Compliant bearing housing for compressor systems

Abstract

The compressor comprises a shell, a motor, a compression mechanism, and a bearing housing. The bearing housing comprises an outer cylindrical rim extending along the longitudinal axis of the bearing housing, a flange extending radially outward from the outer cylindrical rim and defining a first cross-section, and a domed cylindrical body including a step spaced apart from the flange and defining an outer diameter smaller than the outer diameter of the outer cylindrical rim. At least a portion of the outer cylindrical body is attached to the shell of the compressor. The bearing housing comprises an inner cylindrical rim extending from an inner surface into an inner cavity of the bearing housing having a bearing bore. The midpoint of the bearing bore is defined along the longitudinal axis, and the longitudinal axis defines a second cross-section that is longitudinally offset from the first cross-section.

Description

Technology Field

[0001] The field of the present disclosure generally relates to climate control systems, and in particular to compressors having compliant bearing housings. Background Technology

[0002] Compressors for climate control systems compress refrigerant using a compression mechanism, which can be rotatably supported within the compressor housing. To drive the compression mechanism and compress the refrigerant, some compression mechanisms include a drive shaft coupled to one or more motors. The drive shaft may be rotatably supported by one or more bearings, which are axially aligned to avoid jamming, vibration, and other undesirable effects from misaligned support bearings.

[0003] During the assembly of a compressor, installing a bearing housing within the compressor housing can lead to the seat holding the bearing supporting the drive shaft bending and / or deforming. For example, when a bearing housing is press-fitted into the compressor housing, forces applied to the outer part of the bearing housing can cause the entire bearing housing to bend, affecting the concentricity of the seat relative to the bearing and the axial misalignment of the bearing. In some examples, forces applied to the outer part of the bearing housing can cause the bearing to bend, thereby reducing the performance of the bearing and the compressor.

[0004] To maintain the axial alignment of the drive shaft and preserve the performance of the compressor, bearing housings must be firmly attached to the compressor housing. However, welding processes can introduce different rates of thermal expansion between the bearing housing and the compressor housing. Thermal expansion and other stresses caused by the welding process can similarly cause the seat in which the bearing supporting the drive shaft is held to warp.

[0005] It is desirable for the efficient and reliable operation of the compressor to ensure that the climate control system in which the compressor is installed can effectively and efficiently provide cooling and / or heating effects as needed. Additionally, reducing wear on components such as the compressor's bearing assemblies can increase the lifespan of the compressor and the climate control system.

[0006] The technical section forming the background of this invention is intended to introduce to the reader various technical aspects that may be related to the various aspects of the present disclosure described and / or claimed below. This discussion is believed to be helpful in providing supporting information to facilitate a better understanding of the various aspects of the present disclosure to the reader. Accordingly, it should be understood that these statements should be read in this context and should not be read as an acknowledgment of prior art.

[0007] One aspect of the present disclosure relates to a compressor comprising a shell, a motor having a drive shaft rotatably supported within a cavity of the shell, a compression mechanism connected to the drive shaft and operable to compress a working fluid upon rotation of the drive shaft, and a bearing housing comprising a domed cylindrical body defining a longitudinal axis, wherein the inner surface of the domed cylindrical body defines an inner cavity. The domed cylindrical body comprises an outer cylindrical rim extending along the longitudinal axis. A flange extends radially outward from the outer cylindrical rim and defines a first cross-section. A step down is defined spaced apart from the flange. The step down extends along the longitudinal axis and defines an outer dimension smaller than the outer dimension of the outer cylindrical rim. At least a portion of the outer cylindrical rim is attached to the shell. The domed cylindrical body comprises an inner cylindrical rim extending from the inner surface along the longitudinal axis into an inner cavity. The inner wall of the inner cylindrical rim defines a bearing bore extending along the longitudinal axis. The midpoint of the bearing bore defined along the longitudinal axis defines a second cross-section that is longitudinally offset from the first cross-section in a direction extending opposite to the inner surface. The domed cylindrical body includes at least one inner surface that extends parallel to the longitudinal axis and is radially offset from it. The at least one inner surface defines a passage that fluidly couples the environment outside the domed cylindrical body to the inner cavity.

[0008] In another embodiment, the bearing housing for the compressor includes an outer cylindrical rim that defines a longitudinal axis and extends along it. A flange extends radially outward from the outer cylindrical rim, and a rabbet extends radially inward from the outer cylindrical rim. The rabbet is longitudinally offset from the flange. At least a portion of the outer cylindrical rim is attached to the shell of the compressor. The bearing housing includes an inner cylindrical rim that extends along the longitudinal axis. The inner cylindrical rim is positioned radially inward from the outer cylindrical rim and is longitudinally offset from the flange. The inner wall of the inner cylindrical rim defines a longitudinal bore, and the midpoint of the longitudinal bore defined along the longitudinal axis is longitudinally offset from the flange. The bearing housing includes a side web that extends diagonally between the outer cylindrical rim and the inner cylindrical rim. The outer cylindrical rim, inner cylindrical rim, and side webs cooperate to define the domed cylindrical body. The side webs conform and deform due to forces applied to the outer cylindrical rim from the press-fit engagement with the shell of the compressor, and maintain the concentricity of the bearing bore of the inner cylindrical rim.

[0009] In another embodiment, a method for assembling a compressor having a shell and a base comprises the steps of: positioning a bearing within a bearing bore defined within an inner cylindrical rim of a bearing housing; the inner cylindrical rim extending along a longitudinal axis; positioning an outer cylindrical rim of the bearing housing within an inner cavity defined by the shell of the compressor; when positioned within the inner cavity of the shell, a flange extending radially outward from the outer cylindrical rim and defining a first cross-section is positioned adjacent to an end portion of the shell of the compressor; and attaching the outer cylindrical rim of the bearing housing to the shell of the compressor around the perimeter of the flange. An intermediate point of the bearing bore of the bearing housing defined along the longitudinal axis defines a second cross-section that is longitudinally offset from the first cross-section.

[0010] Various improvements to the features mentioned in connection with the aforementioned embodiments of the present disclosure exist. Other features may also be incorporated into the aforementioned embodiments of the present disclosure. These improvements and additional features may exist individually or in any combination. For example, various features discussed below in connection with any of the illustrated embodiments of the present disclosure may be incorporated into any of the described embodiments of the present disclosure alone or in any combination. Brief explanation of the drawing

[0011] FIG. 1 is a perspective view of an exemplary compressor; FIG. 2 is a cross-sectional view of the compressor of FIG. 1 taken along the cross-sectional line (1-1); FIG. 3a is a cross-sectional view of the bearing assembly of the compressor of FIG. 1; FIG. 3b is a detailed cross-sectional view of the bearing assembly of FIG. 3a; FIG. 4 is a perspective view of the drive shaft and unloader of the compressor of FIG. 1, illustrating that the unloader is located at least partially within the recess of the drive shaft; FIG. 5 is a detailed cross-sectional view of the compressor of FIG. 1, illustrating the bearing housing of the compressor of FIG. 1; FIG. 6 is an elevation view of the bearing housing of FIG. 5; FIG. 7 is an elevation cross-sectional view of the bearing housing of FIG. 5; FIG. 8 is a plan view of the bearing housing of FIG. 5; FIG. 9 is an enlarged view of the detailed area shown in FIG. 7; FIG. 10 is an elevation cross-sectional view of the bearing housing of FIG. 5, illustrating a state in which a bearing assembly is retained within the bearing bore of the bearing housing; FIG. 11 is a detailed cross-sectional view of the compressor of FIG. 1, showing the bearing housing welded to the compressor housing of the compressor; FIG. 12a is a graphic representation of a circular drawing of the upper internal dimension of the bearing bore of the bearing housing of FIG. 5, showing the state before the bearing housing is attached to the compressor housing of FIG. 1; FIG. 12b is a graphic representation of a circular drawing of the lower internal dimension of the bearing bore of the bearing housing of FIG. 5, showing the state before the bearing housing is attached to the compressor housing of FIG. 1; FIG. 13a is a graphic representation of a circular drawing of the upper internal dimension of the bearing bore of the bearing housing of FIG. 5, showing the state after the bearing housing is attached to the compressor housing of FIG. 1; FIG. 13b is a graphic representation of a circular drawing of the lower internal dimension of the bearing bore of the bearing housing of FIG. 5, showing the state after the bearing housing is attached to the compressor housing of FIG. 1; FIG. 14a is a graphic representation of a circular drawing of the upper internal dimension of the bearing bore of a conventional bearing housing, showing the state after the conventional bearing housing is attached to a compressor housing; FIG. 14b is a graphic representation of a circular drawing of the lower internal dimension of the bearing bore of a conventional bearing housing, showing the state after the conventional bearing housing is attached to a compressor housing; Fig. 15 is a flowchart of the method for assembling a compressor; and Figure 16 is a schematic diagram of a cooling system including the compressor of Figure 1. Corresponding reference characters represent corresponding parts throughout the drawings. Specific details for implementing the invention

[0012] Referring to FIG. 1, the compressor, which is a scroll compressor in this example, is generally denoted as 100. The compressor (100) generally comprises a compressor housing (102) that forms at least one sealed cavity where refrigerant compression is achieved. The compressor housing (102) comprises a cylindrical shell (104), an end cap (106) located at a first end (108) of the cylindrical shell (104), and a base (110) located at a second end (112) opposite the cylindrical shell (104).

[0013] Referring additionally to FIG. 2, the compressor (100) includes a pivot scroll (122) and a non-pivot scroll (120) operably engaged with a motor assembly (124). At least a portion of the end cap (106), the non-pivot scroll (120), and the cylindrical shell (104) defines at least partially a chamber (128). The cylindrical shell (104) includes an inner surface (105) that defines at least partially a cavity (130). The motor assembly (124) includes a motor stator (134), a rotor (136), and a drive shaft (138). The drive shaft (138) may be press-fitted into the rotor (136) so that the rotor (136) transmits rotational power to the drive shaft (138). In some embodiments, the motor assembly (124) may be a variable speed motor that rotates the drive shaft (138) at any of a plurality of speeds. In the illustrated embodiment, the motor assembly (124) is located within a cylindrical shell (104). In some other embodiments, the compressor (100) may be an open drive compressor driven by the motor assembly (124) located outside the compressor housing (102). The compressor (100) further includes a first bearing assembly (140) and a second bearing assembly (142) capable of rotatably supporting the drive shaft (138).

[0014] The drive shaft (138) may be exposed to one or more loads during refrigerant compression, which may cause deformation of the drive shaft (138). In the embodiments described herein, the compressor (100) may include an unloader (116) that is at least partially retained within a recess (118) formed on the drive shaft (138). The unloader (116) engages with at least one assembly of the first bearing assembly (140) or the second bearing assembly (142) and provides compliance between the drive shaft (138) and at least one bearing assembly of the first or second bearing assemblies (140, 142) to unload forces acting on the first or second bearing assemblies (140, 142) resulting from deformations of the drive shaft (138).

[0015] The drive shaft body (160) defines a longitudinal axis (A1). The axial direction includes a direction aligned with or parallel to the longitudinal axis (A1). The radial direction includes a direction radially relative to the longitudinal axis (A1) and perpendicular to the longitudinal axis (A1). The drive shaft (138) includes the drive shaft body (160) and an eccentric body (162) that can be offset from the drive shaft body (160). The drive shaft body (160) and the eccentric body (162) have a cylindrical shape. The eccentric body (162) includes a longitudinal axis (A2) offset from the longitudinal axis (A1). Refer to FIG. 4. The drive shaft body (160) includes a first end portion (206) and a second end portion (208) that are respectively rotatably supported by first and second bearing assemblies (140, 142). The eccentric body (162) can extend from the first end portion (206).

[0016] The slewing scroll (122) may include an end plate (144) having a spiral wrap (146) extending from a first side (148) and an annular flat surface (150) on a second side (152). The surface (150) may interface with a first bearing assembly (140) as will be described later. The slewing scroll (122) may further include a cylindrical hub (154) protruding downward from the end plate (144). The eccentric body (162) of the drive shaft (138) may be drivenly engaged with a drive bearing (164). The drive bearing (164) transmits rotational motion from the eccentric body (162) to the slewing scroll (122). The drive bearing (164) may be located within the cylindrical hub (154) of the slewing scroll (122). To prevent relative rotation between the pivot scroll (122) and the non-pivot scroll (120), or the upper bearing housing (180), a coupling (166), such as an Oldham coupling, may be engaged with them. At least a portion of the upper bearing housing (180) may partially define the boundary between the chamber (128) and the cavity (130).

[0017] The non-rotating scroll (120) may include an end plate (170) and a spiral wrap (172) protruding downward from the end plate (170). The spiral wrap (172) may be engaged with the spiral wrap (146) of the rotating scroll (122), for example, by the wraps interlocking with each other in a net-like manner, thereby creating a series of moving fluid pockets. As the fluid pockets defined by the spiral wraps (146, 172) move from a radially outer position (e.g., at suction pressure) to a radially inner position (e.g., at discharge pressure higher than suction pressure) through a compression cycle, the volume of the fluid pockets defined by the spiral wraps (146, 172) may decrease. The end plate (170) may include a discharge passage (156) that communicates with at least one of the fluid pockets in the radially inner position and allows a compressed working fluid, such as a refrigerant or a mixture of refrigerant and lubricant (at or near discharge pressure), to flow into the chamber (128) through it.

[0018] To draw the working fluid into the fluid pockets defined by the spiral wrap (172) and spiral wrap (146), an inlet (175) is attached to the compressor housing (102) at the end cap (106), and the working fluid is compressed. After the working fluid is compressed, the compressed working fluid exits the fluid pockets defined by the spiral wrap (172) and spiral wrap (146) into the chamber (128) through the discharge passage (156). The compressed working fluid flows from the chamber (128) into the cavity (130) through one or more passages between the non-swivel scroll (120), the upper bearing housing (180), and the cylindrical shell (104). The compressed working fluid exits the cavity (130) through the discharge fitting (176). The discharge fitting (176) may be attached to the compressor housing (102) in the cylindrical shell (104). A discharge valve assembly (not shown) may be located within a discharge fitting (176) and may generally prevent backflow conditions through the discharge fitting (176). A sealed terminal (178) may be attached to the compressor housing (102) at the base (110).

[0019] The base (110) includes an inner surface (240) defining an inner cavity (244). As will be described in more detail below in this specification, the base (110) defines a first end portion (246) connectable to a part of the lower bearing housing (300).

[0020] Referring to FIG. 2, the compressor (100) includes an upper bearing housing (180) that can be fixed to the compressor housing (102). Additionally, and / or alternatively, the upper bearing housing (180) may be connected to a non-swivel scroll (120). The upper bearing housing (180) includes an annular hub (182) defining a cavity (184) that is sized and molded to accommodate a first bearing assembly (140). The upper bearing housing (180) and the first bearing assembly (140) may cooperate to support a drive shaft (138) for rotational motion therewith. The upper bearing housing (180) may also axially support a swivel scroll (122) for rotational motion therewith.

[0021] Referring to FIGS. 2, 3a, and 3b, the first bearing assembly (140) is a ball bearing comprising an outer ring (190), an inner ring (192), and a plurality of balls (200) positioned between the outer ring (190) and the inner ring (192). In other embodiments, the first bearing assembly (140) may include roller bearings of other types. The inner ring (192) includes an inner surface (202) defining a bearing opening (204). To ensure that the drive shaft body (160) is spaced radially from the inner ring (192), the drive shaft body (160) has a diameter (D) of the bearing opening (204) defined by the inner surface (202) of the inner ring (192). 204 Diameter smaller than ) (D 160 It has ). In some embodiments, the diameter (D 160 ) is the diameter (D 204 It may be between about 0.2 mm and 0.6 mm, which is smaller than ). Accordingly, there may be a radial gap between about 0.1 mm and 0.3 mm between the drive shaft body (160) and the inner surface (202).

[0022] The passage (212) may extend along the length of the drive shaft (138). In some embodiments, oil may also flow from the passage (212) to a bearing through a supply passage (not shown), which extends radially outward from the passage (212). Alternatively, and / or additionally, a refrigerant may flow through the passage (212). In some embodiments, a mixture of oil and refrigerant may flow through the passage (212).

[0023] Referring to FIG. 2, a first counterweight (220) and a second counterweight (222) may be attached to a drive shaft body (160) located between the first and second bearing assemblies (140, 142) to balance the rotation of the drive shaft (138). The first and second counterweights (220, 222) may be configured and positioned so that the inertial force of the first counterweight (220) can offset or balance the sum of the inertial forces of the second counterweight (222), the pivot scroll (122), and the eccentric body (162).

[0024] Referring to FIGS. 3a and 3b, a recess (118) is formed on the drive shaft body (160) at or adjacent to the first end portion (206). The recess (118) may be generally aligned axially with the first bearing assembly (140). The recess (118) is at least partially defined by the first axial end (232), the second axial end (234), and the rear surface (236) formed on the drive shaft body (160). Refer to FIG. 3b. The recess (118) is sized and molded to accommodate and at least partially retain the unloader (116). The unloader (116) includes a channel (260) formed on the outer surface (242) of the unloader (116). The drive shaft body (160) also includes the channel (262). When the unloader (116) is positioned within the recess (118), the channel (260) is aligned with the channel (262) so that a continuous annular channel (266) (see FIG. 4) is formed around the entire circumference of the drive shaft body (160). The annular channel (266) can be sized and molded to optionally accommodate a retaining ring (264) within it. The retaining ring (264) can hold the unloader (116) within the recess (118) during the assembly process. In the illustrated embodiment, the cross-section of the annular channel (266) is circular.

[0025] Returning to FIG. 2 and additionally referring to FIG. 5 through 11, a lower bearing housing is illustrated and is generally identified by reference numeral 300. As will be described in more detail below in this specification, the lower bearing housing (300) is connected to each of the cylindrical shell (104) and the base (110) adjacent to the second end (112) of the cylindrical shell (104).

[0026] The lower bearing housing (300) of this embodiment includes a cylindrical body (302) that defines a longitudinal axis (A3) and extends along it between a first end portion (304) and a second end portion (306) opposite to it. In an exemplary embodiment, the cylindrical body (302) may include any suitable shape including a diagonally extending wall having a linear profile, a curved profile, an arc profile, etc., such as a cup-shaped profile, an elliptical profile, a circular profile, etc., without departing from the scope of this disclosure, but the cylindrical body (302) generally includes a dome-shaped or truncated cone-shaped profile. The cylindrical body (302) includes an outer cylindrical rim (308) that extends along the longitudinal axis (A3) between a first end portion (304) and a second end portion (310) opposite to it of the cylindrical body (302). The flange (312) defines a first cross section (P1) that extends radially outward from the outer cylindrical rim (308) and crosses the longitudinal axis (A3). The flange (312) may be connected to the outer cylindrical rim (308) or formed integrally with it. The flange (312) is suitably connected to the outer cylindrical rim (308) by welding, adhesives, friction fit, press fit, mechanical fasteners, etc. The flange (312) defines a first annular surface (314) that extends along the longitudinal axis (A3) between the flange (312) and the first end portion (304) of the cylindrical body (302), positioned adjacent to and spaced apart from the first end portion (304) of the cylindrical body (302). The first annular surface (314) is sized and molded to be received within the cavity (130) of the cylindrical shell (104) of the compressor housing (102). Refer to FIG. 5.In an exemplary embodiment, although the first annular surface (314) may be defined with any suitable size and shape, such as a slip fit, friction fit, etc., without going beyond the scope of the present disclosure, the first annular surface (314) may be sized and molded to define a press-fit engagement with the inner surface (105) of the cylindrical shell (104).

[0027] The outer cylindrical rim (308) defines a second annular surface (316) extending between the flange (312) and the end portion (310) of the outer cylindrical rim (308). The second annular surface (316) is sized and molded to be received within the inner cavity (244) of the base (110) of the compressor housing (102). Refer to FIG. 5. In an exemplary embodiment, the second annular surface (316) may be defined with any suitable size and shape, such as a slip fit, friction fit, etc., without departing from the scope of the present disclosure, and may be the same or different size and shape as the first annular surface (314), but the second annular surface (316) is sized and molded to be press-fitted into the inner surface (240) of the base (110).

[0028] A step or recess (318) is formed extending along the longitudinal axis (A3) toward the flange (312) through the end portion (310) of the outer cylindrical rim (308) and the second annular surface (316). Refer to FIG. 9. The recess (318) ends at a position spaced apart from the flange (312). In this way, the recess (318) defines an outer dimension smaller than the outer dimension of the second annular surface (316) and reduces the length of the second annular surface (316) along the longitudinal axis (A3) that interfaces with and / or otherwise engages with the inner surface (340) of the base (110). Reducing the length of the second annular surface (316) reduces the amount of bending of the lower bearing housing (300) caused by forming a press-fit engagement with the base (110) compared to the case where the length of the second annular surface (316) is not reduced. The recess (318) may have any suitable length depending on the design needs of the lower bearing housing (300).

[0029] Referring continuously to FIGS. 2 and FIGS. 5 through 11, the cylindrical body (302) includes an inner surface (320) defining an inner cavity (322). An inner cylindrical rim (324) extends from the inner surface (320) into the cavity (322) along the longitudinal axis (A3). The inner cylindrical rim (324) ends at an end portion (326). Although generally depicted as ending at a position axially offset from the first end portion (304) of the outer cylindrical body (302) in the direction extending toward the inner surface (320), the end portion (326) of the inner cylindrical rim (324) may end at any suitable position relative to the first end portion (304) without departing from the scope of the present disclosure. The inner cylindrical rim (324) includes an inner surface (328) defining a through bore (330) extending through each of the first and second end portions (304, 306) of the cylindrical body (302). Although generally depicted as defining a circular cross-sectional profile, the through bore (330) may define any suitable cross-sectional profile and any suitable internal dimensions, and may define a consistent cross-sectional profile and / or internal dimensions along the longitudinal axis (A3) or a variable cross-sectional profile and / or internal dimensions along the longitudinal axis (A3).

[0030] The inner cylindrical rim (324) includes a second inner surface (332) defining a bearing bore (334) that extends along the longitudinal axis and through the end portion (326) of the inner cylindrical rim (324). In some embodiments, the bearing bore (334) may be a counterbore. The bearing bore (334) is sized and molded to accommodate the second bearing assembly (142). Refer to FIG. 10. In an exemplary embodiment, although the bearing bore (334) may be defined by any suitable size and shape, such as a slip fit, friction fit, etc., without departing from the scope of the present disclosure, the bearing bore (334) is sized and molded to define a press-fit engagement with the second bearing assembly (142). In an exemplary embodiment, the bearing bore (334) defines an intermediate point (336) along the longitudinal axis (A3) and, in the embodiments, an intermediate point (338) of the second bearing assembly (142) along the longitudinal axis (A3). The intermediate point (336) of the bearing bore (334) and / or the intermediate point (338) of the second bearing assembly (142) defines a second cross section (P2) oriented across the longitudinal axis (A3). In some embodiments, the second cross section (P2) is oriented parallel to the first cross section (P1). The second cross section (P2) is oriented at a distance (D) from the first cross section (P1) toward the inner surface (320) of the cylindrical body (302). 300 It is offset along the axis by ) amount.

[0031] As will be described in more detail below, when the lower bearing housing (300) is connected to the cylindrical shell (104) and base (110) of the compressor housing (102), the transmission of forces applied to the outer cylindrical rim (308) due to the press-fit engagement between the outer cylindrical rim (308) and the cylindrical shell (104) and base (110), and / or by welding the outer cylindrical rim (308) around the perimeter of the flange (312), is reduced or otherwise mitigated compared to the case where the midpoint (338) of the second bearing assembly (142) and the flange (312) are axially aligned, thereby reducing the bending of the inner cylindrical rim (324) and the second bearing assembly (142) by the axial offset (D) between the first and second cross-sections (P1, P2). 300 ) places the midpoint (338) of the second bearing assembly (142) on a plane different from the flange (312). Refer to FIG. 12a, FIG. 12b, FIG. 13a, FIG. 13b, FIG. 14a, and FIG. 14b.

[0032] Referring further to FIGS. 2 and FIGS. 5 through 11, the cylindrical body (302) includes a side web (342) extending diagonally between the end portion (310) of the outer cylindrical rim (308) and the second end portion (306) of the cylindrical body (302). In an exemplary embodiment, the side web (342) generally defines a linear shape between the end portion (310) of the outer cylindrical rim (308) and the second end portion (306) of the cylindrical body (302). In some embodiments, the side web (342) may define any suitable shape or profile such as arc, curved, hexagonal, etc., may vary along the length of the side web (342), and may be concave, convex, etc. The side web (342) is sized or molded to be compliant so that the forces applied to the outer cylindrical rim (308) cause the side web to deform or otherwise bend while maintaining the circularity of the bearing bore (334) and the axial alignment of the bearing bore (334) with respect to the longitudinal axis (A1). In some embodiments, the side web (342) includes at least one inner surface (344) that extends parallel to the longitudinal axis (A3) of the cylindrical body (302) and is radially offset from it. In this embodiment, there is an inner surface (344) that defines a passage (346) that fluidly connects the environment outside the cylindrical body (302) to the inner cavity (322). In this way, the passage (346) allows fluid to flow from the cavity (130) of the cylindrical shell (104) of the compressor housing (102) to the internal cavity (244) of the base (110) of the compressor housing (102), and vice versa. Refer to FIG. 1. The side web (342) has two passages (346), but may also have any number of passages (346), and the passages (346) may have any size and shape depending on the design parameters of the compressor (100).Although generally described as extending parallel to the longitudinal axis (A3), one or more of the passages (346) may be oriented toward and / or across the longitudinal axis (A3).

[0033] The lower bearing housing (300) may be made or formed from any suitable material such as metallic material, non-metallic material, composite, ceramic, and combinations thereof, and may be formed or manufactured using any suitable manufacturing method such as stamping, welding, 3D printing, machining, hydroforming, etc. In an exemplary embodiment, the lower bearing housing (300) is formed by stamping or hydroforming a metallic material. The metallic material is compatible with a welding process for joining to the material forming the cylindrical shell (104) and / or base (110) of the compressor housing (102).

[0034] Referring to FIG. 11, the lower bearing housing (300) is connected to one or both of the cylindrical shell (104) and the base (110) of the compressor housing (102). A flange (312) is interposed between the second end (112) of the cylindrical shell (104) and the first end portion (246) of the base (110). In some embodiments, one or both of the second end (112) of the cylindrical shell (104) and the first end portion (246) of the base (110) may be in contact with at least one portion of the flange (312). Although generally depicted as having an outer diameter smaller than the outer diameter of the cylindrical shell (104) and the base (110), the flange (312) may have an outer dimension equal to the outer diameter of one or both of the cylindrical shell (104) and the base (110) without departing from the scope of the present disclosure. The lower bearing housing (300) may be connected to one or both of the cylindrical shell (104) and the base (110) using any suitable means such as welding, adhesives, mechanical fasteners, etc. In an exemplary embodiment, the lower bearing housing (300) is connected to at least one of the cylindrical shell (104) and the base (110) by a weld (348). The weld (348) may extend at least partially around the perimeter of the flange (312) and may be a continuous weld or a discontinuous weld. In one embodiment, the weld (348) extends continuously around the entire perimeter of the flange (312).

[0035] Referring to FIGS. 12a, 12b, 13a, and 13b, the side web (342), the axial offset between the first and second cross sections (P1, P2), and the recess (318) of the outer cylindrical rim (308) together or individually alleviate or otherwise reduce the bending and / or deformation of the bearing bore (334) caused by the press-fit engagement and welding of the outer cylindrical rim (308) of the compressor housing (102) and the cylindrical shell (104) and base (110). FIG. 12a illustrates a circular view of the upper internal dimension (ID) of the press-fit engagement between the outer cylindrical rim (308), cylindrical shell (104), and base (110) of the compressor housing, and the bearing bore (334) before welding (e.g., adjacent to the end portion (326) of the inner cylindrical rim (324). FIG. 12b illustrates a circular view of the lower ID of the press-fit engagement between the outer cylindrical rim (308), cylindrical shell (104), and base (110) of the compressor housing, and the bearing bore (334) before welding (e.g., adjacent to the second end portion (306) of the cylindrical body (302). FIG. 13a illustrates a circular view of the upper ID of the bearing bore (334) after welding, and the press-fit engagement between the outer cylindrical rim (308), cylindrical shell (104), and base (110) of the compressor housing. FIG. 13b illustrates a circular view of the lower ID of the bearing bore (334) after welding, and the press-fit engagement between the outer cylindrical rim (308), cylindrical shell (104), and base (110) of the compressor housing.

[0036] Compared to the press-fit engagement between the outer cylindrical rim (308), cylindrical shell (104), and base (110) of the compressor housing shown in FIG. 14a, and the circularity of the upper ID of the bearing bore of the lower bearing housing of the prior art after welding thereof, and the press-fit engagement between the outer cylindrical rim (308), cylindrical shell (104), and base (110) of the compressor housing shown in FIG. 14b, and the circularity of the lower ID of the bearing bore of the lower bearing housing of the prior art after welding thereof, the circularity of the upper and lower IDs of the bearing bore (334) of the lower bearing housing (300) described herein is improved. Unlike discontinuous welds, the lower bearing housing (300) described herein enables the lower bearing housing (300) to be welded to the cylindrical shell (104) and base (110) of the compressor housing (102) around the entire circumference of the compressor housing (102). The continuous circumferential weld improves the axial alignment of the second bearing assembly (142) with respect to the first bearing assembly (140) compared to lower bearing housings other than the lower bearing housing (300) described in this specification, thereby reducing radial loads and vibrations caused by misalignment of the drive shaft (138) within the compressor housing (102).

[0037] Referring to FIG. 15, a method for assembling a compressor is illustrated and is generally identified by reference numeral 1500. The method includes the step (1502) of positioning a bearing within a defined bearing bore within an inner cylindrical rim of a bearing housing. An outer cylindrical rim of the bearing housing is positioned and / or compressed within the inner cavity of the cylindrical shell of the compressor housing so that the flange of the bearing housing is positioned adjacent to a second end portion of the cylindrical shell of the compressor housing (1504). The outer cylindrical rim of the bearing housing is attached and / or welded to the cylindrical shell and / or base of the compressor housing around the perimeter of the flange (1506).

[0038] Referring to FIG. 16, a schematic diagram of an exemplary refrigeration system (1600) is shown. The refrigeration system (1600) includes a compressor (100), an expansion device (1612) (e.g., an expansion valve, an orifice, a capillary tube), a condenser (1614), and an evaporator (1616). The refrigeration system (1600) may include additional components or other components other than those shown and described with reference to FIG. 16 without departing from the scope of the present disclosure. In operation, the compressor (100) receives a working fluid, such as a refrigerant, as a low-pressure gas through a suction line (1620). The compressor (100) compresses the gas, thereby increasing the temperature and pressure of the gas. The pressurized high-temperature gas then flows to the condenser (1614), whereby the high-pressure gas is condensed into a high-pressure liquid. The liquid then flows through the expansion device (1612), which reduces the pressure of the liquid. After passing through the expansion device (1612), the depressurized fluid, which may be a gas or a mixture of gas and liquid, then passes through the evaporator (1616). The evaporator (1616) may include a heat exchanger (not shown), through which the fluid circulates and is cooled by the depressurized refrigerant fluid, as the refrigerant fluid evaporates into a gas in the evaporator (1616). The refrigerant gas is then directed back to the compressor (100) through the suction line (1620), the working fluid is compressed again, and the process is repeated.

[0039] The technical advantages of the methods and systems described herein include reducing the bending of the bearing bore of the bearing housing supporting the drive shaft of the compressor and increasing the roundness. The systems and methods described herein enable the bearing housing to be welded to the compressor housing around the entire perimeter of the compressor housing while maintaining the roundness of the bearing bore and the axial alignment of the bearing bore with respect to the second bearing bore supporting the drive shaft of the compressor.

[0040] As used herein, when used in conjunction with ranges of dimensions, concentrations, temperatures, or other physical or chemical properties or characteristics, the terms “about,” “substantially,” “essentially,” and “approximately” are intended to cover variations that may exist in the upper and / or lower limits of the ranges of properties or characteristics, including, for example, variations arising from rounding, measurement methodologies, or other statistical variations.

[0041] When introducing elements of the present disclosure or its embodiments, the articles “a,” “an,” “the,” and “said” are intended to imply the presence of one or more of the elements. The terms “comprising,” “including,” “containing,” and “having” are intended to imply that additional elements may exist in addition to the comprehensive and listed elements. The use of terms indicating a specific orientation (e.g., “top,” “bottom,” “side,” etc.) is for convenience of description and does not require any specific orientation of the described item.

[0042] Since various modifications may be made to the configurations and methods without departing from the scope of the present disclosure, it is intended that all matters retained in the description and illustrated in the accompanying drawings[] are interpreted as exemplary rather than restrictive.

Claims

Claim 1 A compressor comprises: a shell; a motor having a drive shaft rotatably supported within a cavity of the shell; a compression mechanism connected to the drive shaft and operable to compress a working fluid upon rotation of the drive shaft; and a bearing housing including a dome-shaped cylindrical body defining a longitudinal axis, wherein the inner surface of the dome-shaped cylindrical body defines an internal cavity, and the dome-shaped cylindrical body, An outer cylindrical rim extending along the longitudinal axis, a flange extending radially outward from the outer cylindrical rim and defining a first cross-section, a step defined spaced apart from the flange, the step extending along the longitudinal axis and defining an outer dimension smaller than the outer dimension of the outer cylindrical rim, and at least a portion of the outer cylindrical rim is attached to the shell; An inner cylindrical rim extending from the inner surface into the inner cavity along the longitudinal axis, the inner wall of the inner cylindrical rim defines a bearing bore extending along the longitudinal axis, the midpoint of the bearing bore defined along the longitudinal axis defines a second cross-section, and the second cross-section is longitudinally offset from the first cross-section in a direction extending opposite to the inner surface; and A compressor comprising at least one inner surface extending parallel to the longitudinal axis and radially offset from the longitudinal axis, wherein the at least one inner surface defines a passage that fluidly couples an environment outside the dome-shaped cylindrical body to the inner cavity. Claim 2 A compressor according to claim 1, wherein the outer cylindrical rim of the bearing housing is attached to the shell around the circumference of the outer cylindrical rim. Claim 3 A compressor according to claim 1, wherein the outer cylindrical rim of the bearing housing is attached to the shell around the circumference of the outer cylindrical rim by a weld. Claim 4 In paragraph 3, the compressor, wherein the welded portion extends around the entire circumference of the outer cylindrical rim. Claim 5 A compressor according to claim 1, wherein the outer cylindrical rim of the bearing housing is attached to the shell by a press-fit engagement. Claim 6 In paragraph 5, the bearing housing comprises a side web extending diagonally between the outer cylindrical rim and the inner cylindrical rim, and the side web is a compliant compressor. Claim 7 A compressor according to claim 6, wherein the side web is compliant, and forces applied to the outer cylindrical rim cause at least one part of the side web to deform and maintain the inner cylindrical rim axially and radially aligned with respect to the shell. Claim 8 A compressor according to claim 7, wherein the side web is compliant, and forces applied to the outer cylindrical rim cause at least one part of the side web to deform and maintain the concentricity of the bearing bore of the inner cylindrical rim. Claim 9 A compressor according to claim 1, wherein the compressor further comprises a base, and the base is attached to the outer cylindrical rim of the bearing housing. Claim 10 A compressor according to claim 9, wherein the outer cylindrical rim of the bearing housing is attached to each of the shell and the base by a weld, and the weld extends around the circumference of the outer cylindrical rim. Claim 11 A bearing housing for a compressor comprises: an outer cylindrical rim extending along the longitudinal axis, wherein a flange extends radially outward from the outer cylindrical rim, wherein a rabbit extends radially inward from the outer cylindrical rim, wherein the rabbit is longitudinally offset from the flange, and at least a portion of the outer cylindrical rim is attached to the shell of the compressor; an inner cylindrical rim extending along the longitudinal axis, wherein the inner cylindrical rim is positioned radially inward from the outer cylindrical rim and longitudinally offset from the flange, wherein the inner wall of the inner cylindrical rim defines a longitudinal bore, and the midpoint of the longitudinal bore defined along the longitudinal axis is longitudinally offset from the flange; A bearing housing comprising a side web extending diagonally between the outer cylindrical rim and the inner cylindrical rim, wherein the outer cylindrical rim, the inner cylindrical rim, and the side web cooperate with each other to define a domed cylindrical body, the side web is compliant, and the side web deforms due to forces applied to the outer cylindrical rim from a press-fit engagement with the shell of the compressor and maintains the concentricity of the longitudinal bore of the inner cylindrical rim. Claim 12 In claim 11, the outer cylindrical rim is a bearing housing attached to the shell of the compressor by a weld. Claim 13 In claim 12, the bearing housing, wherein the welded portion extends around the circumference of the outer cylindrical rim. Claim 14 In claim 11, the dome-shaped profile comprises an inner surface defining an inner cavity, and the bearing housing further comprises at least one inner surface parallel to the longitudinal axis and radially offset from the longitudinal axis, wherein the at least one inner surface defines a passage that fluidly couples an environment outside the dome-shaped cylindrical body to the inner cavity. Claim 15 In claim 11, the outer cylindrical rim is attached to each of the shell and base of the compressor by a weld, and the weld extends around the circumference of the outer cylindrical rim, forming a bearing housing. Claim 16 A method for assembling a compressor, wherein the compressor comprises a shell and a base, and the method comprises the steps of: positioning a bearing within a bearing bore defined within an inner cylindrical rim of a bearing housing, wherein the inner cylindrical rim extends along a longitudinal axis; positioning an outer cylindrical rim of the bearing housing within an inner cavity defined by the shell of the compressor, wherein a flange extending radially outward from the outer cylindrical rim when positioned within the inner cavity of the shell is positioned adjacent to an end portion of the shell of the compressor, and the flange defines a first cross-section; and attaching the outer cylindrical rim of the bearing housing to the shell of the compressor around the periphery of the flange, wherein the midpoint of the bearing bore of the bearing housing defined along the longitudinal axis defines a second cross-section, and the second cross-section is longitudinally offset from the first cross-section. Claim 17 In claim 16, the step of attaching the outer cylindrical rim to the shell of the compressor comprises the step of welding the outer cylindrical rim to the shell around the perimeter of the flange of the outer cylindrical rim. Claim 18 In claim 16, the step of attaching the outer cylindrical rim to the shell of the compressor comprises the step of pressing the outer cylindrical rim into the inner cavity of the shell to form a press-fit interlock between the outer cylindrical rim and the shell. Claim 19 A method according to claim 18, further comprising the step of welding the outer cylindrical rim to the shell of the compressor around the perimeter of the flange of the outer cylindrical rim. Claim 20 A method according to claim 16, further comprising the step of attaching the outer cylindrical rim of the bearing housing to the base of the compressor around the circumference of the flange, wherein the step of attaching the outer cylindrical rim to the base of the compressor comprises the step of welding each of the shell and the base of the compressor to the outer cylindrical rim around the circumference of the flange of the outer cylindrical rim.

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