Reciprocating Compressor Piston Valve Nesting

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Solution Overview

Problem

Reciprocating compressor systems face inefficiencies in energy usage and temperature management, particularly in climate-control systems, due to the varying capacity of compressors affecting the speed of heating or cooling and the preheating of working fluids, which reduces system efficiency.

Innovation Solution

The design incorporates a crankcase with a discharge plenum acting as the high side of the compressor, where the discharge valves are mounted on the piston and extend through it, allowing compressed working fluid to flow into the crankcase while preventing preheating of low-pressure fluid, along with a control module that switches between various operating modes to optimize performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If the discharge valve is mounted on the piston and extends through it, then the discharge temperature is reduced and compressor efficiency is increased, but the device complexity increases

Engineering Contradiction:

Improvedischarge temperatureVSAvoiddevice complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The discharge valve is nested within the piston structure, with the valve body extending through the piston and the valve seat formed in the piston interior. This integration of the discharge valve into the piston reduces discharge temperature and improves efficiency while minimizing the increase in device complexity through compact, space-efficient design.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The discharge valve assembly merges multiple components into a unified structure where the valve body, valve seat, and piston form an integrated assembly. The discharge passage extends through the piston to connect the compression chamber with the crankcase, combining sealing, flow control, and structural functions in a single integrated component.

Inventive Principle:

Principle #5Merging (Combining)

2Use of energy by moving object

If the suction plenum provides working fluid directly to the compression chamber, then the energy efficiency is improved, but the loss of time in fluid flow increases

Engineering Contradiction:

Improveenergy efficiencyVSAvoidfluid flow time

Core Design Contradiction:

Use of energy by moving objectVSLoss of time

Solution Approach 1:

The suction plenum is positioned and configured to provide preliminary action by delivering working fluid directly to the compression chamber before compression begins. This direct fluid path pre-positiones the refrigerant for immediate compression, improving energy efficiency by eliminating intermediate flow steps and reducing the time loss in fluid transport.

Inventive Principle:

Principle #10Preliminary action

3Volume of moving object

If the crankcase defines a discharge plenum receiving working fluid at high pressure, then the packaging space is optimized, but the pressure of working fluid increases

Engineering Contradiction:

Improvepackaging spaceVSAvoidpressure of working fluid

Core Design Contradiction:

Volume of moving objectVSStress or pressure

Solution Approach 1:

The crankcase is segmented to define a separate discharge plenum chamber that receives high-pressure working fluid from the compression chamber. This segmentation creates dedicated high-pressure containment space within the crankcase structure, optimizing packaging by utilizing existing crankcase volume rather than adding separate high-pressure vessels, while managing pressure through controlled spatial separation.

Inventive Principle:

Principle #1Segmentation

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 configuration reduces discharge temperature, increases compressor efficiency, and provides packaging space for improved fluid flow, enhancing the energy efficiency and performance of climate-control systems.

Implementation Method 1

The piston and cylinder cooperate to define a compression chamber therebetween

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

The discharge valve may control fluid flow through a discharge passage between the compression chamber and the discharge plenum

Methodology Applied

Scientific EffectPressure gradient: Pressure Gradient

Implementation Method 3

The suction plenum may receive working fluid at a second pressure that is less than the first pressure

Methodology Applied

Scientific EffectPressure differential: Pressure Gradient

Data Source

PatentUS10815979B2Reciprocating compressor having first and second cylinders in selective fluid communication with respective first and second suction plenums

Publication Date: 2020.10.27 COPELAND LP

AI summary

A compressor may include a crankcase, a crankshaft, a piston, a discharge valve and a suction plenum. The crankcase defines a discharge plenum receiving working fluid at a first pressure. The crankshaft is disposed within the discharge plenum. The piston is drivingly connected to the crankshaft and reciprocatingly received in a cylinder. The piston and cylinder cooperate to define a compression chamber therebetween. The discharge valve may control fluid flow through a discharge passage between the compression chamber and the discharge plenum. The suction plenum may receive working fluid at a second pressure that is less than the first pressure. The suction plenum may provide working fluid at the second pressure to the compression chamber.