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> and <CIT> disclose a compressor with a compression mechanism and a driveshaft.

A compressor, useful for understanding the invention, may include a compression mechanism, a driveshaft, and an oil allocation member. The driveshaft drivingly engages the compression mechanism and includes a lubricant passage. The lubricant passage includes an inlet, a first outlet, and a second outlet. The inlet and the first and second outlets are spaced apart from each other in a direction parallel to a rotational axis of the driveshaft such that the first outlet is disposed vertically higher than the inlet and the second outlet is disposed vertically higher than the first outlet. The oil allocation member may be disposed within the lubricant passage and may be fixed relative to the driveshaft. The oil allocation member may include a lower body portion and an upper body portion and may define a first channel, a second channel, and a third channel. The first channel may extend through a lower axial end of the oil allocation member and may receive lubricant flowing upward from the inlet of the lubricant passage. The second channel may receive a first portion of the lubricant from the first channel through an inlet of the second channel. The third channel may receive a second portion of the lubricant from the first channel through an inlet of the third channel. The inlets of the second and third channels may be disposed vertically higher than the first outlet. The lower body portion of the oil allocation member may separate the first channel from the first outlet of the lubricant passage.

In some configurations of the compressor of the above paragraph, the inlets of the second and third channels are disposed between the first and second outlets in the direction parallel to a rotational axis of the driveshaft.

In some configurations of the compressor of any one or more of the above paragraphs, the first portion of the lubricant and the second portion of the lubricant are separated from each other at a location that is vertically higher than the first outlet.

In some configurations of the compressor of the above paragraph, the location at which the first portion of the lubricant and the second portion of the lubricant are separated from each other is vertically lower than the second outlet.

In some configurations of the compressor of any one or more of the above paragraphs, the oil allocation member includes a divider wall that separates the inlet of the second channel from the inlet of the third channel and restricts fluid communication between the second and third channels.

In some configurations of the compressor of any one or more of the above paragraphs, the third channel extends through an upper axial end of the upper body portion.

In some configurations of the compressor of any one or more of the above paragraphs, the first outlet of the lubricant passage extends radially outward through an outer circumferential surface of the driveshaft.

In some configurations, the compressor of any one or more of the above paragraphs may include a bearing rotatably supporting the driveshaft.

In some configurations of the compressor of any one or more of the above paragraphs, the first outlet of the lubricant passage may be aligned with the bearing to provide lubricant to the bearing.

In some configurations of the compressor of any one or more of the above paragraphs, the second outlet of the lubricant passage extends through an upper axial end of the driveshaft.

In some configurations of the compressor of any one or more of the above paragraphs, the upper axial end of the driveshaft is disposed within a hub of a scroll member of the compression mechanism.

In some configurations of the compressor of any one or more of the above paragraphs, the compression mechanism is a scroll compression mechanism including a first scroll member and a second scroll member.

In some configurations of the compressor of any one or more of the above paragraphs, the lubricant passage is an eccentric lubricant passage, and wherein the driveshaft further comprises a concentric lubricant passage that extends through a lower axial end of the driveshaft and is in fluid communication with the eccentric lubricant passage.

The present disclosure provides a compressor that includes a compression mechanism, a driveshaft, and an oil allocation member. The driveshaft drivingly engages the compression mechanism and includes a lubricant passage. The lubricant passage includes an inlet, a first outlet, and a second outlet. The inlet and the first and second outlets are spaced apart from each other in a direction parallel to a rotational axis of the driveshaft such that the first outlet is disposed vertically higher than the inlet and the second outlet is disposed vertically higher than the first outlet. The oil allocation member may be disposed within the lubricant passage and may be fixed relative to the driveshaft. The oil allocation member may define a first channel, a second channel, and a third channel. The first channel may extend through a lower axial end of the oil allocation member and may receive lubricant flowing upward from the inlet of the lubricant passage. The second channel may receive a first portion of the lubricant from the first channel through an inlet of the second channel and provides the first portion of the lubricant to the first outlet of the lubricant passage. The third channel may receive a second portion of the lubricant from the first channel through an inlet of the third channel and provides the second portion of the lubricant to the second outlet of the lubricant passage. The first portion of the lubricant and the second portion of the lubricant may be separated from each other at a location that is vertically higher than the first outlet.

In some configurations of the compressor of any one or more of the above paragraphs, a lower body portion of the oil allocation member separates the first channel from the first outlet of the lubricant passage.

In some configurations of the compressor of any one or more of the above paragraphs, the third channel extends through an upper axial end of the oil allocation member.

In some configurations, the compressor of any one or more of the above paragraphs includes a bearing rotatably supporting the driveshaft.

In some configurations of the compressor of any one or more of the above paragraphs, the first outlet of the lubricant passage is aligned with the bearing to provide lubricant to the bearing.

In some configurations of the compressor of any one or more of the above paragraphs, the inlets of the second and third channels are disposed between the first and second outlets in the direction parallel to a rotational axis of the driveshaft.

With reference to <FIG>, a compressor <NUM> is provided that may include a hermetic shell assembly <NUM>, a first bearing housing assembly <NUM>, a second bearing housing assembly <NUM>, a motor assembly <NUM>, a driveshaft <NUM>, a compression mechanism <NUM>, and a seal assembly <NUM>. As will be described in more detail below, the driveshaft <NUM> may include an oil allocation member <NUM> that divides and distributes oil flowing through the driveshaft <NUM> in a manner that provides adequate amounts of oil to various components of the compressor <NUM> at multiple motor speeds.

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

The motor assembly <NUM> may include a motor stator <NUM> and a rotor <NUM>. The motor stator <NUM> may be attached to the shell <NUM> (e.g., via press fit, staking, and/or welding). The rotor <NUM> may be attached to the driveshaft <NUM> (e.g., via press fit, staking, and/or welding). The driveshaft <NUM> may be driven by the rotor <NUM> and may be supported by the first and second bearings <NUM>, <NUM> for rotation about a rotational axis R. In some configurations, the motor assembly <NUM> is a variable-speed motor. In other configurations, the motor assembly <NUM> could be a multi-speed motor or a fixed-speed motor.

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 first 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. A drive bearing (not shown) may be disposed within the hub <NUM> and may surround the drive bushing <NUM>. The drive bushing <NUM> may include an inner bore in which an eccentric crank pin <NUM> of the driveshaft <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 first 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 fluid 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.

The driveshaft <NUM> may include a main body <NUM> and the eccentric crank pin <NUM>. The crank pin <NUM> may be disposed at a first axial end <NUM> of the main body <NUM>. The driveshaft <NUM> may include a concentric lubricant passage <NUM> and an eccentric lubricant passage <NUM>. The oil allocation member <NUM> may be disposed within the eccentric lubricant passage <NUM>. The concentric lubricant passage <NUM> may extend through a second axial end <NUM> of the main body <NUM> (i.e., a lower axial end of the driveshaft <NUM>).

The eccentric lubricant passage <NUM> is in fluid communication with the concentric lubricant passage <NUM> and extends upward from the concentric lubricant passage <NUM> and through a distal axial end <NUM> of the crank pin <NUM> (i.e., an upper axial end of the driveshaft <NUM>). The eccentric lubricant passage <NUM> may include an inlet <NUM>, a first outlet <NUM> and a second outlet <NUM>. The inlet <NUM> is disposed at the lower end of the eccentric lubricant passage <NUM> and receives lubricant from the concentric lubricant passage <NUM>. The first outlet <NUM> may extend radially outward from the eccentric lubricant passage <NUM> through an outer circumferential surface of the main body <NUM> of the driveshaft <NUM> and may be aligned with the first bearing <NUM> (i.e., a radially extending longitudinal axis of the first outlet <NUM> may intersect the first bearing <NUM>) so that the first outlet <NUM> may provide lubricant directly to the first bearing <NUM>. In some configurations, an outer circumferential surface of the main body <NUM> of the driveshaft <NUM> may include a groove <NUM> (<FIG> and <FIG>) that is in fluid communication with the first outlet <NUM> to aid in distributing lubricant along the first bearing <NUM>. The second outlet <NUM> is formed in the distal end <NUM> of the crank pin <NUM> and provides lubricant to the drive bushing <NUM> and drive bearing within the hub <NUM> of the orbiting scroll <NUM>.

While the driveshaft <NUM> is rotating, lubricant from a lubricant sump <NUM> (defined by the base <NUM> of the shell assembly <NUM>) may be drawn into the concentric lubricant passage <NUM> and may flow into the eccentric lubricant passage <NUM> and through the first and second outlets <NUM>, <NUM>. The oil allocation member <NUM>: (a) divides the flow of lubricant through the eccentric lubricant passage <NUM> into first and second portions, (b) channels the first portion of the lubricant in the eccentric lubricant passage <NUM> to the first outlet <NUM>, and (c) channels the second portion of the lubricant in the eccentric lubricant passage <NUM> to the second outlet <NUM>.

Referring now to <FIG>, the oil allocation member <NUM> may be a generally cylindrical pin including a lower body portion <NUM> and an upper body portion <NUM>. The oil allocation member <NUM> may be disposed within the eccentric lubricant passage <NUM>. Diameters of outer circumferential surfaces <NUM>, <NUM> of the lower and upper body portions <NUM>, <NUM> may be substantially equal to the diameter of the eccentric lubricant passage <NUM>. In some configurations, a retention pin <NUM> (<FIG> and <FIG>) or another fastener may extend through a radially extending aperture <NUM> in the crank pin <NUM> and into a retention aperture <NUM> (<FIG> and <FIG>) in the upper body portion <NUM> of the oil allocation member <NUM> to fixedly retain the oil allocation member <NUM> within the eccentric lubricant passage <NUM>. In some configurations, the oil allocation member <NUM> may be press fit within the eccentric lubricant passage <NUM>.

The lower body portion <NUM> of the oil allocation member <NUM> defines a first channel (a first lubricant flow path) <NUM> (<FIG>, <FIG>, and <FIG>) and a second channel (a second lubricant flow path) <NUM> (<FIG> and <FIG>). The upper body portion <NUM> of the oil allocation member <NUM> defines a third channel (a third lubricant flow path) <NUM> (<FIG> and <FIG>).

The first channel <NUM> extends through a lower axial end <NUM> of the oil allocation member <NUM> and receives lubricant flowing upward through the eccentric lubricant passage <NUM> from the inlet <NUM> of the eccentric lubricant passage <NUM>. The oil allocation member <NUM> may include a divider wall <NUM> disposed at the upper end of the first channel <NUM>. As shown in <FIG>, the divider wall <NUM> defines an inlet <NUM> of the second channel <NUM> and an inlet <NUM> of the third channel <NUM>. The divider wall <NUM> separates the second channel <NUM> from the third channel <NUM> and restricts fluid communication between the second and third channels <NUM>, <NUM>. The divider wall <NUM> and the inlets <NUM>, <NUM> of the second and third channels <NUM>, <NUM> are located vertically higher than the first outlet <NUM> of the eccentric lubricant passage <NUM> and vertically lower than the second outlet <NUM> of the eccentric lubricant passage <NUM>.

As shown in <FIG>, the second channel <NUM> extends from its inlet <NUM> at the divider wall <NUM> down to the first outlet <NUM>. As shown in <FIG>, the third channel <NUM> extends from its inlet <NUM> at the divider wall <NUM> up to the second outlet <NUM> (i.e., the third channel <NUM> extends through an upper axial end <NUM> of the oil allocation member <NUM>). The lower body portion <NUM> of the oil allocation member <NUM> separates the first channel <NUM> from the first outlet <NUM> such that all of the oil that enters the first channel <NUM> flows upward past the first outlet <NUM>. The divider wall <NUM> and the upper body portion <NUM> separate the second channel <NUM> from the second outlet <NUM> of the eccentric lubricant passage <NUM>.

During operation of the compressor <NUM> (i.e., while the driveshaft <NUM> is rotating), lubricant from the lubricant sump <NUM> flows into the concentric lubricant passage <NUM> and into the eccentric lubricant passage <NUM> via the inlet <NUM>. From the inlet <NUM>, the lubricant flows upward in the eccentric lubricant passage <NUM> and into the first channel <NUM> of the oil allocation member <NUM>. The divider wall <NUM> splits the flow of lubricant in the first channel <NUM> into first and second portions. The first portion of the lubricant enters the second channel <NUM> through the inlet <NUM> and flows down the second channel <NUM> and through the first outlet <NUM> to the first bearing <NUM>. The second portion of the lubricant enters the third channel <NUM> through the inlet <NUM> and flows up the third channel <NUM> and through the second outlet <NUM> to the drive bushing <NUM>. After splitting apart from each other, the oil allocation member <NUM> keeps the first and second portions of lubricant separated from each other such that only the first portion of the lubricant can flow through the first outlet <NUM> and only the second portion of the lubricant can flow through the second outlet <NUM>.

In some configurations, the first and second portions of lubricant may be equal in volume (i.e., the divider wall <NUM> directs half of the lubricant from the first channel <NUM> to the second channel <NUM> and directs the other half of the lubricant from the first channel <NUM> to the third channel <NUM>). In other configurations, the divider wall <NUM> and the inlets <NUM>, <NUM> of the second and third channels <NUM>, <NUM> may be sized and/or positioned to provide more than half of the lubricant from the first channel <NUM> to one of the second and third channels <NUM>, <NUM> (i.e., so that one of the first and second portions of the lubricant is greater in volume than the other of the first and second portions). For example, in some configurations, the divider wall <NUM> may be angled relative to the longitudinal axis of the eccentric lubricant passage <NUM> to direct more lubricant into one of the second and third channels <NUM>, <NUM> than the other. Additionally or alternatively, the divider wall <NUM> could be shifted laterally (i.e., to the left or to the right relative to the position shown in <FIG>) to direct more lubricant into one of the second and third channels <NUM>, <NUM> than the other.

As described above, the divider wall <NUM> and the inlets <NUM>, <NUM> of the second and third channels <NUM>, <NUM> are located vertically higher than the first outlet <NUM> of the eccentric lubricant passage <NUM> and vertically lower than the second outlet <NUM> of the eccentric lubricant passage <NUM>. More specifically, the lower tip of the divider wall <NUM> may be disposed at or vertically above a paraboloid curve formed by lubricant in the eccentric lubricant passage <NUM> when the driveshaft <NUM> and motor assembly <NUM> are operating at a minimum operating speed for the particular compressor <NUM> in which the oil allocation member <NUM> is installed. In this manner, at all operating speeds of a given compressor, gravity will force the first portion of the lubricant through the second channel <NUM> and centrifugal force will force the second portion of the lubricant through the third channel <NUM>.

By splitting the flow of lubricant through the first channel <NUM> into the first and second portions at a location that is vertically higher than the first outlet <NUM> and keeping the first and second portions separate from each other, the oil allocation member <NUM> provides adequate amounts of oil to the first and second outlets <NUM>, <NUM> regardless of compressor operating conditions such as rotational speed of the driveshaft <NUM>, oil level in the sump <NUM>, oil quality (viscosity, dilution, temperature, etc.), bearing clearance (clearance between the driveshaft <NUM> and the first bearing <NUM>), refrigerant temperature or pressure above the oil level in the sump <NUM>, etc..

In some configurations, the lower body portion <NUM> of the oil allocation member <NUM> may include one or more support members or protrusions <NUM> (<FIG>, <FIG>, and <FIG>) that extend into first channel <NUM>. The protrusions <NUM> may aid in keeping the lower body portion <NUM> properly positioned within the eccentric lubricant passage <NUM> to keep the first channel <NUM> fluidly separated from the first outlet <NUM>.

While not shown in the drawings, in some configurations, an aperture may extend radially outward from the concentric lubricant passage <NUM> to provide lubricant to the second bearing <NUM>.

In some configurations, the compressor <NUM> may include a positive pump to boost the flow lubricant through the lubricant passages <NUM>, <NUM>.

Claim 1:
A compressor (<NUM>) comprising:
a compression mechanism (<NUM>);
a driveshaft (<NUM>) drivingly engaging the compression mechanism and including a lubricant passage (<NUM>), wherein the lubricant passage includes an inlet (<NUM>), a first outlet (<NUM>), and a second outlet (<NUM>), and wherein the inlet and the first and second outlets are spaced apart from each other in a direction parallel to a rotational axis (R) of the driveshaft such that the first outlet (<NUM>) is disposed vertically higher than the inlet (<NUM>) and the second outlet (<NUM>) is disposed vertically higher than the first outlet (<NUM>); and
an oil allocation member (<NUM>) disposed within the lubricant passage (<NUM>) and fixed relative to the driveshaft, the compressor (<NUM>) characterised by the oil allocation member defining a first channel (<NUM>), a second channel (<NUM>), and a third channel (<NUM>),
wherein:
the first channel (<NUM>) extends through a lower axial end (<NUM>) of the oil allocation member (<NUM>) and receives lubricant flowing upward from the inlet (<NUM>) of the lubricant passage (<NUM>),
the second channel (<NUM>) receives a first portion of the lubricant from the first channel (<NUM>) through an inlet (<NUM>) of the second channel (<NUM>) and provides the first portion of the lubricant to the first outlet (<NUM>) of the lubricant passage (<NUM>),
the third channel (<NUM>) receives a second portion of the lubricant from the first channel (<NUM>) through an inlet (<NUM>) of the third channel (<NUM>) and provides the second portion of the lubricant to the second outlet (<NUM>) of the lubricant passage (<NUM>), and
the first portion of the lubricant and the second portion of the lubricant are separated from each other at a location that is vertically higher than the first outlet (<NUM>).