Scroll decompressor

Abstract

A scroll decompressor includes a cap portion, a body portion, an oil management system, and a sealing mechanism disposed between the cap portion and the body portion. The cap portion includes a scroll assembly and a set of oil separators. The scroll assembly is configured to receive a refrigerant at a first pressure and output the refrigerant at a second pressure that is lower than the first pressure. The set of oil separators is configured to reduce a velocity of the refrigerant exiting the scroll assembly. The body portion includes a top side facing the cap portion and a set of openings formed in the top side. The oil management system is configured to control oil movement between the cap portion and the body portion. The sealing mechanism is configured to block the set of openings.

Description

Atorney Docket No. 59121-103SCROLL DECOMPRESSORCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of US Prov. App. No. 63 / 866,968, filed August 19, 2025 (Atty. Docket No. 59121-98) and US Prov. App. No. 63 / 698,035, filed September 23, 2024 (Atty. Docket No. 59121-6). The entire disclosures of the above applications are incorporated by reference.FIELD

[0002] The present disclosure relates to a scroll decompressor and more particularly to a scroll compressor that is modified to function as a scroll decompressor.BACKGROUND

[0003] The Rankine cycle is a thermodynamic cycle in which heat is converted into work. The heat is supplied externally to a closed loop, typically with water as the working fluid. The Rankine cycle generates about 80% of all electric power used throughout the world, and is used by solar thermal, biomass, coal and nuclear power plants. Rankine-cycle power systems typically transform thermal energy into electrical energy. A conventional Rankine cycle power system employs the following four basic steps: (1) thermal energy is used, in a boiler, to turn water into steam; (2) the steam is sent through a turbine, which, in turn, drives an electric generator; (3) the steam is condensed back into water by discharging the remaining thermal energy in the steam to the environment; and (4) the condensate is pumped back to the boiler. In an ideal Rankine cycle, the expansion is isentropic (i.e., at constant entropy) and the evaporation and condensation processes are isobaric (i.e., at constant pressure). However, irreversibilities in real processes lower cycle efficiency. Those irreversibilities are primarily attributable to two factors: conversion of some energy into heat during expansion of the working fluid during step (2) of the cycle; and inefficiency caused by pressure drops in the heat exchangers during steps (1) and (3).

[0004] During expansion of the working fluid in step (2), only a part of the energy recoverable from the pressure difference is transformed into useful work. The other part is converted into heat and is lost. The efficiency of the expander is stated as a percentage of work that would be performed by a theoretical isentropic expansion, in which entropy remains constant.

[0005] The Organic Rankine Cycle (ORC) has been developed to enable recovery of energy from lower-temperature sources, such as industrial waste heat, geothermal heat, solar ponds, and so forth. The ORC is named for its use of an organic, high-molecular-mass fluid having a liquid-Atorney Docket No. 59121-103 vapor phase change (referred to as a boiling point) that occurs at a lower temperature than the water-steam phase change. Using the ORC, low-temperature heat (e.g., waste heat) can be converted to useful work, which, for example, can be harnessed to generate electricity. For example, the ORC can be applied to heat and power plants, industrial and farming processes (e.g., organic products fermentation), hot exhausts from ovens or furnaces, flue gas condensation, exhaust gases from vehicles, intercooling of a compressor, and the condenser of a power cycle. ORC can also be used to extract useful energy from biomass, geothermal heat sources, solar fields, etc.

[0006] The background description provided here is for the purpose of generally presenting the context of the disclosure. Work of the presently named inventors, to the extent it is described in this background section, as well as aspects of the description that may not otherwise qualify as prior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present disclosure.SUMMARY

[0007] One aspect of the present disclosure provides a scroll decompressor. The scroll decompressor includes a cap portion, a body portion, an oil management system, and a sealing mechanism disposed between the cap portion and the body portion. The cap portion includes a scroll assembly and a set of oil separators. The scroll assembly configured to receive a refrigerant at a first pressure and output the refrigerant at a second pressure that is lower than the first pressure. The set of oil separators is configured to reduce a velocity of the refrigerant exiting the scroll assembly. The body portion includes a top side facing the cap portion and a set of openings formed in the top side. The oil management system is configured to control oil movement between the cap portion and the body portion. The sealing mechanism is configured to block the set of openings.

[0008] Another aspect of the present disclosure provides a method. The method includes obtaining a scroll compressor that includes a cap portion including a scroll assembly, and a body portion in fluid communication with the cap portion. The body portion includes a top side facing the cap portion and a set of openings formed in the top side. The method further includes separating the cap portion from the body portion. The method further includes installing an oil management system on the scroll compressor. The oil management system is configured to control oil movement between the cap portion and the body portion. The method further includes installing a sealing mechanism between the cap portion and the body portion. The sealing mechanism is configured to configured to block the set of openings. The method further includes installing a set of oil separators in the cap portion. The set of oil separators isAtorney Docket No. 59121-103 configured to reduce a velocity of a refrigerant exiting the scroll assembly. The method further includes reattaching the cap portion to the body portion.

[0009] Further areas of applicability of the present disclosure will become apparent from the detailed description, the claims, and the drawings. The detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the disclosure.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The present disclosure will become more fully understood from the detailed description and the accompanying drawings.

[0011] FIG. 1 is a schematic diagram of a system including a heat engine according to the principles of the present disclosure.

[0012] FIG. 2 is a pump and dump well system according to the principles of the present disclosure.

[0013] FIG. 3 is a scroll decompressor according to the principles of the present disclosure.

[0014] FIG. 4 is a perspective view of a cooling system of the scroll decompressor of FIG. 3.

[0015] FIG. 5 is an exploded view of a scroll assembly of the scroll decompressor of FIG. 3.

[0016] FIG. 6 is a perspective view of a system including multiple scroll decompressors according to the principles of the present disclosure.

[0017] FIG. 7 is a flowchart of a method of converting a scroll compressor to function as a scroll decompressor.

[0018] In the drawings, reference numbers may be reused to identify similar and / or identical elements.DETAILED DESCRIPTIONSYSTEM

[0019] FIG. 1 illustrates a system 100 for generating electrical energy from heat. In various implementations, the system 100 includes a heat engine 200, a heat source 600, and a heat sink 800. As will be described in more detail below, the heat engine 200 generates electrical energy from heat produced by the heat source 600 and is cooled by the heat sink 800.HEAT SOURCE

[0020] The heat source 600 may be any source or system that produces heat — a fluid or vapor at a temperature above the ambient temperature of the system 100 — and provides the produced heat to the heat engine 200. The heat source 600 does not need to be at a temperature as high asAtorney Docket No. 59121-103 those required in conventional systems. As will be discussed in more detail below, the heat engine 200 may be used to extract energy from heat sources that are traditionally not used for electrical energy generation. In various implementations, the heat source 600 is a low- temperature heat source. In this regard, the heat source 600 may have a temperature of less than 100 °C, less than 90 °C, less than 80 °C, less than 70 °C, less than 60 °C, or even less than 50 °C. The heat source 600 may be a waste heat source, an exhaust gas, a compressor intercooler, biomass, a geothermal heat source, a solar array, a chiller, a heat pump, a transformer, a data center, or any combination thereof.

[0021] In various implementations, the system 100 includes a hot thermal battery 700. The hot thermal battery 700 may provide heat to the heat engine 200 to ensure continued operation of the heat engine 200. For example, at various times, the heat source 600 may temporarily produce no heat or not enough heat to power the heat engine 200. During these times, the hot thermal battery 700 may replace or supplement the heat provided by the heat source 600. In various implementations, the hot thermal battery 700 is a hot water tank.HEAT SINK

[0022] The heat sink 800 may be any system that provides a cool fluid — a fluid or vapor at a sufficiently low temperature to extract heat from the heat engine 200 — to the heat engine 200. In various implementations, the heat sink 800 is a pump and dump geothermal well cooling system. The heat sink 800 may be referred to herein as the pump and dump geothermal well cooling system 800, or simply the well cooling system 800.

[0023] In FIG. 2, an example of the well cooling system 800 includes an underground water supply 810, a supply pipe 820, a supply pump 830, and a reinjection pipe 840. The supply pump 830 may be powered by a portion of the electrical energy generated by the heat engine 200. The supply pump 830 may pump water from the underground water supply 810 to the heat engine 200. In this regard, water will flow through the supply pipe 820 from the underground water supply 810 to the heat engine 200. Water will then exit the heat engine 200 and flow through the reinjection pipe 840 back into the underground water supply 810. As the water flows through the heat engine 200, the temperature of the water may rise as the water extracts heat from the heat engine 200. Regulatory agencies may require that the water does not suffer a temperature rise beyond local regulations and that net water consumption is minimal or zero. For example, the rise in water temperature may be limited to a threshold of between 1 °C and 18 °C to comply with local regulations.

[0024] In various implementations, the supply pipe 820 has a circular cross-section defining a first diameter DI and the reinjection pipe 840 has a circular cross-section defining a secondAtorney Docket No. 59121-103 diameter D2. The second diameter D2 may be larger than the first diameter D 1. The second diameter D2 being larger than the first diameter DI increases the siphoning effect throughout the well cooling system 800, which, in turn, increases the suction pressure to suck water from the underground water supply 810 and decreases the amount of pumping energy required from the supply pump 830.

[0025] In various implementations, the well cooling system 800 includes an intermediate heat exchanger 850 between the supply pump 830 and the heat engine 200. The intermediate heat exchanger 850 may be used when the water is prevented from direct flow through the heat engine 200, such as in response to water quality concerns.

[0026] Referring back to FIG. 1, in various implementations, the system 100 includes a cold thermal battery 900. The cold thermal battery 900 may ensure sufficient cooling of the heat engine 200 during operation. For example, at various times, the heat sink 800 may temporarily provide no cooling or not enough cooling to sufficiently cool the heat engine 200. During these times, the cold thermal battery 900 may replace or supplement the cooling provided by the heat sink 800. In various implementations, the cold thermal battery 900 is a cold water tank.HEAT ENGINE

[0027] The heat engine 200 may use the Rankine Cycle to generate electrical energy. The heat engine 200 may include a sealed, closed-loop path 210 for a refrigerant 220. In various implementations, the refrigerant 220 is an organic refrigerant having a boiling point below -30° C, such as R-410A, R-454B, R-454C, R-22, R-502, R-507, R-13, R-503, R-23, R-717 (ammonia), or R-744 (carbon dioxide (CO2)). When the refrigerant 220 is an organic refrigerant, the heat engine 200 may be called an Organic Rankine Cycle (ORC) heat engine.

[0028] The sealed, closed-loop path 210 may include a high-pressure zone 230 having a first portion of the refrigerant 220 at a first temperature T1 and a first pressure Pl and a low-pressure zone 240 having a second portion of the refrigerant 220 at a second temperature T2 and a second pressure P2. The second temperature T2 and the second pressure P2 are lower than the first temperature T1 and the first pressure Pl, respectively. The first temperature T1 may be above the boiling point of the refrigerant 220, so that the refrigerant 220 is, at least partially, in a vapor phase in the high-pressure zone 230. The second temperature T2 may be below the boiling point of the refrigerant 220, so that the refrigerant 220 is, at least partially, in a liquid phase in the low-pressure zone 240. The pressure differential between the first pressure Pl and the second pressure P2 may be between 20 bar and 42 bar.

[0029] The high-pressure zone 230 and the low-pressure zone 240 may be separated by a pump 250 and a decompressor 300. The pump 250 may pump the refrigerant 220 from the low-Atorney Docket No. 59121-103 pressure zone 240 to the high-pressure zone 230. As described in more detail below, as the refrigerant 220 flows through the decompressor 300, the decompressor 300 decompresses the refrigerant 220 from the first pressure Pl to the second pressure P2, thereby creating electrical energy. A portion of the electrical energy generated by the decompressor 300 may be used to power the pump 250.

[0030] The high-pressure zone 230 may include an evaporator 260 and the low-pressure zone 240 may include a condenser 270. The evaporator 260 may absorb heat from the heat source 600. As the refrigerant 220 flows through the evaporator 260, the refrigerant 220 may be heated by the heat from the heat source 600. As the refrigerant 220 flows through the condenser 270, the refrigerant 220 may be cooled by the cool fluid from the heat sink 800.SCROLL DECOMPRESSOR

[0031] In various implementations, the decompressor 300 is a scroll decompressor. For example, the decompressor 300 may be a commercially available scroll compressor (such as from Danfoss, Trane, Emerson Electric, Bristol, Copeland, Bitzer, etc.) that has been modified, as described in more detail below, and operated in reverse to function as a scroll decompressor.

[0032] As seen in FIGS. 3, 4, and 5, the decompressor 300 may include a cap portion 400 and a body portion 500. The body portion 500 may be coupled to the cap portion 400. As will be described in more detail below, the body portion 500 may be sealed off from the cap portion 400, such that fluid (the refrigerant 220 or oil) cannot directly flow between the cap portion 400 and the body portion 500.

[0033] The cap portion 400 may include a high-pressure inlet 410, a low-pressure outlet 420, a scroll assembly 430, and a set of oil separators 440. In a traditional scroll compressor, a low- pressure working fluid would flow into the body portion 500 through an inlet, into the scroll assembly 430, where it is compressed, and a high-pressure working fluid would flow out of an outlet in the cap portion 400. To modify the scroll compressor to be a decompressor, the high- pressure inlet 410 is added to the cap portion 400 and the body portion 500 is sealed, such that the working fluid (in some cases, the refrigerant 220) does not flow through the body portion 500. Instead, during operation of the decompressor 300, the refrigerant 220 flows through only the cap portion 400.

[0034] The high-pressure inlet 410 may be connected to the high-pressure zone 230 at one end and the scroll assembly 430 at the other end. The low-pressure outlet 420 may be connected to the low-pressure zone 240. During operation of the heat engine 200, refrigerant 220 may flow from the high-pressure zone 230 into the high-pressure inlet 410 and into the scroll assembly 430. The refrigerant 220 expands within the scroll assembly 430 and flows out of the scrollAtorney Docket No. 59121-103 assembly 430, through the set of oil separators 440, out of the low-pressure outlet 420, and into the low-pressure zone 240.

[0035] In various implementations, the decompressor 300 includes a valve 425 disposed at the opening of the low-pressure outlet 420. In various implementations, the valve 425 is a one-way valve or check valve. In various implementations, the valve 425 allows the refrigerant 220 to flow out of the decompressor 300 through the low-pressure outlet 420 and prevents the refrigerant 220 from flowing into the decompressor 300 through the low-pressure outlet 420.

[0036] The scroll assembly 430 may include a stationary scroll 432 and a moving scroll 434. During operation of the decompressor 300, the moving scroll 434 may move relative to the stationary scroll 432. In various implementations, the moving scroll 434 moves in an orbital motion relative to the stationary scroll 432.

[0037] In traditional scroll compressors, the scroll assembly 430 may have more than one inlet and / or more than one outlet for the working fluid to flow through. For example, a scroll assembly 430 in a traditional scroll compressor may have one or more intermediate discharge valves (IDVs) that increase the efficiency of the scroll compressor. In the decompressor 300, the one or more IDVs may be blocked (e.g., by a plug or blocking plate) so that the scroll assembly 430 has only one inlet and only one outlet. This may increase the efficiency of the decompressor 300.

[0038] As described in more detail below, oil may be used to lubricate the scroll assembly 430. As the refrigerant 220 flows through the scroll assembly 430, the refrigerant 220 may mix with the oil used to lubricate the scroll assembly 430. If too much oil is mixed with the refrigerant 220, the refrigerant 220 may lose its heat transfer properties that make it an effective working fluid for the heat engine 200 and cause the heat engine 200 to no longer function properly. Additionally, if too much oil is carried out of the decompressor 300, the decompressor 300 will eventually run out of oil, causing the scroll assembly 430 to stop working from lack of lubrication.

[0039] The set of oil separators 440 may be disposed between the scroll assembly 430 and the low-pressure outlet 420. The refrigerant 220 may exit the scroll assembly 430 at a high velocity and the set of oil separators 440 may reduce the velocity of the refrigerant 220 prior to the refrigerant 220 exiting the cap portion 400. Reducing the velocity of the refrigerant 220 may cause the oil to fall out of suspension with the refrigerant 220 and collect on a bottom side 450 of the cap portion. The set of oil separators 440 may reduce the velocity of the refrigerant 220 by forcing the refrigerant 220 to travel along a path that is longer than a direct path from the scroll assembly 430 to the low-pressure outlet 420.Atorney Docket No. 59121-103

[0040] Each of the set of oil separators 440 may include at least one of a sloped plate, a helical coil through which the refrigerant 220 flows, or a metal mesh through which the refrigerant 220 flows. In various implementations, the set of oil separators 440 includes three sloped plates. A first sloped plate 440-1 may extend in a first direction. A second sloped plate 440-2 may extend in a second direction transverse to the first direction. A third sloped plate 440-3 may extend in a third direction substantially (+ / - 10 degrees) parallel to the first direction.

[0041] In various implementations, the decompressor 300 includes an oil separator external to the cap portion 400 in addition to or instead of the set of oil separators 440.

[0042] The body portion 500 may include a generator 520 and an oil reservoir 540. The generator 520 may be coupled to the scroll assembly 430 by a shaft 525. As the refrigerant 220 flows through the scroll assembly 430, movement of the scroll assembly 430 may turn the shaft 525, thereby creating mechanical work. The generator 520 may generate electrical energy from the mechanical work of the shaft 525.

[0043] The oil reservoir 540 may hold oil that is used to lubricate the generator 520 and the scroll assembly 430. In various implementations, the shaft 525 extends into the oil reservoir 540 and oil travels up the shaft 525 to lubricate the generator 520 and the scroll assembly 430. In various implementations, the oil reservoir 540 includes an oil level sensor 545. The oil level sensor 545 may sense or measure an amount of oil remaining in the oil reservoir 540. The oil level sensor 545 may shut down operation of the decompressor 300 when the amount of oil remaining in the oil reservoir 540 falls below a threshold amount. In various implementations, the oil level sensor 545 is a float level sensor, a pneumatic sensor, an ultrasonic sensor, a conductive sensor, or any combination thereof.

[0044] In various implementations, the decompressor 300 includes a sealing mechanism 350 disposed between the cap portion 400 and the body portion 500. The sealing mechanism 350 may anything that separates the cap portion 400 from the body portion 500, such that the cap portion 400 and the body portion 500 are not in fluid communication with one another. In a traditional scroll compressor, the cap portion 400 and the body portion 500 are in fluid communication with one another. For example, the body portion 500 may include a set of apertures 555 formed in atop surface 550 of the body portion 500 that faces the cap portion 400 and the cap portion 400 and the body portion 500 may be in flid communication through the set of apertures 555. The sealing mechanism 350 may at least partially block the set of apertures 555. In various implementations, the sealing mechanism 350 completely blocks the set of apertures 555. In various implementations, the sealing mechanism 350 is a sealing plate, such a metal plate. As discussed above, during operation of the decompressor 300, the refrigerant 220Atorney Docket No. 59121-103 only flows through the cap portion 400 since refrigerant entering the body portion 500 and mixing with the oil may negatively impact the functioning of the heat engine 200.

[0045] In various implementations, the decompressor 300 includes an oil management system 370 that controls oil movement between the cap portion 400 and the body portion 500. For example, the oil management system 370 may selectively move oil from the cap portion 400 to the body portion 500. In various implementations, the oil management system 370 returns oil captured by the set of oil separators 440 to the oil reservoir 540. As discussed above, oil captured by the set of oil separators 440 collects on the bottom side 450 of the cap portion 400 and has no way to return to the oil reservoir 540 because the cap portion 400 and the body portion 500 are separated by the sealing mechanism 350. In various implementations, the oil management system 370 prevents movement of oil from the body portion 500 to the cap portion 400.

[0046] The oil management system 370 may include a pipe 372 that connects to the cap portion 400 at a first end 374 of the pipe 372 and that connects to the body portion 500 at a second end 376 of the pipe 372. The oil may flow from the cap portion 400 to the body portion 500 through the pipe 372. The oil management system 370 may also include a valve 378 placed in line with the pipe 372 between the first end 374 and the second end 376. The valve 378 may open when it detects oil and close when no oil is detected. In various implementations, the valve 378 is a one-way valve that only allows oil to flow from the cap portion 400 to the body portion 500.

[0047] In various implementations, the decompressor 300 includes a cooling system 320 to cool the generator 520. In a traditional scroll compressor, the generator 520 is cooled by the cold working fluid that enters the scroll compressor through the body portion 500. In the decompressor 300, no refrigerant 220 flows through the body portion 500 and, even if it did, the refrigerant is at a high temperature when it enters the decompressor 300.

[0048] The cooling system 320 may include a coil 322 wrapped around an exterior surface of the generator 520 and / or the body portion 500. In other words, the cooling system 320 may surround the exterior surface of the generator 520 and / or the body portion 500. A first end 324 of the coil 322 may be connected to the low-pressure zone 240 of the sealed, closed loop path and a second end 326 of the coil 322 may be connected to the high-pressure zone 230 of the sealed, closed-loop path 210. The cooling system 320 may include a bypass valve 328 disposed between the first end 324 and the point where the coils begins to wrap around the generator 520 and / or the body portion 500. During operation of the heat engine 200, a portion of the cool refrigerant 220 from the low-pressure zone 240 is pumped through the coil 322. As the refrigerant 220 makes its way through the coil, the refrigerant 220 absorbs heat created by theAtorney Docket No. 59121-103 generator 520 to keep the generator 520 cool. The hot refrigerant exits the coil 322 and the second end 326 and mixes with the remaining hot refrigerant 220 in the high-pressure zone 230.

[0049] The electrical energy produced by the decompressor 300 may be used to power one or more auxiliary systems 150. In various implementations, the auxiliary system 150 is also the heat source 600. For example, the heat source 600 may be a data center that produces heat and the electrical energy produced by the decompressor 300 is used to power the data center. In various implementations, the auxiliary system 150 is an electric vehicle charging station. In various implementations, the decompressor 300 can synchronize with the electric grid and provide the electrical energy directly back to the electric grid.

[0050] As shown in FIG. 6, in various implementations, the heat engine 200 includes more than one decompressor 300. Using multiple decompressors 300, the heat engine 200 may produce more electrical energy than by using a single decompressor 300.BYPASS MECHANISM

[0051] As illustrated in FIGS. 1 and 3, the heat engine 200 may include a bypass mechanism 280 disposed between the evaporator 260 and the decompressor 300. In various implementations, the bypass mechanism is attached to the high-pressure inlet 410 of the decompressor 300. The bypass mechanism 280 operates between an open position and closed position. In the open position, the bypass mechanism 280 allows the refrigerant 220 to flow through the bypass mechanism 280 into the decompressor 300. In the closed position, the bypass mechanism 280 reroutes the refrigerant 220 through a bypass path 290 that sends the refrigerant 220 into the low-pressure zone 240. In other words, when the bypass mechanism 280 is in the closed position, the bypass mechanism 280 prevents refrigerant 220 from flowing into the decompressor 300. In various implementations, in the closed position, the bypass mechanism 280 reroutes the refrigerant through the low-pressure outlet 420 of the decompressor 300.

[0052] In various implementations, when the bypass mechanism 280 switches to the closed position, the bypass mechanism 280 opens a first valve that allows the refrigerant 220 to flow into the bypass path 290. In various implementations, the pressure from the refrigerant already in the decompressor 300 when the bypass mechanism 280 switches to the closed position forces any refrigerant entering the high-pressure inlet 410 to flow through the bypass path 290. In various implementations, the first valve is a pressure sensitive valve that only opens when the pressure from the refrigerant 220 inside the bypass mechanism exceed a threshold pressure. In various implementations, in addition to opening the first valve, the bypass mechanism 280 closes a second valve that seals off the high-pressure inlet 410 when the bypass mechanism 280 switches to the closed position. With the high-pressure inlet 410 sealed off, the refrigerant mustAtorney Docket No. 59121-103 flow through the bypass path 290. In various implementations, the refrigerant 220 flowing through the bypass path 290 and out of the low-pressure outlet 420 is prevented from flowing back into the decompressor 300 by the valve 425.

[0053] The bypass mechanism 280 prevents the decompressor 300 from entering a runaway state, which is when the decompressor 300 runs faster than its designed speed. If the decompressor speed, usually measured in revolutions per minute (RPM), is higher than the designed speed, system problems may result. Further, if the decompressor speed is higher than a maximum speed, the decompressor 300 itself may be damaged, up to and including a catastrophic mechanical failure.

[0054] In various implementations, the bypass mechanism 280 is a bypass solenoid, such as a continuous duty solenoid that is held in the open position by an electromagnet. As a result, if power is lost, the bypass solenoid closes. This prevents the decompressor 300 from operating without a working bypass mechanism 280, which may prevent failure of the decompressor 300 that could have been avoided if the bypass mechanism 280 was functioning.

[0055] In various implementations, the bypass mechanism 280 normally operates in the open position and switches from the open position to the closed position in response to a control signal. In various implementations, the bypass mechanism 280 may generate its own control signal in response to a determination that the decompressor 300 is entering or may be about to enter a runaway state. For example, the bypass mechanism 280 may include an RPM sensor or receive a speed signal from an RPM sensor.

[0056] In various implementations, the bypass mechanism 280 is in the closed position when the heat engine 200 is started up. This allows the decompressor to be bypassed on startup of the heat engine 200 allowing for easier starting of the heat engine 200.METHOD

[0057] FIG. 7 illustrates a method of converting a scroll compressor to a scroll decompressor.

[0058] The method begins at step 1010, which includes obtaining a scroll compressor. As discussed above, the scroll compressor may be a commercially available scroll compressor (from Danfoss, Trane, Emerson Electric, Bristol, Copeland, Bitzer, etc.) that is modified to operate as a scroll decompressor.

[0059] Step 1020 includes separating the cap portion of the scroll compressor from the body portion of the scroll compressor. The cap portion is separated from the body portion to access the internal components of the scroll compressor to perform the remaining method steps.

[0060] Step 1030 includes adding a high-pressure inlet to the cap portion. Traditional scroll compressors only have an outlet in the cap portion and the inlet is traditionally located in theAtorney Docket No. 59121-103 body portion. Since, in the scroll decompressor, refrigerant only flows through the cap portion, the cap portion may require both an outlet and an inlet (that is, the high-pressure inlet).

[0061] Step 1040 includes installing a set of oil separators in the cap portion.

[0062] Step 1050 includes blocking ports in the scroll assembly, such as with a plug or blocking plate, so there is only one inlet and one outlet to the scroll assembly. A scroll assembly in a traditional scroll compressor may have one or more intermediate discharge valves (IDVs) that increase the efficiency of the scroll compressor. Blocking the IDVs may increase the efficiency of the scroll decompressor.

[0063] Step 1060 includes installing the cooling system around the generator and / or the body portion. In a traditional scroll compressor, the generator is cooled by the cold working fluid that enters the scroll compressor through the body portion. In the scroll decompressor no refrigerant flows through the body portion and, even if it did, the refrigerant is at a high temperature when it enters the scroll decompressor.

[0064] Step 1070 includes installing an oil level sensor in the oil reservoir. Step 1080 includes installing an oil management system 370 onto the scroll compressor. Step 1090 includes installing a sealing plate between the cap portion and the body portion. Step 1100 includes reattaching the cap portion to the body portion. The scroll compressor is ready to be installed and operated as a scroll decompressor, such as the decompressor 300, in the heat engine 200.CLAUSES

[0065] Various example embodiments of the invention are described in the following clauses.

[0066] Clause 1: A scroll decompressor comprising: a cap portion including: a scroll assembly configured to receive a refrigerant at a first pressure and output the refrigerant at a second pressure, wherein the second pressure is lower than the first pressure; and a set of oil separators configured to reduce a velocity of the refrigerant exiting the scroll assembly; a body portion including: a top side facing the cap portion, and a set of openings formed in the top side; an oil management system configured to control oil movement between the cap portion and the body portion; and a sealing mechanism disposed between the cap portion and the body portion and configured to block the set of openings.Atorney Docket No. 59121-103

[0067] Clause 2: The scroll decompressor of clause 1 wherein the body portion includes a generator configured to generate electricity.

[0068] Clause 3: The scroll decompressor of clauses 1-2 wherein: the scroll assembly includes a stationary scroll and a moving scroll configured to move relative to the stationary scroll, and movement of the moving scroll allows the refrigerant to move from the first pressure to the second pressure.

[0069] Clause 4: The scroll decompressor of clauses 2-3 wherein movement of the scroll assembly moves the generator to generate electricity.

[0070] Clause 5: The scroll decompressor of clauses 2-4 wherein the generator is configured to synchronize with an electrical grid.

[0071] Clause 6: The scroll decompressor of clauses 2-5 further comprising a cooling system surrounding an exterior surface of the generator and configured to lower a temperature of the generator.

[0072] Clause 7: The scroll decompressor of clauses 1-6 wherein the oil management system is configured to selectively move oil from the cap portion to the body portion.

[0073] Clause 8: The scroll decompressor of clause 7 wherein the oil management system is configured to prevent movement of oil from the body portion to the cap portion.

[0074] Clause 9: The scroll decompressor of clauses 1-8 wherein reducing the velocity of the refrigerant causes oil mixed into the refrigerant to separate from the refrigerant.

[0075] Clause 10: The scroll decompressor of clauses 1-9 wherein the set of oil separators includes at least one of: a set of sloped plates, a set of helical coils, or a mesh.

[0076] Clause 11: The scroll decompressor of clauses 1-10 wherein the cap portion includes: a high pressure inlet; and a low pressure outlet.

[0077] Clause 12: The scroll decompressor of clause 11 wherein: the low pressure outlet is configured to expel the refrigerant from the cap portion at the second pressure, and the high pressure inlet is coupled to the scroll assembly and configured to allow the refrigerant into the scroll assembly at the first pressure.

[0078] Clause 13: The scroll decompressor of clauses 1-12 wherein the body portion includes an oil reservoir configured to hold oil.Atorney Docket No. 59121-103

[0079] Clause 14: The scroll decompressor of clause 13 further comprising an oil level sensor configured to measure an amount of oil in the oil reservoir.

[0080] Clause 15: The scroll decompressor of clause 14 wherein the scroll decompressor is configured to shut down in response to the amount of oil in the oil reservoir falling below a threshold.

[0081] Clause 16: The scroll decompressor of clauses 1-15 wherein the oil management system includes: a pipe connecting the cap portion to the body portion, and a valve configured to open when it detects oil and close when no oil is detected.

[0082] Clause 17: The scroll decompressor of clauses 1-16, wherein the scroll assembly includes only one inlet and only one outlet.

[0083] Clause 18: A heat engine comprising: the scroll decompressor of clauses 1-17; an evaporator configured to heat the refrigerant using heat absorbed from a heat source; a condenser configured to cool the refrigerant by transferring heat absorbed from the refrigerant to a heat sink, wherein the scroll decompressor is disposed between the evaporator and the condenser; and a pump configured to pump the refrigerant from the condenser to the evaporator.

[0084] Clause 19: A system comprising: the heat engine of clause 18; a heat source configured to provide heat to the evaporator; and a heat sink configured to absorb heat from the refrigerant at the condenser.

[0085] Clause 20: A method comprising: obtaining a scroll compressor that includes: a cap portion including a scroll assembly, and a body portion in fluid communication with the cap portion and including: a top side facing the cap portion, and a set of openings formed in the top side; separating the cap portion from the body portion; installing an oil management system on the scroll compressor, wherein the oil management system is configured to control oil movement between the cap portion and the body portion;Atorney Docket No. 59121-103 installing a sealing mechanism between the cap portion and the body portion, wherein the sealing mechanism is configured to configured to block the set of openings; installing a set of oil separators in the cap portion, wherein the set of oil separators is configured to reduce a velocity of a refrigerant exiting the scroll assembly; and reattaching the cap portion to the body portion.CONCLUSION

[0086] The foregoing description is merely illustrative in nature and is in no way intended to limit the disclosure, its application, or uses. The broad teachings of the disclosure can be implemented in a variety of forms. Therefore, while this disclosure includes particular examples, the true scope of the disclosure should not be so limited since other modifications will become apparent upon a study of the drawings, the specification, and the following claims. In the written description and claims, one or more steps within a method may be executed in a different order (or concurrently) without altering the principles of the present disclosure. Unless indicated otherwise, numbering or other labeling of instructions or method steps is done for convenient reference, not to indicate a fixed order.

[0087] Numerical terms, such as “first,” “second,” and “third,” may be used in the disclosure and claims as unique labels: they are not used to imply a sequence or order unless the context clearly indicates otherwise. In other words, a “second” element could be relabeled as a “first” element without departing from the principles of the present disclosure. Further, the presence of a “second” element does not imply or require the presence of a “first” element. Similarly, the presence of a “first” element does not imply or require the presence of a “second” element.

[0088] Unless the context clearly indicates otherwise, the singular articles “a,” “an,” and “the” before a noun do not restrict the noun to a single instance. The verbs “comprise,” “include,” and “have” are inclusive and therefore specify the presence of elements without excluding the presence of one or more additional elements.

[0089] Further, although each of the embodiments is described above as having certain features, any one or more of those features described with respect to any embodiment of the disclosure can be implemented in and / or combined with features of any of the other embodiments, even if that combination is not explicitly described. In other words, the described embodiments are not mutually exclusive, and permutations of one or more embodiments with one another remain within the scope of this disclosure.

[0090] Spatial and functional relationships between elements are described using various terms, including “connected,” “coupled,” “engaged,” “adjacent,” “next to,” “on top of,” “above,” “below,” and “disposed.” Unless explicitly described as being “direct,” when aAtorney Docket No. 59121-103 relationship between first and second elements is described in the above disclosure, that relationship encompasses a direct relationship where no other intervening elements are present between the first and second elements as well as an indirect relationship where one or more intervening elements are present between the first and second elements.

[0091] The term “set” generally means a grouping of one or more elements. The elements of a set do not necessarily need to have any characteristics in common or otherwise belong together. However, in various implementations a “set” may, in certain circumstances, be the empty set (in other words, the set has zero elements in those circumstances). As an example, a set of search results resulting from a query may, depending on the query, be the empty set. In contexts where it is not otherwise clear, the term “non-empty set” can be used to explicitly denote exclusion of the empty set — that is, a non-empty set will always have one or more elements.

[0092] A “subset” of a first set generally includes some of the elements of the first set. In various implementations, a subset of the first set is not necessarily a proper subset: in certain circumstances, the subset may be coextensive with (equal to) the first set (in other words, the subset may include the same elements as the first set). In contexts where it is not otherwise clear, the term “proper subset” can be used to explicitly denote that a subset of the first set must exclude at least one of the elements of the first set. Further, in various implementations, the term “subset” does not necessarily exclude the empty set. As an example, consider a set of candidates that was selected based on first criteria and a subset of the set of candidates that was selected based on second criteria; if no elements of the set of candidates met the second criteria, the subset may be the empty set. In contexts where it is not otherwise clear, the term “non-empty subset” can be used to explicitly denote exclusion of the empty set.

[0093] The phrase “at least one of A, B, and C” should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR, and should not be construed to mean “at least one of A, at least one of B, and at least one of C.” The phrase “at least one of A, B, or C” should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR. The phrase "A, B, and / or C" should be construed in the same way as the phrase “at least one of A, B, and C.”

Claims

Atorney Docket No. 59121-103CLAIMS1. A scroll decompressor comprising: a cap portion including: a scroll assembly configured to receive a refrigerant at a first pressure and output the refrigerant at a second pressure, wherein the second pressure is lower than the first pressure; and a set of oil separators configured to reduce a velocity of the refrigerant exiting the scroll assembly; a body portion including: a top side facing the cap portion, and a set of openings formed in the top side; an oil management system configured to control oil movement between the cap portion and the body portion; and a sealing mechanism disposed between the cap portion and the body portion and configured to block the set of openings.

2. The scroll decompressor of claim 1 wherein the body portion includes a generator configured to generate electricity.

3. The scroll decompressor of claim 2 wherein: the scroll assembly includes a stationary scroll and a moving scroll configured to move relative to the stationary scroll, and movement of the moving scroll allows the refrigerant to move from the first pressure to the second pressure.

4. The scroll decompressor of claim 2 wherein movement of the scroll assembly moves the generator to generate electricity.

5. The scroll decompressor of claim 2 wherein the generator is configured to synchronize with an electrical grid.

6. The scroll decompressor of claim 2 further comprising a cooling system surrounding an exterior surface of the generator and configured to lower a temperature of the generator.

7. The scroll decompressor of claim 1 wherein the oil management system is configured to selectively move oil from the cap portion to the body portion.Atorney Docket No. 59121-1038. The scroll decompressor of claim 7 wherein the oil management system is configured to prevent movement of oil from the body portion to the cap portion.

9. The scroll decompressor of claim 1 wherein reducing the velocity of the refrigerant causes oil mixed into the refrigerant to separate from the refrigerant.

10. The scroll decompressor of claim 1 wherein the set of oil separators includes at least one of: a set of sloped plates, a set of helical coils, or a mesh.

11. The scroll decompressor of claim 1 wherein the cap portion includes: a high pressure inlet; and a low pressure outlet.

12. The scroll decompressor of claim 11 wherein: the low pressure outlet is configured to expel the refrigerant from the cap portion at the second pressure, and the high pressure inlet is coupled to the scroll assembly and configured to allow the refrigerant into the scroll assembly at the first pressure.

13. The scroll decompressor of claim 1 wherein the body portion includes an oil reservoir configured to hold oil.

14. The scroll decompressor of claim 13 further comprising an oil level sensor configured to measure an amount of oil in the oil reservoir.

15. The scroll decompressor of claim 14 wherein the scroll decompressor is configured to shut down in response to the amount of oil in the oil reservoir falling below a threshold.

16. The scroll decompressor of claim 1 wherein the oil management system includes: a pipe connecting the cap portion to the body portion, and a valve configured to open when it detects oil and close when no oil is detected.

17. The scroll decompressor of claim 1, wherein the scroll assembly includes only one inlet and only one outlet.

18. A heat engine comprising : the scroll decompressor of claim 1 ; an evaporator configured to heat the refrigerant using heat absorbed from a heat source;Atorney Docket No. 59121-103 a condenser configured to cool the refrigerant by transferring heat absorbed from the refrigerant to a heat sink, wherein the scroll decompressor is disposed between the evaporator and the condenser; and a pump configured to pump the refrigerant from the condenser to the evaporator.

19. A system comprising: the heat engine of claim 18; a heat source configured to provide heat to the evaporator; and a heat sink configured to absorb heat from the refrigerant at the condenser.

20. A method comprising: obtaining a scroll compressor that includes: a cap portion including a scroll assembly, and a body portion in fluid communication with the cap portion and including: a top side facing the cap portion, and a set of openings formed in the top side; separating the cap portion from the body portion; installing an oil management system on the scroll compressor, wherein the oil management system is configured to control oil movement between the cap portion and the body portion; installing a sealing mechanism between the cap portion and the body portion, wherein the sealing mechanism is configured to configured to block the set of openings; installing a set of oil separators in the cap portion, wherein the set of oil separators is configured to reduce a velocity of a refrigerant exiting the scroll assembly; and reattaching the cap portion to the body portion.

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