Abstract:
A scroll machine according to the present disclosure can include a shell, a first scroll member, a second scroll member and a valve assembly. The valve assembly can permit intermediate pressure in the shell to flow to an area of suction pressure in the shell. The valve assembly can include a first valve manifold that selectively couples to the shell. A second valve manifold can slidably and non-threadably locate against the first valve manifold. A retainer can couple to the first valve manifold to capture the second valve manifold against the first valve manifold. A valve can selectively connect an intermediate flow exiting the shell through the first and second valve manifolds to a suction flow entering the shell.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 61/729,034, filed on Nov. 21, 2012. 
     
    
     FIELD 
       [0002]    The present disclosure relates generally to scroll compressors and more particularly to a valve assembly that is selectively coupled to a scroll compressor to permit intermediate pressure in a housing of the scroll compressor to flow to an area of suction pressure. 
       BACKGROUND 
       [0003]    This section provides background information related to the present disclosure which is not necessarily prior art. 
         [0004]    Capacity modulation is often a desirable feature to incorporate into the compressors of refrigeration, heat pump, HVAC, or chiller system (generically, “climate control systems”) systems in order to better accommodate the wide range of loading to which the systems may be subjected. Many different approaches have been utilized for providing this capacity modulation feature. These approaches have ranged from control of the suction inlet of the compressor to bypassing compressed discharge gas back into the suction pressure zone of the compressor. With a scroll-type compressor, capacity modulation has often been accomplished by using a delayed suction approach which comprises providing ports at various positions along the scroll wrap which, when opened, allow the initially formed compression chambers between the intermeshing scroll wraps to communicate with the suction zone of the compressor, thereby delaying the point at which the sealed compression chambers are formed and, thus, delaying the start of compression of the suction gas. Such a method of capacity modulation can have the effect of reducing the compression ratio of the compressor. While these delayed suction systems are effective at reducing the capacity of the compressor, they are only able to provide a predetermined amount of compressor unloading with the amount being determined by the position of the unloading ports along the scroll wraps. 
       SUMMARY 
       [0005]    This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features. 
         [0006]    A scroll machine according to the present disclosure can include a shell, a first scroll member, a second scroll member and a valve assembly. The valve assembly can permit intermediate pressure in the shell to flow to an area of suction pressure in the shell. The valve assembly can include a first valve manifold that selectively couples to the shell. A second valve manifold can slidably and non-threadably locate against the first valve manifold. A retainer can couple to the first valve manifold to capture the second valve manifold against the first valve manifold. A valve can selectively connect an intermediate flow exiting the shell through the first and second valve manifolds to a suction flow entering the shell. 
         [0007]    According to additional features, the valve can include a first and a second valve. The first and second valves can be solenoid actuated. The first valve manifold can be threadably coupled to a cylinder mount on the shell. The retainer can be threadably coupled to the first valve manifold. 
         [0008]    According to still other features, one of the first and second valve manifolds can define a first annular groove that fluidly connects a first intermediate flow passage in the first valve manifold with a second intermediate flow passage in the second valve manifold. The first annular groove can permit the first and second intermediate flow passages to connect regardless of a rotational orientation of the second valve manifold relative to the first valve manifold. One of the first and second valve manifolds can define a second annular groove that fluidly connects a first suction flow passage in the first valve manifold with a second suction flow passage in the second valve manifold. The second annular groove can permit the first and second suction flow passages to connect regardless of a rotational orientation of the second valve manifold relative to the first valve manifold. 
         [0009]    According to other features, one of the first and second valve manifolds can define a radial groove having an O-ring disposed therein. One of the first and second valve manifolds can further define three radial grooves, each having an O-ring disposed therein. One of the first valve manifold and the cylinder mount can define a groove defined in an end face. The groove can have an O-ring therein. One of the first and second valve manifolds can include a first end face that opposes the other of the first and second valve manifolds. The first end face can define a first groove having a first O-ring disposed therein. One of the second valve manifold and the retainer can include a second end face that opposes the other of the second valve manifold and retainer. The second end face defines a second groove having a second O-ring disposed therein. 
         [0010]    A method of coupling a valve assembly to a shell of a scroll compressor can include threadably coupling a first valve manifold to a cylinder mount on the shell. A second valve manifold can be slidably and non-threadably advanced onto the first valve manifold. A retainer can be threadably coupled to the first valve manifold whereby the second valve manifold is captured between the first valve manifold and the retainer in an installed position. In the installed position, a valve can connect an intermediate flow exiting the shell through the first and second valve manifolds to a suction flow entering the shell. 
         [0011]    Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
     
    
     
       DRAWINGS 
         [0012]    The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure. 
           [0013]      FIG. 1  is a vertical section view of a scroll-type compressor incorporating a capacity modulation system and valve assembly according to the present disclosure; 
           [0014]      FIG. 2  is a side perspective view of the valve assembly of  FIG. 1 ; 
           [0015]      FIG. 3  is a cross-sectional view taken along lines  3 - 3  of  FIG. 2 ; 
           [0016]      FIG. 4  is a detailed cross-sectional view of the valve assembly as shown in  FIG. 1 ; 
           [0017]      FIG. 5  is a cross-sectional view taken along lines  5 - 5  of  FIG. 4 ; and 
           [0018]      FIG. 6  is a cross-sectional view taken along lines  6 - 6  of  FIG. 4 . 
       
    
    
       [0019]    Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings. 
       DETAILED DESCRIPTION 
       [0020]    Example embodiments will now be described more fully with reference to the accompanying drawings. The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the disclosure, its application, or uses. 
         [0021]    While the present disclosure is suitable for incorporation in many different types of scroll machines, including hermetic machines, open drive machines and non-hermetic machines, for exemplary purposes it will be described herein incorporated in a hermetic scroll refrigerant motor-compressor  10  of the “low side” type (i.e., where the motor and compressor are cooled by suction gas in the hermetical shell, as illustrated in the vertical section shown in  FIG. 1 ). Generally speaking, compressor  10  comprises a cylindrical hermetic housing or shell  12  which includes at the upper end thereof an end cap  14 . End cap  14  is provided with a refrigerant discharge fitting  16  optionally having the usual discharge valve therein. Other elements affixed to the shell  12  include a transversely extending partition  18  which is welded about its periphery at the same point that end cap  14  is welded to shell  12 , a two-piece main bearing housing  20  which is affixed to shell  12  at a plurality of points in any desirable manner, and a valve assembly  22  disposed in communication with the suction pressure zone of compressor  10  inside shell  12 . As will be described in greater detail herein, the valve assembly  22  can control flow between an intermediate pressure and a suction pressure. 
         [0022]    A motor stator  24  is press fit into a frame  26  which is in turn press fit into shell  12 . A crankshaft  28  having an eccentric crank pin  30  at the upper end thereof is rotatably journaled in a bearing  32  in main bearing housing  20  and a second bearing  34  in frame  26 . Crankshaft  28  has at the lower end the usual relatively large diameter oil-pumping 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  is filled with lubricating oil in the usual manner and concentric bore  36  at the bottom of crankshaft  28  is the primary pump acting in conjunction with bore  38 , which acts as a secondary pump, to pump lubricating fluid to all the various portions of compressor  10  which require lubrication. 
         [0023]    Crankshaft  28  is rotatively driven by an electric motor including stator  24  having windings  40  passing therethrough, and a rotor  42  press fit on crankshaft  28  and having one or more counterweights  44 . A motor protector  46 , of the usual type, is provided in close proximity to motor windings  40  so that if the motor exceeds its normal temperature range motor protector  46  will de-energize the motor. 
         [0024]    The upper surface of main bearing housing  20  is provided with an annular flat thrust bearing surface  48  on which is disposed an orbiting scroll member  50  comprising an end plate  52  having the usual spiral vane or wrap  54  on the upper surface thereof, an annular flat thrust surface  56  on the lower surface, and projecting downwardly therefrom a cylindrical hub  58  having a journal bearing  60  therein and in which is rotatively disposed a drive bushing  62  having an inner bore in which crank pin  30  is drivingly disposed. Crank pin  30  has a flat on one surface (not shown) which drivingly engages a flat surface in a portion of the inner bore of drive bushing  62  to provide a radially compliant driving arrangement, such as shown in assignee&#39;s U.S. Pat. No. 4,877,382, the disclosure of which is herein incorporated by reference. 
         [0025]    Wrap  54  meshes with a non-orbiting spiral wrap  64  forming a part of non-orbiting scroll member  66  which is mounted to main bearing housing  20  in any desired manner which will provide limited axial movement of scroll member  66 . The specific manner of such mounting is not relevant to the present inventions. For a more detailed description of the non-orbiting scroll suspension system, see assignee&#39;s U.S. Pat. No. 5,055,010, the disclosure of which is hereby incorporated herein by reference. 
         [0026]    Non-orbiting scroll member  66  has a centrally disposed discharge passageway communicating with an upwardly open recess  72  which is in fluid communication via an opening  74  in partition  18  with a discharge muffler chamber  76  defined by end cap  14  and partition  18 . A pressure relief valve (not shown) is disposed between the discharge muffler chamber  76  and the interior of shell  12 . The pressure relief valve will open at a specified differential pressure between the discharge and suction pressures to vent pressurized gas from the discharge muffler chamber  76 . Non-orbiting scroll member  66  has in the upper surface thereof, a biasing chamber or an annular recess  80  having parallel coaxial side walls in which is sealingly disposed for relative axial movement an annular floating seal  82  which serves to isolate the bottom of recess  80  from the presence of gas under suction and discharge pressure so that it can be placed in fluid communication with a source of intermediate fluid pressure by means of a passageway (not shown). Non-orbiting scroll member  66  is thus axially biased against orbiting scroll member  50  by the forces created by discharge pressure acting on the central portion of scroll member  66  and those created by intermediate fluid pressure acting on the bottom of recess  80 . This axial pressure biasing, as well as various techniques for supporting scroll member  66  for limited axial movement, are disclosed in much greater detail in assignee&#39;s aforesaid U.S. Pat. No. 4,877,328. 
         [0027]    Relative rotation of the scroll members is prevented by the usual Oldham coupling comprising a ring  86  having a first pair of keys  88  (one of which is shown) slidably disposed in diametrically opposed slots  90  (one of which is shown) in scroll member  66  and a second pair of keys (not shown) slidably disposed in diametrically opposed slots in scroll member  50 . Additional description of the operation of the compressor  10  may be found in assignee&#39;s U.S. Pat. No. 6,821,092, the disclosure of which is incorporated herein by reference. 
         [0028]    With additional reference now to  FIGS. 2-4 , the valve assembly  22  will be described in greater detail. The valve assembly  22  is mounted to the non-orbiting scroll member  66 , and may include a valve manifold assembly  110 , a first solenoid valve assembly  112  and a second solenoid valve assembly  114 . As will become appreciated from the following discussion, the first and second solenoid valve assemblies  112  and  114  can cooperate to control flow through the valve manifold assembly  110  between an intermediate pressure in the non-orbiting scroll member  66  and a suction pressure in the shell  12 . 
         [0029]    The valve manifold assembly  110  can include a first valve manifold  120 , a second valve manifold  122  and a retainer nut  124 . The first valve manifold  120  can comprise a first valve manifold body  130 . The first valve manifold body  130  can have a first end  132  that defines threads  134  and a second end  136  that defines threads  138 . The first valve manifold body  130  can further include a first intermediate flow passage  140 . While the flow passage  140  is represented in the drawings as multiple distinct channels, other configurations are contemplated including a single passage or additional passages. The first intermediate flow passage  140  can direct intermediate flow indicated by arrows  142  from an area of intermediate pressure within the non-orbiting scroll member  66 , through a passageway  144 , and into the second valve manifold  122 . The first end  132  can further define an end face  146  having an annular groove  148  containing a first seal  150 , such as an O-ring or a gasket. An intermediate groove  152  can also be defined into the first valve manifold body  130  and can contain second seal  154 , such as an O-ring or a gasket. The first end  132  of the first valve manifold  120  can be received at a port  160  provided on a cylinder mount  162  fixed to the shell  12  by welding or other suitable fastening techniques. Specifically, the threads  134  on the first end  132  of the first valve manifold body  130  can be threadingly received by complementary threads  166  defined on the port  160  of the cylinder mount  162 . The first seal  150  can engage the cylinder mount  162  to further provide a fluid-tight connection. 
         [0030]    The first valve manifold body  130  can further define a first suction flow passage  170  that can direct suction flow indicated by arrows  172  from the second valve manifold  122  and back to the shell  12  through the cylinder mount  162 . Again, it will be appreciated that the flow passage  170  may be configured differently. For example, additional passages may be configured through the first valve manifold body  130 . 
         [0031]    The second valve manifold  122  will now be described in greater detail. The second valve manifold  122  can generally communicate intermediate flow  142  and suction flow  172  between the first valve manifold  120  and the respective first and second solenoid valve assemblies  112  and  114 . The second valve manifold  122  can include a second valve manifold body  180  that can generally define a first annular groove  182  that can communicate with the intermediate flow  142  and a second annular groove  184  that can communicate with the suction flow  172 . 
         [0032]    The second valve manifold  122  can further include an optional pressure tapping aperture  188 . The second valve manifold body  180  can further include radial grooves  190 ,  192  and  194  that can receive third, fourth, and fifth seals  200 ,  202  and  204 , respectively. The second valve manifold body  180  can define second intermediate flow passages  210  ( FIG. 3 ) and second suction flow passages  212  ( FIG. 6 ). The second intermediate flow passages  210  can fluidly communicate with an intermediate flow valve inlet  220 . The second suction flow passages  212  can fluidly communicate with a suction outlet  222  of the first and second solenoid valve assemblies  112  and  114 . The second valve manifold body  180  can additionally define an annular groove  230  ( FIG. 4 ) having an O-ring  232  disposed therein. 
         [0033]    As will be further described herein, the second valve manifold  122  can be slidably installed around the first valve manifold body  130 . Explained in greater detail, the second valve manifold  122  can be slidably advanced along the first valve manifold body  130  without threads. Furthermore, the orientation of the first and second annular grooves  182  and  184  are such that the second valve manifold  122  need not attain a pre-desired rotational orientation relative to the first valve manifold  120 . In this regard, the configuration of the valve assembly  22  disclosed herein can provide an installer with a simplified and robust configuration. 
         [0034]    The retainer nut  124  can generally include threads  240  that can threadably mate with the threads  138  on the first valve manifold body  130 . Advancing of the retainer nut  124  can capture the second valve manifold body  180  relative to the first valve manifold body  130 . The retainer nut  124  can optionally define a pressure tapping aperture  244 . 
         [0035]    The first solenoid valve assembly  112  can include a first solenoid  250  and a first valve  252 . The second solenoid valve assembly can include a second solenoid  254  and a second valve  256 . A first pipe  260  ( FIG. 3 ) can fluidly communicate suction pressure from the first valve  252  and into the second valve manifold  122 . Similarly, a second pipe  262  ( FIG. 3 ) can fluidly communicate a suction pressure from the second valve  256  back to the second valve manifold  122 . 
         [0036]    Operation of the valve assembly according to one example will be described. In general, the solenoids  250  actuate the valves  252  between an open and a closed position. In an open position, flow may be communicated between the intermediate flow valve inlet  220  and the suction outlet  222  ( FIG. 5 ). In a closed position, flow can be precluded between the intermediate flow valve inlet  220  and the suction outlet  222 . It will be appreciated that the valves  252  may also operate in a position between fully open and fully closed. 
         [0037]    A method of assembling the valve assembly  22  relative to the shell  12  will now be described. It will be appreciated that in some examples the first and second solenoid valve assemblies may be already coupled to the second valve manifold body  180  by way of first and second pipes  260 ,  262 . In other examples, these components may be assembled on-site. At the outset, the first valve manifold  120  is threadably coupled relative to the port  160  on the cylinder mount  162 . Next, the second valve manifold  122  is slidably advanced onto the first valve manifold body  130  (in a direction leftward as viewed in  FIG. 4 ) toward the second seal  154 . Again, because the first annular groove  182  can couple the first intermediate flow passage  140  ( FIG. 4 ) on the first valve manifold  120  with the second intermediate flow passage  210  ( FIG. 5 ) regardless of a rotational orientation of the second valve manifold  122 , the installation may be simplified. Similarly, the second annular groove  184  can couple the first suction flow passage  170  ( FIG. 4 ) with the second suction flow passage  212  ( FIG. 6 ) regardless of rotational orientation of the second valve manifold  122 . Next, the retainer nut  124  can be threadably advanced (in a direction leftward as viewed in  FIG. 4 ) onto the threads  138  on the first valve manifold  120 . In an installed position ( FIG. 4 ), the retainer nut  124  influences axial compression of the first and second valve manifolds  120 ,  122  at the second seal  154  as well as axial compression of the retainer nut  124  and second valve manifold  122  at the sixth seal  232 . 
         [0038]    The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure. 
         [0039]    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. 
         [0040]    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. 
         [0041]    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. 
         [0042]    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. 
         [0043]    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.