Scroll compressor with intermediate injection
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Solution Overview
Problem
Existing scroll compressors in HVACR systems lack an efficient mechanism for intermediate pressure injection, which can lead to reduced efficiency and capacity in gas compression processes.
Innovation Solution
The implementation of a scroll compressor design that includes a compressor housing with a suction chamber, a discharge chamber, and an intermediate injection chamber, where the non-orbiting scroll member has an intermediate injection port connecting the intermediate injection chamber to the compression pockets, and is sealed by first and second bands extending between the scroll member and the housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional scroll compressor design is used, then structure is simple, but compression efficiency and capacity are reduced due to lack of intermediate injection
Solution Approach 1:
The compressor housing is segmented into multiple functional chambers: suction chamber, discharge chamber, and intermediate injection chamber. This segmentation allows independent control of different compression stages and enables intermediate injection without complicating the overall scroll mechanism
Solution Approach 2:
An intermediate injection chamber is introduced as a mediator between the suction and discharge chambers. This intermediate chamber receives refrigerant from the suction chamber and injects it into the compression pockets at optimal pressure points, improving compression efficiency while maintaining structural integrity
2Productivity
If intermediate injection chamber is added, then compression capacity is improved, but manufacturing complexity increases
Solution Approach 1:
The compressor housing serves multiple functions: it contains the suction chamber, discharge chamber, and intermediate injection chamber, while also providing mounting surfaces for the scroll members and sealing elements. This multi-functionality reduces the need for additional separate components, simplifying manufacturing despite the enhanced functionality
Solution Approach 2:
The intermediate injection chamber is nested within the compressor housing structure, utilizing the same outer casing. The suction chamber and discharge chamber are also integrated into the housing, creating a nested arrangement that maximizes space utilization and reduces manufacturing steps
3Reliability
If bands are used for sealing, then sealing effectiveness is improved, but assembly complexity increases
Solution Approach 1:
Flexible bands are used as sealing elements between the intermediate injection chamber and both the suction and discharge chambers. These thin film seals conform to the mating surfaces, providing effective sealing while allowing for minor manufacturing tolerances and thermal expansion, thereby maintaining reliability without requiring complex adjustment mechanisms
Data Source
AI summary
A scroll compressor includes a compressor housing containing an orbiting scroll member, a non-orbiting scroll member, a pair of bands disposed between the non-orbiting scroll member and the compressor housing, a suction chamber, a discharge chamber, and an intermediate injection chamber defined by the pair of bands. The non-orbiting scroll member includes an intermediate injection port fluidly connecting the intermediate injection chamber to at least one compression pocket formed by the intermeshed scroll members. A heating, ventilation, air conditioning, and refrigeration system including a refrigerant circuit with a condenser, at least one expander, an evaporator, and the scroll compressor fluidly connected. A method of making a scroll compressor includes placing an upper portion of a compressor housing over a non-orbiting scroll member with bands disposed therebetween, and interference fitting the upper portion onto the non-orbiting scroll member via the bands.