Patent Description:
A climate-control system such as, for example, a heat-pump system, a refrigeration system, or an air conditioning system, 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 one or more compressors circulating a working fluid (e.g., refrigerant or carbon dioxide) between the indoor and outdoor heat exchangers. Efficient and reliable operation of the one or more compressors is desirable to ensure that the climate-control system in which the one or more compressors are installed is capable of effectively and efficiently providing a cooling and/or heating effect on demand.

<CIT> discloses an Oldham's ring with a projection that is deformed to fill a recessed part of a bush.

This section provides a general summary of the disclosure. The invention is defined in the claims. Objectives of the present invention include reducing wear, improving performance, and simplifying fabrication of the compressor's Oldham coupling.

Optionally, the caps are all discrete components that are non-integrally formed.

Each of the caps includes an aperture into which a corresponding post extends. The posts are integrally formed with the body.

The apertures extend entirely through the caps.

Optionally, the posts extend entirely through the corresponding apertures.

The body includes a plurality of integrally formed posts. The caps may be H-shaped. Each of the posts may include a slot receiving a portion of a corresponding one of the caps.

Optionally, the first material is a metal and the second material includes a polymer.

Optionally, the second material includes a metal.

Optionally, the first material is a first metal and the second material includes a second metal.

Optionally, the first material and the second material are both exposed to fluid within a shell of the compressor.

Optionally, the keys are formed entirely from the second material.

Optionally, the caps are attached to the body by swaging.

The keys include posts integrally formed with the annular body, and wherein the caps are fixed to the posts by deformations formed on the posts.

Each of the caps includes an aperture and a pair of grooves, the aperture receiving a corresponding one of the posts, the grooves receiving the deformations formed on the posts.

Optionally, the grooves are open to the aperture and extend through a distal end of the cap.

With reference to <FIG>, a compressor <NUM> is provided according to an example useful for understanding the claimed invention that may include a hermetic shell assembly <NUM>, a bearing housing assembly <NUM>, a motor assembly <NUM>, a compression mechanism <NUM>, and a seal assembly <NUM>. The shell assembly <NUM> may generally form a compressor housing and may include a cylindrical shell <NUM>, an end cap <NUM> at the upper end thereof, a transversely extending partition <NUM>, and a base <NUM> at a lower end thereof. The end cap <NUM> and partition <NUM> may generally define a discharge chamber <NUM>. A discharge fitting <NUM> may be attached to the shell assembly <NUM> at an opening in the end cap <NUM>. A suction gas inlet fitting <NUM> may be attached to the shell assembly <NUM> at another opening and may communicate with a suction chamber <NUM> defined by the shell <NUM> and the partition <NUM>. The partition <NUM> may include a discharge passage <NUM> therethrough providing communication between the compression mechanism <NUM> and the discharge chamber <NUM>.

The bearing housing assembly <NUM> may be affixed to the shell <NUM> and may include a main bearing housing <NUM> and a bearing <NUM>. The main bearing housing <NUM> may house the bearing <NUM> therein and may define an annular flat thrust bearing surface <NUM> on an axial end surface thereof.

The motor assembly <NUM> may include a motor stator <NUM>, a rotor <NUM>, and a driveshaft <NUM>. The motor stator <NUM> may be press fit into the shell <NUM>. The driveshaft <NUM> may be rotatably driven by the rotor <NUM> and may be rotatably supported within the bearing <NUM>. The rotor <NUM> may be press fit on the driveshaft <NUM>. The driveshaft <NUM> may include an eccentric crankpin <NUM>.

The compression mechanism <NUM> may generally include an orbiting scroll <NUM>, a non-orbiting scroll <NUM> and an Oldham coupling <NUM>. The orbiting scroll <NUM> may include an end plate <NUM> having a spiral wrap <NUM> on the upper surface thereof and an annular flat thrust surface <NUM> on the lower surface. The thrust surface <NUM> may interface with the annular flat thrust bearing surface <NUM> on the main bearing housing <NUM>. A cylindrical hub <NUM> may project downwardly from the thrust surface <NUM> and may have a drive bushing <NUM> rotatably disposed therein. The drive bushing <NUM> may include an inner bore in which the crank pin <NUM> is drivingly disposed. A flat surface of the crankpin <NUM> may drivingly engage a flat surface in a portion of the inner bore of the drive bushing <NUM> to provide a radially compliant driving arrangement. The Oldham coupling <NUM> may be engaged with the orbiting and non-orbiting scrolls <NUM>, <NUM> or with the orbiting scroll <NUM> and the main bearing housing <NUM> to prevent relative rotation therebetween.

The non-orbiting scroll <NUM> may include an end plate <NUM> and a spiral wrap <NUM> projecting downwardly from the end plate <NUM>. The spiral wrap <NUM> may meshingly engage the spiral wrap <NUM> of the orbiting scroll <NUM>, thereby creating a series of moving fluid pockets. The fluid pockets defined by the spiral wraps <NUM>, <NUM> may decrease in volume as they move from a radially outer position (at a suction pressure) to a radially intermediate position (at an intermediate pressure) to a radially inner position (at a discharge pressure) throughout a compression cycle of the compression mechanism <NUM>.

The end plate <NUM> may include a discharge passage <NUM>, an intermediate passage <NUM>, and an annular recess <NUM>. The discharge passage <NUM> is in communication with one of the fluid pockets at the radially inner position and allows compressed working fluid (e.g., at the discharge pressure) to flow into the discharge chamber <NUM>. The intermediate passage <NUM> may provide communication between one of the fluid pockets at the radially intermediate position and the annular recess <NUM>. The annular recess <NUM> may receive the seal assembly <NUM> and cooperate with the seal assembly <NUM> to define an axial biasing chamber <NUM> therebetween. The biasing chamber <NUM> receives fluid from the fluid pocket in the intermediate position through the intermediate passage <NUM>. A pressure differential between the intermediate-pressure fluid in the biasing chamber <NUM> and fluid in the suction chamber <NUM> exerts an axial biasing force on the non-orbiting scroll <NUM> urging the non-orbiting scroll <NUM> toward the orbiting scroll <NUM> to sealingly engage the scrolls <NUM>, <NUM> with each other.

As shown in <FIG>, the Oldham coupling <NUM> may be a generally ring-shaped member having an annular body <NUM>, a plurality of first keys <NUM> and a plurality of second keys <NUM>. As shown in <FIG>, the body <NUM> may be supported by the main bearing housing <NUM> to allow the body <NUM> to be slidably movable thereon. The first and second keys <NUM>, <NUM> may extend from the body <NUM> in an axial direction (i.e., in a direction parallel to a rotational axis of the driveshaft <NUM>). As shown in <FIG>, the first keys <NUM> may slidably engage slots (keyways) <NUM> formed in the end plate <NUM> of the orbiting scroll <NUM>, and the second keys <NUM> may slidably engage slots (keyways) <NUM> formed in the end plate <NUM> of the non-orbiting scroll <NUM>. In this manner, the Oldham coupling <NUM> prevents rotation of the orbiting scroll <NUM> relative to the non-orbiting scroll <NUM> while allowing orbital movement of the orbiting scroll <NUM> relative to the non-orbiting scroll <NUM>.

While the first and second keys <NUM>, <NUM> are shown in the figures extending in the same direction from the body <NUM> (i.e., axially upward from the body <NUM>), in some configurations, the first keys <NUM> may extend away from the body <NUM> in a direction opposite a direction from which the second keys <NUM> extend away from the body <NUM>. Further, in some configurations, the second keys <NUM> may slidably engage slots formed in the main bearing housing <NUM> instead of the slots <NUM> in the non-orbiting scroll <NUM>.

As shown in <FIG>, each of the first keys <NUM> may include a post <NUM> and a cap (or insert) <NUM>, and each of the second keys <NUM> may include a post <NUM> and a cap (or insert) <NUM>. The posts <NUM>, <NUM> may be integrally formed with the body <NUM> from a first material (e.g., aluminum, iron, steel or another metal or composite). For example, the body <NUM> and posts <NUM>, <NUM> can be cast as a single, unitary body and/or machined from a single, unitary piece of material.

The caps <NUM>, <NUM> may be discrete components formed from a second material (i.e., a material that is different from the first material) and attached to the posts <NUM>, <NUM>. In some configurations, the caps <NUM>, <NUM> may be made entirely from the second material, rather than just being coated with the second material. The second material can be or include Vespel® (i.e., polymide containing graphite; manufactured by DuPont), bronze (e.g., bismuth bronze, bronze with graphite, bronze with silicone, etc.), aluminum bronze, cast iron, ceramic, polyarletherketone (PAEK) group materials (e.g., resins including polyetheretherketone (PEEK), polyetherketone (PEK), polyetheretheretherketone (PEEEK), polyetherketoneketone (PEKK), polyetheretherketoneketone (PEEKK), polyetherketoneetheretherketone (PEKEEK), polyetheretherketoneetheretherketone (PEEKEEK), or combinations thereof), polyamideimide (PAI) (e.g., Torlon®, manufactured by Solvay), polyphenylene sulfide (PPS), or polyphthalamide (PPA), for example, or other materials with high lubricity.

Each of the caps <NUM>, <NUM> may include an aperture <NUM> that extends entirely through the cap <NUM>, <NUM> and receives a corresponding one of the posts <NUM>, <NUM>. The posts <NUM>, <NUM> may extend entirely through the apertures <NUM> or only partially through the apertures <NUM>. The posts <NUM>, <NUM> can be press-fit into the apertures <NUM>, adhesively bonded therein, secured with fasteners and/or otherwise securely attached.

With the caps <NUM>, <NUM> attached to the posts <NUM>, <NUM>, the keys <NUM>, <NUM> are less susceptible to wear as a result of friction between the keys <NUM>, <NUM> and the walls of the slots <NUM>, <NUM>. That is, the caps <NUM>, <NUM> may isolate the posts <NUM>, <NUM> from some or all of the friction between the keys <NUM>, <NUM> and the walls of the slots <NUM>, <NUM>. Further, because the caps <NUM>, <NUM> may be formed from a material or materials having a high lubricity and/or less prone to wear, the caps <NUM>, <NUM> can extend the life of the Oldham coupling <NUM> and present damage to the Oldham coupling <NUM>. This structure of the keys <NUM>, <NUM> may be particularly beneficial in compressors having certain working fluids or refrigerants, such as propane (e.g., R290) and carbon dioxide, for example. Such working fluids can cause excessive wear on keys of conventional Oldham couplings because such working fluids have a tendency to reduce the effectiveness of lubricants (e.g., oil) in the compressor. It will be appreciated, however, that structure of the keys <NUM>, <NUM> may be beneficial in reducing wear and improving performance in compressors having any type of refrigerant or working fluid.

In some configurations, inserts (not shown) formed from the second material could be fixedly received in the slots <NUM>, <NUM>. The inserts could include slots (keyways) that slidably receive the keys <NUM>, <NUM>, thereby further reducing friction due to the sliding engagement between the keys <NUM>, <NUM> and the scrolls <NUM>, <NUM>.

Referring now to <FIG>, another Oldham coupling <NUM> is provided according to an example useful for understanding the claimed invention that can be incorporated into the compressor <NUM> instead of the Oldham coupling <NUM>. The structure and function of the Oldham coupling <NUM> can be similar or identical to that of the Oldham coupling <NUM>, apart from the differences described below and/or shown in the figures.

As described above with respect to the Oldham coupling <NUM>, the Oldham coupling <NUM> may include a generally annular body <NUM>, a plurality of first keys <NUM> and a plurality of second keys <NUM>. Like the keys <NUM>, <NUM>, the keys <NUM>, <NUM> may include posts <NUM>, <NUM> and caps <NUM>, <NUM>. The posts <NUM>, <NUM> and body <NUM> may be formed from a first material, and the caps <NUM>, <NUM> may be formed from a second material, as described above. The caps <NUM>, <NUM> may include apertures <NUM> extending partially therethrough and receiving the posts <NUM>, <NUM>. In this manner, the posts <NUM>, <NUM> may be completely contained within the apertures <NUM>. The posts <NUM>, <NUM> can be press-fit into the apertures <NUM>, adhesively bonded therein, secured with fasteners and/or otherwise securely attached.

As described above with respect to the Oldham coupling <NUM>, the Oldham coupling <NUM> may include a generally annular body <NUM>, a plurality of first keys <NUM> and a plurality of second keys <NUM>. The keys <NUM>, <NUM> may include posts <NUM>, <NUM> and caps <NUM>, <NUM>. The posts <NUM>, <NUM> and body <NUM> may be formed from a first material, and the caps <NUM>, <NUM> may be formed from a second material, as described above.

As shown in <FIG> and <FIG>, each of the posts <NUM>, <NUM> may include a pair of protrusions <NUM> defining a channel or slot <NUM> therebetween such that the posts <NUM>, <NUM> have a generally U-shaped profile. As shown in <FIG> and <FIG>, the caps <NUM>, <NUM> may be generally H-shaped members having a pair of blocks <NUM> and a crossmember <NUM> extending between and interconnecting the blocks <NUM>. The crossmember <NUM> and blocks <NUM> form a pair of channels or slots <NUM>. When the caps <NUM>, <NUM> are assembled onto the posts <NUM>, <NUM>, the protrusions <NUM> of the posts <NUM>, <NUM> are received into corresponding slots <NUM> of the caps <NUM>, <NUM>, and the cross-members <NUM> of the caps <NUM>, <NUM> are received into the slots <NUM> of the posts <NUM>, <NUM>. In this manner, the caps <NUM>, <NUM> can be press-fit into engagement with the posts <NUM>, <NUM>, adhesively bonded and/or otherwise fixedly secured. As shown in <FIG>, distal edges of the caps <NUM>, <NUM> may protrude further from the body <NUM> that the distal edges of the posts <NUM>, <NUM> such that the posts <NUM>, <NUM> are shielded from friction with the scrolls <NUM>, <NUM>.

Referring now to <FIG>, another Oldham coupling <NUM> (only partially shown in <FIG>) is provided according to an example useful for understanding the claimed invention that can be incorporated into the compressor <NUM> instead of the Oldham coupling <NUM>. The structure and function of the Oldham coupling <NUM> can be similar or identical to that of the Oldham coupling <NUM>, apart from the differences described below and/or shown in the figures.

As described above with respect to the Oldham coupling <NUM>, the Oldham coupling <NUM> may include a generally annular body <NUM> and a plurality of keys <NUM>. The keys <NUM> may include posts <NUM> and caps <NUM>. The posts <NUM> and body <NUM> may be formed from a first material, and the caps <NUM> may be formed from a second material, as described above. The caps <NUM> may include apertures <NUM> that extend partially or entirely therethrough and receive the posts <NUM>. The apertures <NUM> may be sufficiently larger in size than the posts <NUM> to allow the caps <NUM> to move radially (i.e., in directions perpendicular to the rotational axis of the driveshaft <NUM>) relative to the posts <NUM> when the posts <NUM> are received within the apertures <NUM>. Adhesive and/or other fasteners could be used to attach the posts <NUM> to the caps <NUM>.

As described above with respect to the Oldham coupling <NUM>, the Oldham coupling <NUM> may include a generally annular body <NUM> and a plurality of keys <NUM>. The keys <NUM> may include posts <NUM> and caps <NUM>. Each post <NUM> may be integrally formed with a corresponding one of the caps <NUM> and may threadably engage apertures <NUM> formed in the body <NUM>. The body <NUM> may be formed from a first material, and the posts <NUM> and caps <NUM> may be formed from a second material.

As described above with respect to the Oldham coupling <NUM>, the Oldham coupling <NUM> may include a generally annular body <NUM> and a plurality of keys (caps) <NUM>. The keys <NUM> may include threaded apertures <NUM> that are aligned with apertures <NUM> in the body <NUM>. Threaded fasteners <NUM> may extend through corresponding apertures <NUM> in the body <NUM> and threadably engage corresponding apertures <NUM> in the keys <NUM>. The body <NUM> may be formed from a first material, and the keys <NUM> may be formed from a second material.

As described above with respect to the Oldham coupling <NUM>, the Oldham coupling <NUM> may include a generally annular body <NUM> and a plurality of keys (caps) <NUM>. The keys <NUM> may include apertures <NUM> that are aligned with apertures <NUM> in the body <NUM>. Roll pins <NUM> may be pressed into corresponding apertures <NUM>, <NUM> such that the diameters of the pins <NUM> are compressed when received in the apertures <NUM>, <NUM>, thereby fixedly securing the keys <NUM> to the body <NUM>. The body <NUM> may be formed from a first material, and the keys <NUM> may be formed from a second material.

As described above with respect to the Oldham coupling <NUM>, the Oldham coupling <NUM> may include a generally annular body <NUM> and a plurality of keys <NUM>. Each of the keys <NUM> may include a post <NUM> and a pair of caps <NUM>. The posts <NUM> may be integrally formed with the body <NUM> from a first material.

The caps <NUM> may be formed from a second material and may each include a main body <NUM> (e.g., a rectangular block) and a plurality of protrusions <NUM> (e.g., cylindrical or rectangular protrusions) extending from the main body <NUM>. Each post <NUM> may be sandwiched between two caps <NUM>. The protrusions <NUM> of each cap <NUM> may be embedded in a corresponding post <NUM>. In some configurations, the posts <NUM> and body <NUM> may be cast with the caps <NUM> placed in the casting mold such that the posts <NUM> are cast around the protrusions <NUM> (so as to embed the protrusions <NUM> inside of the posts <NUM>). In this manner, the caps <NUM> are fixedly secured to the posts <NUM>.

It will be appreciated that the protrusions <NUM> can be arranged on the main body <NUM> of the cap <NUM> in any suitable manner. For example, the protrusions <NUM> on each cap <NUM> can be arranged in a linear pattern, a staggered pattern, or in a triangular pattern.

As described above, the Oldham coupling <NUM> may include a generally annular body <NUM> and a plurality of keys <NUM>. Each of the keys <NUM> may include an integrally formed post <NUM> and cap <NUM>. The body <NUM> may be formed from a first material, and the keys <NUM> may be formed from a second material. The cap <NUM> may be a rectangular or cubical block, for example. The post <NUM> may be a rectangular block having a plurality of protrusions <NUM> (e.g., cylindrical or rectangular protrusions) extending therefrom. In some configurations, the body <NUM> may be cast with the caps <NUM> placed in the casting mold such that the body <NUM> is are cast around the posts <NUM> (so as to embed the posts <NUM> and protrusions <NUM> inside of the body <NUM>). In this manner, the caps <NUM> are fixedly secured to the body <NUM>.

It will be appreciated that additional or alternative means could be utilized to attach the caps or keys to the body of any of the Oldham couplings <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>. Such additional or alternative attaching means could include swaging, welding, brazing, shrink fitting, crimping, or snap fitting, for example.

As described above with respect to the Oldham coupling <NUM>, the Oldham coupling <NUM> may include a generally annular body <NUM>, a plurality of first keys <NUM> and a plurality of second keys <NUM>. Like the keys <NUM>, <NUM>, the keys <NUM>, <NUM> may include posts <NUM>, <NUM> and caps <NUM>, <NUM>. The posts <NUM>, <NUM> and body <NUM> may be formed from a first material, and the caps <NUM>, <NUM> may be formed from a second material, as described above. As will be described in more detail below, the caps <NUM>, <NUM> may receive the posts <NUM>, <NUM> and may be retained thereon by snap-fit engagement with the posts <NUM>, <NUM>.

As shown in <FIG> and <FIG>, a distal end <NUM> (i.e., an end spaced apart from the body <NUM>) of each of the posts <NUM>, <NUM> include first and second flanges <NUM>, <NUM> and first and second grooves <NUM>, <NUM>. The first flange <NUM> of each post <NUM>, <NUM> is disposed on an inwardly facing side <NUM> of the post <NUM>, <NUM>. The second flange <NUM> of each post <NUM>, <NUM> is disposed on an outwardly facing side <NUM> of the post <NUM>, <NUM>. The inwardly and outwardly facing sides <NUM>, <NUM> face in opposite directions and extend from the body <NUM> to the distal end <NUM>. The first grooves <NUM> may be formed in the inwardly facing sides <NUM> directly adjacent the first flanges <NUM> and between the body <NUM> and the first flanges <NUM>. The second grooves <NUM> may be formed in the outwardly facing sides <NUM> directly adjacent the second flanges <NUM> and between the body <NUM> and the second flanges <NUM>. As shown in <FIG>, the first and second flanges <NUM>, <NUM> extend laterally outward from the posts <NUM>, <NUM> such that a distance D between lateral edges of the first and second flanges <NUM>, <NUM> is greater than a width W1 of a main body <NUM> of the post <NUM>, <NUM> in the same direction.

Each of the caps <NUM>, <NUM> may include an aperture <NUM> that extends entirely through the cap <NUM>, <NUM> and receives a corresponding one of the posts <NUM>, <NUM>. The posts <NUM>, <NUM> may extend entirely through the apertures <NUM> or only partially through the apertures <NUM>. As shown in <FIG>, each of the apertures <NUM> includes a counterbore or recess <NUM> at one axial end and a countersink or chamfer <NUM> at the other axial end.

A portion of the aperture <NUM> disposed axially between the recess <NUM> and the chamfer <NUM> may have a width that is equal to or slightly larger than the width W1 of the main body <NUM> of the corresponding post <NUM>, <NUM> and smaller than the distance D between lateral edges of the first and second flanges <NUM>, <NUM> of the corresponding post <NUM>, <NUM>. The recess <NUM> has a width W2 that is larger than the distance D.

The caps <NUM>, <NUM> can be installed onto the posts <NUM>, <NUM> by pressing the caps <NUM>, <NUM> onto the posts <NUM>, <NUM>. The distal end <NUM> of each post <NUM>, <NUM> is initially inserted through the end of the aperture <NUM> that has the chamber <NUM>. The chamfer <NUM> facilitates the initial insertion of the post <NUM>, <NUM> into the aperture <NUM>. The flanges <NUM>, <NUM> may elastically deform into the grooves <NUM>, <NUM> and/or the aperture <NUM> may expand as the flanges <NUM>, <NUM> are pressed through the portion of the aperture <NUM> between the chamfer <NUM> and the recess <NUM>. Once the flanges <NUM>, <NUM> are inserted past an end surface <NUM> of the recess <NUM>, the deformed flanges <NUM>, <NUM> and/or aperture <NUM> may snap back to their original shape(s). Then, with the flanges <NUM>, <NUM> and/or aperture <NUM> back in their original shape(s), interference between the flanges <NUM>, <NUM> and the end surface <NUM> of the recess prevents the cap <NUM>, <NUM> from sliding back off of the post <NUM>, <NUM>. The above means of attaching the caps <NUM>, <NUM> to the posts <NUM>, <NUM> are advantageous because insertion of the posts <NUM>, <NUM> through the apertures <NUM> can be done with a relatively light amount of force (e.g., <NUM>-<NUM> kN of force) and without any special tooling.

While <FIG> shows a portion of the distal end <NUM> of the post <NUM>, <NUM> protruding out of the end of the aperture <NUM>, in some configurations, the entire post <NUM>, <NUM> may be entirely received within the aperture <NUM> when the cap <NUM>, <NUM> is fully installed on the post <NUM>, <NUM> (i.e., the entire distal end <NUM> may be received within the recess <NUM>).

Referring now to <FIG>, an Oldham coupling <NUM> according to the invention is provided that is incorporated into the compressor <NUM> instead of the Oldham coupling <NUM>. The structure and function of the Oldham coupling <NUM> can be similar or identical to that of the Oldham coupling <NUM>, apart from the differences described below and/or shown in the figures.

As described above with respect to the Oldham coupling <NUM>, the Oldham coupling <NUM> includes a generally annular body <NUM>, a plurality of first keys <NUM> and a plurality of second keys <NUM>. Like the keys <NUM>, <NUM>, the keys <NUM>, <NUM> include posts <NUM>, <NUM> and caps <NUM>, <NUM>. The posts <NUM>, <NUM> and body <NUM> are formed from a first material, and the caps <NUM>, <NUM> are formed from a second material, as described above. As will be described in more detail below, the caps <NUM>, <NUM> receive the posts <NUM>, <NUM> and may be retained thereon by swaging the posts <NUM>, <NUM>.

As shown in <FIG>, each of the caps <NUM>, <NUM> include an aperture <NUM> extending entirely therethrough. That is, the aperture <NUM> extends through a proximal end <NUM> of the cap <NUM>, <NUM> (i.e., the end adjacent the body <NUM>) and a distal end <NUM> of the cap <NUM>, <NUM> (i.e., the end furthest from the body <NUM>). The distal end <NUM> of each cap <NUM>, <NUM> has a groove <NUM> formed therein that intersects the aperture <NUM> (i.e., extends laterally outward from opposite sides of the aperture <NUM>) and extends laterally through opposing sides <NUM>, <NUM> of the cap <NUM>, <NUM>. While not shown in <FIG>, the aperture <NUM> may include a chamfer (similar to chamfer <NUM>) at the proximal end <NUM> of the cap <NUM>, <NUM> to facilitate insertion of the posts <NUM>, <NUM> into the caps <NUM>, <NUM>.

As shown in <FIG> and <FIG>, the posts <NUM>, <NUM> may be initially cast and/or machined (or otherwise formed) to include a constant rectangular profile. With the posts <NUM>, <NUM> in these initial constant-profile forms, the caps <NUM>, <NUM> can easily slide onto the posts <NUM>, <NUM>, as shown in <FIG>. Thereafter, a swaging tool <NUM> can be used to swage or deform a distal end <NUM> of each of the posts <NUM>, <NUM>, as shown in <FIG>.

As shown in <FIG>, the swaging tool <NUM> may include a cavity <NUM> and a rib <NUM> disposed within the cavity <NUM>. A length L of the cavity <NUM> and a width W of the cavity <NUM> may be at least slightly larger than the length and width of the caps <NUM>, <NUM> such that the distal end <NUM> of the caps <NUM>, <NUM> can be received in the cavity <NUM>. The rib <NUM> has a thickness T that is slightly smaller than a thickness of the grooves <NUM> in the caps <NUM>, <NUM> such that the rib <NUM> can be received in the grooves <NUM> while the distal end <NUM> of the caps <NUM>, <NUM> is received in the cavity <NUM>. As shown in <FIG>, the rib <NUM> may include a generally V-shaped central recess <NUM> disposed between a pair of steps <NUM>. The spacing between the steps <NUM> is such that the posts <NUM>, <NUM> can be received between the steps <NUM>.

As described above and shown in <FIG>, the caps <NUM>, <NUM> can easily slide onto the posts <NUM>, <NUM> while the posts <NUM>, <NUM> are in their initial constant-profile forms (e.g., the as-cast or as-machined forms of the posts <NUM>, <NUM>). Thereafter, the swaging tool <NUM> can be placed over the distal end <NUM> of the cap <NUM>, <NUM> with the distal end <NUM> of the post <NUM>, <NUM> received between the steps <NUM> of the rib <NUM>, as shown in <FIG>. Thereafter, a downward force can be applied to the swaging tool <NUM> to press the rib <NUM> into the distal end <NUM> of the post <NUM>, <NUM> to form notches <NUM> and flanges <NUM> (shown in <FIG> and <FIG>) in the post <NUM>, <NUM>. The distance between the outer lateral edges of the flanges <NUM> is greater than the width of the aperture <NUM> such that the flanges <NUM> interfere with end walls <NUM> of the groove <NUM> in the cap <NUM>, <NUM> to prevent the cap <NUM>, <NUM> from sliding off of the post <NUM>, <NUM>.

Claim 1:
A compressor (<NUM>) comprising:
a non-orbiting scroll (<NUM>);
an orbiting scroll (<NUM>) meshingly engaged with the non-orbiting scroll;
a driveshaft (<NUM>) having a crankpin (<NUM>) engaging the orbiting scroll and driving the orbiting scroll in an orbital path relative to the non-orbiting scroll; and
an Oldham coupling (<NUM>) including an annular body (<NUM>) and a plurality of keys (<NUM>, <NUM>) extending from the annular body and slidably received in slots (<NUM>, <NUM>) formed in the orbiting scroll, the annular body formed from a first material, the keys are attached to the annular body, wherein each of the keys (<NUM>, <NUM>) includes a post (<NUM>, <NUM>) and a cap (<NUM>, <NUM>), wherein the posts (<NUM>, <NUM>) are integrally formed with the annular body (<NUM>), wherein the caps (<NUM>, <NUM>) are formed from a second material, wherein each cap (<NUM>, <NUM>) includes an aperture (<NUM>) extending entirely through the cap (<NUM>, <NUM>) and receiving one of the posts (<NUM>, <NUM>),
characterized in that the caps (<NUM>, <NUM>) are fixed to the posts (<NUM>, <NUM>) by deformations formed on the posts, wherein each of the caps (<NUM>, <NUM>) includes a pair of grooves (<NUM>), and wherein the grooves (<NUM>) receive the deformations formed on the posts (<NUM>, <NUM>).