Patent Publication Number: US-2023145998-A1

Title: Co-Rotating Scroll Compressor Having Synchronization Mechanism

Description:
FIELD 
     The present disclosure relates to a co-rotating scroll compressor having a synchronization mechanism. 
     BACKGROUND 
     This section provides background information related to the present disclosure and is not necessarily prior art. 
     A climate-control system (e.g., a heat-pump system, an air-conditioning system, a refrigeration system, etc.) may include a fluid circuit having an outdoor heat exchanger, an indoor heat exchanger, an expansion device disposed between the indoor and outdoor heat exchangers, and a compressor circulating a working fluid between the indoor and outdoor heat exchangers. Efficient and reliable operation of the compressor is desirable to ensure that the climate-control system in which the compressor is installed is capable of effectively and efficiently providing a cooling and/or heating effect on demand. 
     SUMMARY 
     This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features. 
     In one form, the present disclosure discloses a compressor that includes a shell assembly, a first compression member, a bearing housing, and a second compression member. The first compression member is rotatable relative to the shell assembly about a first axis. The bearing housing is coupled to the first compression member and rotatable relative to the shell assembly about the first axis. The bearing housing includes a first pin extending therefrom. The second compression member is rotatable relative to the shell assembly about a second axis that is spaced apart from the first axis (i.e., the first and second axes are not collinear with each other). The second compression member cooperates with the first compression member to define fluid pockets. The second compression member including a base plate and a first pin pocket. The first pin pocket is formed in the base plate and receives the first pin. The first compression member is moveable between a first position in which the first pin is engaged with a surface of the first pin pocket and a second position in which the first pin is disengaged from the surface of the first pin pocket. 
     In some configurations of the compressor of the above paragraph, the first pin pocket is arcuate and the surface of the first pin pocket is a working surface having a first arc center. The first pin pocket further includes a non-working surface having a second arc center that is spaced apart from the first arc center. 
     In some configurations of the compressor of any one or more of the above paragraphs, the working surface spans angularly at least 60 degrees. 
     In some configurations of the compressor of any one or more of the above paragraphs, the working surface has a predetermined angle. The predetermined angle is defined by 360 degrees/number of pins. 
     In some configurations of the compressor of any one or more of the above paragraphs, the first pin is disengaged from the working surface and the non-working surface when the first compression member is in the second position. 
     In some configurations of the compressor of any one or more of the above paragraphs, the first pin pocket further includes a transition surface disposed between the working surface and the non-working surface. The first compression member is movable to a third position in which the first pin is engaged with the transition surface. 
     In some configurations of the compressor of any one or more of the above paragraphs, the bearing housing includes a second pin and the second compression member includes an arcuate-shaped second pin pocket formed in the base plate. The second pin extends through the second pin pocket and is disengaged with a surface of the second pin pocket when the first compression member is in the first position. 
     In some configurations of the compressor of any one or more of the above paragraphs, the second pin is adjacent to the first pin. 
     In some configurations of the compressor of any one or more of the above paragraphs, the bearing housing includes a second pin and the second compression member includes an arcuate-shaped second pin pocket formed in the base plate. The second pin extends through the second pin pocket. 
     In some configurations of the compressor of any one or more of the above paragraphs, the second pin pocket includes a second working surface, a second non-working surface and a transition surface disposed between the second working surface and second the non-working surface. The second pin is engaged with the transition surface when the first compression member is in the first position. The second working surface having a third arc center and spanning angularly at least 60 degrees. 
     In some configurations of the compressor of any one or more of the above paragraphs, the second pin is adjacent to the first pin. 
     In some configurations of the compressor of any one or more of the above paragraphs, a driveshaft is coupled to the first compression member and includes first and second housings that receive respective first and second pins thereby coupling the first compression member and the bearing housing. 
     In some configurations of the compressor of any one or more of the above paragraphs, the first pin is a cylindrically-shaped. 
     In some configurations of the compressor of any one or more of the above paragraphs, the first pin pocket is formed in an outer diametrical surface of the base plate and extends through the base plate. 
     In some configurations of the compressor of any one or more of the above paragraphs, the first pin extends from the bearing housing in an axial direction (e.g., in a direction parallel to the first and second axes). 
     In some configurations of the compressor of any one or more of the above paragraphs, a driveshaft is coupled to the first compression member and includes a first housing that receives the first pin thereby coupling the first compression member and the bearing housing. 
     In another form, the compressor of the present disclosure discloses a shell assembly, a first compression member, a bearing housing, and a second compression member. The first compression member is rotatable relative to the shell assembly about a first axis. The bearing housing is coupled to the first compression member and rotatable relative to the shell assembly about the first axis. The bearing housing includes a plurality of pins extending therefrom. The second compression member is rotatable relative to the shell assembly about a second axis that is spaced apart from the first axis (i.e., the first and second axes are not collinear with each other). The second compression member cooperates with the first compression member to define fluid pockets. The second compression member includes a base plate and pin pockets formed in the base plate and receiving a respective pin. Each of the pin pockets has a working surface. The first compression member is moveable between a first position in which only one of the pins of the plurality of pins is engaged with the working surface of a respective pin pocket and a second position in which the one of the pins of the plurality of pins is disengaged from the working surface of the respective pin pocket. 
     In some configurations of the compressor of the above paragraph, the working surface of each pin pocket has a first arc center and a non-working surface of each pin pocket has a second arc center. The second arc center is spaced apart from the first arc center. 
     In some configurations of the compressor of any one or more of the above paragraphs, each of the pin pockets has a transition surface disposed between the working surface and the non-working surface. Only one of the pins of the plurality of pins is moveably engaged with the transition surface of a respective pin pocket when the first compression member is in the first position. 
     In some configurations of the compressor of any one or more of the above paragraphs, the working surface spans angularly at least 60 degrees. 
     In some configurations of the compressor of any one or more of the above paragraphs, the working surface has a predetermined angle. The predetermined angle is defined by 360 degrees/number of pins. 
     In some configurations of the compressor of any one or more of the above paragraphs, the pin pockets are circumferentially disposed and spaced apart around the base plate and the pins are circumferentially disposed and spaced apart around an axial end surface of the bearing housing. The pin pockets are arcuate-shaped. 
     In some configurations of the compressor of any one or more of the above paragraphs, the pin pockets are formed in an outer diametrical surface of the base plate and extend through the base plate. 
     In yet another form, the compressor of the present disclosure discloses a shell assembly, a first compression member, a second compression member, and a pin. The first compression member is rotatable relative to the shell assembly about a first axis. The second compression member is rotatable relative to the shell assembly about a second axis that is spaced apart from the first axis. The second compression member cooperates with the first compression member to define fluid pockets. The second compression member includes a base plate and an arcuate-shaped pin pocket. The pin pocket is formed in the base plate. The pin is coupled to the first compression member and is received in the pin pocket. The first compression member is moveable between a first position in which the pin is engaged with a surface of the pin pocket and a second position in which the pin is disengaged from the surface of the pin pocket. 
     In some configurations of the compressor of the above paragraph, the surface of the pin pocket is a working surface having a first arc center. The pin pocket further includes a non-working surface having a second arc center that is spaced apart from the first arc center. 
     In some configurations of the compressor of any one or more of the above paragraphs, the working surface spans angularly at least 60 degrees. 
     In some configurations of the compressor of any one or more of the above paragraphs, the pin is disengaged from the working surface and the non-working surface when the first compression member is in the second position. 
     In some configurations of the compressor of any one or more of the above paragraphs, the pin pocket further includes a transition surface disposed between the working surface and the non-working surface. The first compression member is movable to a third position in which the pin is engaged with the transition surface. 
     In some configurations of the compressor of any one or more of the above paragraphs, a bearing housing is coupled to the first compression member via the pin and is rotatable relative to the shell assembly about the first axis. 
     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 
       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. 
         FIG.  1    is a cross-sectional view of a compressor according to the principles of the present disclosure; 
         FIG.  2    is a partial cross-sectional view of the compressor of  FIG.  1   ; 
         FIG.  3    is an exploded view of the compression mechanism and the bearing housing of the compressor of  FIG.  1   ; 
         FIG.  4    is a cross-sectional view of the compressor taken along line  4 - 4  of  FIG.  1   ; and 
         FIG.  5    is a close-up view of a portion of the compressor indicated as area  5  in  FIG.  4   . 
     
    
    
     Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings. 
     DETAILED DESCRIPTION 
     Example embodiments will now be described more fully with reference to the accompanying drawings. 
     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. 
     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. 
     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. 
     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. 
     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. 
     With reference to  FIG.  1   , a compressor  10  is provided that may include a hermetic shell assembly  12 , a bearing housing assembly  14 , a motor assembly  16 , and a compression mechanism  18 . 
     The shell assembly  12  may generally form a compressor housing and may include a cylindrical shell  22 , a first end cap  24  at one end of the shell  22 , a partition  25  and a second end cap  26  at another end of the shell  22 . The shell  22  and the first end cap  24  may cooperate to define a suction-pressure chamber  30 . A suction gas inlet fitting  32  may be attached to the shell assembly  12  at an opening in the first end cap  24 . Suction-pressure working fluid (i.e., low-pressure working fluid) may be drawn into the compression mechanism  18  via the suction gas inlet fitting  32  for compression therein. 
     As shown in  FIGS.  1  and  2   , the partition  25  and the second end cap  26  may cooperate to define a discharge-pressure chamber  33 . The partition  25  may separate the discharge-pressure chamber  33  from the suction-pressure chamber  30 . A discharge gas outlet fitting  34  may be attached to the shell assembly  12  at another opening in the second end cap  26  and may communicate with the discharge-pressure chamber  33 . Discharge-pressure working fluid (i.e., working fluid at a higher pressure than suction pressure) may be discharged by the compression mechanism  18  and may flow into the discharge-pressure chamber  33 . The discharge-pressure working fluid in the discharge-pressure chamber  33  may exit the compressor  10  through the discharge-gas-outlet fitting  34 . In some configurations, a discharge valve (e.g., a check valve) may be disposed within or adjacent the discharge-gas-outlet fitting  34  and may allow fluid to exit the discharge-pressure chamber  33  through the discharge-gas-outlet fitting  34  and prevent fluid from entering the discharge-pressure chamber  33  through the discharge-gas-outlet fitting  34 . 
     The bearing housing assembly  14  may be disposed within the suction-pressure chamber  30  and may include a main bearing housing  38  and a bearing  40 . The main bearing housing  38  may house the bearing  40  therein. The bearing  40  may be a rolling element bearing or any other suitable type of bearing. As shown in  FIGS.  4  and  5   , the main bearing housing  38  may include a plurality of cylindrically-shaped pins  41  extending in an axial direction from an axial end surface  42  of the main bearing housing  38 . The pins  41  may be spaced apart from each other and may be disposed circumferentially around the axial end surface  42  of the main bearing housing  38 . Each pin  41  may have a proximate end  43  and a distal end  44 . The proximate end  43  may extend from the axial end surface  42  of the main bearing housing  38 . The distal end  44  may be coupled to driveshaft  46  such that the bearing housing  38  is coupled to the driveshaft  46 . In some configurations, the pins  41  may be separate components that are attached to the axial end surface  42  of the main bearing housing  38  through threads or a press-fit instead of being integrally formed with the axial end surface  42  of the main bearing housing  38 . 
     The motor assembly  16  may be disposed within the suction-pressure chamber  30  and may include a motor stator  52  and a rotor  54 . The motor stator  52  may be attached to the shell  22  (e.g., via press fit, staking, and/or welding). The rotor  54  may be attached to driveshaft  46  (e.g., via press fit, staking, and/or welding). The driveshaft  46  may be driven by the rotor  54  and may be supported by bearing  59  for rotation relative to the shell assembly  12 . The bearing  59  may be fixed to the first end cap  24  of the shell assembly  12 . In some configurations, the motor assembly  16  is a variable-speed motor. In other configurations, the motor assembly  16  could be a multi-speed motor or a fixed-speed motor. 
     The driveshaft  46  may include a driveshaft section  56  and a hub section  58 . The driveshaft section  56  may include a suction passage  62 . The suction passage  62  provides fluid communication between the suction gas inlet fitting  32  and the compression mechanism  18 . An inlet  65  of the suction passage  62  may be disposed at or near a first end  67  of the driveshaft section  56  adjacent the suction gas inlet fitting  32 . An outlet  66  of the suction passage  62  may be disposed at or near a second end  69  of the driveshaft section  56  adjacent to the compression mechanism  18 . 
     The hub section  58  may extend from the second end  69  of the driveshaft section  56  and may include a first portion  70 , a second portion  72  and a flange  74 . The first portion  70  extends in a radial direction from the second end  69  of the driveshaft section  56  (in a direction perpendicular to a rotational axis A 1  of driveshaft  46 ) and the second portion  72  extends in an axial direction from a periphery of the first portion  70  (in a direction parallel to a rotational axis A 1  of driveshaft  46 ). The flange  74  extends in a radial direction from an end of the second portion  72  and includes a plurality of pin housings  75 . As shown in  FIG.  3   , the pin housings  75  are spaced apart from each other and are circumferentially disposed around the flange  74 . Each pin  41  extending from the main bearing housing  38  is received in a respective pin housing  75 , thereby coupling the main bearing housing  38  and the driveshaft  46  to each other. In this manner, rotation of the driveshaft  46  causes corresponding rotation of the main bearing housing  38  about the rotational axis A 1  of the driveshaft  46 . 
     The compression mechanism  18  may be disposed within the suction-pressure chamber  30 . The compression mechanism  18  may include a first compression member and a second compression member that cooperate to define fluid pockets (i.e., compression pockets) therebetween. For example, the compression mechanism  18  may be a co-rotating scroll compression mechanism in which the first compression member is a first scroll member (i.e., a driver scroll member)  76  and the second compression member is a second scroll member (i.e., a driven scroll member)  78 . 
     The first scroll member  76  may include a first end plate  80  and a first spiral wrap  82  extending from the first end plate  80 . The first end plate  80  is disposed within and fixed to the hub section  58  of the driveshaft  46  such that the hub section  58  surrounds the first spiral wrap  82 . In some configurations, the first scroll member  76  and the driveshaft  46  may be a single component as opposed two separate components fixed to each other. The first end plate  80  may include a radially extending passage  84   a  and an axially extending passage  84   b . The radially extending passage  84   a  is formed in the first end plate  80  and extends from a central area of the first end plate  80  to the axially extending passage  84   b . The axially extending passage  84   b  extends from an end of the radially extending passage  84   a  to a suction inlet  85  of the first scroll member  76 . In this way, suction gas flowing through the suction passage  62  may flow through the passages  84   a ,  84   b  and into an outermost pocket of the fluid pockets via the suction inlet  85 . A portion of the suction gas flowing through the passages  84   a ,  84   b  may exit into the suction pressure-chamber  30 . 
     The second scroll member  78  defines a second rotational axis A 2  that is parallel to the rotational axis A 1  and offset from the rotational axis A 1 . The second scroll member  78  may include a second end plate  86 , a cylindrical hub  88  extending from one side of the second end plate  86 , and a second spiral wrap  90  extending from the opposite side of the second end plate  86 . A bearing support member  92  (e.g., a generally cylindrical shaft or body with a discharge passage  93 ) is fixed relative to the partition  25  and includes a first end  94  extending at least partially into the discharge-pressure chamber  33  and a second end  96  extending through the bearing  40  and into the hub  88  (the bearing  40  and the hub  88  are disposed within the suction-pressure chamber  30 ). The discharge passage  93  extends axially through the bearing support member  92  (i.e., through the first and second ends  94 ,  96 ) and provides fluid communication between the compression mechanism  18  and the discharge-pressure chamber  33 . The hub  88  of the second scroll member  78  is rotatably supported by a bearing  98  (e.g., a needle bearing) that is positioned between the hub  88  and the bearing support member  92 . 
     A sealing assembly  102  is disposed within the main bearing housing  38  and includes a housing  104  and a sealing member  106 . The housing  104  is press-fitted within the main bearing housing  38  such that an outer diametrical surface  107  of the housing  104  is sealingly engaged with an inner diametrical surface  108  of the main bearing housing  38 . The sealing member  106  is disposed within the housing  104  and is sealingly engaged with an outer diametrical surface  109  of the bearing support member  92 . In this way, fluid discharged from the fluid pockets of the compression mechanism  18  is prevented from flowing to the bearing  40  and to the suction chamber  30 . 
     The first and second spiral wraps  82 ,  90  are intermeshed with each other and cooperate to form a plurality of fluid pockets (i.e., compression pockets) therebetween. Rotation of the first scroll member  76  about the rotational axis A 1  and rotation of the second scroll member  78  about the second rotational axis A 2  causes the fluid pockets to decrease in size as they move from a radially outer position to a radially inner position, thereby compressing the working fluid therein from the suction pressure to the discharge pressure. 
     The second end plate  86  may be disposed axially between the first end plate  80  and the main bearing housing  38 . Annular seals  110  may be disposed within a groove  111  formed in the axial end surface  42  of the main bearing housing  38  and may sealingly and slidably engage the second end plate  86  to form an annular biasing chamber  112 . The annular seals  110  keep the biasing chamber  112  sealed off from the suction-pressure chamber  30  and the discharge gas while still allowing relative movement between the main bearing housing  38  and the second scroll member  78 . The second end plate  86  may include a biasing passage (not shown) that provides fluid communication between an intermediate-pressure compression pocket and the biasing chamber  112 . 
     The second end plate  86  may include a discharge passage  114  and a plurality of arcuate shaped pin pockets or scallops  116  ( FIGS.  3 - 5   ). The discharge passage  114  extends through the second end plate  86  and provides fluid communication between a radially innermost one of the fluid pockets and the discharge-gas-outlet fitting  34  (via the passage  93  in the bearing support member  92 ). A discharge valve (e.g., a reed valve or other check valve) may be disposed within or adjacent the discharge passage  114  or at the end  94  of the bearing support member  92 . The discharge valve allows working fluid to be discharged from the compression mechanism  18  through the discharge passage  114  and into the bearing support member  92  and prevents working fluid in the bearing support member  92  from flowing back into to the compression mechanism  18 . A portion of the discharge gas flowing out of the discharge passage  114  may flow through the passage  93  of the bearing support member  92 , into the discharge-pressure chamber  33  and out of the compressor  10  through the discharge-gas-outlet fitting  34 . Another portion of discharge gas flowing out of the discharge passage  114  may flow around the second end  96  of the bearing support member  92  and through the bearing  98  and may flow into a pocket  115  formed radially between the hub  88  and the bearing housing  38 . In this way, discharge gas within the pocket  115  and intermediate working fluid in the biasing chamber  112  axially biases the second scroll member  78  toward the first scroll member  76 . 
     The pin pockets  116  and the pins  41  form the synchronization mechanism. As shown in  FIGS.  3 - 5   , the pin pockets  116  may be spaced apart from each other and may be formed in an outer diametrical surface  117  of the second end plate  86 . The pin pockets  116  may also be disposed around the second end plate  86  and may receive a respective pin  41  of the main bearing housing  38  (each pin  41  extends through a respective pin pocket  116  formed in the second end plate  86 ). As shown in  FIG.  5   , each pin pocket  116  defines a working surface  118 , a non-working surface  120  and a transition surface  122 . 
     The working surface  118  has a first arc center X. The working surface  118  spans an angle A. In some configurations, the angle A may be at least 60 degrees. The working surface  118  may span an angle A that is defined by 360/Npin, where Npin is the number of pins. Each pin  41  is configured to engage a corresponding working surface  118  during a portion of the revolution of the first scroll member  76 , which causes energy from the driveshaft  46  to be transferred to the second scroll member  78  thereby rotating the second scroll member  78  about the second rotational axis A 2 . For example, in the embodiment shown in the figures, one pin  41   a  of the six pins  41  is configured to engage a corresponding working surface  118  (the other pins  41  are disengaged from corresponding working surfaces  118 ) at any given time. In this way, compressor  10  provides for radial compliance (i.e., displacement of the rotational axis A 1  relative to the rotational axis A 2 ). 
     The non-working surface  120  has a second arc center Y that is spaced apart from the first arc center X. Each pin  41  is spaced apart from a corresponding non-working surface  120  during its path of movement within the pin pocket  116  (the pin  41  does not engage the non-working surface  120  as the driveshaft  46  and the bearing housing  38  rotate about the first rotational axis A 1 ). The transition surface  122  is disposed between the working surface  118  and the non-working surface  120 . Each pin  41  is configured to be moveably engaged to a corresponding transition surface  122  after engaging the corresponding working surface  118  and prior to disengaging from the second end plate  86 . When one pin  41  engages the corresponding transition surface  122 , an adjacent pin  41  engages the corresponding working surface  118 . For example, as shown in  FIG.  4   , pin  41   b  is engaged with the corresponding transition surface  122  as the adjacent pin  41   a  engages the corresponding working surface  118 . During further rotation of the driveshaft  46 , the pin  41   b  will disengage from the corresponding transition surface  122  as pin  41   a  traverses the corresponding working surface  118 . 
     One of the benefits of the compressor  10  of the present disclosure is the pins  41  being configured to engage the second end plate  86  to rotate the second scroll member  78  while still providing for radial compliance.