Compressor Oil Separator Using Nested Mesh for Gas-Liquid Separation
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Solution Overview
Problem
Current high-side compressors in climate-control systems face inefficiencies in separating lubricant oil from discharge gas, leading to reduced performance and maintenance challenges due to inadequate oil separation methods.
Innovation Solution
The compressor design incorporates a shell, compression mechanism, bearing housing, shroud, stator, and rotor with specific passages and surface features, including a top cap oil separator and counterweight passages, to facilitate efficient oil separation and collection, utilizing mesh materials and surface features like axial scallops and grooves to enhance oil-gas separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional oil separation methods are used in high-side compressors, then the structure remains simple, but oil separation efficiency is insufficient leading to reduced compressor performance
Solution Approach 1:
The oil separator is nested within the discharge housing, utilizing the existing compressor structure. The separator integrates with the discharge housing cavity, eliminating the need for separate external separation units while improving oil-gas separation efficiency through the nested configuration.
Solution Approach 2:
The patent employs a mesh material with porous structure as the oil separator element. This porous mesh allows gas to pass through while trapping oil droplets, significantly improving separation efficiency without requiring complex mechanical separation mechanisms.
2Ease of manufacture
If inadequate oil separation is used, then the compressor structure remains simple, but maintenance needs increase due to oil contamination
Solution Approach 1:
The oil separator system operates automatically without external intervention. The mesh separator self-captures oil droplets from the discharge gas, and the oil collects in the sump where it is automatically returned to the oil reservoir, reducing maintenance requirements without complicating the manufacturing process.
Solution Approach 2:
The system continuously separates and recovers oil from the discharge gas stream. The mesh separator discards oil droplets into the sump, and the oil is recovered and returned to the lubrication system, reducing maintenance frequency while maintaining manufacturing simplicity.
3Reliability
If advanced oil separation components are added, then oil separation efficiency improves, but device complexity increases
Solution Approach 1:
The oil separator, discharge housing, and oil return system are merged into a single integrated assembly. The mesh separator is positioned within the discharge housing cavity, and the oil return passages are integrated into the housing structure, improving separation performance while minimizing the number of discrete components.
Solution Approach 2:
The discharge housing serves multiple functions: it contains the mesh oil separator, collects separated oil in the sump, provides oil return passages to the compressor, and maintains structural support. This multi-functionality improves separation performance without increasing the overall component count.
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
This design improves oil separation efficiency, reduces maintenance needs, and enhances the overall performance of the compressor by effectively separating oil from gas, ensuring reliable operation and extended component life.
Implementation Method 1
At least a portion of the oil collection surface may be lined with mesh material
Implementation Method 2
separating oil from the gas based on the pressure differential and mesh material interaction
Implementation Method 3
Oil can be delivered to the scrolls using a pressure differential between discharge-pressure fluid and suction-pressure fluid
Implementation Method 4
heating the shell and placing the shell around the internal compressor assembly; and allowing the shell to return to ambient temperature, thereby creating a shrink fit
Data Source
AI summary
A compressor may include a shell, a compression mechanism, a bearing housing, a shroud, a stator, and a rotor. The compression mechanism includes a scroll member that is attached to the shell. The shroud is rotatably fixed relative to the shell and attached to the bearing housing. The stator is fixed relative to the shell. The shroud may have an annular body including an inner surface defining a center shroud passage. The stator may have an outer surface defining a stator passage. An outer surface of the rotor and an inner surface of the stator may be spaced apart and define a discharge gap in fluid communication with the center shroud passage and the stator passage. A continuous passage may extend between a top surface of the scroll member and a bottom surface of the shroud and may be in fluid communication with the shroud passage.