Patent Description:
A scroll compressor is one type of compressor. Scroll compressors generally include a pair of scroll members which orbit relative to each other to compress air or a refrigerant. A typical scroll compressor includes a first, stationary scroll member having a base and a generally spiral wrap extending from the base and a second, orbiting scroll member having a base and a generally spiral wrap extending from the base. The spiral wraps of the first and second orbiting scroll members are interleaved, creating a series of compression chambers. The second, orbiting scroll member is driven to orbit the first, stationary scroll member by a rotating shaft. Some scroll compressors employ an eccentric pin on the rotating shaft that drives the second, orbiting scroll member.

<CIT> discusses a compressor configured too receive an economizer flow to an intermediate compression chamber inside the compressor.

<CIT> discusses an insert for an economizer, insertable into an economizer flow passage to provide a desired port area.

This disclosure relates generally to a scroll compressor. More specifically, this disclosure relates to providing economizer flow into a scroll compressor in a heating, ventilation, air conditioning, and refrigeration (HVACR) system. The invention is defined in the attached independent claim. Further, optional features are defined in the dependent claims appended thereto.

According to the invention there is provided a scroll compressor according to attached independent claim <NUM>.

A heating, ventilation, air conditioning, and refrigeration (HVACR) system according to attached independent claim <NUM> is disclosed. The HVACR system includes a refrigerant circuit. The refrigerant circuit includes a compressor as defined in independent claim <NUM>, a condenser, an expansion device, an economizer, and an evaporator, fluidly connected, wherein a working fluid flows therethrough.

References are made to the accompanying drawings that form a part of this disclosure, and which illustrate embodiments in which the systems and methods described in this Specification can be practiced.

This disclosure relates generally to a scroll compressor. More specifically, this disclosure relates to providing economizer flow into a scroll compressor in a heating, ventilation, air conditioning, and refrigeration (HVACR) system.

In an HVACR system, an economizer can be included. The economizer can receive a working fluid in a mixed state (e.g., a mixture of a liquid working fluid and a gaseous working fluid) and can provide a portion of the working fluid to a compressor in the HVACR system. The working fluid from the economizer can be provided to the compressor at an intermediate pressure and can, for example, include the gaseous portion of the working fluid received by the economizer. Inclusion of the economizer can, for example, increase an efficiency of the HVACR system, increase a capacity of the HVACR system, or increase both efficiency and a capacity of the HVACR system.

In an HVACR system where the compressor is, for example, a scroll compressor, providing the working fluid from the economizer to the compressor can be challenging. For example, the insertion of the intermediate pressure working fluid typically requires complex connections to ensure the working fluid is provided to an appropriate location in the compression process (e.g., a closed compression pocket). The complex connections can cause difficulties during the compressor manufacturing and assembly process. Additionally, the complex connections can result in additional pressure drop of the working fluid as it is provided to the compressor. The additional pressure drop can, for example, reduce an effectiveness of the economizer.

Embodiments of this disclosure are directed to a scroll compressor including an intermediate pressure chamber for providing working fluid to the compressor from the economizer. The intermediate pressure chamber can be provided at a location between the non-orbiting scroll member and an outermost cap of the scroll compressor. The intermediate pressure chamber is a simpler design that can result in a reduced pressure drop relative to prior scroll compressors. As a result of the embodiments described in this Specification, an effectiveness of the economizer can be increased, resulting in an increased amount of subcooling in the condenser and a larger capacity for the evaporator in the HVACR system. Additionally, the simpler assembly can result in reduced manufacturing efforts.

Embodiments of this disclosure are realized through providing the working fluid from the economizer to the compressor at a location that typically includes a higher pressure working fluid (e.g., at a discharge pressure). In an embodiment, this can include an unconventional usage of the typical discharge outlet of the scroll compressor. Such an embodiment can include repurposing what has been previously used as the discharge outlet for the scroll compressor so that working fluid from the economizer can be provided to the compressor through the discharge outlet (i.e., working fluid enters the discharge outlet and is provided to the scroll members for compression) instead of fluid being output from the scroll compressor at the discharge outlet. Other embodiments can include providing a new discharge outlet location and a new economizer injection inlet location that generally is at a location of the scroll compressor that is typically at the discharge pressure.

Embodiments of this disclosure can have the intermediate pressure chamber including a helical channel that fluidly connects an economizer injection inlet to a compression inlet port. The helical channel may have an inner surface that is continuously curved which reduces sudden directional changes of a flow path of a working fluid flowing through the helical channel. Reducing sudden directional changes of the flow path reduces the pressure drop and/or the velocity reduction within the flow path. The continuously curved inner surface reduces the pressure drop and/or velocity reduction of the working fluid between the economizer injection inlet and the compressor inlet port.

Embodiments of this disclosure may also be utilized in HVACR systems utilizing new-age refrigerants which typically have a reduced capacity. The inclusion of the economizer and the improved delivery of the working fluid from the economizer to the compressor can, for example, boost capacity of the HVACR system, thereby reducing an impact of switching to the new age refrigerants.

<FIG> is a schematic diagram of a refrigerant circuit <NUM>, according to an embodiment. The refrigerant circuit <NUM> generally includes a compressor <NUM>, a condenser <NUM>, an expansion device <NUM>, an evaporator <NUM>, an economizer <NUM>, and an expansion device <NUM> fluidly connected to form a closed fluid circuit. In an embodiment, the expansion device <NUM> can be referred to as the main expansion device <NUM> and the expansion device <NUM> can be referred to as the economizer expansion device <NUM>.

The refrigerant circuit <NUM> is an example and can be modified to include additional components. For example, in an embodiment, the refrigerant circuit <NUM> can include other components such as, but not limited to, one or more flow control devices, a receiver tank, a dryer, a suction-liquid heat exchanger, or the like.

The refrigerant circuit <NUM> can generally be applied in a variety of systems used to control an environmental condition (e.g., temperature, humidity, air quality, or the like) in a space (generally referred to as a conditioned space). Examples of such systems include, but are not limited to, HVACR systems, transport refrigeration systems, or the like.

The compressor <NUM>, condenser <NUM>, expansion device <NUM>, evaporator <NUM>, economizer <NUM>, and expansion device <NUM> are fluidly connected via refrigerant lines <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, and <NUM>. In an embodiment, the refrigerant lines <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> can alternatively be referred to as the refrigerant conduits <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> or the like.

In an embodiment, the refrigerant circuit <NUM> can be configured to be a cooling system (e.g., an air conditioning system) capable of operating in a cooling mode. In an embodiment, the refrigerant circuit <NUM> can be configured to be a heat pump system that can operate in both a cooling mode and a heating/defrost mode.

The refrigerant circuit <NUM> can operate according to generally known principles. The refrigerant circuit <NUM> can be configured to heat or cool a gaseous process fluid (e.g., a heat transfer medium or fluid such as, but not limited to, air or the like), in which case the refrigerant circuit <NUM> may be generally representative of an air conditioner or heat pump.

In operation, the compressor <NUM> compresses a working fluid (e.g., a heat transfer fluid such as a refrigerant or the like) from a relatively lower pressure gas (e.g., suction pressure) to a relatively higher-pressure gas (e.g., discharge pressure). In an embodiment, the compressor <NUM> can be a positive displacement compressor. In an embodiment, the positive displacement compressor can be a screw compressor, a scroll compressor, a reciprocating compressor, or the like.

The relatively higher-pressure gas is also at a relatively higher temperature, which is discharged from the compressor <NUM> and flows through refrigerant line <NUM> to the condenser <NUM>. The working fluid flows through the condenser <NUM> and rejects heat to a process fluid (e.g., water, air, etc.). The cooled working fluid, which is now in a liquid form, flows to the expansion device <NUM> via the refrigerant line <NUM>. The expansion device <NUM> reduces the pressure of the working fluid. As a result, a portion of the working fluid is converted to a gaseous form.

An "expansion device" may also be referred to as an expander. In an embodiment, the expander may be an expansion valve, expansion plate, expansion vessel, orifice, or the like, or other such types of expansion mechanisms. It is to be appreciated that the expander may be any type of expander used in the field for expanding a working fluid to cause the working fluid to decrease in temperature.

The working fluid, which is now in a mixed liquid and gaseous form flows to the economizer <NUM> via the refrigerant lines <NUM> and <NUM>. The gaseous portion of the mixed liquid and gaseous working fluid flows via the refrigerant line <NUM> and the liquid portion of the mixed liquid and gaseous working fluid flows via the refrigerant line <NUM>. In an embodiment, the mixed liquid and gaseous working fluid can flow to the economizer <NUM> via a single refrigerant line (e.g., the refrigerant line <NUM>), and the economizer <NUM> can result in a separate flow of the liquid portion of the working fluid flowing from the economizer <NUM> via the refrigerant line <NUM> and the gaseous portion of the working fluid flowing to the compressor <NUM> via the refrigerant line <NUM>.

From the economizer <NUM>, a gaseous portion of the working fluid flows from the economizer <NUM> to the compressor <NUM> via the refrigerant line <NUM>. The gaseous portion of the working fluid that flows to the compressor <NUM> is at an intermediate pressure between the relatively lower pressure working fluid and the relatively higher pressure working fluid (e.g., a pressure that is between the discharge pressure and the suction pressure).

A liquid portion of the working fluid flows from the economizer <NUM> to the expansion device <NUM> via the refrigerant line <NUM>. The expansion device <NUM> reduces the pressure of the working fluid. The working fluid flows through the evaporator <NUM> and absorbs heat from a process fluid (e.g., water, air, etc.), heating the working fluid, and converting it to a gaseous form. The gaseous working fluid then returns to the compressor <NUM> via the refrigerant line <NUM>. The above-described process continues while the refrigerant circuit is operating, for example, in a cooling mode (e.g., while the compressor <NUM> is enabled).

<FIG> is a schematic diagram of a portion of a compressor <NUM>, according to an embodiment.

The compressor <NUM> can be used in the refrigerant circuit <NUM> (<FIG>) as the compressor <NUM>. It is to be appreciated that the compressor <NUM> can also be used for purposes other than in a refrigerant circuit. For example, the compressor <NUM> can be used to compress air or gases other than a heat transfer fluid (e.g., natural gas, etc.). It is to be appreciated that the compressor <NUM> includes additional features that are not described in detail in this Specification. For example, the compressor <NUM> includes a lubricant sump for storing lubricant to be introduced to the moving features of the compressor <NUM>.

The illustrated compressor <NUM> is a single-stage scroll compressor. More specifically, the illustrated compressor <NUM> is a single-stage vertical scroll compressor. It is to be appreciated that the principles described in this Specification are not intended to be limited to single-stage scroll compressors and that they can be applied to multi-stage scroll compressors having two or more compression stages. Generally, the embodiments as disclosed in this Specification are suitable for a compressor with a vertical or a near vertical crankshaft (not shown in <FIG>, see <FIG> and <FIG>). It is to be appreciated that the embodiments may also be applied to a horizontal compressor.

The compressor <NUM> includes an economizer injection inlet <NUM> that leads to an intermediate pressure chamber <NUM>. The economizer injection inlet <NUM> can be a tube, connection, other fitting, or the like. The economizer injection inlet <NUM> can accordingly be alternatively referred to as the economizer injection tube <NUM>, the economizer injection connection <NUM>, or the economizer injection connection <NUM>.

In prior compressors, the economizer injection inlet <NUM> is generally a discharge outlet and the intermediate pressure chamber <NUM> is a high pressure (e.g., discharge pressure) chamber.

In operation, working fluid in a gaseous form and at an intermediate pressure can be received at the economizer injection inlet <NUM> from the economizer (e.g., economizer <NUM> and refrigerant line <NUM> in <FIG>). The working fluid is provided to the intermediate pressure chamber <NUM>, and subsequently to a compression chamber <NUM> (e.g., in closed pressure pockets) in the compression chamber <NUM> via compression inlet ports <NUM>, <NUM>.

The compression inlet ports <NUM>, <NUM> are formed in a non-orbiting scroll member <NUM> (alternatively can be referred to as the fixed scroll <NUM>) of the compressor <NUM>. Working fluid that has been compressed in the compression chamber <NUM> is provided from the compressor <NUM> via discharge outlet <NUM>. The compressed working fluid (e.g., at a discharge pressure) is then provided to the condenser (e.g., condenser <NUM> via refrigerant line <NUM> in <FIG>).

The compressor <NUM> includes a housing <NUM> having a plurality of portions 66A - 66C. The housing <NUM> can alternatively be referred to as the enclosure <NUM> or the like. The upper portion 66A of the housing <NUM> is an outermost housing of the compressor <NUM> and can be referred to as the outer cap 66A. The intermediate portion 66B of the housing <NUM> is disposed between the compression chamber <NUM> and the upper portion 66A and can be referred to as the intermediate cap 66B. The intermediate portion 66B and the upper portion 66A of the housing <NUM> form a volume therebetween, which is the intermediate pressure chamber <NUM>. The lower portion 66C of the housing <NUM> provides the remainder of the housing <NUM> for the compressor <NUM>.

A discharge seal <NUM> (e.g., a gasket, O-ring, face seal, or the like) and an intermediate seal <NUM> (e.g., a gasket, O-ring, face seal, or the like) function to isolate the intermediate pressure chamber <NUM> from the discharge outlet <NUM> (e.g., working fluid at a discharge pressure) and a suction chamber <NUM> (e.g., working fluid at a suction pressure). The discharge seal <NUM> can be sealingly engaged with the non-orbiting scroll member <NUM> and the upper portion 66A of the housing <NUM>. The intermediate seal <NUM> can be sealingly engaged with the non-orbiting scroll member <NUM> and the intermediate portion 66B of the housing <NUM>.

In operation, the compressor <NUM> can receive an intermediate pressure working fluid via the economizer injection inlet <NUM> and provide that working fluid to the compression chamber <NUM> via the compression inlet ports <NUM>, <NUM>, where the working fluid is compressed and ultimately discharged via the discharge outlet <NUM>.

In an embodiment, to ensure that working fluid is flowing into the compression chamber <NUM> via the compression inlet ports <NUM>, <NUM>, and not outward, the pressure of the working fluid at the compression inlet ports <NUM>, <NUM> may generally be higher than the pressure of the working fluid in the compression chamber <NUM>. In an embodiment, because pressure of the compression chamber <NUM> is cyclic in a scroll compressor, the pressure of the compression chamber <NUM> at the location of the compression inlet ports <NUM>, <NUM> may briefly be less than the pressure of the working fluid at the compression inlet ports <NUM>, <NUM>. However, the intermediate pressure chamber <NUM> may reduce an impact of any pressure wave that could flow backwards from the normal flow direction. In an embodiment, a one-way valve (e.g., a check valve) could be included to ensure that working fluid cannot flow backwards from the normal flow direction.

The specific location of the compression inlet ports <NUM>, <NUM> with respect to the compression process can be varied.

In an embodiment, the location of the compression inlet ports <NUM>, <NUM> can be selected so that the pressure in the compression chamber <NUM> is relatively near the suction pressure (e.g., at a location in which compression is just beginning). In the illustrated embodiment, this is a location at a relatively outer extent of the compression chamber <NUM>. In such an embodiment, the provision of the working fluid to the compression process can increase a capacity of the HVACR system, but may also increase energy required, which may reduce an efficiency of the HVACR system.

In an embodiment, the location of the compression inlet ports <NUM>, <NUM> can be selected so that the pressure in the compression chamber <NUM> is relatively near the discharge pressure (e.g., at a location near the discharge). In the illustrated embodiment, this is a location at a relatively inner extent of the compression chamber <NUM>. In such an embodiment, the provision of the working fluid to the compression process can increase the efficiency of the HVACR system, but may only slightly improve the capacity of the HVACR system.

In an embodiment, the location of the compression inlet ports <NUM>, <NUM> can be selected so that the pressure in the compression chamber <NUM> is between the suction pressure and the discharge pressure. The selection of the location of the compression inlet ports <NUM>, <NUM> can accordingly be balanced between increasing capacity and maintaining efficiency. Such a location may be selected based on, for example, modeling the anticipated efficiency and capacity changes, testing to determine the optimal location, or combinations thereof.

The compression inlet ports <NUM>, <NUM> can be bored or otherwise drilled or formed in the non-orbiting scroll member <NUM> of the compressor <NUM>. In an embodiment, the non-orbiting scroll member <NUM> can be cast or otherwise manufactured to include the compression inlet ports <NUM>, <NUM>. The compression inlet ports <NUM>, <NUM> can be designed to minimize a pressure drop of the working fluid having an intermediate pressure. For example, the diameter, the length, and combinations thereof can be controlled to provide the working fluid at, for example, a desired flowrate. Further, an orientation of the compression inlet ports <NUM>, <NUM> can be controlled. For example, the compression inlet ports <NUM>, <NUM> are oriented at an angle θ relative to a longitudinal axis L1 of the compressor <NUM>. The angle θ can be measured along a longitudinal axis L2, L3 of the compression inlet ports <NUM>, <NUM>. In an embodiment, the angle θ can vary. In an embodiment, the angle θ can be <NUM>°. In an embodiment, an angle of the compression inlet ports <NUM>, <NUM> can also be varied with respect to a direction into or out from the page.

<FIG> is a sectional view of a compressor <NUM>, according to an embodiment. It is to be appreciated that features of the compressor <NUM> can be the same as or similar to the features from the compressor <NUM>, according to an embodiment.

The illustrated compressor <NUM> is a single-stage scroll compressor. More specifically, the illustrated compressor <NUM> is a single-stage vertical scroll compressor. It is to be appreciated that the principles described in this Specification are not intended to be limited to single-stage scroll compressors and that they can be applied to multi-stage scroll compressors having two or more compression stages. Generally, the embodiments as disclosed in this Specification are suitable for a compressor with a vertical or a near vertical crankshaft (e.g., crankshaft <NUM>). It is to be appreciated that the embodiments may also be applied to a horizontal compressor.

The compressor <NUM> is illustrated in sectional side view. The compressor <NUM> includes a housing <NUM>. The housing <NUM> includes an upper portion 102A, an intermediate portion 102B, and a lower portion 102C. The upper portion 102A of the housing <NUM> is an outermost housing of the compressor <NUM> and can alternatively be referred to as the outer cap 102A. The intermediate portion 102B of the housing <NUM> is disposed between the compression chamber <NUM> and the upper portion 102A of the housing <NUM>, and can be referred to as the intermediate cap 102B. The intermediate portion 102B and the upper portion 102A form a volume therebetween, which is the intermediate pressure chamber <NUM>. The lower portion 102C provides the remainder of the housing <NUM> for the compressor <NUM>.

The compressor <NUM> includes a suction inlet (not shown in the sectional side view of <FIG>) and a discharge outlet <NUM>. In the illustrated embodiment, the discharge outlet <NUM> is oriented in line with a driveshaft <NUM> of the compressor <NUM>. In the illustrated embodiment, the discharge outlet <NUM> is therefore oriented such that working fluid is discharged vertically upward (with respect to the page). It is to be appreciated that other orientations of the discharge outlet <NUM> may be possible (e.g., horizontal, angled, or the like).

The compressor <NUM> includes an orbiting scroll member <NUM> and a non-orbiting scroll member <NUM>. The non-orbiting scroll member <NUM> can alternatively be referred to as, for example, the stationary scroll <NUM>, the fixed scroll <NUM>, or the like. The non-orbiting scroll member <NUM> is aligned in meshing engagement with the orbiting scroll member <NUM> by an Oldham coupling <NUM>.

The compressor <NUM> includes the driveshaft <NUM>. The driveshaft <NUM> can alternatively be referred to as the crankshaft <NUM>. The driveshaft <NUM> can be rotatably driven by, for example, an electric motor <NUM>. The electric motor <NUM> can generally include a stator <NUM> and a rotor <NUM>. The driveshaft <NUM> is fixed to the rotor <NUM> such that the driveshaft <NUM> rotates along with the rotation of the rotor <NUM>. The electric motor <NUM>, stator <NUM>, and rotor <NUM> operate according to generally known principles. The driveshaft <NUM> can, for example, be fixed to the rotor <NUM> via an interference fit or the like. The driveshaft <NUM> can, in an embodiment, be connected to an external electric motor, an internal combustion engine (e.g., a diesel engine or a gasoline engine), or the like. It will be appreciated that in such embodiments the electric motor <NUM>, stator <NUM>, and rotor <NUM> would not be present in the compressor <NUM>.

The compressor <NUM> includes an economizer injection inlet <NUM>. The economizer injection inlet <NUM> is disposed in the upper portion 102A of the housing <NUM>. In the illustrated embodiment, a longitudinal axis L4 of the economizer injection inlet <NUM> is parallel to an axis L5 of the driveshaft <NUM>. The economizer injection inlet <NUM> is configured to be fluidly connected to an economizer (e.g., the economizer <NUM> in <FIG>). In an embodiment, the economizer injection inlet <NUM> and the discharge outlet <NUM> can be, for example, machined connections or tubes that are welded to the housing <NUM>. In an embodiment, the housing <NUM>, economizer injection inlet <NUM>, and discharge outlet <NUM> can be a single piece, unitary construction.

The economizer injection inlet <NUM> is in fluid communication with an intermediate pressure chamber <NUM>. The intermediate pressure chamber <NUM> is fluidly connected to compression chamber <NUM> via a plurality of compression inlet ports <NUM>, <NUM>.

The compression inlet ports <NUM>, <NUM> are formed in the non-orbiting scroll member <NUM> of the compressor <NUM>. Working fluid that has been compressed in the compression chamber <NUM> is provided from the compressor <NUM> via discharge outlet <NUM>. The compressed working fluid (e.g., at a discharge pressure) is then provided to the condenser (e.g., condenser <NUM> via refrigerant line <NUM> in <FIG>).

A discharge seal <NUM> (e.g., a gasket, O-ring, face seal, or the like) and an intermediate seal <NUM> (e.g., a gasket, O-ring, face seal, or the like) can function to isolate the intermediate pressure chamber <NUM> from the discharge outlet <NUM> (e.g., working fluid at a discharge pressure) and a suction chamber <NUM> (e.g., working fluid at a suction pressure). The discharge seal <NUM> sealingly engages the upper portion 102A of the housing <NUM> and the non-orbiting scroll member <NUM>. The intermediate seal <NUM> sealingly engages the intermediate portion 102B of the housing <NUM> and the non-orbiting scroll member <NUM>.

In an embodiment, the location of the compression inlet ports <NUM>, <NUM> can be selected so that the pressure in the compression chamber <NUM> is relatively near the discharge pressure (e.g., at a location near discharge). In the illustrated embodiment, this is a location at a relatively inner extent of the compression chamber <NUM>. In such an embodiment, the provision of the working fluid to the compression process can increase the efficiency of the HVACR system, but may only slightly improve the capacity of the HVACR system.

The compression inlet ports <NUM>, <NUM> can be bored or otherwise drilled or formed in the non-orbiting scroll member <NUM> of the compressor <NUM>. In an embodiment, the non-orbiting scroll member <NUM> can be cast or otherwise manufactured to include the compression inlet ports <NUM>, <NUM>. The compression inlet ports <NUM>, <NUM> can be designed to minimize a pressure drop of the working fluid having an intermediate pressure. For example, the diameter, the length, and combinations thereof can be controlled to provide the working fluid at, for example, a desired flowrate. Further, an orientation of the compression inlet ports <NUM>, <NUM> can be controlled. For example, the compression inlet ports <NUM>, <NUM> are oriented at an angle θ relative to a longitudinal axis L5 of the compressor <NUM>. The angle θ can be measured along a longitudinal axis L6, L7 of the compression inlet ports <NUM>, <NUM>. In an embodiment, the angle θ can vary. In an embodiment, the angle θ can be <NUM>°. In an embodiment, an angle of the compression inlet ports <NUM>, <NUM> can also be varied with respect to a direction into or out from the page.

<FIG> is a top view of the compressor <NUM> in <FIG>, according to an embodiment. As illustrated in <FIG>, the economizer injection inlet <NUM> and the discharge outlet <NUM> are both disposed in the upper portion 102A of the housing <NUM>. The discharge outlet <NUM> is disposed centrally with respect to the compressor <NUM>. The economizer injection inlet <NUM> is disposed offset from the center of the compressor <NUM>. Line <NUM> - <NUM> is also shown in <FIG>, indicating along which line the section of <FIG> is displayed.

<FIG> is a sectional view of a compressor <NUM>, according to an embodiment. It is to be appreciated that features of the compressor <NUM> can be the same as or similar to the features from the compressor <NUM> or the compressor <NUM>, according to an embodiment. For simplicity of this Specification, features identified by like reference numbers will not be described in further detail.

The compressor <NUM> is illustrated in sectional side view. The compressor <NUM> includes housing <NUM>. The housing <NUM> includes an upper portion 202A and a lower portion 202B. The upper portion 202A can alternatively be referred to as the cap 202A. The upper portion 202A is an outermost portion of the housing <NUM> of the compressor <NUM>. The upper portion 202A and the non-orbiting scroll member <NUM> form a volume therebetween, which is the intermediate pressure chamber <NUM>. The lower portion 202B provides the remainder of the housing <NUM> for the compressor <NUM>.

The compressor <NUM> includes an economizer injection inlet <NUM> (<FIG>). The economizer injection inlet <NUM> is disposed in the upper portion 202A of the housing <NUM>. In the illustrated embodiment, a longitudinal axis of the economizer injection inlet <NUM> is parallel to an axis of the driveshaft <NUM>. The economizer injection inlet <NUM> is configured to be fluidly connected to an economizer (e.g., the economizer <NUM> in <FIG>). In an embodiment, the economizer injection inlet <NUM> and the discharge outlet <NUM> can be, for example, machined connections or tubes that are welded to the housing <NUM>. In an embodiment, the housing <NUM>, economizer injection inlet <NUM>, and discharge outlet <NUM> can be a single piece, unitary construction.

The economizer injection inlet <NUM> is in fluid communication with compression chamber <NUM> via a plurality of compression inlet ports <NUM>, <NUM>. In the illustrated embodiment, the housing portion 202A forms a sealing engagement with the non-orbiting scroll member <NUM>. The compression inlet ports <NUM>, <NUM> are formed in the non-orbiting scroll member <NUM> of the compressor <NUM>. Working fluid that has been compressed in the compression chamber <NUM> is provided from the compressor <NUM> via discharge outlet <NUM>. The compressed working fluid (e.g., at a discharge pressure) is then provided to the condenser (e.g., condenser <NUM> via refrigerant line <NUM> in <FIG>).

A discharge seal <NUM> (e.g., a gasket, O-ring, face seal, or the like) and intermediate seals <NUM> (e.g., a gasket, O-ring, face seal, or the like) can function to isolate the compression inlet ports <NUM>, <NUM> from the discharge outlet <NUM> (e.g., working fluid at a discharge pressure) and a suction chamber <NUM> (e.g., working fluid at a suction pressure). The discharge seal <NUM> sealingly engages the upper portion 202A of the housing <NUM> and the non-orbiting scroll member <NUM>. The intermediate seals <NUM> sealingly engage the upper portion 202A of the housing <NUM> and the non-orbiting scroll member <NUM>. In the illustrated embodiment, there are two intermediate seals <NUM>. The intermediate seals <NUM> form a volume through which the working fluid from the economizer <NUM> can be provided to the compression chamber <NUM>. Thus the intermediate seals <NUM> sealingly engage between the upper portion 202A of the housing <NUM> and the non-orbiting scroll member <NUM>.

The compression inlet ports <NUM>, <NUM> can be bored or otherwise drilled or formed in the non-orbiting scroll member <NUM> of the compressor <NUM>. In an embodiment, the non-orbiting scroll member <NUM> can be cast or otherwise manufactured to include the compression inlet ports <NUM>, <NUM>. The compression inlet ports <NUM>, <NUM> can be designed to minimize a pressure drop of the working fluid having an intermediate pressure. For example, the diameter, the length, and combinations thereof can be controlled to provide the working fluid at, for example, a desired flowrate. Further, an orientation of the compression inlet ports <NUM>, <NUM> can be controlled. For example, the compression inlet ports <NUM>, <NUM> are oriented at an angle θ relative to a longitudinal axis L5 of the compressor <NUM>. The angle θ can be measured along a longitudinal axis L8, L9 of the compression inlet ports <NUM>, <NUM>. In an embodiment, the angle θ can vary. In an embodiment, the angle θ can be <NUM>°. In an embodiment, an angle of the compression inlet ports <NUM>, <NUM> can also be varied with respect to a direction into or out from the page.

<FIG> is a top view of the compressor <NUM> in <FIG>, according to an embodiment. As illustrated in <FIG>, the economizer injection inlet <NUM> and the discharge outlet <NUM> are both formed in the upper portion 202A of the housing <NUM>. The discharge outlet <NUM> is disposed centrally with respect to the compressor <NUM>. The economizer injection inlet <NUM> is disposed offset from the center of the compressor <NUM>. Line <NUM> - <NUM> is also shown in <FIG>, indicating along which line the section of <FIG> is displayed.

<FIG> is a perspective view of a partial cutaway of a compressor <NUM> with a first helical channel <NUM> and a second helical channel <NUM>, according to an embodiment. It is to be appreciated that the compressor <NUM> in some embodiments can have features similar to the compressor <NUM>, the compressor <NUM>, and/or the compressor <NUM>, except as described below. For simplicity of this Specification, features identified by like reference numbers will not be described in further detail.

In an embodiment, the compressor <NUM> is a compressor in a refrigerant circuit for compressing a working fluid (e.g., the compressor <NUM> of the refrigerant circuit <NUM> in <FIG>). It is to be appreciated that the compressor <NUM> includes additional features shown but not described in detail in this Specification. For example, the compressor <NUM> in an embodiment can include a lubricant sump for storing lubricant to be introduced to the moving features of the compressor <NUM>.

The illustrated compressor <NUM> is a single stage scroll compressor. More specifically, the illustrated compressor <NUM> is a single-stage vertical scroll compressor. It is to be appreciated that the principles described in this Specification are not intended to be limited to single-stage scroll compressors and that they can be applied to multi-stage scroll compressors having two or more compression stages. Generally, the embodiments as disclosed in this Specification are suitable for a compressor with a vertical or a near vertical crankshaft. It is to be appreciated that the embodiments may also be applied to a horizontal compressor.

The compressor <NUM> includes a housing <NUM>. The housing <NUM> includes an upper portion 702A and a lower portion 702B. The upper portion 702A can also be referred to as a cap. The upper portion 702A is an outermost portion of the housing <NUM> of the compressor <NUM>. The upper portion 702A and a non-orbiting scroll member <NUM> form a volume therebetween, which is an intermediate pressure chamber <NUM>. The lower portion 702B provides the remainder of the housing <NUM> for the compressor <NUM>. The lower portion 702b can be referred to as a shell.

The compressor <NUM> includes an economizer injection inlet <NUM>. The economizer injection inlet <NUM> is disposed in the upper portion 702A of the housing <NUM>. In the illustrated embodiment, a longitudinal axis L6 of the economizer injection inlet <NUM> is parallel to an axis L5 of the driveshaft <NUM> (shown in <FIG>). The economizer injection inlet <NUM> is configured to be fluidly connected to an economizer of the refrigerant circuit (e.g., the economizer <NUM> in <FIG>). In an embodiment, the economizer injection inlet <NUM> and the discharge outlet <NUM> can be, for example, machined connections or tubes that are welded to the housing <NUM>. In an embodiment, the housing <NUM>, economizer injection inlet <NUM>, and discharge outlet <NUM> can be a single piece, unitary construction.

The economizer injection inlet <NUM> is in fluid communication with a compression chamber <NUM> via a plurality of compression inlet ports <NUM>, <NUM>. The compression inlet port <NUM> is obscured in <FIG> (e.g., see <FIG>). In the illustrated embodiment in <FIG>, the housing portion 702A forms a sealing engagement with the non-orbiting scroll member <NUM>. The compression inlet ports <NUM>, <NUM> are formed in the non-orbiting scroll member <NUM> of the compressor <NUM>. Working fluid that has been compressed in the compression chamber <NUM> is discharged from the compressor <NUM> via the discharge outlet <NUM>. The compressed working fluid (e.g., at a discharge pressure) is then provided to a condenser in the refrigerant circuit (e.g., to the condenser <NUM> via the refrigerant line <NUM> in <FIG>).

In operation, the compressor <NUM> can receive an intermediate pressure working fluid via the economizer injection inlet <NUM> and provide the intermediate pressure working fluid to the compression chamber <NUM> via the compression inlet ports <NUM>, <NUM>. The intermediate pressure working fluid is then further compressed and ultimately discharged via the discharge outlet <NUM>.

In an embodiment, to ensure that working fluid is flowing into the compression chamber <NUM> via the compression inlet ports <NUM>, <NUM>, and not outward, the pressure of the working fluid at the compression inlet ports <NUM>, <NUM> may generally be higher than the pressure of the working fluid in the compression chamber <NUM>. For example, the pressure of the working fluid at the first compression inlet port <NUM> may generally be higher than the pressure of the working fluid in the pressure pocket of the compression chamber <NUM> at the first compression inlet port <NUM>. The pressure of the working fluid at the compression inlet ports <NUM>, <NUM> is between the suction pressure and discharge pressure of the compression chamber <NUM>.

In an embodiment, because pressure of the compression chamber <NUM> is cyclic in a scroll compressor, the pressure of the compression chamber <NUM> at the location of the compression inlet ports <NUM>, <NUM> may briefly be less than the pressure of the working fluid at the compression inlet ports <NUM>, <NUM>. However, the intermediate pressure chamber <NUM> may reduce an impact of any pressure wave that could flow backwards from the normal flow direction.

In an embodiment, a one-way valve <NUM> (e.g., a check valve) may be included to ensure that working fluid cannot flow backwards from the normal flow direction.

The specific location of the compression inlet ports <NUM>, <NUM> with respect to the compression process and/or the angle of the compression inlet ports <NUM>, <NUM> can vary in embodiments as similarly discussed above regarding the inlet ports <NUM>, <NUM><NUM>, <NUM> of the compressors <NUM>, <NUM>.

As illustrated in <FIG>, the intermediate pressure working fluid has a main flow path F entering into the intermediate pressure chamber <NUM>. The main flow path F has an inlet end FIN, where the intermediate pressure working fluid entering into the intermediate pressure chamber <NUM>, and an outlet end FOUT. The outlet end FOUT of the main flow path F diverges into a first portion F1 that follows a first circumferential direction D1 of the housing <NUM> (D1 shown in <FIG>) and a second portion F2 that follows a second circumferential direction D2 of the housing <NUM> (D2 shown in <FIG>). For example, the first circumferential direction D1 is opposite to the second circumferential direction D2. The main flow path F diverges into the inlet end F1IN of the first portion F1 and the inlet end F2IN of the second portion F2. The inlet end F1IN of the first portion F1 and the inlet end F2IN of the second portion F2 diverge at the economizer injection inlet <NUM>. An outlet end F1OUT of the first portion F1 and the outlet end F2OUT (obscured in <FIG>) of the second portion F2 connect with the first compression inlet port <NUM> and the second compression inlet port <NUM>, respectively.

The intermediate pressure chamber <NUM> has a first helical channel <NUM> that fluidly connects the economizer injection inlet <NUM> (alternatively referred as an economizer inlet) to the first compression inlet port <NUM>. The first helical channel <NUM> defines the first portion F1 of the main flow path F. The first helical channel <NUM> has an inner surface S1 that is continuously curved to reduce or to eliminate sudden directional changes in the intermediate pressure working fluid flowing through the first helical channel <NUM>. The reduction in the sudden directional changes reduces the pressure drop within the flow path and can allow the intermediate pressure working fluid to maintain more of its velocity from the economizer injection inlet <NUM> to a compression inlet port. The continuously curved inner surface reduces the pressure drop and/or velocity drop between the economizer injection inlet <NUM> and the first compressor inlet port <NUM>.

The intermediate pressure chamber <NUM> also includes a second helical channel <NUM> that fluidly connects the economizer injection inlet <NUM> to the second compression inlet port <NUM>. The second helical channel <NUM> defines the second portion F2 of the main flow path F. The second helical channel <NUM> having an inner surface S2 that is continuously curved to reduce or to eliminate sudden directional changes in to the intermediate pressure working fluid the second helical channel <NUM>. The continuously curved inner surface S2 reduces the pressure drop and/or velocity drop between the economizer injection inlet <NUM> and the second compressor inlet port <NUM>, as similarly discussed with respect to the first helical channel <NUM>. In an embodiment, a helical channel <NUM>, <NUM> was observed to have at or about a <NUM>% increase in the flowrate over a non-helical channel.

The first helical channel <NUM> may represent a portion of a helix. The helix may be conical or circular. As shown in <FIG>, the first helical channel <NUM> can extend less than a full turn of the helix (e.g., less than <NUM> degrees when viewed along the axis L5). In an embodiment, the first helical channel <NUM> can extend at least <NUM> degrees of a helix when viewed along the axis L5 (e.g., in top view, in bottom view, or the like). In an embodiment, the first helical channel <NUM> can extend at least <NUM> degrees of a helix when viewed along the axis L5. The second helical channel <NUM> may represent a portion of another helix that is conical or circular. The second helical channel <NUM> can, independently, extend along a helix as discussed above for the first helical channel <NUM> (e.g., less than full turn, at least <NUM> degrees, at least <NUM> degrees, or the like).

In an embodiment, the compressor <NUM> may include a single compression inlet port <NUM>, <NUM>. In such an embodiment, the intermediate chamber <NUM> may have a single helical channel <NUM>, <NUM>.

In an embodiment illustrated in <FIG>, the first helical channel <NUM> descends axially while circumferentially following a circumferential curvature of the compressor housing <NUM>. The first helical channel <NUM> descends axially from an axial position A1 of the economizer injection inlet <NUM> to an axial position A2 of the first compression inlet port <NUM>. The axial descent may be completed gradually and continuously from the economizer injection inlet <NUM> to the compressor inlet port <NUM>. In an embodiment, a rate of axial descent of the first helical channel <NUM> may be varied along a flow path of the helical channel.

The intermediate pressure chamber <NUM> can include a first helical channel <NUM> and a second helical channel <NUM>. The first helical channel <NUM> fluidly connects an economizer injection inlet <NUM> to a first compression inlet port <NUM>. The second compression inlet port <NUM> (shown in <FIG>) fluidly connects the economizer injection inlet <NUM> to a second compression inlet port <NUM> (shown in <FIG>). The first helical channel <NUM> follows one of the circumferential directions of the housing <NUM>, and the second helical channel <NUM> follows the other of the circumferential directions of the housing <NUM>.

<FIG> is a top view of the compressor <NUM> in <FIG>, according to an embodiment. As illustrated in <FIG>, the economizer injection inlet <NUM> and the discharge outlet <NUM> are both formed in the upper portion 702A of the housing <NUM>. In an embodiment, the discharge outlet <NUM> is disposed centrally with respect to the compressor <NUM>. In an embodiment, the economizer injection inlet <NUM> is disposed offset from the center of the compressor <NUM>.

<FIG> is a partial cross sectional view of the compressor <NUM>, according to an embodiment. The cross-sectional view is along the line <NUM>-<NUM> in <FIG>. The intermediate pressure working fluid enters the intermediate pressure chamber <NUM> from the economizer injection inlet <NUM>. The intermediate pressure working fluid having a flow path with the main flow path F and diverging into the first helical channel <NUM> and the second helical channel <NUM>. As shown in <FIG>, the inlet ends of the first helical channel <NUM> and the second helical channel <NUM> branch from the economizer inlet <NUM>.

<FIG> is a partial cross-sectional view of the compressor <NUM>, according to an embodiment. The cross sectional view is along the line <NUM>-<NUM> of <FIG>. The first helical channel <NUM> connects to the first compression inlet port <NUM> at the outlet end F1OUT of the first portion F1 of the main flow path F. The second helical channel <NUM> connects to the second compression inlet port <NUM> at the outlet end F2OUT of the second portion F2 of the main flow path F.

As similarly discussed above regarding the compressor <NUM>, a discharge seal <NUM> (e.g., see <FIG>) and intermediate seals <NUM> (e.g., see <FIG>) can function to isolate the compression inlet ports <NUM>, <NUM> from the discharge outlet <NUM> (e.g., working fluid at a discharge pressure) and a suction chamber <NUM> (e.g., working fluid at a suction pressure). The discharge seal <NUM> sealingly engages the upper portion 702A of the housing <NUM> and the non-orbiting scroll member <NUM>. The intermediate seals <NUM> sealingly engage the upper portion 702A of the housing <NUM> and the non-orbiting scroll member <NUM>. In the illustrated embodiment, there are two intermediate seals <NUM>. The intermediate seals <NUM> can form/seal a volume (e.g., the intermediate pressure chamber <NUM>) through which the working fluid from the economizer can be provided to the compression chamber <NUM>. Thus, the intermediate seals <NUM> sealingly engage between the upper portion 702A of the housing <NUM> and the non-orbiting scroll member <NUM>.

<FIG> is a top perspective view of the non-orbiting scroll member <NUM> of the housing <NUM> of the compressor <NUM>, according to an embodiment. The non-orbiting scroll member <NUM> as illustrated in <FIG> shows a portion of the inner surface S1 of the first helical channel <NUM> and a portion of the inner surface S2 of the second helical channel <NUM>. In an embodiment and as shown in <FIG>, the inner surface S2 of the second helical channel <NUM> connects to the second compression inlet port <NUM> at a second transition portion <NUM>. The second transition portion <NUM> can be formed in non-orbiting scroll member <NUM>.

As shown in <FIG>, each helical channel <NUM>, <NUM> has a circumferential curvature. The circumferential curvature of the first helical channel <NUM> may follow the first circumferential direction D1 of the compressor housing <NUM>. The circumferential curvature of the second helical channel <NUM> may follow the second circumferential direction D2 of the compressor housing.

As shown in <FIG>, the non-orbiting scroll member <NUM> can also include a first transition portion <NUM> that connects the inner surface S1 of the first helical channel <NUM> to the first compression inlet <NUM>. The first transition portion <NUM> for the first compression inlet <NUM> can have a similar configuration as discussed with respect to the second transition portion <NUM> for the second compression inlet <NUM>.

<FIG> is an enlarged view of the second helical channel <NUM> in <FIG>. As shown in <FIG> and <FIG>, the second transition portion <NUM> has a plurality of convex and concave transitions <NUM>. The transitions <NUM> guide the second portion F2 of the main flow path F from an axial position A2 (see <FIG>) of the second helical channel <NUM> to an axial position A3 (see <FIG>) of the second compression inlet port <NUM>. The transitions <NUM> guide the second portion F2 axially, radially, and/or circumferentially from the second helical channel <NUM> (partially shown in <FIG>) into the intermediate compression chamber <NUM>. The transitions <NUM> can reduce sudden directional changes from the second helical channel <NUM> into the second compressor inlet port <NUM> and therefore reduce the pressure drop and/or velocity drop from the second helical channel <NUM> to the second compression inlet port <NUM>.

According to one embodiment, the transitions <NUM> form a "kidney bean" shape in the non-orbiting scroll member <NUM>. As shown in <FIG>, the transitions <NUM> form a kidney bean shape when viewed along the axis L5 (as shown in <FIG>) in a direction from axial positions A1 to A3 (as shown in <FIG>). The "kidney bean" shape connects the second helical channel <NUM> with the second compression inlet port <NUM>. The kidney bean shape of the transitions <NUM> provide continuously curved surfaces that from the second helical channel <NUM> into the second compression inlet <NUM> such that the flow path of the process fluid gradually descends into the second compression inlet ports <NUM>. The working fluid is guided circumferentially, axially, and/or radially towards the second compression inlet port <NUM>. As the result, the transition into the second compression inlet port <NUM> occurs gradually without any sudden directionally change(s) and with enters the compression chamber <NUM> with higher pressure and/or at a higher flowrate.

The terminology used in this Specification is intended to describe particular embodiments and is not intended to be limiting. The terms "a," "an," and "the" include the plural forms as well, unless clearly indicated otherwise. The terms "comprises" and/or "comprising," when used in this Specification, specify the presence of the 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, and/or components.

Claim 1:
A scroll compressor (<NUM>, <NUM>, <NUM>, <NUM>), comprising:
a compressor housing (<NUM>, <NUM>, <NUM>, <NUM>) having a plurality of portions including an upper housing portion (66A, 102A, 202A, 702A) and a lower housing portion (66C, 102C, 202B, 702B);
an orbiting scroll member (<NUM>) disposed within the compressor housing; wherein a non-orbiting scroll member (<NUM>, <NUM>, <NUM>) disposed within the compressor housing, wherein the orbiting scroll member and the non-orbiting scroll member are intermeshed thereby forming a compression chamber (<NUM>, <NUM>) within the compressor housing, the non-orbiting scroll including one or more compression inlet ports (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>);
an economizer injection inlet (<NUM>, <NUM>, <NUM>, <NUM>) formed through the compressor housing and in fluid communication with the compression chamber via each of the one or more compression inlet ports; and
a discharge outlet (<NUM>, <NUM>) in fluid communication with the compression chamber, wherein
the economizer injection inlet is formed through the upper housing portion, and the discharge outlet is formed through the upper housing portion;
characterized in that an intermediate pressure chamber (<NUM>, <NUM>, <NUM>) is formed in the compressor housing between the non-orbiting scroll member and the compressor housing, the intermediate pressure chamber being fluidly connected to the economizer injection inlet and the one or more compression inlet ports; and
a seal (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) is disposed between the upper housing portion of the compressor housing and the non-orbiting scroll member and configured to isolate the intermediate pressure chamber from the discharge outlet.