Abstract: A compressor is provided with an electrical connection within the length of the stator winding or another component, to reduce the total height of the compressor. The compressor includes a motor having a stator and a rotor, wherein the stator extends along an axis for a fixed axial length and the rotor rotates about the axis. The compressor also includes a set of terminal pins extending through the housing for providing electrical connection to the motor. The terminal pins are mounted onto the inside of the housing of the compressor and within the axial length of the stator. A connector having cooperating slots slides in a direction generally parallel, tangential or a combination thereof to the axis of rotation to connect the terminal pins to the motor.

Abstract: An improved scroll compressor having an axially movable non-orbiting scroll eliminates the need for a separator plate. With the elimination of the separator plate, a back pressure chamber is provided to resist the discharge pressure which will be directed against a rear face of the non-orbiting scroll. In other embodiments, a seal on the rear of the non-orbiting scroll contacts the inner periphery of the end cap. Various ways of increasing the discharge pressure volume, or eliminating undesirable noise are also disclosed. Further, several ways of connecting the end cap to the center shell are also disclosed.

Abstract: A number of improvements increase the flow of lubricant within a scroll compressor. A centrifugal oil separator is mounted on the discharge port to remove oil from the refrigerant. The oil is returned through a leak path such that the oil can easily return back to a suction pressure chamber. The leak path is preferably upstream of a check valve. Thus, at shutdown, the leak path will not allow upstream components to also equalize in pressure with the suction pressure chamber of the compressor. Further, a number of embodiments include ways of resisting flow of refrigerant through the leak path, while still allowing oil flow. A number of valve elements are described which perform this function. Alternatively, labyrinth flow paths, or positioning of the return paths such that it will be closed when the compressor is shut down are disclosed.

Abstract: Counterweight size is reduced by removing material from an electric motor rotor for a machine, such as a compressor. The material is removed asymmetrically with respect to shaft centerline to provide maximum benefit. Counterweight size reduction results in decrease of compressor dimensional envelope and weight.

Abstract: Scroll compressors having a non-orbiting scroll the type that moves axially for a limited distance are provided with an economizer fluid tube. The economizer tube is received within an opening in the non-orbiting scroll such that the non-orbiting scroll can move relative to the tube. This is an improvement over the prior art, and provides a more secure and simple connection.

Abstract: A scroll compressor is positioned in a housing having an end cap defining an oil sump. A shaft extends towards the oil sump and has an oil pick-up tube. A magnet is positioned on the end cap through a number of embodiments which properly position the magnet adjacent to the oil pick-up tube. In one embodiment a protrusion extends upwardly from the end cap and into an inner periphery of the magnet to position the magnet.

Abstract: A scroll compressor includes back-pressure chamber seals which are mounted eccentrically relative to a shaft rotational axis. Because of the seal eccentricity, the back chamber force, which prevents fixed and orbiting scroll separation, also acts eccentrically. The eccentric back chamber force creates an overturning moment. The direction of eccentricity is selected such that this overturning moment counteracts the scroll tipping moment of the tangential gas force. Therefore, the back chamber force and thrust force between the non-orbiting and orbiting scrolls are minimized. Also the back chamber area between the seals is reduced. The reduction of thrust force minimizes scroll wear and reduces friction, while back chamber area reduction frees up additional space in the scroll environment which can be utilized for other purposes.

Abstract: A scroll compressor includes a non-orbiting scroll wherein the base is sealed to the housing. That is, the non-orbiting scroll provides the function of the scroll member, and also the function typically provided by a separator. A heat shield is positioned between the discharge pressure chamber and the base of the non-orbiting scroll. Leakage paths are provided to allow refrigerant to communicate between the discharge pressure chamber and spaces between the heat shield and the non-orbiting scroll.

Abstract: A unique protection circuit for a sealed compressor incorporates oil structure which directs a heated oil onto a motor protection circuit. The motor protection circuit is of the type which shuts down operation of an electric motor when a predetermined temperature is sensed. The motor protection circuit is positioned adjacent to an oil return path which is opened when a high temperature is experienced in the compressor pump unit. The valve in the path opens to allow flow of the returned oil onto the motor protection switch. The motor protection switch is then actuated to stop further operation of the motor. In another embodiment, the motor protection switch is immersed in the oil sump. Again, when the oil temperature increases to a predetermined amount, the motor protection switch stops further operation of the motor.

Abstract: A non-orbiting scroll has structure which interfits with the crankcase towers. The crankcase towers are circumferentially spaced by gaps, and the non-orbiting scroll has tabs which extend into those gaps. The crankcase towers preferably fit into grooves in the non-orbiting scroll. The crankcase towers and the grooves on the non-orbiting scroll properly position the non-orbiting scroll and the crankcase relative to each other. The tabs extending into the gaps between the crankcase towers prevent the ingress of welding material into the compressor housing.

Abstract: A scroll compressor has a fixed scroll and an orbiting scroll nested with one another within a shell. A hub extends axially from a lower surface of the orbiting scroll with a central bore formed therein. A crankshaft, having an eccentric pin extending axially from one end thereof, is drivable by a motor. A passageway for the delivery of a lubricant extends through the crankshaft and the eccentric pin. A slider block is received by the central bore, and a pin bore, which extends axially through the slider block, receives the eccentric pin. An axially extending projection maintains a gap between the slider block and the orbiting scroll which enhances the flow of lubricant to bearing surfaces of the scroll compressor.

Abstract: A scroll compressor has a check valve plate assembly with a reinforcing device to increase the strength of the check valve plate. The check valve plate is stamped from a relatively thin steel reed material. Notched areas are provided during stamping to enable the formation of rolled laterally spaced pins which provide an axis along which the check valve plate may pivot. The reinforcing device is in the form of a slot rolled pin, a spiral rolled pin, or a solid pin, fitted within a bore formed by the rolled laterally spaced pins of the check valve plate. The notched areas of the check valve plate are weakened due to the reduction of the local cross sectional area of the laterally spaced pins. Insertion of the reinforcing device significantly reduces the incidence of cracking that occurs at the notched areas of the check valve plate.

Abstract: An improved housing for scroll compressor has the end cap housing formed integrally with the fixed scroll member. The end cap housing is preferably welded to a tubular housing enclosing the scroll compressor. Most preferably, the end housing has inner and outer tubular portions and the tubular housing extends upwardly into a channel between the inner and outer tubular portions. A muffler is preferably formed integrally with the end cap and extends to a side of the end cap. The present invention further includes heat transfer fins extending from the end cap. The positioning of the muffler to the side decreases the overall length of the compressor. The use of the fins increases the efficiency of compression as heat is removed from the compression chambers. The use of the unique combined end cap and fixed scroll which is welded to the tubular housing simplifies assembly.

Abstract: An improved compressor incorporates structure for facilitating the alignment of a suction tube with the motor stator windings. In one embodiment, the motor stator is provided with a protective coating such that the refrigerant entering the compressor housing through the suction tube does not damage the motor windings. In another feature, the chamber housing is bumped out in the location where the suction tube is mounted such that the distance between the radially inner end of the suction tube and the radially outer portion of the windings is increased. The above provides better protection for the motor windings in a sealed compressor wherein the suction tube is axially aligned with the motor windings.

Abstract: A generalized technique is provided for maximizing the volumetric displacement of a gas within a scroll compressor having a scroll set including a fixed scroll wrap and an orbiting scroll wrap. The scroll wraps are designed to minimize the generating radius Rg for at least the outer portion of the wrap and achieve a high generating radius for at least the inner portion of the wrap. The generating radius can be either evaluated as the absolute value or the mean value taken as an integration from the outer extremity of the wrap inward.

Abstract: A sealed compressor incorporates a relatively thin counterweight. The relatively thin counterweight is able to fit within a much smaller space than prior art cast counterweights. The relatively thin counterweight allows the reduction of the overall length of the sealed compressor, and thus provides very valuable benefits.

Abstract: A scroll compressor is provided within a sealed housing. Although the invention is shown with regard to a scroll compressor, it should be understood that aspects of the invention have benefit to any type sealed compressor. A lower bearing is attached directly to a housing end cap. The lower bearing is easily and accurately attached to the end cap, and reduces the complexity and cost of assembly of a sealed compressor. In particular, the end cap is provided with upset portions spaced circumferentially by gaps. The bearing is secured to the upset portions by welding. Oil can flow through the gaps and into a space beneath the bearing such that it can reach oil passages in the shaft.

Abstract: A method of reducing the height of a sealed compressor incorporates the use of a non-cylindrical portion of the stator windings on the compressor motor. A non-cylindrical portion provides a space between the sealed housing and the windings that can accommodate an additional component. In one embodiment, the additional component is the electrical connection, and in another embodiment, the additional component is an oil heater. Typically, these components were mounted axially beyond the extent of the motor stator, and thus required additional space. The present invention thus allows a smaller height compressor profile.

Abstract: Several discharge check valve arrangements for scroll compressors move the check valve closer to the discharge port and the compression chambers. This reduces the amount of discharge pressure backflow, and thus reduces the amount of reverse rotation at shutdown. In one type of check valve arrangement, a plug is mounted within a check valve chamber to provide a stop for the check valve. The plug allows the check valve to seat against its valve seat while the compressor is operating to allow gas to flow around the check valve into a discharge plenum. At shutdown, the check valve arrangement is constructed to cause the check valve to rapidly close the discharge port. In other arrangements, the discharge check valve assembly may be mounted in a separator plate as a separate valve plug. This embodiment is similar to an earlier embodiment in the basic operation of the check valve.

Abstract: An improved seal for defining a back pressure chamber in a scroll compressor includes a tab extending toward the rear face of the orbiting scroll. The tab reduces the contact force created against the rear face of the orbiting scroll by the gas pressure in the back pressure chamber. Thus, the inventive seal increases seal life.