Scroll Compressor Epoxy Sealing and Single-Side Machining

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Solution Overview

Problem

Small scroll type devices are high in cost compared to other compression devices, and existing sealing methods like epoxy sealants or floating orbiting scrolls face issues such as internal leakage due to differential thermal expansion and expensive application processes.

Innovation Solution

A low-cost scroll device design featuring a fixed scroll with heat transfer fins, an orbiting scroll with involute and bearing bores machined from a single side, idler shaft assemblies with secured bearings, a front counterweight, tip seals, and an epoxy coating application method that allows assembly only once, reducing machining time and costs while preventing leakage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If epoxy sealants are used to seal the scroll device, then sealing effectiveness is improved, but the application process becomes expensive and complex

Engineering Contradiction:

Improvesealing effectivenessVSAvoidapplication process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by pre-coating the scroll surfaces with epoxy sealant before assembly, and pre-installing seals in grooves before the scrolls are mounted together. This eliminates the need for complex post-assembly sealing operations and allows the epoxy to cure in place without disassembly.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent segments the sealing function into multiple components: tip seals installed in grooves on the scroll surfaces, epoxy sealant applied to specific areas, and O-rings positioned in designated locations. This segmentation allows each sealing element to be prepared and installed independently, simplifying the overall process.

Inventive Principle:

Principle #1Segmentation

2Reliability

If the orbiting scroll is designed to float radially for sealing, then sealing is achieved, but internal leakage occurs due to differential thermal expansion

Engineering Contradiction:

ImprovesealingVSAvoiddimensional stability

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The patent applies parameter changes by modifying the physical state of the sealing interface through epoxy coating, which creates a rigid, thermally stable barrier that prevents the differential thermal expansion issues associated with floating radial seals. The epoxy layer changes the thermal and mechanical parameters of the seal interface.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses composite materials by combining the metal scroll surfaces with an epoxy sealant coating. This composite structure leverages the strength and thermal stability of epoxy to prevent internal leakage caused by thermal expansion differences between the orbiting and fixed scrolls.

Inventive Principle:

Principle #40Composite materials

3Stability of the object's composition

If bearings are secured with retaining screws, then bearing stability is improved, but manufacturing steps increase

Engineering Contradiction:

Improvebearing stabilityVSAvoidmanufacturing steps

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The patent applies preliminary action by pre-installing the retaining screws into the bearing bores before mounting the bearings themselves. This preliminary preparation simplifies the assembly process and ensures proper positioning without requiring additional manufacturing steps.

Inventive Principle:

Principle #10Preliminary action

4Loss of time

If machining is performed from a single side of the orbiting scroll, then manufacturing time is reduced, but bearing bores alignment may be compromised

Engineering Contradiction:

Improvemachining timeVSAvoidbearing bores alignment

Core Design Contradiction:

Loss of timeVSManufacturing precision

Solution Approach 1:

The patent applies dimensionality change by designing the bearing bores to be drilled at an angle from the single accessible side of the orbiting scroll, rather than requiring perpendicular access from both sides. This angular approach allows all bearing bores to be machined from one side while maintaining proper alignment through careful angular positioning.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 reduces manufacturing costs, minimizes internal leakage, and simplifies the epoxy application process, making scroll devices more affordable and reliable for small applications.

Implementation Method 1

a fixed scroll having a plurality of heat transfer fins extending therefrom

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

with a fan mounted to the scroll device for circulating air past the heat transfer fins

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS11067080B2Low cost scroll compressor or vacuum pump

Publication Date: 2021.07.20 AIR SQUARED LLC

AI summary

A low cost scroll device and methods of manufacturing the same are described. The scroll device includes, for example, a drive pin hole and bearing bores machined into a scroll of the scroll device from the same side as the involute of the scroll; idler shaft assemblies with no more than one bearing in the orbiting scroll for mechanically coupling the orbiting scroll to the fixed scroll; and an epoxy coating applied using a process that requires assembly of the scroll device only once.