevated gas temperature. The flexibility of the cylindrical shape of known motor caps also results in insufficient stiffness which produces increased noise radiation, and which compromises performance when the motor cap is used as a transportation stop within the top of the compressor assembly. In addition to poor stiffness and poor sound insulation properties, the substantially flat top walls of known cylindrical motor caps also require flat top compressor shell housings, which housings exhibit low stiffness and provide an undesirably high surface areas for sound transmission.  
           [0005]    Therefore, what is needed is an improved construction and assembly of suction gas feed assemblies in compressors, particularly in small hermetically sealed, reciprocating units. What is further needed is a motor cap which provides strong suction, minimized superheat, and adequate motor cooling, while providing increased structural stiffness and decreased sound radiation.  
         SUMMARY OF THE INVENTION  
         [0006]    one embodiment of the present invention, the apparatus is a suction gas feed assembly for a gas compressor unit having an electric motor which drives a piston type compressor. One end of the motor is interconnected with and adjacent the piston crankshaft to drive the compressor mechanism, while the other end of the motor is substantially unencumbered. The suction feed assembly of this embodiment includes a motor cap or shroud having a circumferential sidewall which blends into a top wall to form a generally cylindrical, inverted bowl-shaped closed end. The other end of the generally cylindrical motor cap includes a generally circular open end (“opening”) that is configured for substantial sealing contact with the unencumbered end of the motor. The sidewalls further include a gas inlet aperture for the entry of gas into the cap, and a suction conduit aperture adapted to receive a suction conduit that provides passage for the gas to the porting or valving of the compressor assembly.  
           [0007]    In another embodiment, the end cap includes a sidewall and closed top wall, the top wall being contoured and having protruding portions and recessed portions which together function to control and direct gas flow to provide strong suction, minimized superheat, and adequate motor cooling, while providing increased structural stiffness and decreased sound radiation.  
           [0008]    In yet another embodiment, the end cap has a profile that incorporates substantially spherical dimensional parameters to minimize cap size while maximizing strength and stiffness, reducing the surface area for sound radiation, and permitting use of a compressor housing having generally spherical or cylindrical dimensional parameters to reduce overall size of the compressor unit.  
           [0009]    In a further embodiment, the gas inlet aperture is provided along a substantially vertical panel portion of the sidewall, which is adjacent to a bridge-shaped portion of the top wall. In this embodiment, the aperture and the adjacent top wall and sidewall portions are positioned, aligned, sized and shaped so as to provide strong suction, minimized superheat, and adequate motor cooling, while providing increased structural stiffness and decreased sound radiation.  
           [0010]    One advantage of the invention is that it accommodates many types of presently manufactured compressors, including single or multiple cylinder compressors, their motors and the aforesaid auxiliary components.  
           [0011]    Another advantage of the invention is that it provides increased capacity for precise alignment of the gas inlet aperture with the gas return aperture of the compressor housing to producing strong suction, minimized superheat, and adequate motor cooling.  
           [0012]    Another advantage of the present invention is that the configuration of the motor cap of the present invention increases structural stiffness, while decreasing vibration and sound radiation.  
           [0013]    Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]    The invention will be further understood from the following description and drawings which show a preferred embodiment of the present invention, wherein:  
         [0015]    [0015]FIG. 1 is a side perspective view of the motor cap of the present invention installed in a hermetically sealed compressor unit;  
         [0016]    [0016]FIG. 2 is a three-quarter perspective view of the motor cap of the present invention;  
         [0017]    [0017]FIG. 3 is a top view of the motor cap of the present invention;  
         [0018]    [0018]FIG. 4 is a front side view of the motor cap of the present invention;  
         [0019]    [0019]FIG. 5 is a rear side view of the motor cap of the present invention;  
         [0020]    [0020]FIG. 6 is a side cross-sectional view of the motor cap of the present invention sectioned along line VI-VI of FIG. 3; and  
         [0021]    [0021]FIG. 7 is a side partial cross-sectional view of the motor cap taken along line VII-VII of FIG. 3. 
     
    
       [0022]    Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.  
       DESCRIPTION OF PREFERRED EMBODIMENTS  
       [0023]    The motor cap of the present invention preferably has a generally cylindrical shape, and is dimensioned to accommodate attachment to an electric motor and suction line conduit in a typical hermetic compressor unit such as the compressor unit shown in U.S. Pat. No. 5,538,404 (the disclosure of which is incorporated herein by reference) to form a suction gas feed assembly.  
         [0024]    [0024]FIG. 1 shows an embodiment of the suction gas feed assembly of the present invention for a hermetic compressor unit having a shell  10 , an electric motor  12  which drives a compressor mechanism, assembly, or device (not shown) having pistons for compression of gas and ports or valves to control gas intake and exhaust. As shown, one end of the motor  12  is substantially unencumbered, i.e. the end of the motor  12  opposite the compressor mechanism. As shown in FIGS. 1 and 2, the feed assembly comprises a motor cap  16  having substantially a cylindrical circumferential side wall  20  and a closed top wall  40 . The motor cap  16  includes an opening  17  disposed substantially opposite closed top wall  40 . The circumferential side wall  20  extends from the opening  17  to the closed top wall  40 , and thus the motor cap  16  has a shape generally similar to an inverted bowl.  
         [0025]    The opening  17  is configured or adapted to be mounted in substantial sealing contact with the unencumbered end of the motor  12 . Thus, when mounted, the motor cap  16  can serve as a suction plenum for the compressor by substantially enclosing the unencumbered end of the motor  12 . The feed assembly of this embodiment further includes suction conduit  18  having one end mounted in a suction conduit aperture  26  (See FIGS. 3 and 4) located in the sidewall  20  of the motor cap  16  and the other end being connected to the compressor ports or valves for the communication of gas to the compressor mechanism. In FIGS. 1, 3, and  4 , the suction conduit aperture  26  is located in a first substantially vertical panel section  24  located in the front portion  22  of the sidewall  20 . As shown in FIG. 3, the suction conduit aperture  26  is preferably disposed in substantial vertical and horizontal alignment with a gas inlet aperture  32  located in a second substantially vertical panel section  30  of a substantially opposed portion  28  of the side wall  20 . In a preferred embodiment, the gas inlet aperture  32  is also in substantial alignment with a gas return aperture  60  located in the shell  10 , as shown in FIG. 1. For purposes of this application, “substantially aligned” or “in substantial alignment” means that the horizontal and vertical center of each of the respective features may be in direct vertical and horizontal alignment (no offset), or may be offset vertically and/or horizontally from about 1 degree to about 15 degrees. This aligned configuration of the gas return aperture  60  and the gas inlet aperture  32  provides a substantially uninterrupted flow of suction gas through the motor cap  16  to provide motor cooling, while minimizing superheat of the refrigerant gas.  
         [0026]    As previously described, the opening  17  of the motor cap  16  is dimensioned to provide a substantially gas-tight frictional connection to the motor  12 . For connection to motor  12 , mounting mechanisms or means are provided on the circumferential sidewall  20  of motor cap  16  to assist in making a compressed, tight, sliding fit between the motor  12  and the motor cap  16 . The mounting mechanisms can include mounting apertures  34  located along the circumferential sidewall  20  disposed or positioned so as to engage corresponding mounting clips, tabs, or bolts (not shown) on the motor  12 . Preferably, at least two (2) mounting apertures  34  are provided, each spaced along the circumference of the sidewall  20 . As shown in the drawing, the spacing is preferably at about every 180 degrees along the 360 degree circumference of the sidewall  20 . The preferred spacing, combined with the contoured shape and dimensions of the motor cap  16  provide improved stiffness and decreased vibration and noise attenuation, while providing a good seal between the cap  16  and motor  12  for efficient gas suction and flow.  
         [0027]    In preferred embodiments, as shown in FIG. 3, the motor cap  16  has a substantially circular horizontal geometry defined by a major axis (A-A) and a minor axis (B-B). The outer diameter of the motor cap measured along the major axis is preferably between about 4 to about 7 inches, and the diameter measured along the minor axis is preferably between about 3 to about 6 inches. In this embodiment, the opening  17  has an outer perimeter of between 15 and 25 inches, and a base area of between 25 and 40 square inches. This geometry provides the basis for proper alignment of the various motor cap  16  features such as the gas inlet aperture  32  and suction conduit aperture  26 , as well as the other features of the motor cap  16  further described herein. For example, as shown in FIGS. 1 and 3, the suction conduit aperture  26  and the gas inlet aperture  32  are spaced apart a distance of from about one third to one-half of the total maximum circumferential dimension of the side wall  20 , which dimension corresponds to the outer perimeter of the opening  17 . Preferably, both the suction conduit aperture  26  and gas inlet aperture  32  are located in the same hemispherical section defined by the major axis A-A. This configuration creates a stronger uninterrupted flow through the hemisphere containing the apertures  26 ,  32 .  
         [0028]    As previously discussed, the gas inlet aperture  32  and suction conduit aperture  26  are preferably substantially opposed and are substantially aligned parallel to the major axis (A-A). More preferably, the gas inlet aperture  32  is offset from the major axis by between about one (1) to about twelve (12) degrees as shown by the angle α in FIG. 3, and the suction conduit aperture  26  is offset from the major axis (A-A) by about between zero (0) and about six (6) degrees. Preferably, the gas inlet aperture  32  and the suction conduit aperture  26  are mounted in substantially opposed, substantially vertical, substantially planar panel sections  30 ,  24  which panel sections  30 ,  24  are preferably disposed substantially parallel to the minor axis. More preferably, the gas inlet aperture  32  is also substantially aligned with a gas return aperture located in the compressor housing  10 .  
         [0029]    [0029]FIGS. 2 and 5 provide a rear view of the motor cap  16  that show additional features of the motor cap  16 . The gas inlet aperture  32  and the second substantially vertical panel section  30  are shown. The gas inlet aperture  32  is preferably located in the upper three-quarters of the panel section  30 , thereby increasing the rigidity of the lower panel section adjacent the opening  17 . As shown in FIG. 5, preferably, the height of the panel section  30  below the gas inlet aperture  32 , represented by the height “G” in FIG. 6, is between 0.50 inches and 1.5 inches measured from the opening  17 . Preferably, the shape of the aperture  32  mirrors the shape of the panel section  30 , and is sized to include from about 40% to about 80% of the surface area of the panel section  30 . To provide optimum suction gas flow, the height of the panel section  30  exceeds the height of the immediate adjacent sidewall portions by about 40-120%, and preferably by about 80-100%.  
         [0030]    As shown in FIG. 4 and discussed above, the sidewall  20  preferably includes preferably includes a front portion  22  having a substantially vertical, substantially planar first panel portion  24  disposed substantially parallel to the minor axis (B-B). Preferably, the tallest point of the motor cap  16  as measured from the opening  17 , such as represented by the height “K” in FIG. 6, is formed by the top wall  40  adjacent the first panel portion  22 . More preferably, the tallest point of the motor cap  16  is formed by the top wall  40  adjacent the first panel portion  22  and the recessed cylindrical portion  42 , and is between about 2.2 to 3.2 inches in height.  
         [0031]    Preferably, the first panel portion  24  originates at the intersection with the top wall  40 , and extends from about one half to two thirds of the length of the side wall  20 . More preferably, the panel portion  24  extends downward from the top wall  40  about two-thirds of the height of the side wall  20  before transitioning into an outwardly curved arcuate front wall portion  25  that terminates at the open end  17 . Most preferably, the outwardly curved arcuate front wall portion  25  includes a substantially vertical portion which is substantially parallel to the panel portion  24 . In preferred embodiments, the height of the substantially vertical portion of the arcuate front wall portion  25 , represented by the height “H” in FIG. 6, is between about 0.750 and 1.5 inches as measured from the opening  17 . In the embodiment shown, the panel portion  24  also includes the suction conduit aperture  26 , preferably in substantial alignment with the gas inlet aperture  32  located in the opposing rear portion  28  of the sidewall  20 .  
         [0032]    As shown in FIGS. 5 and 6, the side wall  20  and top wall  40  intersect to form an outwardly curved annular circumferential portion  50  extending around the circumference or perimeter of the motor cap  16 . Other features of the top wall  40  are shown in FIGS. 1, 2,  3 ,  5 ,  6 , and  7 , including protruding and recessed portions which function to direct and control gas flow to provide a substantially uninterrupted flow through at least one hemisphere of the motor cap to provide strong suction, minimized superheat, and adequate motor cooling. For example, the top wall  40  includes a recessed cylindrical portion  42  which may be positioned anywhere on the top wall  40  of the motor cap  16 . The function of the recessed cylindrical portion  42  is to reduce the internal volume of the motor cap  16  when mounted to the motor  12 , while also providing a recessed portion for receiving a transportation stop, such as a spring mounting attached to the compressor housing or shell  10 . Preferably, the recessed cylindrical portion  42  is positioned at the intersection of the major axis (A-A) and minor axis (B-B) of the horizontal geometry of the motor cap  16  at about the center of the top wall  40 . Preferably, the longitudinal axis of the recessed cylindrical portion is substantially vertical. Most preferably, the longitudinal axis of the recessed cylindrical portion is substantially parallel to the panel portions  24  and  30 . In the preferred embodiment, the diameter of the recessed cylindrical portion is between about 1.3 to 1.7 inches, and the depth of the recessed cylindrical portion is between about 0.60 to 0.80 inches as measured from the highest point on the top wall  40 .  
         [0033]    Another feature of the top wall  40  is a raised bridge portion  44  adjacent the rear panel section  30 . The raised bridge portion  44  includes a longitudinal peak  46  and sloping portions  48 . Preferably, the peak  46  is essentially horizontal, having a longitudinal axis which is in substantial alignment with the major axis (A-A). The peak  46  extends across the top wall  40  from the intersection with the raised second panel section  30  of the sidewall  20  to the recessed cylindrical portion  42 . More preferably, the height of the peak, as shown by the height “J” in FIG. 6, is between about 2.0 to 3.0 inches as measured from the opening  17 . The raised bridge portion  44  further includes at least two sloping portions  48  which originate at, and are centered on, the longitudinal axis of the peak  46 . Preferably, the sloping portions are symmetric about the peak  46 , and are annularly outwardly curved. More preferably, the sloping portions are annularly outwardly radially curved. As shown in FIG. 3, the sloping portions  48  collectively extend from about 15 degrees to about 80 degrees around the outwardly curved annular circumferential portion  50  of the motor cap  16 . The sloping portions  48  form a tunnel-like chamber which acts to funnel incoming gas through the inlet aperture  32 , across the motor end, and into the suction conduit aperture  26 . In the preferred embodiment shown in FIG. 3, the peak  46  is directly aligned over the center of the inlet aperture  32 , and the peak  46  and inlet aperture  32  are offset from about zero (0) to about twelve (12) degrees from the major (A-A) axis as shown by the angle α in FIG. 3. In this embodiment, the inlet aperture  32 , peak  44 , and suction aperture  26  are all located in the same hemisphere defined by the major axis. In this embodiment, the sloping portions  48  of the raised bridge portions are symmetric about the peak  46 , and each sloping portion extends from about 8 to about 40 degrees around the outwardly curved annular circumferential portion  50  of the motor cap  16  as measured from the peak  46 , and as shown by the angle β in FIG. 3, before blending into the top wall  40 . Preferably, the lowest height of the sidewall occurs immediately adjacent the point where each sloping portion  48  blends into the top wall  40 .  
         [0034]    The sloping portions  48 , in combination with the recessed cylindrical portion  42 , effectively reduce the volume of the motor cap  16 , further improving gas flow and motor cooling by eliminating undesirable areas of flow within the cap  16 . These recessed portions of the top wall  40 , when combined with the protruding portions including the peak  44  and vertical panel sections  24 ,  30  create a substantially uninterrupted flow of suction gas through the motor cap. In the preferred embodiment having the apertures  26 ,  32  and the peak  44  all located in the same hemisphere as defined by the major axis, a strong substantially uninterrupted flow of refrigerant gas is created in that hemisphere, resulting excellent motor cooling and minimized superheat. This configuration further allows for additional motor protrusion into opposite hemisphere of motor cap  16  without significantly adversely affecting motor cooling, or suction gas flow and temperature.  
         [0035]    For optimum performance, the volume and flow volume of the motor cap  16  must be considered. Preferably, the opening  17  of the motor cap  16  has a base area of between about 25 to 40 square inches, and the total internal volume of the motor cap  16  is between about 45 to 65 cubic inches. More preferably, the motor cap  16  retains a flow area volume of between 30-40 cubic inches when mounted on the motor  12  (as a result of motor protrusion(s) into the motor cap  16 ). Most preferably, the ratio of the flow area volume of the motor cap  16  when installed on the motor  12  to the volume of the uninstalled motor cap  16  is between 60% and 75%.  
         [0036]    Another relevant relationship is that of the volume of the motor cap  16  relative to the volume of the compressor shell  10 . In preferred embodiments, the motor cap  16  of the present invention is installed on a motor  12  and mounted within a compressor housing  10 . For optimum performance, the compressor housing is generally cylindrical, and has a volume of between about 300 to about 450 cubic inches. More preferably, the ratio of the motor cap  16  volume in cubic inches to the compressor housing  10  volume in cubic inches is between about 12% to about 18%. Most preferably, the ratio of the net flow volume of the motor cap  16  when installed on the motor  12  to the total volume of the compressor housing  10  is between about 9% to about 15%.  
         [0037]    While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.