Scroll Compressor Insert Plate for Wear-Resistant Face Sealing
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Solution Overview
Problem
Scroll machines and refrigeration systems face challenges due to high mechanical loads and compressive forces, which affect the service life and sealing effectiveness of scroll units, leading to wear and requiring robust, heavy constructions.
Innovation Solution
Incorporating an insert plate into the base of the scroll units, made of a harder material like metal, with a sealing surface that interacts with the scroll rib tip, and utilizing a face seal to enhance sealing and reduce wear, along with features like lubricating notches and injection ports to improve efficiency and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If scroll units are made robust to withstand high mechanical loads and compressive forces, then reliability and service life are improved, but weight and device complexity increase
Solution Approach 1:
The base of the scroll unit is segmented into a pocket region and a remaining base region, with the pocket receiving a face seal element. This segmentation allows the sealing function to be separated from the structural base, enabling the use of lighter materials in the base while maintaining reliability through the specialized face seal component.
Solution Approach 2:
The invention employs composite construction by combining the base material (aluminum or aluminum alloy) with a face seal element made of harder material such as metal or stainless steel. This composite approach allows the base to remain lightweight while the face seal provides the necessary wear resistance and sealing performance under high mechanical loads.
2Reliability
If scroll units are made robust to withstand high mechanical loads, then reliability is improved, but device complexity increases
Solution Approach 1:
The base is divided into a pocket region and remaining base region, creating a modular structure where the face seal element can be independently installed and maintained. This segmentation simplifies the overall design by separating sealing functions from structural functions, making the system easier to manufacture and service despite improved reliability requirements.
Solution Approach 2:
The face seal element acts as an intermediary component between the scroll rib tip and the base. This intermediary element absorbs the wear and sealing demands, protecting the base structure and simplifying its design requirements. The face seal element can be replaced independently if worn, reducing overall system complexity for maintenance.
3Reliability
If sealing surfaces are made harder to resist wear, then reliability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The sealing function is segmented into a separate face seal element that can be manufactured with high precision independently from the base. This allows the base to be manufactured with standard aluminum casting tolerances, while the face seal element receives specialized precision manufacturing and surface treatment to achieve the required sealing effectiveness and wear resistance.
Solution Approach 2:
The composite construction combines the base material with a face seal element made of harder material such as metal or stainless steel. This allows the sealing surface to have the necessary hardness and wear resistance while the base remains easier to manufacture. The face seal element can be separately heat-treated and precision-finished to achieve high sealing performance without requiring the entire base to meet stringent manufacturing precision requirements.
4Ease of manufacture
If aluminum or aluminum alloy is used for scroll units, then ease of manufacture is improved, but wear resistance deteriorates
Solution Approach 1:
The invention uses a composite construction where the base is made of aluminum or aluminum alloy for ease of manufacture, light weight, and good thermal conductivity, while the face seal element is made of harder material such as metal or stainless steel. This composite approach allows the base to be easily manufactured using standard aluminum casting processes, while the face seal element provides the necessary wear resistance at the sealing surface through its harder material composition and specialized surface treatment.
Solution Approach 2:
The face seal element provides localized enhanced quality at the sealing surface where wear resistance is critical. The rest of the base can remain as standard aluminum alloy optimized for manufacturing ease. This local quality enhancement allows the sealing surface to have superior wear resistance properties without requiring the entire scroll unit to be made from harder, more difficult-to-manufacture materials.
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 solution reduces wear on scroll units, enhances sealing effectiveness, and increases the operating limits and efficiency of the scroll machine by minimizing mechanical stress and improving lubrication and sealing performance.
Implementation Method 1
a lubricant film is present between the scroll rib tip and the sealing surface
Data Source
AI summary
A scroll machine, in particular a scroll compressor, has a first scroll unit with a base and a scroll rib protruding from the base with a scroll rib tip, a second scroll unit with a base and a scroll rib protruding from the base with a scroll rib tip. The first scroll unit can be moved along an orbital path relative to the second scroll unit and the first scroll unit and the second scroll unit engage with each other to form pressure chambers, and the scroll rib of a scroll rib tip having a face seal abuts sealingly to the base of the respective other scroll unit. The base of the first scroll unit and/or the base of the second scroll unit include(s) a pocket with an insert plate arranged in the pocket. Also contemplated is a refrigeration system.