Vapor injection structure for compressor

Abstract

A scroll compressor includes a compression mechanism assembled with a valve assembly disposed in a housing. The compression mechanism comprises a fixed scroll and a movable scroll. The stationary scroll includes a pocket having a first recess with a first injection port and a second recess with a second injection port. And the double-reed structure of the valve assembly is arranged in the recess of the fixed vortex.

Description

Technical Field

[0001] The present disclosure relates to compressors, and more particularly to steam injection structures for compressors. Background Art

[0002] As is well known, vehicles typically include a heating, ventilation and air conditioning (HVAC) system. In some applications, a scroll compressor is used to compress the refrigerant circulating through the refrigerant circuit of the HVAC system. More specifically, such a refrigerant circuit can be configured for use with a steam injection scroll compressor that optimizes the capacity of the steam injection scroll compressor by utilizing two different refrigerant inputs at different pressures and / or temperatures compared to a single input scroll compressor. This is typically achieved by returning a portion of the refrigerant toward the steam injection scroll compressor after initially leaving the compression chamber of the steam injection scroll compressor. Depending on the configuration of the refrigerant circuit, the returned refrigerant can be expanded via a corresponding expansion element, supercooled via a corresponding heat exchanger, or separated via a cyclone separator, etc., and any combination thereof, before reentering the steam injection scroll compressor to ensure that the returned refrigerant has the desired characteristics of a given application.

[0003] Typically, a scroll compressor includes a stationary fixed scroll and a movable scroll nested relative to the fixed scroll and configured to orbit relative to the fixed scroll. The orbiting motion of the movable scroll and the similar spiral shape of each of the fixed scroll and the movable scroll continuously form corresponding pairs of substantially symmetrical compression chambers between the fixed scroll and the movable scroll. Each pair of compression chambers in the compression chamber is usually symmetrical about the centralized discharge port of the steam injection scroll compressor. The refrigerant usually enters each compression chamber in the compression chamber via one or more inlet ports formed at the radially outermost portion adjacent to the fixed scroll, and then the orbiting motion of the movable scroll relative to the fixed scroll causes the volume of each compression chamber in the compression chamber to gradually decrease, so that the pressure of the refrigerant in each compression chamber arranged in the compression chamber gradually increases as the refrigerant approaches the radial central discharge port.

[0004] The difference between the steam injection scroll compressor and the conventional scroll compressor is that the returned refrigerant is injected into each compression chamber in the symmetrically formed compression chamber at a corresponding intermediate position between the inlet port arranged radially at the outermost side of the fixed scroll and the discharge port arranged centrally. Since there are paired symmetrical compression chambers between the mating scrolls, it is beneficial to introduce the returned refrigerant at two different injection openings, which are arranged substantially symmetrically in a similar manner relative to the discharge port arranged centrally, so that each compression chamber in the paired compression chambers receives the returned refrigerant flow at a similar position during the compression process. Therefore, the injected refrigerant enters each compression chamber in the compression chamber at a position corresponding to the area of ​​the fixed scroll that repeatedly experiences the pressure of the refrigerant flowing radially inward, which pressure is generally between the suction pressure formed at the inlet port of the fixed scroll and the discharge pressure formed at the discharge port of the fixed scroll. The injected refrigerant comes from the injection chamber of the steam injection scroll compressor, which is configured to receive the returned refrigerant in the injection chamber before reintroducing the returned refrigerant back into the compression chamber.

[0005] In addition, the continuous orbit of the movable vortex relative to the fixed vortex causes each of the injection openings formed in the fixed vortex to be subjected to variable pressure during each orbit of the movable vortex based on whether the corresponding part of the movable vortex has passed through the corresponding injection opening relative to each orbit cycle. Therefore, each of the injection openings of the fixed vortex must be associated with a corresponding check valve to ensure that the returning refrigerant is injected into the corresponding compression chamber along a single flow direction. Specifically, the check valve ensures that the returning refrigerant can enter the corresponding compression chamber only when the refrigerant already arranged in the compression chamber is at a relatively low pressure lower than the pressure of the injected refrigerant. The check valve also prevents the following from occurring: any compressed refrigerant at a relatively high pressure higher than the pressure of the injected refrigerant flows through the injection opening, through the injection chamber and toward any component arranged upstream of the injection chamber relative to the returning refrigerant, such as the aforementioned cyclone separator, in the reverse direction (backflow).

[0006] Such a check valve may be provided as a ball valve which is biased to a closed position by a spring or the like until the pressure of the injected refrigerant exceeds the pressure of the refrigerant present in the corresponding compression chamber. However, it has been found that the use of such a ball valve may result in an undesirable pressure drop in the injected refrigerant which reduces the output capacity of the steam injection scroll compressor. Other disadvantages of such a ball valve may be the need for multiple components resulting in increased manufacturing complexity, the need for increased axial packaging space to accommodate the movement of the ball relative to the spring, and inconsistent distribution of the injected refrigerant to each of a pair of injection openings.

[0007] Such a check valve may also be configured as a reed valve having a flexible metal reed that flexes in response to a pressure differential across the reed valve. However, such a reed valve is conventionally configured to include repeated metal-to-metal contact, which greatly reduces the durability of such a reed valve and also introduces noise, vibration and harshness (NVH) issues that may potentially be experienced by passengers of the vehicle. Furthermore, conventional reed valves are part of a complex injection valve assembly that requires many parts and complex sealing structures. Summary of the invention

[0008] Technical issues

[0009] Therefore, it is desirable to develop a simplified and durable injection valve assembly for a scroll compressor to minimize manufacturing time and cost, increase discharge chamber volume, and prevent NVH from occurring during operation of the injection valve assembly.

[0010] Solution to the problem

[0011] In accordance with and consistent with the presently described subject matter, a simplified and durable injection valve assembly for a scroll compressor has surprisingly been designed to minimize manufacturing time and cost, increase discharge chamber volume, and prevent NVH during operation of the injection valve assembly.

[0012] In one embodiment, a valve assembly for a scroll compressor includes: a reed structure configured to cooperate with a fixed scroll of the scroll compressor, wherein the reed structure selectively allows fluid to flow through at least one of a first injection port and a second injection port of the scroll compressor; a valve member disposed adjacent to the reed structure, wherein the valve member includes a first injection orifice and a second injection orifice formed through the valve member, and wherein the first injection orifice is fluidically connected to the first injection port of the scroll compressor, and the second injection orifice is fluidically connected to the second injection port of the scroll compressor; and a valve gasket disposed adjacent to the valve member.

[0013] In another embodiment, a valve assembly for a scroll compressor includes: a reed structure having a first reed and a second reed, wherein the first reed is configured to be received in a first recessed portion of a fixed scroll of the scroll compressor, and the second reed is configured to be received in a second recessed portion of the fixed scroll of the scroll compressor; a valve member disposed adjacent to the reed structure, wherein the valve member includes a first injection orifice and a second injection orifice formed through the valve member, and wherein the first injection orifice is fluidically connected to a first injection port of the scroll compressor, and the second injection orifice is fluidically connected to a second injection port of the scroll compressor; and a valve gasket disposed adjacent to the valve member.

[0014] In another embodiment, a scroll compressor includes: a compression mechanism, which includes a fixed scroll and a movable scroll, wherein the fixed scroll includes a recess having a first injection port and a second injection port formed in the recess; and a valve assembly, which is connected to the fixed scroll, and the valve assembly includes: a reed structure, which is at least partially disposed in the recess of the fixed scroll; a valve member, which is disposed adjacent to the reed structure, wherein the valve member includes a first injection orifice and a second injection orifice formed through the valve member, and wherein the first injection orifice is fluidically connected to the first injection port of the scroll compressor, and the second injection orifice is fluidically connected to the second injection port of the scroll compressor; and a valve gasket, which is disposed adjacent to the valve member.

[0015] As an aspect of some embodiments, a reed structure includes a first reed configured to selectively allow fluid to flow through a first injection port of a scroll compressor.

[0016] As an aspect of some embodiments, the reed structure includes a second reed configured to selectively allow fluid to flow through a second injection port of the scroll compressor.

[0017] As an aspect of some embodiments, the first injection port is in fluid communication with an injection chamber formed in the scroll compressor.

[0018] As an aspect of some embodiments, the second injection port is in fluid communication with an injection chamber formed in the scroll compressor.

[0019] As an aspect of some embodiments, the reed structure includes a first reed configured to selectively allow fluid to flow through a first injection port of the non-orbiting scroll.

[0020] As an aspect of some embodiments, the reed structure includes a second reed configured to selectively allow fluid to flow through a second injection port of the non-orbiting scroll.

[0021] As an aspect of some embodiments, at least a portion of the reed structure is in direct contact with at least one surface of a non-orbiting scroll of the scroll compressor.

[0022] As an aspect of some embodiments, the first injection port is located in a first recess formed in a pocket of the non-orbiting scroll.

[0023] As an aspect of some embodiments, the second injection port is located in a second recessed portion formed in a pocket of the non-orbiting scroll.

[0024] As an aspect of some embodiments, the scroll compressor further includes a housing portion configured to receive at least a portion of the non-orbiting scroll therein, wherein the valve gasket is configured to provide a substantially fluid tight seal between the valve member and the housing portion of the scroll compressor.

[0025] As an aspect of some embodiments, the valve gasket includes a flange formed around a periphery of the valve gasket, and wherein the flange is configured to be compressed between the valve member and a housing portion of the scroll compressor.

[0026] As an aspect of some embodiments, the scroll compressor further includes a housing portion including an inner wall, wherein the inner wall defines an injection chamber and is configured to cooperate with the valve assembly.

[0027] Other areas of applicability will become apparent from the description provided herein.The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

[0029] Figure 1 is a cross-sectional view taken through a compression mechanism of a scroll compressor according to an embodiment of the present disclosure;

[0030] Figure 2 yes Figure 1 An axial end view of a fixed scroll of a compression mechanism, wherein the fixed scroll is shown alone;

[0031] Figure 3 is an exploded and partial perspective view of relevant components of a scroll compressor required for illustrating an injection valve assembly of a scroll compressor;

[0032] Figure 4 is a partial axial end perspective view of an injection valve assembly coupled to a fixed scroll of a scroll compressor;

[0033] Figure 5 is a partial axial end perspective view of a fixed scroll of a scroll compressor without an injection valve assembly coupled thereto;

[0034] Figure 6 is a partial cross-sectional view of a portion of a non-orbiting scroll without an injection valve assembly coupled thereto;

[0035] Figure 7 is an axial end perspective view of a first housing portion of a scroll compressor having a wall defining an injection chamber;

[0036] Figure 8 is a perspective cross-sectional view of a fixed scroll coupled to a first housing portion of a scroll compressor;

[0037] Fig. 9is a partial perspective cross-sectional view of a portion of a non-orbiting scroll, wherein an injection valve assembly is coupled to a first housing portion of a scroll compressor;

[0038] Fig.10 is an enlarged partial perspective cross-sectional view of a portion of a non-orbiting scroll wherein an injection valve assembly is coupled to a first housing portion of a scroll compressor; and

[0039] Fig.11 is an enlarged partial axial end view of a portion of an injection valve assembly coupled to a non-orbiting scroll of a scroll compressor; and

[0040] Fig.12 is an enlarged partial perspective cross-sectional view of a portion of a non-orbiting scroll with an injection valve assembly coupled to a first housing portion of a scroll compressor. DETAILED DESCRIPTION

[0041] The following technical descriptions of one or more disclosed themes, manufactures and uses are essentially exemplary only, and are not intended to limit the scope, application or use of any specific disclosure claimed in the present application or in other such applications that may claim priority of the present application or be submitted according to the priority of the patent authorized by the present application. With respect to the disclosed method, the order of the steps presented is essentially exemplary, and therefore, the order of the steps may be different in various embodiments. As used herein, "one" and "a kind of" indicate that there is "at least one" item; where possible, there may be multiple such items. Unless otherwise expressly indicated, all numerical values ​​in this description should be understood to be modified by the word "about" when describing the broadest scope of the technology, and all geometric and spatial descriptors should be understood to be modified by the word "substantially". "About" indicates that the calculated value or measurement allows some slight imprecision when applied to a numerical value (wherein, approximately the exact value of the value to a certain extent; approximately or reasonably close to the value; approximately). If for some reason the imprecision provided by "about" and / or "substantially" is not understood with its ordinary meaning in the art, "about" and / or "substantially" as used herein at least indicates the variations that may result from ordinary methods of measuring or using such parameters.

[0042] Unless otherwise expressly indicated, all documents cited in this detailed description, including patents, patent applications, and scientific literature, are incorporated herein by reference. In the event of any conflict or ambiguity between a document incorporated by reference and this detailed description, the detailed description shall prevail.

[0043] Although the open-ended term "comprising" is used herein as a synonym for non-limiting terms such as includes, contains, or having to describe and claim embodiments of the present technology, more restrictive terms such as "consisting of" or "consisting essentially of" may alternatively be used to describe embodiments. Thus, for any given embodiment reciting materials, components, or process steps, the present technology also specifically includes embodiments consisting of or consisting essentially of such materials, components, or process steps, without including additional materials, components, or processes (for consisting of) and without including additional materials, components, or processes (for consisting essentially of) that affect significant characteristics of the embodiment, even if such additional materials, components, or processes are not explicitly recited in this application. For example, a recitation of a composition or process reciting elements A, B, and C specifically contemplates embodiments consisting of and consisting essentially of A, B, and C, without including element D, which may be recited in the art, even if element D is not explicitly described herein as not included.

[0044] As mentioned herein, unless otherwise stated, all composition percentages are by weight of total composition. Unless otherwise stated, the disclosure of ranges includes endpoints and includes all different values ​​and further divided ranges in the entire range. Therefore, for example, the range of "from A to B" or "from about A to about B" includes A and B. The disclosure of values ​​and value ranges for specific parameters (such as amount, weight percentage, etc.) does not exclude other values ​​and value ranges useful herein. It is conceivable that two or more specific exemplified values ​​for a given parameter can define the endpoints of the range of values ​​that may be claimed for the parameter. For example, if parameter X is exemplified herein as having value A and also exemplified as having value Z, it is conceivable that parameter X can have a value range from about A to about Z. Similarly, it is conceivable that the disclosure of two or more value ranges of parameters (whether these ranges are nested, overlapping or different) includes all possible combinations of the range of values ​​that can be claimed using the endpoints of the disclosed ranges. For example, if parameter X is illustrated herein as having a value in a range of 1 to 10, or 2 to 9, or 3 to 8, it is also contemplated that parameter X can have other ranges of values, including 1 to 9, 1 to 8, 1 to 3, 1 to 2, 2 to 10, 2 to 8, 2 to 3, 3 to 10, 3 to 9, etc.

[0045] When an element or layer is referred to as "on another element or layer", "engaged to", "connected to" or "coupled to" another element or layer, the element or layer may be directly on another element or layer, directly engaged to another element or layer, directly connected to another element or layer, or directly coupled to another element or layer, or there may be an intermediate element or layer. On the contrary, when an element is referred to as "directly on another element or layer", "directly engaged to", "directly connected to" or "directly coupled to" another element or layer, there may be no intermediate element or layer. Other words used to describe the relationship between elements (for example, "between" and "directly between", "adjacent" and "directly adjacent", etc.) should be interpreted in a similar manner. As used herein, the term "and / or" includes any and all combinations of one or more associated listed items.

[0046] Although the terms first, second, third, etc. can be used in this article to describe each element, component, region, layer and / or section, these elements, components, regions, layers and / or sections should not be limited by these terms. These terms can only be used to distinguish an element, component, region, layer or section from another region, layer or section. Unless the context clearly indicates, terms such as "first", "second" and other numerical terms do not imply order or sequence when used in this article. Therefore, without departing from the teachings of the example embodiments, the first element, component, region, layer or section discussed below can be referred to as the second element, component, region, layer or section.

[0047] For ease of description, spatially relative terms such as "inside", "outside", "below", "below", "lower", "above", "upper", etc. may be used herein to describe the relationship of one element or feature to another element or feature as illustrated in the accompanying drawings. Spatially relative terms may be intended to cover different orientations of the device in use or operation in addition to the orientation depicted in the accompanying drawings. For example, if the device in the accompanying drawings is turned over, the elements described as being "below" or "below" other elements or features will then be oriented to be "above" other elements or features. Therefore, the example term "below" can cover both the above and below orientations. The device can be oriented in other ways (rotated 90 degrees or in other orientations), and the spatially relative descriptors used herein are interpreted accordingly.

[0048] Figures 1 to 12Portions of a steam injection scroll compressor 1 having an injection valve assembly 30 according to an embodiment of the present disclosure are illustrated. The scroll compressor 1 may be provided as a component of an HVAC system of a motor vehicle, and more specifically, as a component for circulating a refrigerant of an associated refrigerant circuit in heat exchange communication with air to be delivered to a passenger compartment of an associated motor vehicle. The refrigerant may also be in heat exchange relationship with additional components of the motor vehicle requiring thermal conditioning, such as a battery or other electronic components associated with the operation of various different systems of the motor vehicle. References to the refrigerant used hereinafter may refer to the refrigerant when provided alone as a gas or as a mixture of a gas and a liquid. Although the scroll compressor 1 is described as a refrigerant for an HVAC system, it should be readily understood that the structure disclosed herein may be adapted for use with any fluid that requires compression relative to any associated fluid system as desired.

[0049] like Figure 1 As best shown in cross section in FIG. 1 , the scroll compressor 1 includes a compression mechanism formed by a fixed scroll 5 having an axially extending first helical structure 6 and a movable scroll 7 having an axially extending second helical structure 8. The second helical structure 8 extends in an opposite axial direction relative to the first helical structure 6, wherein each of the spirals of the second helical structure 8 is nested in each of the spaces formed between adjacent spirals of the first helical structure 6. The first helical structure 6 and the second helical structure 8 are positioned relative to each other to form a plurality of compression chambers 9 between the first helical structure 6 and the second helical structure 8 during operation of the compression mechanism of the scroll compressor 1.

[0050] The fixed scroll 5 includes at least one inlet opening 11 adjacent to the radially outermost portion of the fixed scroll 5 for introducing refrigerant into each of the compression chambers 9. In the embodiment provided, the fixed scroll 5 includes a plurality of inlet openings 11 circumferentially spaced from each other in the outer circumferential wall 12 of the fixed scroll 5, wherein each of the inlet openings 11 is configured as a hole, a recess or other form of passage that allows the refrigerant to flow radially inward into one of the compression chambers 9. The refrigerant typically enters the fixed scroll 5 through one of the inlet openings 11 at a relatively low pressure, which is typically referred to as the suction pressure of the scroll compressor 1. The fixed scroll 5 also includes a discharge opening 13 formed at the radially innermost end of the first spiral structure 6, through which the refrigerant leaves each of the compression chambers 9 after having been compressed in each of the compression chambers 9. Therefore, the discharge opening 13 is located at or near the radial center of the fixed scroll 5. The compressed refrigerant thus leaves the mating scrolls 5, 7 at a relatively high pressure greater than the relatively low pressure suction pressure, wherein the relatively high pressure is referred to as the discharge pressure of the scroll compressor 1. A reed valve assembly including a reed valve 2 and a retainer 3 may be employed to selectively allow compressed refrigerant to flow out of the fixed scroll 5. As illustrated, the reed valve assembly may be coupled to the fixed scroll by at least one coupling element 4 (e.g., a mechanical fastener). However, other coupling means may be employed if desired.

[0051] The movable scroll 7 is configured to orbit relative to the fixed scroll 5 in the following manner: each of the compression chambers 9 moves circumferentially and radially inward toward the discharge opening 13. During the repeated orbiting motion of the movable scroll 7, the shape and position of each of the compression chambers 9 are correspondingly changed relative to the fixed shape and position of the fixed scroll 5. This motion causes a decrease in the flow rate of each of the compression chambers 9 when each of the compression chambers 9 approaches the discharge opening 13 disposed radially inward, thereby causing the compression of the refrigerant discussed previously.

[0052] Figure 1 The diagram shows a cross section through the fixed scroll 5 and the movable scroll 7 when the compression mechanism is in a position with two pairs of opposite compression chambers 9. Each of the compression chambers 9 forming one of the pairs of compression chambers comprises a substantially identical shape rotated 180 degrees relative to the other of the paired and opposite compression chambers 9. The first pair of compression chambers 9 is disposed proximate to the radial center of each of the spiral structures 6, 8 (generally corresponding to the position of the discharge opening 13), while the second pair of compression chambers 9 is formed radially outside the first pair of compression chambers 9, closer to the inlet opening 11.

[0053] The fixed scroll 5 includes an end wall 14, and the end wall 14 includes Figure 2 The inner face 15 shown in FIG. Figure 3 and Figure 4 The inner face 15 faces the orbiting scroll 7, wherein the first spiral structure 6 extends axially from the inner face 15. The outer face 16 faces away from the orbiting scroll 7 and faces the previously mentioned valve assembly 30 (in Figure 3 The discharge opening 13 , the first injection port 17 and the second injection port 18 are all formed through the end wall 14 from the inner face 15 to the outer face 16 of the end wall 14 . Figure 2 The inner face 15 of the end wall 14 is shown, wherein the orbiting scroll 7 is omitted to better illustrate the positioning of the discharge opening 13 and the injection ports 17 , 18 relative to the configuration of the first spiral structure 6 .

[0054] The pocket 19 may be formed to extend axially into the outer face 16 of the fixed scroll 5. Although the pocket 19 shown is generally V-shaped, it should be understood that the pocket 19 may have any suitable shape, size, and configuration as desired. In some embodiments, the pocket 19 may be formed by a central portion 20 and opposite leg portions 21, 22 extending outwardly from the central portion 20. Figure 5 and Figure 6 As best seen in FIG. 1 , the outer face 16 of the fixed scroll 5 also includes a first recess 23 and a spaced recess 24. The recesses 23, 24 are formed in the leg portions 21, 22 of the pocket 19, respectively. Each of the recesses 23, 24 is defined by a corresponding surface 27, 28 inclined at a certain angle relative to the plane of the outer face 16 of the fixed scroll 5. The axial depth of each of the recesses 23, 24 gradually increases as the recesses 23, 24 extend away from the central portion 20 into the leg portions 21, 22. The inclination angle of surfaces 27, 28 may be about 3 to 5 degrees. It should be understood that surfaces 27, 28 may have any suitable inclination angle as desired. An opening 25 may also be formed in the pocket 19, and more specifically, in the central portion 20 of the pocket 19. The opening 25 may be configured to receive a coupling element 26 (e.g., a mechanical fastener) to couple the valve assembly 30 to the fixed scroll 5.

[0055] like Figure 3 , Figure 5 and Figure 6As shown in FIG. 1 , each of the injection ports 17, 18 is formed in a corresponding one of the recessed portions 23, 24 of the outer face 16. The first injection port 17 and the second injection port 18 are substantially oppositely positioned relative to the centrally disposed discharge opening 13, wherein each of the injection ports 17, 18 is also radially spaced apart from the discharge opening 13 at a substantially equal distance. The substantially opposite positioning of the injection ports 17, 18 allows the first injection port 17 to be in fluid communication with the first compression chamber of each pair of the opposite pairs of compression chambers 9, and allows the second injection port 18 to be in fluid communication with the second compression chamber of each pair of the opposite pairs of compression chambers 9. Therefore, each of the compression chambers 9 that travel radially inward toward the discharge opening 13 can be in fluid communication with one of the injection ports 17, 18 at a substantially similar radial position relative to the discharge opening 13, which also corresponds to the refrigerant disposed in each of the opposite and paired compression chambers 9 having a similar pressure when in fluid communication with the corresponding one of the injection ports 17, 18. The pressure of the refrigerant when reaching each of the injection ports 17 , 18 may be referred to as an intermediate pressure, which has a value between the suction pressure and the discharge pressure described previously.

[0056] Now refer to Figure 3 , the parts of the scroll compressor 1 related to the operation of the valve assembly 30 are shown in an exploded view, so that it is easier to determine the assembly method of the scroll compressor 1. The movable scroll 7 and the parts required for causing the orbiting motion of the movable scroll 7 are omitted, but it should be easily understood by those skilled in the art that in the absence of the movable scroll 7 and the parts required for causing the orbiting motion of the movable scroll 7, the operation method of the valve assembly 30 is easy to understand from the illustrated stereoscopic view.

[0057] The first housing portion 110 of the scroll compressor 1 is an open-ended and hollow structure, which is configured to cooperate with the second housing portion (not shown) of the scroll compressor 1 to enclose the internal components of the scroll compressor 1. The first housing portion 110 defines a housing cavity 111, which is configured to receive the fixed scroll 5 and the valve assembly 30 in the housing cavity 111. It should be understood that alternative configurations of the housing components of the scroll compressor 1 can be provided, as long as the relevant structure for guiding the refrigerant flow remains as described below, and the alternative configuration includes the use of additional housing components or the use of housing components with an alternatively arranged joint between the housing components. More specifically, any combination of housing components can be utilized, as long as the housing cavity 111 is configured to receive the fixed scroll 5 and the valve assembly 30 in the housing cavity 111 in a manner that promotes the operation of the valve assembly 30 as disclosed below.

[0058] The housing cavity 111 is in fluid communication with a refrigerant return passage 112. The refrigerant return passage 112 provides fluid communication between the housing cavity 111 and another component (not shown) of the associated refrigerant circuit through which the refrigerant passes after being initially compressed in the compression mechanism of the scroll compressor 1. For example, the component may be a separator (not shown), such as a cyclone separator, disposed downstream of the compression mechanism and upstream of the low-pressure side of the scroll compressor 1 relative to the general flow direction of the refrigerant through the refrigerant circuit. The refrigerant return passage 112 is configured to receive a partial flow of the refrigerant after the refrigerant branches off from the refrigerant circuit. The partial flow of the refrigerant may have a pressure between the discharge pressure and the suction pressure and may bypass at least one component of the refrigerant circuit disposed upstream of the low-pressure side of the scroll compressor 1. In some cases, the component from which the refrigerant branches back toward the refrigerant return passage 112 may be disposed immediately downstream of the compression mechanism and even disposed relative to a downstream arrangement portion of the scroll compressor 1 itself. It should be understood that while remaining within the scope of the present disclosure, refrigerant may be returned to the refrigerant return passage 112 from any component of the refrigerant circuit so long as the refrigerant has the desired properties for being injected back into the compression chamber 9 during the compression process occurring within the compression mechanism.

[0059] like Figure 7 and Figure 8 As shown in the figure, the refrigerant return passage 112 leads to the injection chamber 113 of the first shell part 110. The injection chamber 113 is an open space defined by an axially extending inner wall 114, which is formed in the shell cavity 111 between the refrigerant return passage 112 and the valve assembly 30. Depending on the condition of the returning refrigerant, the refrigerant entering the injection chamber 113 can be a gaseous vapor or a combination of a gaseous vapor and a liquid. As shown, the wall 114 can be configured to correspond to the shape, size and configuration of the valve assembly 30, and can include one or more protrusions 115 extending inwardly into the injection chamber 113. Although the protrusions 115 shown have a generally leaf-like or tongue-like shape, it should be understood that each of the protrusions 115 can have any shape, size and configuration as desired. For example, the protrusions 115 can each have a generally rectangular shape with square ends or a completely irregular shape.

[0060] Return to reference Figure 3 The valve assembly 30 includes a double reed structure 40, a valve member 60 and a valve gasket 80. Figure 3 The assembling direction of the valve assembly 30 shown by the separation direction of the components forming the valve assembly 30 in the exploded view of FIG. 3 is hereinafter referred to as the axial direction of the valve assembly 30. The axial direction of the valve assembly 30 also corresponds to the axial direction of each of the constituent components of the valve assembly 30, as used hereinafter.

[0061] The double spring structure 40 is a thin and flat plate-like body, which includes a first main surface 41 and an oppositely arranged second main surface 42 (at Fig. 9 and Fig.10 ). The major surfaces 41, 42 are arranged parallel to each other and perpendicular to the axial direction of the valve assembly 30. The first major surface 41 is configured to abut a surface of the recess 19, and the second major surface 42 is configured to abut a valve member 60, as explained in more detail below.

[0062] The double reed structure 40 includes a first reed 43, a second reed 44 and a connecting portion 45. The reeds 43, 44 and the connecting portion 45 are integrally formed into a one-piece structure. However, it should be understood that the reed structure 40 may include multiple parts if necessary. When the reeds 43, 44 are not flexed during the operation of the scroll compressor 1, the first reed 43 and the second reed 44 extend longitudinally away from the connecting portion 45 in a substantially opposite direction perpendicular to the axial direction of the valve assembly 30. In the embodiment provided, the reeds 43, 44 and the connecting portion 45 are formed to have a substantially V-shaped configuration, but each of the reeds 43, 44 and the connecting portion 45 can have any shape, size and configuration, as long as the reed structure 40 can be received in the recess 19 of the fixed scroll 5 and / or the connecting portion 45 extends between the reeds 43, 44 and connects the reeds 43, 44 to form the described integral structure with the reeds 43, 44. Thus, the wall 114 of the first housing portion 110 may also have a generally V-shaped configuration corresponding to the shape, size, and configuration of the leaf spring structure 40 .

[0063] The first spring 43 includes an arm 47 extending longitudinally between a pivot portion 48 and an end portion 49. The pivot portion 48 forms an axis about which the remainder of the first spring 43 (including the end portion 49 disposed at the distal end of the arm 47 opposite the pivot portion 48) flexes relative to the fixed connection portion 45. Figure 3 , Fig. 9 and Fig.11 As shown in , the end portion 49 is arranged in alignment with the first injection orifice 65 of the valve member 60 relative to the axial direction of the valve assembly 30. The arm 47 may include a generally rectangular shape, and the end portion 49 may include a generally curved peripheral shape. For example, the end portion 49 may include an elliptical shape, an oval shape, a rounded rectangular shape, etc., to ensure that the end portion 49 can cover the first injection orifice 65 when engaging the valve member 60 around the periphery of the first injection orifice 65.

[0064] The second spring 44 includes an arm 51 extending longitudinally between a pivot portion 52 and an end portion 53. The pivot portion 52 forms an axis about which the remainder of the second spring 44 (including the end portion 53 disposed at the distal end of the arm 51 opposite the pivot portion 52) flexes relative to the fixed connection portion 45. Figure 3 As shown in the figure, the end portion 53 is arranged in alignment with the second injection orifice 66 of the valve member 60 relative to the axial direction of the valve assembly 30. The arm 51 may include a generally rectangular shape, and the end portion 53 may include a generally curved peripheral shape. For example, the end portion 53 may include an elliptical shape, an oval shape, a rounded rectangular shape, etc., to ensure that the end portion 53 can cover the second injection orifice 66 when engaging the valve member 60 around the periphery of the second injection orifice 66.

[0065] The double reed structure 40 also includes an opening 58 disposed in the connecting portion 45. The opening 58 is formed in alignment with the opening 25 formed in the recess 19 of the fixed scroll 5. The opening 58 is configured to receive the coupling element 26 passing through the opening 58 when the valve assembly 30 is in an assembled configuration to correctly position the double reed structure 40 relative to the fixed scroll 5 and / or the wall 114. In some embodiments, the protrusion 115 of the wall 114 ensures that the reed structure 40 can be clamped and / or supported for controlling the corresponding pivoting portions 48, 52 of the reeds 43, 44. The stiffness of each of the reeds 43, 44 of the reed structure 40 can be inversely proportional to the pivoting length of the reeds 43, 44. In some embodiments, the position of the pivoting portions 48, 52 and / or the pivoting length of the reeds 43, 44 can be controlled by the size, shape and configuration of the protrusion 115 of the wall 114. For example, an increase in the inward extension of the protrusion 115 into the injection chamber 113 can move the position of the pivot portions 48, 52 toward the end portions 49, 53, resulting in a shorter pivot length of the reeds 43, 44, and thereby causing the reed structure 40 to be stiffer. Conversely, a decrease in the inward extension of the protrusion 115 into the injection chamber 113 can move the position of the pivot portions 48, 52 away from the end portions 49, 53, resulting in a longer pivot length of the reeds 43, 44, and thereby causing the reed structure 40 to be more flexible.

[0066] The double reed structure 40 is formed of a resiliently flexible material, thereby allowing each of the arms 47, 51 of the reeds 43, 44 to flex about the corresponding pivot portions 48, 52 away from a plane generally defined by the double reed structure 40. The resiliently flexible material is selected to allow each of the reeds 43, 44 to undergo repeated elastic deformation about the pivot portions 48, 52 while still allowing each of the reeds 43, 44 to rebound to its initial position, wherein the reeds 43, 44 are arranged substantially perpendicular to the axial direction of the valve assembly 30 and parallel to the major surfaces 41, 42 of the connecting portion 45 of the double reed structure 40. The flexure of each of the reeds 43, 44 away from the corresponding injection orifices 17, 18 requires a force to be applied to each of the reeds 43, 44 that overcomes the spring force generated by the elasticity of each of the reeds 43, 44 at each of the corresponding pivot portions 48, 52. Therefore, the double reed structure 40 can be formed of a suitable metal material such as aluminum, steel or alloys thereof.

[0067] like Figure 3 as well as Figures 9 to 12 As shown in , the valve member 60 can be disposed in the recess 19 of the fixed scroll 5, and includes a substantially flat first main surface 61 and an oppositely arranged and substantially flat second main surface 62, wherein the main surfaces 61, 62 are arranged parallel to each other and perpendicular to the axial direction of the valve assembly 30. The first main surface 61 faces the double reed structure 40, and the second main surface 62 faces the refrigerant return passage 112 and the valve gasket 80. In some embodiments, the valve member 60 is seated in the recess 19 of the fixed scroll 5 adjacent to the reed structure 40. Preferably, when the valve member 60 is assembled with the fixed scroll 5, the second main surface 62 of the valve member 60 and the outer face 16 of the fixed scroll 5 are substantially coplanar.

[0068] The valve member 60 includes a first injection orifice 65 and a spaced-apart second injection orifice 66. Each of the injection orifices 65, 66 extends from the first main surface 61 of the valve member 60 through the valve member 60 to the second main surface 62 of the valve member 60 relative to the axial direction. The spacing between the injection orifices 65, 66 relative to the direction perpendicular to the axial direction may be substantially similar to or equal to the spacing between the first injection port 17 and the second injection port 18 formed through the fixed scroll 5. Each of the injection orifices 65, 66 is in fluid communication with a corresponding one of the injection ports 17, 18. In some embodiments, the first injection orifice 65 is in fluid communication with the first injection port 17, and the second injection orifice 66 is in fluid communication with the second injection port 18.

[0069] Each of the injection orifices 65, 66 is shown as having an elongated peripheral shape, wherein the elongated directions of each of the injection orifices 65, 66 are arranged in parallel. The injection orifices 65, 66 may be otherwise referred to as injection slots 65, 66 due to their elongated configuration. Each of the injection orifices 65, 66 is shown as having an elongated shape, but other rounded and elongated shapes may also be used, such as an elliptical shape, an oval shape, a rounded rectangular shape, etc. The elongated shape of each of the injection orifices 65, 66 beneficially provides an increased cross-sectional flow area through the injection orifices 65, 66 compared to a purely circular cross-sectional shape, which in turn increases the total force that can be exerted by the returning refrigerant through each of the injection orifices 65, 66 relative to a given pressure of the refrigerant. However, other shapes including a circular shape may also be used while still having the remaining beneficial characteristics of the valve assembly 30.

[0070] The valve member 60 also includes an opening 68 formed therethrough. The opening 68 is formed in alignment with the openings 25, 58 formed in the pocket 19 of the fixed scroll 5 and the double reed structure 40, respectively. The opening 68 is configured to receive the coupling element 26 therethrough when the valve assembly 30 is in an assembled configuration to properly position the double reed structure 40 and the valve member 60 relative to the fixed scroll 5.

[0071] like Figures 9 and 10 as well as Fig.12 As best shown in , the valve gasket 80 is disposed between the periphery of the second main surface 62 of the valve member 60 and the inner surface of the wall 114 defining the injection chamber 113. The valve gasket 80 has a first main surface 81 and a second main surface 82. The second main surface 82 also includes a flange 83 protruding axially from its periphery, wherein the flange 83 is configured to sealingly engage the wall 114 of the first housing portion 110. The flange 83 circumferentially engages the wall 114 to surround the injection chamber 113. The fixed scroll 5 is received in the housing cavity 111, wherein the flange 81 is compressed between the second main surface 62 of the valve member 60 and the wall 114 for creating a substantially fluid-tight seal in a manner that isolates the injection chamber 113 and the valve assembly 30 from the low-pressure side of the scroll compressor 1. The compression of the valve gasket 80 is achieved by the clamping force generated by the coupling of the fixed scroll 5 to the first housing portion 110. In some embodiments, the non-orbiting scroll 5 is coupled to the first housing portion 110 by one or more fasteners (eg, head bolts).

[0072] The valve gasket 80 also includes a first injection orifice 85 and a spaced-apart second injection orifice 86. Each of the injection orifices 85, 86 extends through the valve gasket 80 from the first main surface 81 of the valve gasket 80 to the second main surface 82 relative to the axial direction. Each of the injection orifices 85, 86 is in fluid communication with a corresponding one of the injection orifices 65, 66 of the valve member 60 and / or the injection chamber 113. In some embodiments, the first injection orifice 85 is in fluid communication with the first injection orifice 65 of the valve member 60, and the second injection orifice 86 is in fluid communication with the second injection orifice 66 of the valve member 60. Therefore, the injection chamber 113 is in fluid communication with the first injection port 17 via the injection orifices 65, 85 and is in fluid communication with the second injection port 18 via the injection orifices 66, 86.

[0073] Each of the injection orifices 85, 86 is shown as having an elongated peripheral shape, wherein the elongated directions of each of the injection orifices 85, 86 are arranged in parallel. The injection orifices 85, 86 may be otherwise referred to as injection slots 85, 86 due to their elongated configuration. Each of the injection orifices 85, 86 is shown as having an elongated shape, but other rounded and elongated shapes may also be used, such as an elliptical shape, an oval shape, a rounded rectangular shape, etc. The elongated shape of each of the injection orifices 85, 86 beneficially provides an increased cross-sectional flow area through the injection orifices 85, 86 compared to a purely circular cross-sectional shape, which in turn increases the total force that can be applied by the returning refrigerant through each of the injection orifices 85, 86 relative to a given pressure of the refrigerant. However, other shapes including a circular shape may also be used while still having the remaining beneficial characteristics of the valve assembly 30.

[0074] The valve gasket 80 also includes an opening 88 formed therethrough. The opening 88 is formed in alignment with the openings 25, 58, 68 formed in the pocket 19 of the fixed scroll 5, the double reed structure 40, and the valve member 60, respectively. The opening 88 is configured to receive the coupling element 26 therethrough when the valve assembly 30 is in an assembled configuration to properly position the double reed structure 40, the valve member 60, and the valve gasket 80 relative to the fixed scroll 5.

[0075] As described above, at least a portion of the valve gasket 80 may be formed of a resiliently compressible material adapted to sealingly engage each of the corresponding surfaces of the valve member 60 and the wall 114 of the first housing portion 110. The valve gasket 80 may be formed of a metallic material and / or a non-metallic material (e.g., a polymer material, an elastomer) as desired.

[0076] The operation of the valve assembly 30 is now described. Because the flow configuration of the refrigerant is substantially the same with respect to each of the partial refrigerant flows entering each of the injection ports 17, 18, only the partial refrigerant flow flowing from the injection chamber 113 formed in the shell portion 110 to the first injection port 17 is described in detail below, wherein it should be understood that corresponding and similar components associated with the other partial refrigerant flow flowing from the injection chamber 113 to the second injection port 18 operate in the same manner.

[0077] During operation of the scroll compressor 1, at least a portion of the refrigerant discharged from the compression mechanism formed by the mating scrolls 5, 7 is returned to the injection chamber 113 via the refrigerant return passage 112. The end portion 49 of the first reed 43 is configured to normally extend across and cover the first injection orifice 65 of the valve member 60 to prevent undesired flow of the returning refrigerant from the injection chamber 113 and toward the first injection port 17. The compression mechanism of the scroll compressor 1 is operated so that the first injection port 17 repeatedly experiences a variable pressure of the refrigerant within the compression mechanism according to the progress of each subsequent compression chamber 9 through the first injection port 17.

[0078] When the variable pressure from the refrigerant originating from the compression mechanism to which the first injection port 17 is subjected is relatively high, the end portion 49 of the first reed 43 is held against the surface of the valve member 60 surrounding the first injection orifice 65 to continuously prevent the refrigerant in the injection chamber 113 from flowing toward the first injection port 17. However, when the variable pressure from the refrigerant originating from the compression mechanism to which the first injection port 17 is subjected is relatively low, the pressure of the refrigerant in the injection chamber 113 eventually exceeds the relatively low pressure originating from the compression mechanism, and a pressure difference is established on the opposite surfaces of the end portion 49 of the first reed 43. When the force of the pressure of the refrigerant in the injection chamber 113 exceeds the combined force of the pressure of the refrigerant originating from the compression mechanism and the spring force generated by the elasticity of the first reed 43 at its pivot portion 48, the first reed 43 pivots about the axis defined by the pivot portion 48 and toward the first recessed portion 23 formed in the pocket 19 of the fixed scroll 5. The pivoting of the first reed 43 causes the refrigerant in the injection chamber 113 to pass through the first injection orifice 85 of the valve gasket 80, through the first injection orifice 65 of the valve member 60, and around the now axially spaced end portion 49 of the first reed 43 through the open space formed by the first recess 23 to reach the first injection port 17. The refrigerant is then injected into the corresponding compression chamber 9 while having a higher pressure than the refrigerant already disposed in the compression chamber 9 and originating from one of the inlet openings 11 of the fixed scroll 5, which allows the compression capacity of the scroll compressor 1 to be increased by reintroducing a higher pressure refrigerant into the compression mechanism at an intermediate position of the compression process.

[0079] The first reed 43 eventually elastically rebounds to a position that blocks flow from the injection chamber 113 through the valve assembly 30 based on the cycle of the compression mechanism and the pressure difference generated on the opposite side of the first reed 43. Therefore, the valve assembly 30 acts as a check valve for preventing refrigerant from flowing in an undesired direction relative to the first reed 43, which in turn prevents refrigerant from the compression mechanism from flowing back into the injection chamber 113 in an undesired flow direction. The described process is repeatedly performed when the pressure experienced by the first injection port 17 changes with respect to each passage through the compression chamber 9 formed by the orbiting of the movable scroll 7 relative to the fixed scroll 5.

[0080] The valve assembly 30 shown and described provides a number of advantageous features. Figures 3 to 12 It is easy to understand that the valve assembly 30 is simple and compact in design, and therefore requires fewer components than a conventional check valve. The integral formation of the recess 19 in the fixed scroll 5, the double reed structure 40, and the integral injection chamber 113 formed in the housing portion 110 simplify the manufacture of the valve assembly 30 and reduce the cost of the valve assembly 30. The seal between the injection chamber 113 and the discharge chamber formed in the housing portion 110 is achieved by a single valve gasket 80. In addition, the valve assembly 30 and / or the corresponding wall 114 allow a smaller injection chamber 113 and an increase in the volume of the discharge chamber formed in the housing portion 110, which in turn leads to a reduction in discharge pulsation noise.

[0081] These example embodiments are provided so that the present disclosure will be thorough and the scope will be fully conveyed to those skilled in the art. Many specific details, such as examples of specific parts, devices and methods, are set forth to provide a thorough understanding of the embodiments of the present disclosure. It will be readily understood by those skilled in the art that specific details need not be adopted, and the example embodiments can be implemented in many different forms, and none of them should be construed as limiting the scope of the present disclosure. In some example embodiments, well-known processes, well-known device structures and well-known technologies are not described in detail. Some embodiments, materials, compositions and methods may be subjected to equivalent changes, modifications and variations within the scope of the present technology, and substantially similar results may be obtained.

Claims

1. A valve assembly for a scroll compressor, the valve assembly comprising: a reed structure configured to cooperate with a non-orbiting scroll of the scroll compressor, wherein the reed structure selectively allows fluid to flow through at least one of a first injection port and a second injection port of the scroll compressor; a valve member disposed adjacent the reed structure, wherein the valve member includes a first injection orifice and a second injection orifice formed therethrough, and wherein the first injection orifice is in fluid communication with the first injection port of the scroll compressor and the second injection orifice is in fluid communication with the second injection port of the scroll compressor; and A valve gasket is disposed adjacent to the valve member.

2. The valve assembly according to claim 1, wherein: The reed structure includes a first reed configured to selectively allow the fluid to flow through the first injection port of the scroll compressor.

3. The valve assembly according to claim 2, wherein: The reed structure includes a second reed configured to selectively allow the fluid to flow through the second injection port of the scroll compressor.

4. The valve assembly according to claim 1, wherein: At least one of the first injection port and the second injection port is in fluid communication with an injection chamber formed in the scroll compressor.

5. The valve assembly according to claim 1, wherein: At least a portion of the reed structure is in direct contact with at least one surface of the non-orbiting scroll of the scroll compressor.

6. The valve assembly according to claim 1, wherein: The valve gasket is configured to provide a substantially fluid tight seal between the valve member and a housing portion of the scroll compressor.

7. The valve assembly according to claim 1, wherein: The valve gasket includes a flange formed around a periphery of the valve gasket, and wherein the flange is configured to be compressed between the valve member and a housing portion of the scroll compressor.

8. A valve assembly for a scroll compressor, the valve assembly comprising: a reed structure having a first reed and a second reed, wherein the first reed is configured to be received in a first recessed portion of a fixed scroll of the scroll compressor, and the second reed is configured to be received in a second recessed portion of the fixed scroll of the scroll compressor; a valve member disposed adjacent the reed structure, wherein the valve member includes a first injection orifice and a second injection orifice formed therethrough, and wherein the first injection orifice is in fluid communication with a first injection port of the scroll compressor and the second injection orifice is in fluid communication with a second injection port of the scroll compressor; and A valve gasket is disposed adjacent to the valve member.

9. The valve assembly according to claim 8, wherein: The first reed is configured to selectively allow fluid to flow through the first injection port of the scroll compressor.

10. The valve assembly according to claim 8, wherein: The second reed is configured to selectively allow fluid to flow through the second injection port of the scroll compressor.

11. The valve assembly according to claim 8, wherein: The first injection port is located in the first recessed portion of the non-orbiting scroll.

12. The valve assembly according to claim 8, wherein: The second injection port is located in the second recessed portion of the non-orbiting scroll.

13. A scroll compressor, comprising: a compression mechanism including a fixed scroll and a movable scroll, wherein the fixed scroll includes a pocket having a first injection port and a second injection port formed therein; and A valve assembly is coupled to the fixed scroll, the valve assembly comprising: a reed structure, the reed structure being at least partially disposed in the recess of the fixed scroll; a valve member disposed adjacent the reed structure, wherein the valve member includes a first injection orifice and a second injection orifice formed therethrough, and wherein the first injection orifice is in fluid communication with a first injection port of the scroll compressor and the second injection orifice is in fluid communication with a second injection port of the scroll compressor; and A valve gasket is disposed adjacent to the valve member.

14. The scroll compressor according to claim 13, wherein: The reed structure includes at least one reed configured to selectively allow fluid to flow through at least one of the first injection port and the second injection port of the non-orbiting scroll.

15. The scroll compressor according to claim 13, wherein: The first injection port is located in a first recessed portion formed in the pocket of the non-orbiting scroll.

16. The scroll compressor according to claim 13, wherein: The second injection port is located in a second recessed portion formed in the pocket of the non-orbiting scroll.

17. The scroll compressor according to claim 13, wherein: At least one of the first injection port and the second injection port is in fluid communication with an injection chamber formed in the scroll compressor.

18. The scroll compressor of claim 13, further comprising a housing portion configured to receive at least a portion of the non-orbiting scroll therein, wherein: The valve gasket is configured to provide a substantially fluid tight seal between the valve member and the housing portion of the scroll compressor.

19. The scroll compressor according to claim 18, wherein: The valve gasket includes a flange formed around a periphery of the valve gasket, and wherein the flange is configured to be compressed between the valve member and the housing portion of the scroll compressor.

20. The scroll compressor of claim 13, further comprising a housing portion, the housing portion comprising an inner wall, wherein: The inner wall defines an injection chamber and is configured to cooperate with the valve assembly.

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