Economizer injection in a reciprocating compressor

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Solution Overview

Problem

Multi-stage compressors used in vapor compression systems with economizers increase size, complexity, and cost due to separate compressor stages and refrigerant mixing within the second stage.

Innovation Solution

A reciprocating compressor design with a cylinder head featuring distinct suction, discharge, and economizer regions, and valves to manage refrigerant flows, including a solenoid-operated economizer valve controlled by a sensor and controller to optimize pressure and movement, eliminating the need for two separate compression stages.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If multi-stage compression is used to compress economizer refrigerant, then compression capability is improved, but device complexity increases

Engineering Contradiction:

Improvecompression capabilityVSAvoidcompressor structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent merges the economizer refrigerant compression function into the single-stage compressor by providing a separate economizer bore within the same cylinder head. This allows the single-stage compressor to perform both main refrigerant compression and economizer refrigerant compression simultaneously, eliminating the need for separate multi-stage compression mechanisms while maintaining compression capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cylinder head is segmented into multiple functional bores: a main bore for primary refrigerant compression and a separate economizer bore for economizer refrigerant compression. Each bore has its own piston and valve system, allowing independent operation while sharing the common crankcase and drive mechanism, thus reducing overall system complexity.

Inventive Principle:

Principle #1Segmentation

2Productivity

If separate compressor stages are used for main and economizer refrigerant compression, then compression efficiency is improved, but compressor footprint increases

Engineering Contradiction:

Improvecompression efficiencyVSAvoidcompressor footprint

Core Design Contradiction:

ProductivityVSArea of stationary object

Solution Approach 1:

The economizer bore is nested within the cylinder head structure alongside the main bore, with both bores sharing the common crankcase, crankshaft, and overall compressor housing. This nested arrangement allows two compression functions to coexist within a single compressor footprint, eliminating the need for separate multi-stage compression chambers that would increase the overall compressor size.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Productivity

If economizer refrigerant is injected into the conduit between compressor stages, then refrigeration efficiency is improved, but device complexity increases

Engineering Contradiction:

Improverefrigeration efficiencyVSAvoidconduit system

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent extracts the economizer refrigerant injection function from the inter-stage conduit system and relocates it to a separate economizer bore within the compressor. The economizer compressor directly discharges into the suction line or evaporator, eliminating the need for complex inter-stage conduits and injection valves while maintaining refrigeration efficiency through direct economizer refrigerant delivery.

Inventive Principle:

Principle #2Taking out (Extraction)

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

Reduces compressor footprint, complexity, and cost by integrating economizer refrigerant injection directly into the cylinder, enhancing efficiency and reducing the number of required stages.

Implementation Method 1

moving a piston within the cylinder to increase a pressure within the cylinder

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

an economizer valve selectively operable to fluidly couple the economizer region and the first bore

Methodology Applied

Scientific EffectSolenoid actuation: Solenoid

Data Source

PatentUS12398926B2Economizer injection in a reciprocating compressor

Publication Date: 2025.08.26 CARRIER CORP

AI summary

A compressor includes a cylinder block having a first bore and a cylinder head overlapping the cylinder block. The cylinder head has a second bore aligned with the first bore. The second bore is separated into a plurality of distinct regions including a suction region and an economizer region. A plurality of valves includes a suction valve selectively operable to fluidly couple the suction region and the first bore, and an economizer valve selectively operable to fluidly couple the economizer region and the first bore.