Discharge Passages For Compressors and Compressors Including Same

Abstract

A scroll includes a body including a first side and an opposing second side. The first side includes two or more outlets and a bridge defined between the outlets. The second side includes an inlet and a spiral wrap extending therefrom. The body defines a discharge passage extending between the inlet and the outlets. The reed is positionable between an open position where the reed does not obstruct the outlets and a closed position wherein the reed blocks at least a portion of the outlets and rests against the bridge.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This patent application claims priority to India Application No. 202511010682, filed on Feb. 8, 2025, the disclosure of which is incorporated by reference herein in its entirety as part of the present application.FIELD

[0002] The field of the disclosure relates generally to scroll compressors and, more particularly, to scroll compressors including a scroll defining a discharge passage with a plurality of outlets.BACKGROUND

[0003] Scroll compressors compress a working fluid, e.g., refrigerant, using a non-orbiting scroll member and an orbiting scroll member that cooperate to form sealed pockets therebetween. During operation of the scroll compressor, motion of the orbiting scroll member relative to the non-orbiting scroll member continuously changes the volume of the sealed pockets to compress the working fluid within.

[0004] Conventionally, compressed working fluid exits the sealed pocket between the meshed scrolls through a discharge port which is regulated by a reed or check valve assembly. The reed valve assembly includes a flexible reed that flexes between an open position where the reed flexes away from the discharge port and does not obstruct the flow of compressed working fluid exiting the discharge port and a closed position where the reed covers the discharge port blocking the flow of compressed working fluid from exiting the sealed pocket between the meshed scrolls. In some known compressors, a bridge insert may be positioned between the reed and the discharge port. The bridge insert spans across the discharge port and supports a distal end of the reed reducing closing stresses on the reed, however the bridge insert requires additional manufacturing processes and increases assembly times, while reducing compressor efficiency by blocking a portion of an outlet area of the discharge port.

[0005] This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the disclosure, which are described and / or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art.SUMMARY

[0006] In one aspect, a discharge assembly for use with a compressor for compressing a working fluid is provided. The discharge assembly includes a reed valve assembly comprising a reed and a backer and a scroll including a body including a first side and an opposing second side, the first side including two or more outlets and a bridge defined between the outlets, the second side including an inlet and a spiral wrap extending therefrom. The body defines a discharge passage extending between the inlet and the outlets, wherein the reed is positionable between an open position where the reed does not obstruct the outlets and a closed position wherein the reed blocks at least a portion of the outlets and rests against the bridge.

[0007] In another aspect, a compressor is provided. The compressor includes a driveshaft, a motor operably connected to the driveshaft, and a compression mechanism connected to the driveshaft. The compression mechanism includes a scroll including a body including a first side and an opposing second side, the first side including two or more outlets and a bridge defined between the outlets, the second side including an inlet and a spiral wrap extending therefrom. The body defines a discharge passage extending between the inlet and the outlets.

[0008] Various refinements exist of the features noted in relation to the above-mentioned aspects of the present disclosure. Further features may also be incorporated in the above-mentioned aspects of the present disclosure as well. These refinements and additional features may exist individually or in any combination. For instance, various features discussed below in relation to any of the illustrated embodiments of the present disclosure may be incorporated into any of the above-described aspects of the present disclosure, alone or in any combination.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] FIG. 1 is a perspective view of an example compressor.

[0010] FIG. 2 is a cross-sectional view of the compressor shown in FIG. 1 taken along line 2-2 including a scroll assembly.

[0011] FIG. 3 is an upper perspective view of the scroll assembly removed from the compressor shown in FIG. 2.

[0012] FIG. 4 is an assembly view of the scroll assembly shown in FIG. 3 including a scroll defining a discharge passage and a reed valve assembly including a backer and a reed.

[0013] FIG. 5 is an upper perspective view of the scroll shown in FIG. 4.

[0014] FIG. 6 is a lower perspective view of the scroll shown in FIG. 4.

[0015] FIG. 7 is a top view of the scroll shown in FIG. 4.

[0016] FIG. 8 is a bottom view of the scroll shown in FIG. 4.

[0017] FIG. 9 is an upper perspective cross-sectional view of the scroll taken along line 9-9 in FIG. 7.

[0018] FIG. 10 is a lower perspective cross-sectional view of the scroll taken along line 10-10 in FIG. 7.

[0019] FIG. 11 is an upper perspective cross-sectional view of the scroll taken along line 11-11 in FIG. 7.

[0020] FIG. 12 is a lower perspective cross-sectional view of the scroll taken along line 12-12 in FIG. 7.

[0021] FIG. 13 is a perspective view of a discharge passage volume of the discharge passage formed in the scroll of the compressor shown in FIG. 1.

[0022] FIG. 14 is a perspective view of another example compressor.

[0023] FIG. 15 is a cross-sectional view of the compressor shown in FIG. 14 taken along line 14-14 including a scroll assembly.

[0024] FIG. 16 is an upper perspective view of the scroll assembly removed from the compressor shown in FIG. 15.

[0025] FIG. 17 is an assembly view of the scroll assembly shown in FIG. 16 including a scroll defining a discharge passage and a reed valve assembly.

[0026] FIG. 18 is an upper perspective view of the scroll shown in FIG. 17.

[0027] FIG. 19 is a lower perspective view of the scroll shown in FIG. 17.

[0028] FIG. 20 is a top view of the scroll shown in FIG. 17.

[0029] FIG. 21 is a bottom view of the scroll shown in FIG. 17.

[0030] FIG. 22 is an upper perspective cross-sectional view of the scroll taken along line 22-22 in FIG. 20.

[0031] FIG. 23 is a lower perspective cross-sectional view of the scroll taken along line 23-23 in FIG. 20.

[0032] FIG. 24 is a perspective view of a discharge passage volume of the discharge passage formed in the scroll of the compressor shown in FIG. 14.

[0033] FIG. 25 is a top view of another example discharge passage formed in an example scroll.

[0034] FIG. 26 is a bottom view of the scroll shown in FIG. 25.

[0035] FIG. 27 is a perspective view of a discharge passage volume of the discharge passage shown in FIG. 25.

[0036] FIG. 28 is a top view of another example discharge passage formed in an example scroll.

[0037] FIG. 29 is a bottom view of the scroll shown in FIG. 28.

[0038] FIG. 30 is a perspective view of a discharge passage volume of the discharge passage shown in FIG. 28.

[0039] FIG. 31 is a graph showing closing and opening stresses for a reed closing against the four outlets of the discharge passage of the compressor shown in FIG. 1, the two outlets of the discharge passage of the compressor of FIG. 14, and a another discharge assembly including a another reed and another discharge passage.

[0040] FIG. 32A is a perspective view of the reed illustrating the position of outlets of the discharge passage of the scroll for use in the compressor shown in FIG. 1.

[0041] FIG. 32B is a top view of contact area on the reed shown in FIG. 32A.

[0042] FIG. 32C is a bottom view of sealing distribution between the reed and the discharge passage shown in FIG. 32A.

[0043] FIG. 33 is a perspective view of compressed working fluid flow exiting the four outlets of the discharge passage of the compressor shown in FIG. 1.

[0044] FIG. 34A is a perspective view of the reed illustrating the position of outlets of the discharge passage of the scroll for use in the compressor shown in FIG. 14.

[0045] FIG. 34B is a top view of contact area on the reed shown in FIG. 34A.

[0046] FIG. 34C is a bottom view of sealing distribution between the reed and the discharge passage shown in FIG. 34A.

[0047] FIG. 35 is a perspective view of compressed working fluid flow exiting the four outlets of the discharge passage of the compressor shown in FIG. 15.

[0048] FIG. 36 is a table showing metrics for the four outlets of the discharge passage of the compressor shown in FIG. 1, the two outlets of the discharge passage of the compressor shown in FIG. 14, compared to a another discharge assembly including a another reed and a another discharge passage.

[0049] Corresponding reference characters indicate corresponding parts throughout the drawings.DETAILED DESCRIPTION

[0050] Referring to FIG. 1, a view of an example compressor is indicated generally at 100. The compressor 100 includes a compressor housing 102 forming at least one sealed cavity within which refrigerant compression is accomplished. The compressor housing 102 includes a shell 104, an end cap 106 positioned at a first end 118 of the shell 104, and a base 108 positioned at an opposing second end 120 of the shell 104. In the illustrated example, the shell 104 is cylindrical in shape and the end cap 106 and the base 108 are each generally dome-shaped, such that the compressor housing 102 has a generally oval-shaped profile. The shell 104, the end cap 106, and / or the base 108 may be differently shaped depending on a desired shape and profile of the compressor housing 102. The end cap 106 and / or the base 108 may be attached at the respective ends 118, 120 of the shell 104 using any suitable means to join components. For example, the end cap 106 and / or the base 108 may be welded or bolted to the shell 104.

[0051] The compressor 100 includes an inlet fitting 110 attached to the compressor housing 102 at an inlet opening (not shown) through which working fluid (e.g., refrigerant) enters the at least one sealed cavity formed by the compressor housing 102. For example, the working fluid is drawn into the compressor 100 via the inlet fitting 110 and compressed in the at least one sealed cavity. After the working fluid is compressed, the compressed working fluid exits the compressor 100 through a discharge opening 112. A discharge fitting 114 may be attached to the compressor housing 102 at the discharge opening 112. In the example compressor 100, the discharge opening 112 is located on the base 108, and the discharge fitting 114 is attached to the base 108 at the discharge opening 112, enabling compressed working fluid to exit a second chamber 117 (FIG. 2) defined by the base 108. In the example compressor 100, the working fluid in the second chamber 117 is at discharge pressure, and the second chamber 117 may alternatively be referred to as a discharge chamber. A discharge valve assembly (not shown) may be disposed within the discharge fitting 114 to prevent a reverse flow condition. A hermetic electric terminal 115 may also be attached to the compressor housing 102, for example, to the shell 104.

[0052] FIG. 2 is a cross-section view of the compressor 100. The compressor 100 includes the compressor housing 102 including the shell 104, the end cap 106, positioned at the first end 118 of the shell 104 and defining the first chamber 116, and the base 108, positioned at the second end 120 of the shell 104 and defining the second chamber 117. The compressor 100 also includes a motor assembly 122 and a compression mechanism (e.g., a scroll assembly), indicated generally at 204, installed in the compressor housing 102 and operably connected to the motor assembly 122.

[0053] The motor assembly 122 includes a motor stator 124 and a rotor 126. The rotor 126 may be press fit on a driveshaft 128 positioned within the compressor housing 102 and may transmit rotational power to the driveshaft 128. The motor assembly 122 may be a variable-speed motor for rotating the driveshaft 128 at any of a plurality of speeds. In the illustrated embodiment, the motor assembly 122 is disposed within the shell 104. In some other embodiments, the compressor 100 may be an open drive compressor driven by a motor assembly 122 that is disposed outside of the compressor housing 102.

[0054] The driveshaft 128 is rotatably supported within a first bearing housing assembly 206 and 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 proximate the first end 118 of the shell 104 and the second bearing housing assembly 130 is located proximate the second end 120 of the shell 104 (e.g., within the base 108). The driveshaft 128 extends through the first bearing housing assembly 206 and includes an eccentric body 132 extending axially beyond the first bearing housing assembly 206.

[0055] The first bearing housing assembly 206 includes a primary bearing 134 and the second bearing housing assembly 130 includes a secondary bearing 136. The primary and secondary bearings 134, 136 rotationally support the driveshaft 128 within the respective bearing housing assembly 206, 130. The first bearing housing assembly 206 includes the primary bearing 134 and a main bearing housing 208. The primary bearing 134 and / or the secondary bearing 136 may be rolling element bearings having an inner ring defining a bearing surface and bearing opening for receiving the driveshaft 128, an outer ring spaced radially outward from the inner ring, and a plurality of balls or rollers disposed between the inner ring and the outer ring. Alternatively, in some embodiments, the primary bearing 134 and / or secondary bearing 136 are journal bearings, and the driveshaft 128 rotationally supported by the journal bearings 134 and / or 136 within a bearing opening and relative to a stationary bearing inner surface. The primary bearing 134 and / or the secondary bearing 136 may be any suitable bearing type.

[0056] The compression mechanism 204 includes an orbiting scroll 226 and a non-orbiting scroll 228. The orbiting scroll 226 includes a generally disk-shaped orbiting plate 230 defining opposing radial surfaces. An orbiting spiral wrap 232 extends axially from one of the surfaces of the orbiting plate 230, and the surface opposite the orbiting spiral wrap 232 includes a cylindrical hub 236 extending axially therefrom. A drive bushing 239 is disposed in the cylindrical hub 236 and receives the eccentric body 132 of the driveshaft 128 that extends through the main bearing housing 208. The eccentric body 132 drivingly engages the drive bushing 239 in the cylindrical hub 236 of the orbiting scroll 226, and facilitates transmitting rotational motion of the driveshaft 128 to orbiting motion of the orbiting scroll 226 relative to the main bearing housing 208 and / or the non-orbiting scroll 228. A coupling (e.g., an Oldham coupling), not labeled, may be engaged with the orbiting scroll 226 and the main bearing housing 208 and / or the non-orbiting scroll 228 to limit or prevent relative rotation therebetween.

[0057] The non-orbiting scroll 228 includes a non-orbiting body 238 defining an upper surface 241 and an opposing lower surface 242. In some embodiments, the non-orbiting scroll 228 may include an annular wall 244. A non-orbiting spiral wrap 240 extends, generally axially, from the lower surface 242 and faces the orbiting spiral wrap 232. The non-orbiting scroll 228 also includes a raised portion 246 extending axially from the upper surface 241 of the non-orbiting body 238.

[0058] The non-orbiting spiral wrap 240 engages, or meshes, with the orbiting spiral wrap 232 of the orbiting scroll 226, defining a series of fluid pockets. Orbiting motion of the orbiting scroll 226 translates to movement of the fluid pockets defined by the spiral wraps 232 and 240, whereby the fluid pockets decrease in volume to compress working fluid in the fluid pockets. During a compression cycle of the compression mechanism 204, the fluid pockets defined by the spiral wraps 232 and 240 decrease in volume as orbiting motion of the orbiting scroll 226 translates to movement of the fluid pockets from a radially outer position 250 (at a suction pressure) to a radially intermediate position (at an intermediate pressure) to a radial inner position 252 (at a discharge pressure).

[0059] FIGS. 14-15 depicts another example compressor, indicated generally at 500, including the compression mechanism 204 including the orbiting scroll 226 and the non-orbiting scroll 228. The compressor 500 has one or more similar elements and features to the compressor 100, described above with reference to FIGS. 2-13, including similar components and features labeled with like annotation numbering.

[0060] Compressors 100 and 500 include a discharge assembly 300 including a scroll 302 and a reed valve assembly 304. At least one of the non-orbiting scroll 228 or the orbiting scroll 226 may be the scroll 302. In the illustrated embodiments, the scroll 302 is the non-orbiting scroll 228, described above. In alternative embodiments, the scroll 302 is the orbiting scroll 226.

[0061] The scroll 302 includes a discharge passage 310 defined by a discharge boundary 312, formed through the body 238 of the scroll 302, for releasing compressed working fluid (e.g., refrigerant) compressed by the compression mechanism 204. In particular, the discharge passage 310 is in communication with one of the fluid pockets defined by the spiral wraps 232 and 240 at the radial inner position 252 and allows compressed working fluid at the discharge pressure to flow into the first chamber 116.

[0062] The scroll 302 may include one or more intermediate port(s) 260 extending through the body 238. Each intermediate port 260 is located radially outward from the discharge passage 310 and allows communication with one of the fluid pockets defined by the spiral wraps 232 and 240 at the radially intermediate position. Flow of the working fluid through the intermediate ports 260 from a respective fluid pocket into the first chamber 116 may be regulated by a valve assembly 262 (e.g., a reed valve assembly) located or connected to the upper surface 241 of the body 238.) Shown in FIGS. 2 and 13. For example, the valve assembly 262 may be located adjacent the intermediate port 260 to selectively permit or restrict flow of working fluid into the first chamber 116. Additionally, and / or alternatively, one or more of the intermediate port(s) 260 may be a sensor port for receiving a sensor (e.g., a temperature sensor or a pressure sensor) for monitoring an operating parameter (e.g., temperature or pressure) within the respective fluid pocket during operation of the compression mechanism 204.

[0063] The inlet fitting 110 may be positioned at one or more different locations on the compressor housing 102 depending on the desired entry point of the working fluid within the at least one sealed cavity formed by the compressor housing 102. For example, the inlet fitting 110 may be fluidically connected to an inlet port 264 formed through the scroll assembly 204 through which working fluid is supplied to a pocket of the scroll assembly 204 at, or in proximity to, the radially outer position 250. In the embodiment illustrated in FIGS. 1-12, the inlet port 264 is formed through the upper surface 241 of the body 238 and extends generally parallel to the longitudinal axis A100. In the embodiment illustrated in FIGS. 14-23, the inlet port 264 is formed through the annular wall 244 of the scroll 302 and extends generally perpendicularly relative to the longitudinal axis A100.

[0064] Referring to FIGS. 9-12, the discharge passage 310 extends between an inlet 370 defined by an inlet boundary 372 formed on the lower surface 242 of the body 238 and an outlet 380 defined by an outlet boundary 382 formed on the upper surface 241 of the body 238. The compressed working fluid exits the space between the spiral wraps 232, 240, at the radial inner position 252, and enters into the discharge passage 310 through the inlet 370 and exits the discharge passage 310 through the outlet 380 and into the chamber 116. In the illustrated embodiment, the discharge passage 310 includes four outlets 380. In the embodiment illustrated in FIGS. 14-23, the discharge passage 310 includes a pair of outlets 380, e.g., two outlets 380. In the embodiments illustrated herein, the discharge passage 310 includes a solitary inlet 370.

[0065] Referring to FIGS. 9-12, the discharge passage 310 includes a scroll discharge port 390 and two or more discharge communication ports 392. The discharge communication ports 392 extend from a first intermediary end 394 to the outlet 380 and the scroll discharge port 390 extends from the inlet 370 to a second intermediary end 396. The scroll discharge port 390 includes a scroll discharge port depth d390 extending between the inlet 370 and the second intermediary end 396. The discharge communication ports 392 includes a discharge communication port depth d392 extending between the first intermediary end 394 and the outlet 380. FIGS. 13 and 24. In some embodiments, the discharge communication port depth d392 is longer than the scroll discharge port depth d390. In some embodiments, the discharge communication port depth d392 is approximately the same as the scroll discharge port depth d390. In the illustrated embodiment, the discharge passage 310 includes four discharge communication ports 392. The outlet depth d392 of each of the plurality of the discharge communication ports 392 may be approximately the same depth. In the embodiment illustrated in FIGS. 14-23, the discharge passage 310 includes two outlets 380 and two discharge communication ports 392. In the embodiments illustrated herein, the discharge passage 310 includes a solitary scroll discharge port 390.

[0066] In the illustrated embodiment, the discharge communication ports 392 each have a tapered bore end. Alternatively, one or more of the discharge communication ports 392 has a planar bore end. In the illustrated embodiment, each of the discharge communication ports 392 are circular in shape and have approximately the same diameter. In alternative embodiments, the discharge communication ports 392 and / or the outlets 380 may have different dimensions, e.g., different diameters or shapes.

[0067] The body 238 further includes a bridge surface 400 formed between the outlets 380. In the embodiment illustrated in FIGS. 1-12, the bridge surface 400 is disposed between the four outlets 380 and is shaped similar to a cross-shape having a central portion and four radially extending portions positioned between adjacent outlets 380. The radially extending portions of the cross-shape may include one or more concave portions shaped complementary to an arched boundary of the adjacent outlets 380.

[0068] FIGS. 13, 24, 27, and 30 illustrate a discharge volume of the discharge passage 310 defined by the discharge boundary 312. In some embodiments, at least a portion of the discharge communication ports 392 are not in alignment, in an axial direction and / or a radial direction, with the respective scroll discharge port 390. For example, a width and / or a diameter of the scroll discharge port 390 may be less than a width and / or diameter of an outer perimeter 408 surrounding the plurality of discharge communication ports 392.

[0069] In the embodiments illustrated in FIGS. 14-23, the bridge surface 400 spans between the two outlets 380. In reference to FIGS. 25-30, the outlets 380 and the bridge surface 400 may have alternative shapes and / or dimensions. For example, in some alternative embodiments, the outlets 380 have an oval or bean shape and the bridge surface 400 includes an annular portion. FIGS. 25-27. In some other alternative embodiments, the bridge is T-shaped and the outlets 380 are wedge shaped. FIG. 28-30.

[0070] The reed valve assembly 304, mounted to the upper surface 241 of the body 238, regulates compressed working fluid exiting the discharge passage 310 through the outlets 380. The reed valve assembly 304 includes a reed 410, a backer 412, and the reed valve assembly 304 may be mounted to the compressor 100 using any suitable fastener 414. When the reed valve assembly 304 is mounted to the upper surface 241, the reed 410 is disposed between the upper surface 241 and the backer 412. A portion of the reed 410 may bend between a closed position and an open position. When the reed 410 is in the closed position the reed 410 substantially obstructs the discharge passage 310, e.g., each of the outlets 380, and the reed 410 may be in contact with the upper surface 241 on or around the outer perimeter 408 surrounding the outlets 380. When the reed 410 is in the open position the reed 410 does not substantially obstruct the outlets 380 of the discharge passage 310. For example, when the reed 410 is in the open position at least a portion of the reed 410 may be flexed away from the upper surface 341 towards an arched portion 420 of the backer 212.

[0071] FIGS. 32A-C and FIGS. 34A-C illustrate the position of the outlets 380 relative to an outer boundary 422 of the reed 410. The reed 410 is sized and shaped such that the reed 410 covers all of the outlets 380 of the discharge passage 310 when the reed 410 is arranged in the closed position. In the illustrated embodiment, the reed 410 includes an outer boundary 422 and each of the four outlets 380 are contained within the boundary 422 and spaced a clearance distance Cd to the perimeter 480, when the reed 410 is arranged in the closed position. In the embodiments shown in FIGS. 32A-C, two of the outlets 380 include a center that is parallel to a longitudinal axis of the reed 410 and two of the outlets 380 have a center that is perpendicular to the longitudinal axis of the reed 410. In other embodiments, the plurality of outlets 380 may have different arrangements or patterns relative to the outer boundary 422 of the reed 410.

[0072] FIGS. 32B and 34B show the distribution of closing stresses on the reed 410, the bridge surface 400 supports a distal end of the reed 410 reducing an unsupported length of the reed 410 thereby reducing closing and opening stresses of the reed 410. In addition, contact between the reed 410 and the bridge surface 400 prevents the reed 410 from flexing into the discharge passage 310 improving the seal between the reed 410 and the outlets 380 of the discharge passage 310.

[0073] Referring to FIGS. 32C and 34C which shows a sealing profile between the reed 410 and the outlets 380, when the reed 410 is in the closed position, and the reed 410 covers the plurality of outlets 380, the reed 410 contacts, and is in sealing engagement with, the bridge surface 400 as well as the outer perimeter 408 surrounding the plurality of outlets 380.

[0074] In some embodiments, the scroll 302 includes a recessed area 430 defined by a recessed boundary 432 formed in the upper surface 241 of the scroll 302. The outlets 380 are positioned within the recessed area 430 and surrounded by the recessed boundary 432. The outer boundary 422 of the reed 410 extends beyond the recessed boundary 432 such that at least a portion of the reed 410 may rest on the upper surface 241 of the scroll 302 in an area surrounding the recessed area 430. The reed 410 may be flexible such that at least a portion of the reed 410 may flex into the recessed area 430 and at least a portion of the reed 410 rests on and / or is in sealing engagement with the area surrounding the outlets 380 and the bridge surface 400, ensuring a seal between the reed 410 and an area surrounding the recessed boundary 432 while the reed 410 is supported by the bridge surface 400.

[0075] Referring again to FIGS. 8 and 19, the inlet boundary 372, defining the inlet 370 of the discharge passage 310, is sized and shaped to be positioned adjacent to the radially inner position of the spiral wrap 240. For example, the inlet boundary 372 defining the inlet 370 may be generally kidney shaped having a portion that is arched similar to an arched portion of the scroll 340 and an indented portion shaped complementary to a central end of the scroll 340.

[0076] FIG. 33 is a perspective view of compressed working fluid flow exiting the four outlets 380 of the discharge passage 310 of the compressor 100, shown in FIG. 1. The working fluid exits the four outlets 380 such that the working fluid flows in 360° radially outward from the scroll assembly 204. FIG. 35 is a perspective view of compressed working fluid flow exiting the two outlets 380 of the discharge passage 310 of the compressor 500, shown in FIG. 14. The working fluid exits the two outlets 380 such that the working fluid flows in 120° radially outward from the scroll assembly 204.

[0077] FIG. 31 is a graph showing the driver opening and closing stress of the reed during operation and the fatigue acceptance criteria including an acceptable region. For the embodiments described herein, the scroll assemblies including the plurality of outlets 380, are contained within the acceptable region.

[0078] FIG. 36 is a table showing metrics for the four outlets 380 of the discharge passage 310 of the compressor 100, shown in FIG. 1, the two outlets 380 of the discharge passage 310 of the compressor 500 shown in FIG. 14, compared to a another discharge assembly including another reed and another discharge passage. One or more discharge parameters, e.g., mass flow, pressure, refrigerant density, may be the same or approximately the same, between a conventional HVE reed, and embodiments including the two outlets 380 and embodiments including the four outlets 380. In some embodiments, the discharge passage may include multiple restrictions. For example, working fluid may flow around the reed when the reed is in the open position, and then the working fluid may flow through a port. The restrictions may be in series. The effective flow area is calculated based on, at least in part, the restrictions around the open valve. The pressure difference and the power loss are based on a pressure difference across the open valve are also presented in FIG. 38.

[0079] In embodiments described herein, the scroll defining a discharge passage includes a bridge that supports a portion of the reed reducing the closing stresses on the reed while improving sealing engagement between the reed and boundaries of outlets of the discharge passage. In embodiments described herein the scroll includes a bridge spanning between two or more outlets to the discharge passage. The bridge is formed integrally with the scroll and does not require additional manufacturing processes or assembly of additional components.

[0080] Embodiments of the scroll described herein including the bridge, reduces an unsupported span length of the reed while maintaining the flow area of the outlets. Embodiments of the scroll described herein includes a recessed area, surrounding the outlets of the discharge passage, which has a footprint contained within an outer boundary of the reed such that at least a portion of the reed flexes into the recessed area improving the seal between the reed and the boundary of the recessed area.

[0081] As used herein, the terms “about,”“substantially,”“essentially” and “approximately” when used in conjunction with ranges of dimensions, concentrations, temperatures or other physical or chemical properties or characteristics is meant to cover variations that may exist in the upper and / or lower limits of the ranges of the properties or characteristics, including, for example, variations resulting from rounding, measurement methodology or other statistical variation.

[0082] When introducing elements of the present disclosure or the embodiment(s) thereof, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,”“including,”“containing” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. The use of terms indicating a particular orientation (e.g., “top”, “bottom”, “side”, etc.) is for convenience of description and does not require any particular orientation of the item described.

[0083] As various changes could be made in the above constructions and methods without departing from the scope of the disclosure, it is intended that all matter contained in the above description and shown in the accompanying drawing[s] shall be interpreted as illustrative and not in a limiting sense.

Examples

Embodiment Construction

[0050]Referring to FIG. 1, a view of an example compressor is indicated generally at 100. The compressor 100 includes a compressor housing 102 forming at least one sealed cavity within which refrigerant compression is accomplished. The compressor housing 102 includes a shell 104, an end cap 106 positioned at a first end 118 of the shell 104, and a base 108 positioned at an opposing second end 120 of the shell 104. In the illustrated example, the shell 104 is cylindrical in shape and the end cap 106 and the base 108 are each generally dome-shaped, such that the compressor housing 102 has a generally oval-shaped profile. The shell 104, the end cap 106, and / or the base 108 may be differently shaped depending on a desired shape and profile of the compressor housing 102. The end cap 106 and / or the base 108 may be attached at the respective ends 118, 120 of the shell 104 using any suitable means to join components. For example, the end cap 106 and / or the base 108 may be welded or bolted t...

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This patent application claims priority to India Application No. 202511010682, filed on Feb. 8, 2025, the disclosure of which is incorporated by reference herein in its entirety as part of the present application.FIELD

[0002] The field of the disclosure relates generally to scroll compressors and, more particularly, to scroll compressors including a scroll defining a discharge passage with a plurality of outlets.BACKGROUND

[0003] Scroll compressors compress a working fluid, e.g., refrigerant, using a non-orbiting scroll member and an orbiting scroll member that cooperate to form sealed pockets therebetween. During operation of the scroll compressor, motion of the orbiting scroll member relative to the non-orbiting scroll member continuously changes the volume of the sealed pockets to compress the working fluid within.

[0004] Conventionally, compressed working fluid exits the sealed pocket between the meshed scrolls through a discharge port which is regulated by a reed or check valve assembly. The reed valve assembly includes a flexible reed that flexes between an open position where the reed flexes away from the discharge port and does not obstruct the flow of compressed working fluid exiting the discharge port and a closed position where the reed covers the discharge port blocking the flow of compressed working fluid from exiting the sealed pocket between the meshed scrolls. In some known compressors, a bridge insert may be positioned between the reed and the discharge port. The bridge insert spans across the discharge port and supports a distal end of the reed reducing closing stresses on the reed, however the bridge insert requires additional manufacturing processes and increases assembly times, while reducing compressor efficiency by blocking a portion of an outlet area of the discharge port.

[0005] This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the disclosure, which are described and / or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art.SUMMARY

[0006] In one aspect, a discharge assembly for use with a compressor for compressing a working fluid is provided. The discharge assembly includes a reed valve assembly comprising a reed and a backer and a scroll including a body including a first side and an opposing second side, the first side including two or more outlets and a bridge defined between the outlets, the second side including an inlet and a spiral wrap extending therefrom. The body defines a discharge passage extending between the inlet and the outlets, wherein the reed is positionable between an open position where the reed does not obstruct the outlets and a closed position wherein the reed blocks at least a portion of the outlets and rests against the bridge.

[0007] In another aspect, a compressor is provided. The compressor includes a driveshaft, a motor operably connected to the driveshaft, and a compression mechanism connected to the driveshaft. The compression mechanism includes a scroll including a body including a first side and an opposing second side, the first side including two or more outlets and a bridge defined between the outlets, the second side including an inlet and a spiral wrap extending therefrom. The body defines a discharge passage extending between the inlet and the outlets.

[0008] Various refinements exist of the features noted in relation to the above-mentioned aspects of the present disclosure. Further features may also be incorporated in the above-mentioned aspects of the present disclosure as well. These refinements and additional features may exist individually or in any combination. For instance, various features discussed below in relation to any of the illustrated embodiments of the present disclosure may be incorporated into any of the above-described aspects of the present disclosure, alone or in any combination.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] FIG. 1 is a perspective view of an example compressor.

[0010] FIG. 2 is a cross-sectional view of the compressor shown in FIG. 1 taken along line 2-2 including a scroll assembly.

[0011] FIG. 3 is an upper perspective view of the scroll assembly removed from the compressor shown in FIG. 2.

[0012] FIG. 4 is an assembly view of the scroll assembly shown in FIG. 3 including a scroll defining a discharge passage and a reed valve assembly including a backer and a reed.

[0013] FIG. 5 is an upper perspective view of the scroll shown in FIG. 4.

[0014] FIG. 6 is a lower perspective view of the scroll shown in FIG. 4.

[0015] FIG. 7 is a top view of the scroll shown in FIG. 4.

[0016] FIG. 8 is a bottom view of the scroll shown in FIG. 4.

[0017] FIG. 9 is an upper perspective cross-sectional view of the scroll taken along line 9-9 in FIG. 7.

[0018] FIG. 10 is a lower perspective cross-sectional view of the scroll taken along line 10-10 in FIG. 7.

[0019] FIG. 11 is an upper perspective cross-sectional view of the scroll taken along line 11-11 in FIG. 7.

[0020] FIG. 12 is a lower perspective cross-sectional view of the scroll taken along line 12-12 in FIG. 7.

[0021] FIG. 13 is a perspective view of a discharge passage volume of the discharge passage formed in the scroll of the compressor shown in FIG. 1.

[0022] FIG. 14 is a perspective view of another example compressor.

[0023] FIG. 15 is a cross-sectional view of the compressor shown in FIG. 14 taken along line 14-14 including a scroll assembly.

[0024] FIG. 16 is an upper perspective view of the scroll assembly removed from the compressor shown in FIG. 15.

[0025] FIG. 17 is an assembly view of the scroll assembly shown in FIG. 16 including a scroll defining a discharge passage and a reed valve assembly.

[0026] FIG. 18 is an upper perspective view of the scroll shown in FIG. 17.

[0027] FIG. 19 is a lower perspective view of the scroll shown in FIG. 17.

[0028] FIG. 20 is a top view of the scroll shown in FIG. 17.

[0029] FIG. 21 is a bottom view of the scroll shown in FIG. 17.

[0030] FIG. 22 is an upper perspective cross-sectional view of the scroll taken along line 22-22 in FIG. 20.

[0031] FIG. 23 is a lower perspective cross-sectional view of the scroll taken along line 23-23 in FIG. 20.

[0032] FIG. 24 is a perspective view of a discharge passage volume of the discharge passage formed in the scroll of the compressor shown in FIG. 14.

[0033] FIG. 25 is a top view of another example discharge passage formed in an example scroll.

[0034] FIG. 26 is a bottom view of the scroll shown in FIG. 25.

[0035] FIG. 27 is a perspective view of a discharge passage volume of the discharge passage shown in FIG. 25.

[0036] FIG. 28 is a top view of another example discharge passage formed in an example scroll.

[0037] FIG. 29 is a bottom view of the scroll shown in FIG. 28.

[0038] FIG. 30 is a perspective view of a discharge passage volume of the discharge passage shown in FIG. 28.

[0039] FIG. 31 is a graph showing closing and opening stresses for a reed closing against the four outlets of the discharge passage of the compressor shown in FIG. 1, the two outlets of the discharge passage of the compressor of FIG. 14, and a another discharge assembly including a another reed and another discharge passage.

[0040] FIG. 32A is a perspective view of the reed illustrating the position of outlets of the discharge passage of the scroll for use in the compressor shown in FIG. 1.

[0041] FIG. 32B is a top view of contact area on the reed shown in FIG. 32A.

[0042] FIG. 32C is a bottom view of sealing distribution between the reed and the discharge passage shown in FIG. 32A.

[0043] FIG. 33 is a perspective view of compressed working fluid flow exiting the four outlets of the discharge passage of the compressor shown in FIG. 1.

[0044] FIG. 34A is a perspective view of the reed illustrating the position of outlets of the discharge passage of the scroll for use in the compressor shown in FIG. 14.

[0045] FIG. 34B is a top view of contact area on the reed shown in FIG. 34A.

[0046] FIG. 34C is a bottom view of sealing distribution between the reed and the discharge passage shown in FIG. 34A.

[0047] FIG. 35 is a perspective view of compressed working fluid flow exiting the four outlets of the discharge passage of the compressor shown in FIG. 15.

[0048] FIG. 36 is a table showing metrics for the four outlets of the discharge passage of the compressor shown in FIG. 1, the two outlets of the discharge passage of the compressor shown in FIG. 14, compared to a another discharge assembly including a another reed and a another discharge passage.

[0049] Corresponding reference characters indicate corresponding parts throughout the drawings.DETAILED DESCRIPTION

[0050] Referring to FIG. 1, a view of an example compressor is indicated generally at 100. The compressor 100 includes a compressor housing 102 forming at least one sealed cavity within which refrigerant compression is accomplished. The compressor housing 102 includes a shell 104, an end cap 106 positioned at a first end 118 of the shell 104, and a base 108 positioned at an opposing second end 120 of the shell 104. In the illustrated example, the shell 104 is cylindrical in shape and the end cap 106 and the base 108 are each generally dome-shaped, such that the compressor housing 102 has a generally oval-shaped profile. The shell 104, the end cap 106, and / or the base 108 may be differently shaped depending on a desired shape and profile of the compressor housing 102. The end cap 106 and / or the base 108 may be attached at the respective ends 118, 120 of the shell 104 using any suitable means to join components. For example, the end cap 106 and / or the base 108 may be welded or bolted to the shell 104.

[0051] The compressor 100 includes an inlet fitting 110 attached to the compressor housing 102 at an inlet opening (not shown) through which working fluid (e.g., refrigerant) enters the at least one sealed cavity formed by the compressor housing 102. For example, the working fluid is drawn into the compressor 100 via the inlet fitting 110 and compressed in the at least one sealed cavity. After the working fluid is compressed, the compressed working fluid exits the compressor 100 through a discharge opening 112. A discharge fitting 114 may be attached to the compressor housing 102 at the discharge opening 112. In the example compressor 100, the discharge opening 112 is located on the base 108, and the discharge fitting 114 is attached to the base 108 at the discharge opening 112, enabling compressed working fluid to exit a second chamber 117 (FIG. 2) defined by the base 108. In the example compressor 100, the working fluid in the second chamber 117 is at discharge pressure, and the second chamber 117 may alternatively be referred to as a discharge chamber. A discharge valve assembly (not shown) may be disposed within the discharge fitting 114 to prevent a reverse flow condition. A hermetic electric terminal 115 may also be attached to the compressor housing 102, for example, to the shell 104.

[0052] FIG. 2 is a cross-section view of the compressor 100. The compressor 100 includes the compressor housing 102 including the shell 104, the end cap 106, positioned at the first end 118 of the shell 104 and defining the first chamber 116, and the base 108, positioned at the second end 120 of the shell 104 and defining the second chamber 117. The compressor 100 also includes a motor assembly 122 and a compression mechanism (e.g., a scroll assembly), indicated generally at 204, installed in the compressor housing 102 and operably connected to the motor assembly 122.

[0053] The motor assembly 122 includes a motor stator 124 and a rotor 126. The rotor 126 may be press fit on a driveshaft 128 positioned within the compressor housing 102 and may transmit rotational power to the driveshaft 128. The motor assembly 122 may be a variable-speed motor for rotating the driveshaft 128 at any of a plurality of speeds. In the illustrated embodiment, the motor assembly 122 is disposed within the shell 104. In some other embodiments, the compressor 100 may be an open drive compressor driven by a motor assembly 122 that is disposed outside of the compressor housing 102.

[0054] The driveshaft 128 is rotatably supported within a first bearing housing assembly 206 and 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 proximate the first end 118 of the shell 104 and the second bearing housing assembly 130 is located proximate the second end 120 of the shell 104 (e.g., within the base 108). The driveshaft 128 extends through the first bearing housing assembly 206 and includes an eccentric body 132 extending axially beyond the first bearing housing assembly 206.

[0055] The first bearing housing assembly 206 includes a primary bearing 134 and the second bearing housing assembly 130 includes a secondary bearing 136. The primary and secondary bearings 134, 136 rotationally support the driveshaft 128 within the respective bearing housing assembly 206, 130. The first bearing housing assembly 206 includes the primary bearing 134 and a main bearing housing 208. The primary bearing 134 and / or the secondary bearing 136 may be rolling element bearings having an inner ring defining a bearing surface and bearing opening for receiving the driveshaft 128, an outer ring spaced radially outward from the inner ring, and a plurality of balls or rollers disposed between the inner ring and the outer ring. Alternatively, in some embodiments, the primary bearing 134 and / or secondary bearing 136 are journal bearings, and the driveshaft 128 rotationally supported by the journal bearings 134 and / or 136 within a bearing opening and relative to a stationary bearing inner surface. The primary bearing 134 and / or the secondary bearing 136 may be any suitable bearing type.

[0056] The compression mechanism 204 includes an orbiting scroll 226 and a non-orbiting scroll 228. The orbiting scroll 226 includes a generally disk-shaped orbiting plate 230 defining opposing radial surfaces. An orbiting spiral wrap 232 extends axially from one of the surfaces of the orbiting plate 230, and the surface opposite the orbiting spiral wrap 232 includes a cylindrical hub 236 extending axially therefrom. A drive bushing 239 is disposed in the cylindrical hub 236 and receives the eccentric body 132 of the driveshaft 128 that extends through the main bearing housing 208. The eccentric body 132 drivingly engages the drive bushing 239 in the cylindrical hub 236 of the orbiting scroll 226, and facilitates transmitting rotational motion of the driveshaft 128 to orbiting motion of the orbiting scroll 226 relative to the main bearing housing 208 and / or the non-orbiting scroll 228. A coupling (e.g., an Oldham coupling), not labeled, may be engaged with the orbiting scroll 226 and the main bearing housing 208 and / or the non-orbiting scroll 228 to limit or prevent relative rotation therebetween.

[0057] The non-orbiting scroll 228 includes a non-orbiting body 238 defining an upper surface 241 and an opposing lower surface 242. In some embodiments, the non-orbiting scroll 228 may include an annular wall 244. A non-orbiting spiral wrap 240 extends, generally axially, from the lower surface 242 and faces the orbiting spiral wrap 232. The non-orbiting scroll 228 also includes a raised portion 246 extending axially from the upper surface 241 of the non-orbiting body 238.

[0058] The non-orbiting spiral wrap 240 engages, or meshes, with the orbiting spiral wrap 232 of the orbiting scroll 226, defining a series of fluid pockets. Orbiting motion of the orbiting scroll 226 translates to movement of the fluid pockets defined by the spiral wraps 232 and 240, whereby the fluid pockets decrease in volume to compress working fluid in the fluid pockets. During a compression cycle of the compression mechanism 204, the fluid pockets defined by the spiral wraps 232 and 240 decrease in volume as orbiting motion of the orbiting scroll 226 translates to movement of the fluid pockets from a radially outer position 250 (at a suction pressure) to a radially intermediate position (at an intermediate pressure) to a radial inner position 252 (at a discharge pressure).

[0059] FIGS. 14-15 depicts another example compressor, indicated generally at 500, including the compression mechanism 204 including the orbiting scroll 226 and the non-orbiting scroll 228. The compressor 500 has one or more similar elements and features to the compressor 100, described above with reference to FIGS. 2-13, including similar components and features labeled with like annotation numbering.

[0060] Compressors 100 and 500 include a discharge assembly 300 including a scroll 302 and a reed valve assembly 304. At least one of the non-orbiting scroll 228 or the orbiting scroll 226 may be the scroll 302. In the illustrated embodiments, the scroll 302 is the non-orbiting scroll 228, described above. In alternative embodiments, the scroll 302 is the orbiting scroll 226.

[0061] The scroll 302 includes a discharge passage 310 defined by a discharge boundary 312, formed through the body 238 of the scroll 302, for releasing compressed working fluid (e.g., refrigerant) compressed by the compression mechanism 204. In particular, the discharge passage 310 is in communication with one of the fluid pockets defined by the spiral wraps 232 and 240 at the radial inner position 252 and allows compressed working fluid at the discharge pressure to flow into the first chamber 116.

[0062] The scroll 302 may include one or more intermediate port(s) 260 extending through the body 238. Each intermediate port 260 is located radially outward from the discharge passage 310 and allows communication with one of the fluid pockets defined by the spiral wraps 232 and 240 at the radially intermediate position. Flow of the working fluid through the intermediate ports 260 from a respective fluid pocket into the first chamber 116 may be regulated by a valve assembly 262 (e.g., a reed valve assembly) located or connected to the upper surface 241 of the body 238.) Shown in FIGS. 2 and 13. For example, the valve assembly 262 may be located adjacent the intermediate port 260 to selectively permit or restrict flow of working fluid into the first chamber 116. Additionally, and / or alternatively, one or more of the intermediate port(s) 260 may be a sensor port for receiving a sensor (e.g., a temperature sensor or a pressure sensor) for monitoring an operating parameter (e.g., temperature or pressure) within the respective fluid pocket during operation of the compression mechanism 204.

[0063] The inlet fitting 110 may be positioned at one or more different locations on the compressor housing 102 depending on the desired entry point of the working fluid within the at least one sealed cavity formed by the compressor housing 102. For example, the inlet fitting 110 may be fluidically connected to an inlet port 264 formed through the scroll assembly 204 through which working fluid is supplied to a pocket of the scroll assembly 204 at, or in proximity to, the radially outer position 250. In the embodiment illustrated in FIGS. 1-12, the inlet port 264 is formed through the upper surface 241 of the body 238 and extends generally parallel to the longitudinal axis A100. In the embodiment illustrated in FIGS. 14-23, the inlet port 264 is formed through the annular wall 244 of the scroll 302 and extends generally perpendicularly relative to the longitudinal axis A100.

[0064] Referring to FIGS. 9-12, the discharge passage 310 extends between an inlet 370 defined by an inlet boundary 372 formed on the lower surface 242 of the body 238 and an outlet 380 defined by an outlet boundary 382 formed on the upper surface 241 of the body 238. The compressed working fluid exits the space between the spiral wraps 232, 240, at the radial inner position 252, and enters into the discharge passage 310 through the inlet 370 and exits the discharge passage 310 through the outlet 380 and into the chamber 116. In the illustrated embodiment, the discharge passage 310 includes four outlets 380. In the embodiment illustrated in FIGS. 14-23, the discharge passage 310 includes a pair of outlets 380, e.g., two outlets 380. In the embodiments illustrated herein, the discharge passage 310 includes a solitary inlet 370.

[0065] Referring to FIGS. 9-12, the discharge passage 310 includes a scroll discharge port 390 and two or more discharge communication ports 392. The discharge communication ports 392 extend from a first intermediary end 394 to the outlet 380 and the scroll discharge port 390 extends from the inlet 370 to a second intermediary end 396. The scroll discharge port 390 includes a scroll discharge port depth d390 extending between the inlet 370 and the second intermediary end 396. The discharge communication ports 392 includes a discharge communication port depth d392 extending between the first intermediary end 394 and the outlet 380. FIGS. 13 and 24. In some embodiments, the discharge communication port depth d392 is longer than the scroll discharge port depth d390. In some embodiments, the discharge communication port depth d392 is approximately the same as the scroll discharge port depth d390. In the illustrated embodiment, the discharge passage 310 includes four discharge communication ports 392. The outlet depth d392 of each of the plurality of the discharge communication ports 392 may be approximately the same depth. In the embodiment illustrated in FIGS. 14-23, the discharge passage 310 includes two outlets 380 and two discharge communication ports 392. In the embodiments illustrated herein, the discharge passage 310 includes a solitary scroll discharge port 390.

[0066] In the illustrated embodiment, the discharge communication ports 392 each have a tapered bore end. Alternatively, one or more of the discharge communication ports 392 has a planar bore end. In the illustrated embodiment, each of the discharge communication ports 392 are circular in shape and have approximately the same diameter. In alternative embodiments, the discharge communication ports 392 and / or the outlets 380 may have different dimensions, e.g., different diameters or shapes.

[0067] The body 238 further includes a bridge surface 400 formed between the outlets 380. In the embodiment illustrated in FIGS. 1-12, the bridge surface 400 is disposed between the four outlets 380 and is shaped similar to a cross-shape having a central portion and four radially extending portions positioned between adjacent outlets 380. The radially extending portions of the cross-shape may include one or more concave portions shaped complementary to an arched boundary of the adjacent outlets 380.

[0068] FIGS. 13, 24, 27, and 30 illustrate a discharge volume of the discharge passage 310 defined by the discharge boundary 312. In some embodiments, at least a portion of the discharge communication ports 392 are not in alignment, in an axial direction and / or a radial direction, with the respective scroll discharge port 390. For example, a width and / or a diameter of the scroll discharge port 390 may be less than a width and / or diameter of an outer perimeter 408 surrounding the plurality of discharge communication ports 392.

[0069] In the embodiments illustrated in FIGS. 14-23, the bridge surface 400 spans between the two outlets 380. In reference to FIGS. 25-30, the outlets 380 and the bridge surface 400 may have alternative shapes and / or dimensions. For example, in some alternative embodiments, the outlets 380 have an oval or bean shape and the bridge surface 400 includes an annular portion. FIGS. 25-27. In some other alternative embodiments, the bridge is T-shaped and the outlets 380 are wedge shaped. FIG. 28-30.

[0070] The reed valve assembly 304, mounted to the upper surface 241 of the body 238, regulates compressed working fluid exiting the discharge passage 310 through the outlets 380. The reed valve assembly 304 includes a reed 410, a backer 412, and the reed valve assembly 304 may be mounted to the compressor 100 using any suitable fastener 414. When the reed valve assembly 304 is mounted to the upper surface 241, the reed 410 is disposed between the upper surface 241 and the backer 412. A portion of the reed 410 may bend between a closed position and an open position. When the reed 410 is in the closed position the reed 410 substantially obstructs the discharge passage 310, e.g., each of the outlets 380, and the reed 410 may be in contact with the upper surface 241 on or around the outer perimeter 408 surrounding the outlets 380. When the reed 410 is in the open position the reed 410 does not substantially obstruct the outlets 380 of the discharge passage 310. For example, when the reed 410 is in the open position at least a portion of the reed 410 may be flexed away from the upper surface 341 towards an arched portion 420 of the backer 212.

[0071] FIGS. 32A-C and FIGS. 34A-C illustrate the position of the outlets 380 relative to an outer boundary 422 of the reed 410. The reed 410 is sized and shaped such that the reed 410 covers all of the outlets 380 of the discharge passage 310 when the reed 410 is arranged in the closed position. In the illustrated embodiment, the reed 410 includes an outer boundary 422 and each of the four outlets 380 are contained within the boundary 422 and spaced a clearance distance Cd to the perimeter 480, when the reed 410 is arranged in the closed position. In the embodiments shown in FIGS. 32A-C, two of the outlets 380 include a center that is parallel to a longitudinal axis of the reed 410 and two of the outlets 380 have a center that is perpendicular to the longitudinal axis of the reed 410. In other embodiments, the plurality of outlets 380 may have different arrangements or patterns relative to the outer boundary 422 of the reed 410.

[0072] FIGS. 32B and 34B show the distribution of closing stresses on the reed 410, the bridge surface 400 supports a distal end of the reed 410 reducing an unsupported length of the reed 410 thereby reducing closing and opening stresses of the reed 410. In addition, contact between the reed 410 and the bridge surface 400 prevents the reed 410 from flexing into the discharge passage 310 improving the seal between the reed 410 and the outlets 380 of the discharge passage 310.

[0073] Referring to FIGS. 32C and 34C which shows a sealing profile between the reed 410 and the outlets 380, when the reed 410 is in the closed position, and the reed 410 covers the plurality of outlets 380, the reed 410 contacts, and is in sealing engagement with, the bridge surface 400 as well as the outer perimeter 408 surrounding the plurality of outlets 380.

[0074] In some embodiments, the scroll 302 includes a recessed area 430 defined by a recessed boundary 432 formed in the upper surface 241 of the scroll 302. The outlets 380 are positioned within the recessed area 430 and surrounded by the recessed boundary 432. The outer boundary 422 of the reed 410 extends beyond the recessed boundary 432 such that at least a portion of the reed 410 may rest on the upper surface 241 of the scroll 302 in an area surrounding the recessed area 430. The reed 410 may be flexible such that at least a portion of the reed 410 may flex into the recessed area 430 and at least a portion of the reed 410 rests on and / or is in sealing engagement with the area surrounding the outlets 380 and the bridge surface 400, ensuring a seal between the reed 410 and an area surrounding the recessed boundary 432 while the reed 410 is supported by the bridge surface 400.

[0075] Referring again to FIGS. 8 and 19, the inlet boundary 372, defining the inlet 370 of the discharge passage 310, is sized and shaped to be positioned adjacent to the radially inner position of the spiral wrap 240. For example, the inlet boundary 372 defining the inlet 370 may be generally kidney shaped having a portion that is arched similar to an arched portion of the scroll 340 and an indented portion shaped complementary to a central end of the scroll 340.

[0076] FIG. 33 is a perspective view of compressed working fluid flow exiting the four outlets 380 of the discharge passage 310 of the compressor 100, shown in FIG. 1. The working fluid exits the four outlets 380 such that the working fluid flows in 360° radially outward from the scroll assembly 204. FIG. 35 is a perspective view of compressed working fluid flow exiting the two outlets 380 of the discharge passage 310 of the compressor 500, shown in FIG. 14. The working fluid exits the two outlets 380 such that the working fluid flows in 120° radially outward from the scroll assembly 204.

[0077] FIG. 31 is a graph showing the driver opening and closing stress of the reed during operation and the fatigue acceptance criteria including an acceptable region. For the embodiments described herein, the scroll assemblies including the plurality of outlets 380, are contained within the acceptable region.

[0078] FIG. 36 is a table showing metrics for the four outlets 380 of the discharge passage 310 of the compressor 100, shown in FIG. 1, the two outlets 380 of the discharge passage 310 of the compressor 500 shown in FIG. 14, compared to a another discharge assembly including another reed and another discharge passage. One or more discharge parameters, e.g., mass flow, pressure, refrigerant density, may be the same or approximately the same, between a conventional HVE reed, and embodiments including the two outlets 380 and embodiments including the four outlets 380. In some embodiments, the discharge passage may include multiple restrictions. For example, working fluid may flow around the reed when the reed is in the open position, and then the working fluid may flow through a port. The restrictions may be in series. The effective flow area is calculated based on, at least in part, the restrictions around the open valve. The pressure difference and the power loss are based on a pressure difference across the open valve are also presented in FIG. 38.

[0079] In embodiments described herein, the scroll defining a discharge passage includes a bridge that supports a portion of the reed reducing the closing stresses on the reed while improving sealing engagement between the reed and boundaries of outlets of the discharge passage. In embodiments described herein the scroll includes a bridge spanning between two or more outlets to the discharge passage. The bridge is formed integrally with the scroll and does not require additional manufacturing processes or assembly of additional components.

[0080] Embodiments of the scroll described herein including the bridge, reduces an unsupported span length of the reed while maintaining the flow area of the outlets. Embodiments of the scroll described herein includes a recessed area, surrounding the outlets of the discharge passage, which has a footprint contained within an outer boundary of the reed such that at least a portion of the reed flexes into the recessed area improving the seal between the reed and the boundary of the recessed area.

[0081] As used herein, the terms “about,”“substantially,”“essentially” and “approximately” when used in conjunction with ranges of dimensions, concentrations, temperatures or other physical or chemical properties or characteristics is meant to cover variations that may exist in the upper and / or lower limits of the ranges of the properties or characteristics, including, for example, variations resulting from rounding, measurement methodology or other statistical variation.

[0082] When introducing elements of the present disclosure or the embodiment(s) thereof, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,”“including,”“containing” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. The use of terms indicating a particular orientation (e.g., “top”, “bottom”, “side”, etc.) is for convenience of description and does not require any particular orientation of the item described.

[0083] As various changes could be made in the above constructions and methods without departing from the scope of the disclosure, it is intended that all matter contained in the above description and shown in the accompanying drawing[s] shall be interpreted as illustrative and not in a limiting sense.

Examples

Embodiment Construction

[0050]Referring to FIG. 1, a view of an example compressor is indicated generally at 100. The compressor 100 includes a compressor housing 102 forming at least one sealed cavity within which refrigerant compression is accomplished. The compressor housing 102 includes a shell 104, an end cap 106 positioned at a first end 118 of the shell 104, and a base 108 positioned at an opposing second end 120 of the shell 104. In the illustrated example, the shell 104 is cylindrical in shape and the end cap 106 and the base 108 are each generally dome-shaped, such that the compressor housing 102 has a generally oval-shaped profile. The shell 104, the end cap 106, and / or the base 108 may be differently shaped depending on a desired shape and profile of the compressor housing 102. The end cap 106 and / or the base 108 may be attached at the respective ends 118, 120 of the shell 104 using any suitable means to join components. For example, the end cap 106 and / or the base 108 may be welded or bolted t...

Claims

1. A discharge assembly for use with a compressor for compressing a working fluid, the discharge assembly comprises:a reed valve assembly comprising a reed and a backer; anda scroll including a body including a first side and an opposing second side, the first side including two or more outlets and a bridge defined between the outlets, the second side including an inlet and a spiral wrap extending therefrom, the body defines a discharge passage extending between the inlet and the outlets, wherein the reed is positionable between an open position where the reed does not obstruct the outlets and a closed position wherein the reed blocks at least a portion of the outlets and rests against the bridge.

2. The discharge assembly of claim 1, wherein the discharge passage includes a first portion extending from the inlet to a first intermediary end and a second portion extending from a second intermediary end to the outlets, wherein the first and second intermediary ends are positioned halfway between the first side and second side of the body.

3. The discharge assembly of claim 1, wherein the discharge passage includes a first portion extending from the inlet to a first intermediary end and a second portion extending from a second intermediary end to the outlets, wherein the first portion of the discharge passage is a solitary passage.

4. The discharge assembly of claim 1, wherein the discharge passage includes a first portion extending from the inlet to a first intermediary end and a second portion extending from a second intermediary end to the outlets, wherein at least a portion of the first portion of the discharge passage is not aligned with the second portion of the discharge passage.

5. The discharge assembly of claim 1, wherein the discharge passage includes a first portion extending from the inlet to a first intermediary end and a second portion extending from a second intermediary end to the outlets, wherein the first intermediary end and the second intermediary end are spaced apart such that the first portion and the second portion overlap along an axial direction.

6. The discharge assembly of claim 1, wherein at least a portion of the inlet is shaped complementary to a portion of the spiral wrap.

7. The discharge assembly of claim 1, wherein the outlets include a pair of outlets separated by the bridge.

8. The discharge assembly of claim 1, wherein the outlets include a first pair of outlets and a second pair of outlets separated by the bridge.

9. The discharge assembly of claim 1, wherein the bridge is cross-shaped.

10. The discharge assembly of claim 1, wherein the outlets are circular in shape.

11. The discharge assembly of claim 1, wherein the bridge is formed integrally with the body.

12. A compressor comprising:a driveshaft;a motor operably connected to the driveshaft; anda compression mechanism connected to the driveshaft, wherein the compression mechanism includes a scroll including a body including a first side and an opposing second side, the first side including two or more outlets and a bridge defined between the outlets, the second side including an inlet and a spiral wrap extending therefrom, the body defines a discharge passage extending between the inlet and the outlets.

13. The compressor of claim 12, wherein the discharge passage includes a first portion extending from the inlet to a first intermediary end and a second portion extending from a second intermediary end to the outlets, wherein the first and second intermediary ends are positioned halfway between the first side and second side of the body.

14. The compressor of claim 12, wherein the discharge passage includes a first portion extending from the inlet to a first intermediary end and a second portion extending from a second intermediary end to the outlets, wherein the first portion of the discharge passage is a solitary passage.

15. The compressor of claim 12, wherein the discharge passage includes a first portion extending from the inlet to a first intermediary end and a second portion extending from a second intermediary end to the outlets, wherein at least a portion of the first portion of the discharge passage is not aligned with the second portion of the discharge passage.

16. The compressor of claim 12, wherein the discharge passage includes a first portion extending from the inlet to a first intermediary end and a second portion extending from a second intermediary end to the outlets, wherein the first intermediary end and the second intermediary end are spaced apart such that the first portion and the second portion overlap along an axial direction.

17. The compressor of claim 12, wherein at least a portion of the inlet is shaped complementary to a portion of the spiral wrap.

18. The compressor of claim 12, wherein the outlets include a pair of outlets separated by the bridge.

19. The compressor of claim 12, wherein the outlets include a first pair of outlets and a second pair of outlets separated by the bridge.

20. The compressor of claim 19, wherein the bridge is cross-shaped.

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