Compressor and method of assembling a compressor

Abstract

This invention relates to a compressor and a method of assembling a compressor. The compressor includes a compressor housing having an upper end and a lower end and defining an internal volume, the upper end including an annular axial boss. A main bearing housing is positioned to engage the axial boss. A scroll assembly is positioned to engage a top surface of the main bearing housing. The scroll assembly includes a moving scroll and a stationary scroll. An end cap is attached to the compressor housing at the upper end and includes an internal feature that seats the scroll assembly to engage the main bearing housing. When the end cap is attached to the compressor housing, at least one of the stationary scroll and the main bearing housing is pressed between the axial boss of the compressor housing and the internal feature of the end cap.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 756,086, filed February 8, 2025, entitled “Compressor having internal features on the endcap and methods of assembling the compressor,” the entire contents of which are incorporated herein by reference. Technical Field

[0003] The art generally relates to scroll compressors, and more specifically, to scroll compressors including sub-assemblies that facilitate the mounting of compressor components (e.g., scroll, bearing housing, drive shaft) as a single unit within the compressor and the alignment of the compressor components within the compressor. Background Technology

[0004] A scroll compressor uses a stationary scroll component and a moving scroll component to compress the refrigerant. The stationary and moving scroll components work together to form a sealing cavity between them. During the operation of the scroll compressor, the movement of the moving scroll component relative to the stationary scroll component continuously changes the volume of the sealing cavity to compress the refrigerant within it.

[0005] A scroll compressor typically includes one or more bearings that support the rotation of a drive shaft, and a drive bearing for transmitting the rotational motion of the drive shaft to the circumferential motion of the scroll components.

[0006] During operation, misalignment between compressor components can create opportunities for excessive deflection of the drive shaft under applied loads, potentially leading to wear on compressor components such as bearings. With increasing demands for efficient and reliable operation of compressors used to ensure that climate control systems equipped with compressors can effectively and efficiently provide cooling and / or heating as needed, the tolerance for misalignment between the main bearing housing and the scroll assembly is constantly decreasing. Furthermore, methods are being sought to reduce wear on components of scroll compressors, such as bearing assemblies, and to increase the lifespan of both the compressor and the climate control system.

[0007] During operation, the compressor can be operated to rotate its components. Aligning the compressor components along the axial direction of rotation ensures efficient operation and minimizes wear on the compressor components. When misaligned, the compressor experiences additional wear, thus reducing its lifespan. Summary of the Invention

[0008] In one aspect, a compressor includes a compressor housing having an upper end and a lower end and defining an internal volume, the upper end including an annular axial boss. A main bearing housing is positioned to engage the axial boss. A scroll assembly is positioned to engage a top surface of the main bearing housing. The scroll assembly includes a moving scroll and a stationary scroll. An end cap is attached to the compressor housing at the upper end and includes an internal feature for seating the scroll assembly to engage the main bearing housing. When the end cap is attached to the compressor housing, at least one of the stationary scroll and the main bearing housing is pressed between the axial boss of the compressor housing and the internal feature of the end cap.

[0009] Another method is a method of assembling a compressor. The method includes positioning a main bearing housing to engage with an annular axial boss at the upper end of a compressor housing. The method also includes positioning a scroll assembly to engage with a top surface of the main bearing housing, wherein the scroll assembly includes a moving scroll and a stationary scroll. The method further includes engaging at least one of the main bearing housing and the stationary scroll with an internal feature of an end cover. The method further includes pressing at least one of the main bearing housing and the stationary scroll between the internal feature of the end cover and the axial boss of the compressor housing, and while the main bearing housing and the stationary scroll are pressed between the internal feature of the end cover and the axial boss, attaching the end cover to the upper end of the compressor housing such that the attachment of the end cover to the compressor housing maintains a clamping force on at least one of the main bearing housing and the stationary scroll.

[0010] Various improvements exist regarding the features indicated in the foregoing aspects. Other features may also be incorporated into the foregoing aspects. These improvements and additional features may exist individually or in any combination. For example, the various features discussed below with respect to any embodiment of the illustrated embodiments may be incorporated individually or in any combination into any of the foregoing aspects. Attached Figure Description

[0011] The following figures illustrate various aspects of this disclosure.

[0012] Figure 1 This is a 3D view of an example compressor.

[0013] Figure 2 yes Figure 1 The compressor shown is a cross-sectional view taken along line 2-2.

[0014] Figure 3A This is a three-dimensional view of the bayonet fit between the main bearing housing and the scroll assembly.

[0015] Figure 3B It is a three-dimensional view of the bayonet fit between the main bearing housing and the scroll assembly.

[0016] Figure 3C It is a cross-sectional view of the compressor including the main bearing housing attached to the scroll assembly via a bayonet fitting.

[0017] Figure 4A It is a perspective view of an example end cap including internal features.

[0018] Figure 4B It includes Figure 4A The example end cap shown is a side cross-sectional view of the compressor.

[0019] Figure 4C It includes Figure 4A The example end cap shown is a top cross-sectional view of the compressor.

[0020] Figure 5A This is a perspective view of another example end cap including internal features.

[0021] Figure 5B It includes Figure 5A The example end cap shown is a side cross-sectional view of the compressor.

[0022] Figure 5C It includes Figure 5A The example end cap shown is a top cross-sectional view of the compressor.

[0023] Figure 6A This is a perspective view of another example end cap including internal features.

[0024] Figure 6B It includes Figure 6A The example end cap shown is a side cross-sectional view of the compressor.

[0025] Figure 6C It includes Figure 6A The example end cap shown is a top cross-sectional view of the compressor.

[0026] Throughout the accompanying figures, the corresponding figure labels indicate the relevant parts. Detailed Implementation

[0027] Reference Figure 1The view of the example compressor is generally indicated by 100. The compressor 100 includes a compressor housing 102 that forms at least one sealed cavity within which refrigerant compression is performed. The compressor housing 102 includes an outer shell 104, an end cap 106 positioned at a first end 118 of the outer shell 104, and a base 108 positioned at the opposite second end 120 of the outer shell 104. In the illustrated example, the outer shell 104 is cylindrical in shape, and the end cap 106 and base 108 are each generally dome-shaped, such that the compressor housing 102 has a generally elliptical profile. The outer shell 104, end cap 106, and / or base 108 can be shaped differently depending on the desired shape and profile of the compressor housing 102. The end cap 106 and / or base 108 can be attached to the respective ends 118, 120 of the outer shell 104 using any suitable means for connecting components. For example, end cap 106 and / or base 108 may be welded or bolted to housing 104. In the example compressor, end cap 106 includes one or more internal features (discussed later). Internal features 107 position and align one or more compressor components within compressor housing 102. The attachment between end cap 106 and compressor housing 102 applies a clamping force to secure the compressor components within compressor housing 102. This attachment of internal features 107 of end cap 106 to the upper axial portion of compressor housing 102 applies a clamping force to the compressor components. This clamping force orients the compressor components within compressor housing 102. Orienting the compressor components includes axially aligning the compressor components within compressor housing 102 and / or seating the compressor components within compressor housing 102. Orienting the compressor components for axial alignment reduces wear on the compressor components during compressor operation. For example, compressor components may include main bearing housings or scroll assemblies and are oriented by the clamping force between end cap 106 and housing 104. In some embodiments, the internal feature 107 on the end cap 106 positions the scroll assembly 204 to engage with the top surface of the main bearing housing 208, and the attachment of the end cap 106 to the housing 104 presses at least one of the fixed scroll 228 and the main bearing housing 208 between the internal feature 107 and the annular axial boss of the housing 104.

[0028] Compressor 100 includes an inlet fitting 110 attached to compressor housing 102 at an inlet opening (not shown), through which working fluid (e.g., refrigerant) enters at least one sealed cavity formed by compressor housing 102. For example, the working fluid is drawn into compressor 100 via inlet fitting 110 and compressed in at least one sealed cavity. After compression, the compressed working fluid exits compressor 100 through pipe 112. Compressor housing 102 may have a discharge fitting 114 attached to pipe 112. In the example compressor 100, pipe 112 is located on base 108, and discharge fitting 114 is attached to base 108 at pipe 112 such that compressed working fluid can exit a second chamber 117 defined by base 108. Figure 2 In the example compressor 100, the working fluid in the second chamber 117 is at discharge pressure, and the second chamber 117 can alternatively be referred to as the discharge chamber. A discharge valve assembly (not shown) may be provided within the discharge fitting 114 to prevent reverse flow. The compressor housing 102, such as the outer casing 104, may also be attached with hermetic electrical terminals 115.

[0029] Figure 2 This is a cross-section of compressor 100. Compressor 100 includes a compressor housing 102, which includes an outer casing 104, an end cap 106 positioned at a first end 118 of the outer casing 104 and defining a first chamber 116, and a base 108 positioned at a second end 120 of the outer casing 104 and defining a second chamber 117. Compressor 100 also includes a motor assembly 122 and a compression mechanism (e.g., a scroll assembly), generally indicated by 204, which is mounted in the compressor housing 102 and operatively connected to the motor assembly 122.

[0030] Motor assembly 122 includes a motor stator 124 and a rotor 126. The rotor 126 can be press-fitted onto a drive shaft 128 positioned within the compressor housing 102 and can transmit rotational power to the drive shaft 128. Motor assembly 122 can be a variable-speed motor for rotating the drive shaft 128 at any of a plurality of speeds. In the illustrated embodiment, motor assembly 122 is disposed within housing 104. In some other embodiments, compressor 100 can be an open-drive compressor driven by motor assembly 122 disposed outside compressor housing 102.

[0031] Drive shaft 128 is rotatably supported within a first bearing housing assembly 206 and a second bearing housing assembly 130. The first bearing housing assembly 206 and the second bearing housing assembly 130 are axially displaced and located on opposite sides of the motor assembly 122. The first bearing housing assembly 206 is located near a first end 118 of the housing 104, and the second bearing housing assembly 130 is located near a second end 120 of the housing 104 (e.g., within the base 108). Drive shaft 128 extends through the first bearing housing assembly 206 and includes an eccentric body 132 that extends axially beyond the first bearing housing assembly 206.

[0032] The first bearing housing assembly 206 includes a main bearing 134, and the second bearing housing assembly 130 includes a secondary bearing 136. The main bearing 134 and the secondary bearing 136 rotatably support the drive shaft 128 within their respective bearing housing assemblies 206 and 130. The first bearing housing assembly 206 includes the main bearing 134 and the main bearing housing 208. The main bearing 134 and / or the secondary bearing 136 may be rolling element bearings having: an inner ring defining a bearing surface and a bearing opening for receiving the drive shaft 128; an outer ring radially spaced outward relative to the inner ring; and a plurality of spherical elements or rollers disposed between the inner and outer rings. Alternatively, in some embodiments, the main bearing 134 or / or the secondary bearing 136 is a journal bearing, and the drive shaft 128 is rotatably supported by the journal bearing 134 and / or the journal bearing 136 within the bearing opening and relative to a fixed inner bearing surface. The main bearing 134 and / or the secondary bearing 136 can be any suitable bearing type. Figure 3C In the illustrated embodiment, the internal feature 107 on the interior of the end cap 106 and the upper axial portion of the outer casing 104 secure the main bearing housing 208 within the compressor housing 102. When the end cap 106 is attached, the engagement between the internal feature 107 and the outer casing 104 causes the main bearing housing 208 to sit on the annular axial boss of the outer casing 104 and axially aligns the drive shaft 128 with the auxiliary bearing 136, such that the main bearing housing 208 and the auxiliary bearing 136 are aligned by a clamping action established between the internal feature 107 and the outer casing 104.

[0033] The scroll assembly 204 engages with the top surface of the main bearing housing 208. The scroll assembly 204 includes a moving scroll 226 and a stationary scroll 228. The moving scroll 226 includes a generally disc-shaped moving plate 230 defining opposing radial surfaces. A moving helical scroll 232 extends axially from one of the surfaces of the moving plate 230, and the surface opposite to the moving helical scroll 232 includes a cylindrical hub 236 extending axially therefrom. A drive bushing 239 is disposed in the cylindrical hub 236, and the drive bushing 239 receives an extension of the drive shaft 128 through an eccentric body 132 of the main bearing housing 208. The eccentric body 132 is drivenly engaged with the drive bushing 239 in the cylindrical hub 236 of the moving scroll 226, and facilitates the transmission of rotational motion of the drive shaft 128 to the circumferential motion of the moving scroll 226 relative to the main bearing housing 208 and / or the stationary scroll 228. Unmarked couplings (e.g., cross-slider couplings) may engage with the moving scroll 226 and the main bearing housing 208 and / or the stationary scroll 228 to limit or prevent relative rotation between them.

[0034] The fixed vortex 228 includes a fixed body 238 defining an upper surface 241 and an opposite lower surface 242. In some embodiments, the fixed vortex 228 may include an annular wall 244. The fixed helical vortex 240 extends generally axially from the lower surface 242 and faces the moving helical vortex 232. Figure 2 In the illustrated embodiment, the fixed scroll 228 further includes a protrusion 246 extending axially from the upper surface 241 of the fixed body 238. The fixed scroll 228 also includes a plurality of circumferentially spaced flanges on the radially outer surface of the fixed scroll 228 for bayonet connection to the main bearing housing 208, and a scroll alignment hole 312 defined by the scroll assembly 204 and extending through the scroll assembly 204.

[0035] The stationary helical scroll 240 engages or meshes with the moving helical scroll 232 of the moving scroll 226, thereby defining a series of fluid cavities. The circumferential motion of the moving scroll 226 is converted into the motion of the fluid cavities defined by the helical scrolls 232 and 240, thereby reducing the volume of the fluid cavities to compress the working fluid within them. During the compression cycle of the scroll assembly 204, the volume of the fluid cavities defined by the helical scrolls 232 and 240 decreases as the circumferential motion of the moving scroll 226 is converted into the motion of the fluid cavities from a radially outer position 250 (at suction pressure) to a radially intermediate position (at intermediate pressure) and finally to a radially inner position 252 (at discharge pressure).

[0036] Figures 4A to 6CAn example compressor 100 is illustrated, including one or more internal features 107 on an end cap 106. Each internal feature 107 is shaped to orient and secure at least one compressor component between the end cap 106 and the compressor housing 104. One or more internal features 107 may be positioned on an inner surface relative to a suction inlet 109 on the end cap 106. The positioning of the one or more internal features 107 on the end cap 106 facilitates both gas flow in the high-side compressor and the implementation of a direct suction pipe having a rotational locking engagement with a fixed scroll 228. In the example compressor 100, at least one compressor component is positioned on an upper axial boss of the compressor housing 104. The end cap 106 encloses at least one compressor component and is attached to the compressor housing 104. In the example compressor 100, the end cap 106 is attached to the compressor housing 104 using a weld 111.

[0037] At least one compressor component includes a main bearing housing 208 and / or a scroll assembly 204. One or more bolts 901 can attach the scroll assembly 204 to the main bearing housing 208. Figures 3A to 3C In the illustrated embodiment, the scroll assembly 204 and the main bearing housing 208 are attached via a bayonet engagement 300. The bayonet engagement 300 includes a scroll retaining feature 302 and a main bearing retaining feature 304. The bayonet engagement 300 prevents axial separation between the scroll retaining feature 302 and the main bearing retaining feature 304 during operation of the compressor 100. In some embodiments, the bayonet engagement 300 includes a plurality of circumferentially extending grooves formed on the main bearing retaining feature, which extends radially from the radially outer surface of the main bearing housing 208, each groove configured to receive a corresponding flange on the stationary scroll 228.

[0038] The main bearing alignment hole 314 extends from the top surface of the main bearing housing 208 and terminates within the main bearing housing 208. When the bayonet engagement 300 is engaged, the alignment pin 310 extends through the scroll alignment hole 312 and into the main bearing alignment hole 314 to maintain angular alignment between the scroll assembly 204 and the main bearing housing 208 and to maintain axial connection between the plurality of flanges and the plurality of slots, thereby preventing accidental disengagement of the bayonet engagement.

[0039] The scroll retaining feature 302 includes at least one radially projecting flange 306 configured to engage with a corresponding groove 308 formed in the main bearing retaining feature 304. The main bearing retaining feature 304 sits on and engages with an annular axial boss on the compressor housing 104. To engage the bayonet fitting 300, the scroll retaining feature 302 is axially positioned to align with the main bearing retaining feature 304, such as... Figure 3AAs shown in the diagram, the vortex assembly 204 rotates to engage the flange 306 with the corresponding groove 308 of the main bearing retaining feature 304, as shown in the diagram. Figure 3B As shown in the illustrated embodiment, the bayonet engagement 300 is secured by an alignment pin 310 to maintain the axial connection between the scroll assembly 204 and the main bearing housing 208 and to prevent accidental disconnection. Figure 3C As shown in the illustrated embodiment, an alignment pin 310 is inserted through a vortex alignment hole 312 formed on the vortex assembly 204 and a corresponding main bearing housing alignment hole 314 formed on the main bearing housing 208. When the bayonet engagement 300 is engaged to angularly align the vortex assembly 204 and the main bearing housing 208, the vortex alignment hole 312 and the main bearing housing alignment hole 314 are aligned. For example, the main bearing alignment hole 314 is formed on the top surface of the main bearing 208. The alignment pin 310 prevents rotational movement between the vortex assembly 204 and the main bearing housing 208 to maintain the axial connection of the bayonet engagement 300, thereby preventing disengagement. In some embodiments, a portion of the internal feature 107 and a portion of the main bearing retaining feature 304 cooperate to define a vent that facilitates the flow of working fluid from the vortex assembly 204 toward the end cap 106.

[0040] like Figure 3C As shown in the illustrated embodiment, the main bearing retaining feature 304 and the scroll retaining feature 302 are fixed between the inner feature 107 and the compressor housing 104. The main bearing retaining feature 304 extends radially from the main bearing housing 208 and is positioned on the housing 104. The scroll retaining feature 302 extends radially from the scroll assembly 204 and supports the inner feature 107 of the end cap 106. The end cap 106 is attached to the housing 104 by a weld 111 to fix the scroll assembly 204 and the main bearing housing 208 between the inner feature 107 and the compressor housing 104. Therefore, the engagement of the inner feature 107 and the housing 104 axially constrains the scroll assembly 204 and the main bearing housing 208 between the axial bosses of the inner feature 107 and the housing 104, and prevents axial movement of the fixed scroll 228 within the compressor 100. The applied clamping force is maintained by the attachment of the end cap 106.

[0041] The attachment between the scroll assembly 204 and the main bearing housing 208 further maintains relative axial alignment within the compressor housing 102. For example, the attachment between the scroll assembly 204 and the main bearing housing 208 includes one or more internal features 107 formed on the inner surface of the end cap 106, which defines a radially inner surface of the end cap 106. The attachment between the housing 104 and the end cap 106 applies a clamping force to at least one compressor component. For example, the attachment between the end cap 106 and the housing 104 maintains preload and radial alignment of at least one compressor component positioned between the internal features 107 of the end cap 106 and the housing 104. The preload between the end cap 106 and the housing 104 primarily serves to seat at least one compressor component against the compressor housing 102. Alignment of at least one compressor component with the compressor 100 is achieved by the engagement of the internal features 107 and the housing 104. In an exemplary embodiment, the internal features 107 include four machine pads located on the radially inner surface of the end cap 106. The weld 111 ensures the attachment between the end cap 106 and the housing 104 to maintain the positional and axial alignment of at least one compressor component.

[0042] Figures 4A to 4C An embodiment of an example compressor 100 is illustrated, including an internal feature 107 formed on the inner surface of an end cap 106. Figure 4A An embodiment of an end cap 106 including one or more internal features 107 formed on the inner surface of the end cap 106 is illustrated. For example, the internal features 107 include four machine gaskets located on the inner surface of the end cap 106. Figures 4A to 4C In the illustrated embodiment, the internal feature 107 is formed of additional material on the internal portion of the end cap 106. For example... Figure 4B As shown, the internal feature 107 includes additional material defining a machine liner with a smaller inner diameter compared to the inner surface of the end cap 106. The bottom of the machine liner may be formed as a boss that contacts a compressor component. The boss extends inward along the length of the inner diameter of the internal feature 107. Figure 4B As shown, the bottom of the machine liner and the upper axial boss of the compressor housing 104 orient each compressor component within the compressor housing 102. The main bearing housing 208 is clamped between the bottom of the machine liner and the upper end of the compressor housing 104.

[0043] Figure 4CThe illustration shows a top sectional view of compressor components within compressor 100, depicting one or more vents 940 located within the compressor housing between end cap 106 and compressor housing 104. One or more vents 940 are defined by an internal feature 107 of end cap 106 and portions of at least one compressor component, including main bearing housing 208 and / or fixed scroll 228. The vents 940 may be positioned on the portion of end cap 106 located between the internal features 107. The vents 940 facilitate gas flow in a high-side compressor, such as compressor 100.

[0044] Figures 5A to 5C An embodiment of an example compressor 100 is illustrated, including an internal feature 107 formed by stamping an end cap 106. Figure 5A An embodiment of an end cap 106 including internal features 107 formed by stamping an end cap 106 is illustrated. For example, the end cap 106 may be stamped to reduce the inner diameter of a portion of the end cap 106. In some embodiments, a portion of the end cap 106 is first stamped to form a shoulder, and then processed to form the internal features 107 as one or more machine pads. In one example, four machine pads are formed on the inner portion of the end cap 106. The inner surface of the shoulder defines the internal features 107 on the inner surface of the end cap 106. The inner surface of each internal feature may include a boss. The boss is positioned to engage one or more compressor components. Figure 5B As shown, the boss of the internal feature 107 positions the scroll assembly 204 to engage with the top surface of the main bearing housing 208 and to be positioned on the upper axial boss of the compressor housing 104. In some embodiments, the scroll assembly 204 and the main bearing housing 208 can be attached by one or more bolts 901. In other embodiments, the scroll assembly 204 and the main bearing housing 208 are attached by a bayonet engagement 300. The clamping force between the internal feature 107 and the compressor housing 104 is transmitted through the scroll assembly 204 and the main bearing housing 208 to orient at least one compressor component. Figure 5C The illustration shows a top sectional view of the compressor components within the compressor 100. One or more vents 210 extend beyond the top of the scroll assembly 204 to provide fluid communication between the scroll assembly 204 and the end cap 106.

[0045] Figure 6A An embodiment of an example compressor 100 is illustrated, including an internal feature 107 comprising a groove on the inner surface of an end cap 106. This groove may be continuous or discontinuous along the inner surface of the end cap 106. The internal feature 107 extends axially along the inner surface of the end cap 106. Figure 6BAs illustrated, the internal feature 107 is machined to have a larger inner diameter than the inner surface of the end cap 106. For example, this inner surface includes an undercut extending from the bottom of the end cap 106 to a location where at least one compressor component contacts the internal feature 107. The change in diameter between the internal feature 107 and the inner surface of the compressor 100 forms a boss that contacts at least one compressor component. Figure 6C The illustration shows a top sectional view of at least one compressor component within the compressor 100. One or more vents 210 are formed between the inner surface of the end cover 106 and the at least one compressor component.

[0046] A method of assembling a compressor includes positioning a main bearing housing to engage an annular axial boss at the upper end of a compressor housing, and positioning a scroll assembly to engage a top surface of the main bearing housing, the scroll assembly comprising a moving scroll and a stationary scroll. The method further includes aligning an internal feature on an end cap with at least one of the main bearing housing or the stationary scroll and engaging the internal feature with the component. An axial clamping force is then applied such that at least one of the main bearing housing or the stationary scroll is pressed between the internal feature of the end cap and the annular axial boss of the compressor housing, thereby axially retaining the main bearing housing and the stationary scroll. While the components are being pressed, the end cap is attached to the upper end of the compressor housing such that this attachment maintains the clamping force after external forces, such as welding, are removed. In some embodiments, forming the internal feature on the end cap includes stamping a portion of the end cap and machining the stamped portion to form the internal feature, for example, machining four machine gaskets on the inner portion of the end cap. In other embodiments, forming the internal feature includes machining a continuous groove along the inner surface of the end cap. In some implementations, attaching the vortex assembly to the upper surface of the main bearing housing includes using one or more fasteners.

[0047] Another method of assembling a compressor includes: positioning a main bearing housing to engage with an annular axial boss at the upper end of the compressor housing; engaging a groove on the main bearing housing with a flange on the scroll assembly to connect the main bearing housing to the scroll assembly; aligning a main bearing alignment hole on the main bearing housing with a scroll alignment hole on the scroll assembly; and inserting an alignment pin through the scroll alignment hole and into the main bearing alignment hole to maintain angular alignment between the main bearing housing and the scroll assembly and to maintain their axial connection. The method also includes aligning an internal feature on an end cap with the scroll assembly; pressing the main bearing housing and the scroll assembly between the internal feature formed on the end cap and the annular axial boss of the compressor housing; and attaching the end cap to the upper end of the compressor housing while the main bearing housing and the scroll assembly are pressed together, such attachment maintaining a clamping force on the main bearing housing and the scroll assembly. In some embodiments, the connected main bearing housing and scroll assembly are positioned on an axial boss of the compressor housing such that the main bearing housing contacts the upper end of the compressor housing and the scroll assembly is attached to the main bearing housing via a bayonet engagement. In some embodiments, positioning the end cap on the compressor housing includes contacting the upper surface of the scroll assembly and radially contacting the compressor housing.

[0048] As used herein, when used in conjunction with ranges of size, concentration, temperature or other physical or chemical properties or characteristics, the terms “about,” “basically,” “essentially,” and “approximately” are intended to cover variations that may exist within the upper and / or lower limits of the range of properties or characteristics, including variations caused, for example, by rounding, measurement methods, or other statistical changes.

[0049] When elements of this disclosure or embodiments thereof are introduced, the terms “a,” “an,” “the,” and “the” are intended to indicate the presence of one or more elements. The terms “comprising,” “including,” “containing,” and “having” are intended to be inclusive and mean that additional elements may be present in addition to the listed elements. The use of terms indicating a particular orientation (e.g., “top,” “bottom,” “side,” etc.) is for ease of description and does not require any particular orientation of the described object.

[0050] Since various changes can be made to the above structures and methods without departing from the scope of this disclosure, it is intended that all content contained in the above description and shown in the accompanying drawings should be interpreted as illustrative and not as restrictive.

Claims

1. A compressor, comprising: A compressor housing having an upper end and a lower end, the compressor housing defining an internal volume portion, wherein the upper end includes an annular axial boss; Main bearing housing, the main bearing housing being positioned to engage with the axial boss; A scroll assembly, positioned to engage with the top surface of the main bearing housing, the scroll assembly comprising a moving scroll and a stationary scroll; and An end cap is attached to the compressor housing at the upper end of the compressor housing. The end cap includes an internal feature for seating the scroll assembly in engagement with the main bearing housing. When the end cap is attached to the compressor housing, at least one of the stationary scroll and the main bearing housing is pressed between the axial boss of the compressor housing and the internal feature of the end cap.

2. The compressor according to claim 1, wherein, The end cap is attached to the compressor housing via one or more welded joints.

3. The compressor according to claim 1, wherein, The internal feature of the end cap includes one or more machine gaskets formed on the inner surface of the end cap, wherein the one or more machine gaskets engage with at least one of the main bearing housing or the fixed scroll.

4. The compressor according to claim 3, wherein, The internal feature section includes four machine pads.

5. The compressor according to claim 3, wherein, Each of the one or more machine liner pads is a machined portion of the stamped feature on the end cap.

6. The compressor according to claim 1, wherein, The internal feature extends from the radial inner surface of the end cap.

7. The compressor according to claim 1, wherein, The internal feature includes a boss that seats at least one of the main bearing housing and the fixed scroll against the axial boss of the compressor housing.

8. The compressor according to claim 1, wherein, The main bearing housing and the scroll assembly are axially constrained by the end cover and the compressor housing.

9. The compressor according to claim 1, wherein, The internal features of the end cap align the vortex suction inlet and the end cap suction inlet.

10. The compressor according to claim 1, wherein, The internal feature portion of the end cap and the main bearing housing cooperate to form a vent, which facilitates the flow of working fluid from the vortex assembly to the end cap.

11. The compressor according to claim 1, wherein, The fixed vortex is attached to the main bearing housing by one or more fasteners.

12. The compressor according to claim 1, wherein, When at least one of the fixed scroll and the main bearing housing is pressed between the axial boss of the compressor housing and the internal feature of the end cover, the main bearing housing and the auxiliary bearing are aligned through the engagement between the internal feature of the end cover and the compressor housing.

13. The compressor according to claim 1, wherein, When the end cap is attached to the compressor housing, the main bearing housing is seated in the axial boss of the compressor housing.

14. A method for assembling a compressor, the method comprising: Position the main bearing housing to engage with the annular axial boss at the upper end of the compressor housing; The scroll assembly is positioned to engage with the top surface of the main bearing housing, wherein the scroll assembly includes a moving scroll and a stationary scroll; At least one of the main bearing housing and the fixed vortex is engaged with the internal feature of the end cover; Pressing at least one of the main bearing housing and the fixed scroll between the internal feature of the end cover and the axial boss of the compressor housing; and While at least one of the main bearing housing and the fixed scroll is pressed between the internal feature of the end cover and the axial boss, the end cover is attached to the upper end of the compressor housing such that the attachment of the end cover to the compressor housing maintains a pressing force on at least one of the main bearing housing and the fixed scroll.

15. The method according to claim 14, wherein, Pressing at least one of the main bearing housing and the fixed scroll also includes applying a clamping force between the upper end of the compressor housing and the internal feature of the end cover.

16. The method according to claim 15, wherein, The clamping force is applied axially to hold the main bearing housing and the fixed scroll between the internal feature of the end cover and the axial boss of the compressor housing.

17. The method of claim 14, further comprising forming the internal feature portion on the end cap by means of: A portion of the end cap is stamped; and The stamped portion of the end cap is processed to form the internal feature portion.

18. The method according to claim 17, wherein, The internal feature is formed by forming four machine gaskets on the internal portion of the end cap.

19. The method of claim 14, further comprising forming the internal feature on the end cap by machining a continuous groove along the inner surface of the end cap.

20. The method of claim 14, further comprising attaching the vortex assembly to the upper surface of the main bearing housing, wherein, Attaching the vortex assembly to the main bearing housing includes using one or more fasteners.

Images