Reciprocating Compressor Intermediate-Pressure Injection for Dual Cylinders

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing reciprocating compressors face challenges in efficiently managing multiple compression mechanisms, particularly in injecting fluid at an intermediate pressure from a single external source, which affects energy consumption and discharge-pressure refrigerant delivery in climate-control systems.

Innovation Solution

A reciprocating compressor design incorporating a housing with dual compression mechanisms and a housing cover featuring intermediate-fluid ports and passages, allowing fluid at an intermediate pressure to be stored and selectively injected into cylinders via a sleeve and collar assembly, enabling efficient fluid management across multiple pistons.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a single external source is used to inject fluid at intermediate pressure into multiple compression mechanisms, then device complexity is reduced, but fluid distribution and pressure control become more difficult

Engineering Contradiction:

Improvefluid injection system structureVSAvoidfluid pressure control

Core Design Contradiction:

Device complexityVSEase of operation

Solution Approach 1:

The single external fluid source is segmented into multiple independent injection circuits, each with its own injection valve and passage leading to different compression mechanisms. This allows independent control of fluid injection to each cylinder while maintaining a single external source.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A fluid distribution manifold acts as an intermediary component between the single external fluid source and multiple compression mechanisms. The manifold includes multiple outlets that can independently control fluid distribution to different cylinders through controlled opening/closing of injection valves.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If fluid is injected at intermediate pressure into multiple cylinders, then compression efficiency is improved, but energy consumption increases

Engineering Contradiction:

Improvecompression efficiencyVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

Fluid injection is performed periodically rather than continuously. Injection valves are opened only during specific phases of the compression cycle when intermediate pressure fluid can be effectively introduced into cylinders, and closed during other phases to prevent unnecessary energy consumption.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

Fluid injection is applied locally to specific cylinders based on their operational state. Not all cylinders receive fluid injection simultaneously - only those that are in the appropriate phase of the compression cycle, optimizing the balance between compression efficiency and energy consumption.

Inventive Principle:

Principle #3Local quality

3Productivity

If multiple compression mechanisms are used to increase discharge pressure, then refrigerant delivery is improved, but system complexity and energy consumption increase

Engineering Contradiction:

Improvedischarge-pressure refrigerant deliveryVSAvoidcompression mechanism arrangement

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

Multiple compression mechanisms (cylinders) are merged into a single integrated system sharing common components including the fluid distribution manifold, injection valves, and external fluid source. This combining approach allows multiple cylinders to operate in coordination while reducing overall system complexity compared to separate systems.

Inventive Principle:

Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The design minimizes energy consumption while ensuring sufficient discharge-pressure refrigerant delivery, enhancing the efficiency and reliability of climate-control systems by optimizing fluid injection and compression processes.

Implementation Method 1

The first fluid storage plenum and the second fluid storage plenum are configured to store the fluid at the intermediate pressure therein

Methodology Applied

Scientific EffectPressure differential: Pressure Gradient

Implementation Method 2

Both the first compression mechanism and the second compression mechanism are configured to compress a working fluid from a suction pressure to a discharge pressure

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS20250389264A1Reciprocating Compressor And Fluid Injection System

Publication Date: 2025.12.25 COPELAND LP

AI summary

A compressor includes a housing, a first compression mechanism and a second compression mechanism disposed in the housing, and a valve. Both the first compression mechanism and the second compression mechanism are configured to compress a working fluid from a suction pressure to a discharge pressure. The first compression mechanism includes a first cylinder housing having a first fluid storage plenum. The second compression mechanism includes a second cylinder housing having a second fluid storage plenum. An intermediate-fluid port is in selective fluid communication with the valve. The intermediate-fluid port is in fluid communication with the first fluid storage plenum via a first intermediate-fluid passage and the second fluid storage plenum via a second intermediate-fluid passage. Working fluid at an intermediate pressure enters the intermediate-fluid port through the valve. The intermediate pressure is greater than the suction pressure and less than the discharge pressure.