Compressor Discharge Valve Assembly Noise Reduction
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Solution Overview
Problem
Compressor discharge valve assemblies in climate-control systems face challenges in efficiently controlling fluid flow and reducing noise and wear due to the complexity of valve operation and pressure differentials, leading to inefficiencies and increased size.
Innovation Solution
The compressor design incorporates a discharge valve member and a valve backer mechanism that utilizes a movable and fixed portion with a tip and recessed portion to control fluid flow independently of pressure differentials, allowing for precise control of valve opening and closing, reducing noise and wear by integrating the valve backer with the driveshaft, and optimizing the compressor's size and sealing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a traditional discharge valve assembly is used to control fluid flow, then fluid flow control is achieved, but noise and wear increase due to pressure differentials
Solution Approach 1:
The patent extracts the valve backer from the traditional valve assembly and integrates it with the driveshaft, separating the flow control function from the valve operation mechanism. This extraction allows the valve member to respond purely to pressure differentials while the integrated valve backer provides mechanical assistance only when needed, reducing noise and wear from excessive mechanical intervention.
Solution Approach 2:
The valve backer is merged with the driveshaft into a single integrated component, eliminating separate parts and reducing complexity. This merging allows the driveshaft to directly assist valve closing when pressure differentials are insufficient, improving control efficiency while reducing the number of potential failure points and sources of noise.
2Device complexity
If the valve backer is integrated with the driveshaft, then device complexity is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The valve backer is segmented into distinct functional zones: a tip portion for contacting the valve member, a recessed portion for allowing valve opening, and an annular hub for mounting on the driveshaft. This segmentation allows each zone to be optimized independently for its specific function, balancing manufacturing precision requirements with functional performance.
Solution Approach 2:
Different portions of the valve backer have different geometric properties tailored to their specific functions. The tip portion has a specific contact surface geometry for reliable valve closing, while the recessed portion provides clearance for valve opening. This local quality optimization reduces overall manufacturing precision requirements by allowing each area to be precisely made only where needed.
3Ease of operation
If the tip portion contacts the movable portion during rotation, then valve closing is forced, but wear may increase
Solution Approach 1:
The valve backer rotates with the driveshaft, creating periodic contact with the movable portion of the valve member. This periodic action allows the tip portion to assist valve closing only during specific portions of the rotation cycle when pressure differentials are insufficient, rather than maintaining continuous mechanical contact. This reduces wear while maintaining effective valve closing control.
Solution Approach 2:
The valve backer acts as an intermediary between the driveshaft and the valve member, transferring rotational motion into controlled valve closing assistance only when needed. This intermediary role allows the system to use rotational energy to supplement pressure differential control without requiring direct continuous mechanical coupling, reducing wear on the valve member.
4Adaptability or versatility
If the recessed portion is axially aligned with the movable portion, then valve opening is allowed, but fluid flow control precision may decrease
Solution Approach 1:
The recessed portion provides partial mechanical assistance for valve opening by being axially aligned with the movable portion during part of the rotation cycle. This partial action allows the valve to open more easily when pressure differentials are insufficient, while the valve member's inherent responsiveness to pressure differentials maintains precise flow control. The recessed portion provides just enough assistance without over-controlling the valve position.
Data Source
AI summary
A compressor may include a shell, a non-orbiting scroll, an orbiting scroll, and a discharge valve member. The shell may define a discharge chamber. The non-orbiting scroll may be disposed within the discharge chamber and includes a first end plate and a first spiral wrap extending from the first end plate. The orbiting scroll may be disposed within the discharge chamber and includes a second end plate and a second spiral wrap extending from the second end plate. The first and second spiral wraps mesh with each other to define fluid pockets therebetween. The second end plate includes a discharge passage extending therethrough. The discharge valve member may be attached to the second end plate and may be movable between an open position allowing fluid flow from the discharge passage to the discharge chamber and a closed position restricting fluid flow from the discharge passage to the discharge chamber.