Scroll Compressor Leakage Reduction via Differential Lap Thickness
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Solution Overview
Problem
In scroll compressors with orbiting and fixed scrolls made of materials with different strengths, the unnecessarily large scroll lap thickness leads to increased refrigerant leakage gaps and performance deterioration due to equal basic circle radius and phase angle values for both scrolls.
Innovation Solution
The scroll compressor design includes scroll laps for the fixed and orbiting scrolls with distinct phase angles and thicknesses, where the scroll lap thickness of the higher material strength scroll is set to be less than that of the lower material strength scroll, with specific coordinate expressions for each, to optimize the shape and reduce leakage gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the scroll lap thickness is set to be substantially equal for both orbiting scroll and fixed scroll, then the structural strength is ensured, but the refrigerant leakage gaps are increased and performance deteriorates
Solution Approach 1:
The patent applies local quality by setting different scroll lap thicknesses for different parts of the system. Specifically, the orbiting scroll has a first scroll lap thickness while the fixed scroll has a second scroll lap thickness that is different from the first. This allows each component to have the optimal thickness for its specific functional requirements, ensuring sufficient strength where needed while minimizing leakage gaps in other areas.
2Ease of manufacture
If the basic circle radius and phase angle are set to be substantially equal for both scrolls, then the manufacturing is simplified, but the refrigerant leakage gaps increase due to unnecessarily large scroll lap thickness
Solution Approach 1:
The patent applies parameter changes by modifying the scroll lap thickness parameter differently for the orbiting scroll and fixed scroll. While the basic circle radius and phase angle remain substantially equal for both scrolls (maintaining manufacturing simplicity), the scroll lap thickness parameter is changed to have different values. This selective parameter differentiation resolves the contradiction by allowing simplified manufacturing of the overall structure while optimizing the critical thickness parameter to reduce leakage gaps.
Data Source
Figure 1
Figure 2~3
AI summary
A scroll compressor 100 includes a fixed scroll 1 and an orbiting scroll 2, which are made of materials having different strengths and include respective scroll laps. The scroll lap of one of the fixed scroll 1 and the orbiting scroll 2 having a lower material strength has a shape satisfying coordinates expressed as x = a{cosφ + (φ ± α)sinφ} where a represents a basic circle radius, φ represents an involute angle, and α represents a phase angle and y = a{sinφ - (φ ± α)cosφ} where a represents a basic circle radius, φ represents an involute angle, and α represents a phase angle with the involute angle used as a parameter, and tl = 2aα where tl represents a scroll lap thickness, a represents a basic circle radius, and α represents a phase angle. The scroll lap of one of the fixed scroll 1 and the orbiting scroll 2 having a higher material strength has a shape having a phase angle β set as β < α, and satisfying coordinates expressed as x = a{cosφ + (φ ± β)sinφ} where a represents a basic circle radius, φ represents an involute angle, and β represents a phase angle and y = a{sinφ - (φ ± β)cosφ} where a represents a basic circle radius, φ represents an involute angle, and β represents a phase angle with the involute angle used as a parameter, and th = 2aβ where th represents a scroll lap thickness, a represents a basic circle radius, and β represents a phase angle. The scroll lap thickness th of the one of the fixed scroll 1 and the orbiting scroll 2 having the higher material strength is set to be less than the scroll lap thickness tl of the one of the fixed scroll 1 and the orbiting scroll 2 having the lower material strength.