CAPACITY-MODULATED SCROLL COMPRESSOR

Abstract

A compressor may include a shell defining an internal volume containing compressed working fluid and first and second scrolls disposed within the internal volume. The first scroll may include a first spiral wrap. The second scroll may include a second spiral wrap, a suction inlet opening and a capacity-modulation aperture. The second spiral wrap may engage the first spiral wrap to define a pocket therebetween. The suction inlet opening may be sealed off from the internal volume. The capacity-modulation aperture may receive a valve member that is movable between a first position allowing leakage of fluid from the pocket to the suction inlet opening and a second position restricting leakage of fluid from the pocket.

Description

FIELD

The present disclosure relates to a capacity-modulated scroll compressor.

BACKGROUND

This section provides background information related to the present disclosure and is not necessarily prior art.

A climate-control system such as, for example, a heat-pump system, a refrigeration system, or an air conditioning system, may include a fluid circuit having an outdoor heat exchanger, an indoor heat exchanger, an expansion device disposed between the indoor and outdoor heat exchangers, and one or more compressors circulating a working fluid (e.g., refrigerant or carbon dioxide) between the indoor and outdoor heat exchangers. Efficient and reliable operation of the one or more compressors is desirable to ensure that the climate-control system in which the one or more compressors are installed is capable of effectively and efficiently providing a cooling and/or heating effect on demand.

SUMMARY

This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.

In one form, the present disclosure provides a compressor that may include a shell, first and second scrolls and a valve member. The shell may define an internal volume. The first scroll may be disposed within the internal volume and may include a first spiral wrap. The second scroll may be disposed within the internal volume and may include a second spiral wrap engaged with the first spiral wrap to form a pocket between the first and second spiral wraps. The second scroll may include a suction inlet opening, a discharge passage and a capacity-modulation aperture. The suction inlet opening may receive the fluid at a first pressure and may be isolated from the internal volume. The discharge passage may discharge the fluid to the internal volume at a second pressure that is higher than the first pressure. The valve member may be at least partially disposed within the capacity-modulation aperture and may be movable between a first position in which the valve member restricts fluid to flow around a tip of the first spiral wrap to restrict fluid communication between the suction inlet opening and the pocket and a second position in which the valve member allows fluid-flow around the tip of the first spiral wrap to provide fluid communication between the suction inlet opening and the pocket.

In some embodiments, the first scroll may be an orbiting scroll and the second scroll may be a non-orbiting scroll.

In some embodiments, an end of the valve member may be exposed to fluid within a fluid chamber. The fluid chamber may communicate with the internal volume when the valve member is in a first position and may communicate with the suction inlet opening when the valve member is in a second position.

In some embodiments, the compressor may include an actuation valve movable between a first position allowing fluid communication between the fluid chamber and the internal volume and restricting fluid communication between the fluid chamber and the suction inlet opening and a second position restricting fluid communication between the fluid chamber and the internal volume and allowing fluid communication between the fluid chamber and the suction inlet opening.

In some embodiments, moving the actuation valve into the second position allows the fluid chamber to fluidly communicate with the suction inlet opening through an aperture formed in an end plate of the second scroll.

In some embodiments, the actuation valve may include a pulse-width-modulated valve.

In some embodiments, the valve member may move between the first and second positions in response to response to a change in a pressure differential between the fluid chamber and the pocket.

In some embodiments, the valve member may include first and second portions. The first portion may contact the first spiral wrap and may be disposed between the second portion and the first spiral wrap. The first portion may be formed from a material that allows the first portion to wear faster than the second portion.

In another form, the present disclosure provides a compressor that may include first and second scrolls, first and second valve members, a manifold and an actuation valve. The first scroll may include a first end plate and a first spiral wrap extending from the first end plate. The second scroll may include a second end plate and a second spiral wrap extending from the first end plate and engaged with the first spiral wrap. The second end plate may include a suction inlet opening and first and second capacity-modulation apertures extending therethrough. The first and second valve members may be at least partially disposed within the first and second capacity-modulation apertures, respectively, and movable therein to selectively provide first and second leakage paths around a tip of the first spiral wrap. The manifold may include first and second chambers and a fluid passageway fluidly connecting the first and second chambers. The manifold may be positioned such that the first and second chambers are aligned with the first and second capacity-modulation apertures, respectively, such that portions of the first and second valve members are exposed to the first and second chambers. The actuation valve may be in fluid communication with the fluid passageway and may be movable between a first position providing fluid communication between the fluid passageway and the suction inlet opening and a second position providing fluid communication between the fluid passageway and a fluid source having a fluid pressure that is greater than a fluid pressure of the suction inlet opening.

In some embodiments, the first and second capacity-modulation apertures may be positioned so that the first and second leakage paths fluidly connect the suction inlet opening with one or more pockets defined by the first and second spiral wraps.

In some embodiments, the compressor may include first and second pockets defined by the first and second spiral wraps. The first and second pockets may be sealed off from the suction inlet opening when the first scroll is in a first orbital position. The first and second capacity-modulation apertures may be positioned so that when the first scroll is in the first orbital position and the actuation valve is in the first position, the first leakage path allows leakage from the first pocket to the second pocket and the second leakage path allows leakage from the second pocket to the suction inlet opening.

In some embodiments, the second scroll may include a third capacity-modulation apertures disposed between the first and second capacity-modulation apertures.

In some embodiments, the compressor may include a third valve member at least partially disposed within the third aperture and movable therein to selectively provide a third leakage path around a tip of the first spiral wrap. The manifold may include a third chamber in communication with the fluid passageway and aligned with the third capacity-modulation aperture.

In some embodiments, the compressor may include a shell defining an internal volume in which the first and second scrolls are disposed. In some embodiments, the internal volume may be the fluid source.

In some embodiments, the suction inlet opening may be sealed off from the internal volume.

In some embodiments, the fluid passageway may be in communication with the suction inlet opening through an aperture formed in the second end plate when the actuation valve is in the first position.

In some embodiments, the first scroll may be an orbiting scroll and the second scroll may be a non-orbiting scroll.

In some embodiments, the actuation valve may be a pulse-width-modulated valve.

In some embodiments, the first and second valve members may each include first and second portions. The first portion may contact the first spiral wrap and may be disposed between the second portion and the first spiral wrap. The first portion may be formed from a material that allows the first portion to wear faster than the second portion.

In another form, the present disclosure provides a high-side compressor that may include a shell defining an internal volume containing compressed working fluid and first and second scrolls disposed within the internal volume. The first scroll may include a first spiral wrap. The second scroll may include a second spiral wrap, a suction inlet opening and a capacity-modulation aperture. The second spiral wrap may engage the first spiral wrap to define a pocket therebetween. The suction inlet opening may be sealed off from the internal volume. The capacity-modulation aperture may receive a valve member that is movable between a first position allowing leakage of fluid from the pocket to the suction inlet opening and a second position restricting leakage of fluid from the pocket.

In some embodiments, the valve member allows leakage of fluid from said pocket around a tip of said first spiral wrap to said suction inlet opening.

In some embodiments, the second scroll may include another capacity-modulation aperture receiving another valve member that is movable therein between a first position allowing leakage of fluid from the pocket to the suction inlet opening and a second position restricting leakage of fluid from the pocket.

In some embodiments, the high-side compressor may include another pocket defined by the first and second spiral wraps. The pockets may be sealed off from the suction inlet opening when the first scroll is in a first orbital position. The capacity-modulation apertures may be positioned so that when the first scroll is in the first orbital position and the valve members are in the first positions, a leakage path is formed that extends from one pocket, through the other pocket and into the suction inlet opening.

In some embodiments, the first scroll may be an orbiting scroll and the second scroll may be a non-orbiting scroll.

In some embodiments, the high-side compressor may include another valve member movable within another capacity-modulation aperture formed in the second scroll between a first position allowing leakage of fluid from the pocket to the suction inlet opening and a second position restricting leakage of fluid from the pocket.

In some embodiments, the valve members may be independently controlled and movable independently of each other between the first and second positions.

In some embodiments, the high-side compressor may include a manifold and an actuation valve operable in a first position to supply fluid to the valve members at a first pressure to move the valve members to the first position and operable in a second position to supply fluid to the valve members at a second pressure that is higher than the first pressure to move the valve members to the second position.

In some embodiments, an end plate of the second scroll may include a fluid passageway in communication with the suction inlet opening. The actuation valve may be in communication with a fluid passageway in the first position.

In some embodiments, the actuation valve may be in communication with the internal volume in the second position.

In some embodiments, the valve members may allow leakage of fluid around a tip of the first spiral wrap to the suction inlet opening.

In some embodiments, the actuation valve may be a pulse-width modulated valve.

In some embodiments, the valve member may include first and second portions. The first portion may contact the first spiral wrap and may be disposed between the second portion and the first spiral wrap. The first portion may be formed from a material that allows the first portion to wear faster than the second portion.

Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

FIG. 1 is a cross-sectional view of a compressor according to the principles of the present disclosure;

FIG. 2 is a perspective view of a non-orbiting scroll and capacity-modulation assembly of the compressor of FIG. 1;

FIG. 3 is an exploded perspective view of the non-orbiting scroll and capacity-modulation assembly of FIG. 2;

FIG. 4 is a bottom view of the non-orbiting scroll;

FIG. 5 is a top view of the non-orbiting scroll and capacity-modulation assembly in a capacity-modulation mode;

FIG. 6 is a cross-sectional view of the non-orbiting scroll and capacity-modulation assembly taken through line 6-6 of FIG. 5;

FIG. 7 is a cross-sectional view of the non-orbiting scroll and capacity-modulation assembly taken through line 7-7 of FIG. 5;

FIG. 8 is a top view of the non-orbiting scroll and capacity-modulation assembly in a full-capacity mode;

FIG. 9 is a cross-sectional view of the non-orbiting scroll and capacity-modulation assembly taken through line 9-9 of FIG. 8;

FIG. 10 is a partial cross-sectional view of the non-orbiting scroll, orbiting scroll, and capacity-modulation assembly in the full-capacity mode;

FIG. 11 is a partial cross-sectional view of the non-orbiting scroll, orbiting scroll, and capacity-modulation assembly in the capacity-modulation mode;

FIG. 12 is a bottom view of the non-orbiting scroll including a first orbital position of the orbiting scroll;

FIG. 13 is a bottom view of the non-orbiting scroll including a second orbital position of the orbiting scroll;

FIG. 14 is a bottom view of the non-orbiting scroll including a third orbital position of the orbiting scroll;

FIG. 15 is a bottom view of the non-orbiting scroll including a fourth orbital position of the orbiting scroll;

FIG. 16 is a partial cross-sectional view of another non-orbiting scroll, orbiting scroll, and capacity-modulation assembly in a full-capacity mode according to the principles of the present disclosure;

FIG. 17 is a partial cross-sectional view of the non-orbiting scroll, orbiting scroll, and capacity-modulation assembly of FIG. 16 in the capacity-modulation mode;

FIG. 18 is a top view of another non-orbiting scroll according to the principles of the present disclosure;

FIG. 19 is a partial cross-sectional view of the non-orbiting scroll of FIG. 18, another orbiting scroll, and another capacity-modulation assembly in a full-capacity mode according to the principles of the present disclosure;

FIG. 20 is a partial cross-sectional view of the non-orbiting scroll, orbiting scroll, and capacity-modulation assembly of FIG. 19 in the capacity-modulation mode;

FIG. 21 is a partial cross-sectional view of another non-orbiting scroll, orbiting scroll, and capacity-modulation assembly in a full-capacity mode according to the principles of the present disclosure;

FIG. 22 is a partial cross-sectional view of the non-orbiting scroll, orbiting scroll, and capacity-modulation assembly of FIG. 21 in the capacity-modulation mode;

FIG. 23 is a partial cross-sectional view of another non-orbiting scroll, orbiting scroll, and capacity-modulation assembly in a full-capacity mode according to the principles of the present disclosure; and

FIG. 24 is a partial cross-sectional view of another non-orbiting scroll, orbiting scroll, and capacity-modulation assembly in a full-capacity mode according to the principles of the present disclosure.

Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

DETAILED DESCRIPTION

Example embodiments will now be described more fully with reference to the accompanying drawings.

Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

With reference to FIGS. 1-15, a high-side compressor 10 is provided that may include a shell assembly 12, a motor assembly 14, a compression mechanism 16 and a capacity-modulation assembly 18. The shell assembly 12 may include a cylindrical shell 20, an end cap 22 at an upper end of the shell 20 and a base 24 at a lower end of the shell 20. The shell 20, end cap 22 and base 24 may cooperate to define an internal volume 26 containing high-pressure working fluid discharged by the compression mechanism 16. The high-pressure working fluid may exit the internal volume 26 through a discharge fitting 28 attached to the end cap 22 or the shell 20, for example. A suction-inlet conduit 30 may be attached to the end cap 22 or the shell 20, for example, and may extend through the internal volume 26 and provide suction-pressure working fluid to the compression mechanism 16. Suction-pressure fluid within the suction-inlet conduit 30 may be fluidly isolated or sealed off from the internal volume 26.

The motor assembly 14 may be disposed entirely within the internal volume 26 and may include a stator 32, a rotor 34, and a driveshaft 36. The stator 32 may be press fit into the shell 20. The rotor 34 may be press fit on the driveshaft 36 and may transmit rotational power to the driveshaft 36. The driveshaft 36 may be rotatably supported by first and second bearing-housing assemblies 37, 39. The driveshaft 36 may include an eccentric crank pin 38 drivingly engaging the compression mechanism 16.

The compression mechanism 16 may be disposed entirely within the internal volume 26 and may include an orbiting scroll 40 and a non-orbiting scroll 42. The orbiting scroll 40 may include an end plate 44 having a spiral wrap 46 extending therefrom. A cylindrical hub 48 may project downwardly from the end plate 44 and may include a drive bushing 50 disposed therein. The crank pin 38 may drivingly engage the drive bushing 50. An Oldham coupling 52 may be engaged with the orbiting scroll 40 and the first bearing-housing assembly 37 or the non-orbiting scroll 42 to prevent relative rotation between the orbiting and non-orbiting scrolls 40, 42.

The non-orbiting scroll 42 may include an end plate 54 and a spiral wrap 56 projecting downwardly from the end plate 54. The spiral wrap 56 may meshingly engage the spiral wrap 46 of the orbiting scroll 40, thereby creating a series of moving fluid pockets. The fluid pockets defined by the spiral wraps 46, 56 may decrease in volume as they move from a radially outer position (at a low pressure) to a radially intermediate position (at an intermediate pressure) to a radially inner position (at a high pressure) throughout a compression cycle of the compression mechanism 16.

As shown in FIGS. 3 and 4, the end plate 54 may include a suction-inlet opening 58, a discharge passage 60, first, second and third capacity-modulation apertures 62, 64, 66, and a suction-communication aperture 68. The suction-inlet opening 58 may sealingly engage the suction-inlet conduit 30 so that suction-pressure working fluid from the suction-inlet conduit 30 may be drawn into the compression mechanism 16 (at the radially outer position) for subsequent compression between the spiral wraps 46, 56. The first, second and third capacity-modulation apertures 62, 64, 66 may be counterbored through-holes, each including an annular shoulder 67 (FIG. 6). The suction-communication aperture 68 may extend through the end plate 54 and may be in fluid communication with the suction-inlet opening 58 via a recess 70 (FIG. 4). The discharge passage 60 may be in communication with one of the fluid pockets at the radially inner position and allows compressed working fluid to flow into the internal volume 26. A discharge valve (not shown) may provide selective fluid communication between the discharge passage 60 and the internal volume 26.

The capacity-modulation assembly 18 may include a manifold 74, a plurality of capacity-modulation valve assemblies 76, and an actuation valve 78. The manifold 74 can be fastened to the end plate 54 of the non-orbiting scroll 42 by a plurality of fasteners 80 and/or by welding and/or any other fastening means. In some embodiments, the manifold 74 could be integrally formed with the non-orbiting scroll 42.

The manifold 74 may include first and second legs 81, 82 and first, second and third hubs 83, 84, 85. The first leg 81 may extend between the first and second hubs 83, 84. The second leg 82 may extend between the second and third hubs 84, 85. The first and second legs 81, 82 may include first and second passageways 86, 87 (FIGS. 5 and 8), respectively, that are in fluid communication with each other. An end portion 88 of the first leg 81 may include an L-shaped passageway 89 (FIG. 7) in communication with the suction-communication aperture 68 in the non-orbiting scroll 42. In some embodiments, the manifold 74 could include tubing to interconnect the hubs 83, 84, 85 rather than the integrally formed legs 81, 82.

Each of the first, second and third hubs 83, 84, 85 may define a cavity 90 (FIG. 6). Each cavity 90 may be in fluid communication with one or both of the first and second passageways 86, 87 of the first and second legs 81, 82 through a corresponding port 91. The manifold 74 may be arranged relative to the end plate 54 such that the cavities of the first, second and third hubs 83, 84, 85 are substantially coaxially aligned with the first, second and third capacity-modulation apertures 62, 64, 66, respectively. Gaskets 92 (FIG. 3) may be disposed between the hubs 83, 84, 85 and the end plate 54 to provide a seal around the capacity-modulation apertures 62, 64, 66 and the cavities 90.

Each of the capacity-modulation valve assemblies 76 may include a valve member 94 and a spring 96. Each valve member 94 may include a head portion 98 and a stem portion 100. As shown in FIG. 6, the head portion 98 of each valve member 94 may be movably received within the cavity 90 of a corresponding one of the first, second and third hubs 83, 84, 85. A fluid chamber 79 (FIG. 7) may be defined by the cavity 90 and the valve member 94 (e.g., between an end wall 97 of the cavity 90 and an end 99 of the head portion 98). An O-ring 103 (FIG. 6) may engage a periphery of the head portion 98 to provide a sealed relationship between the head portion 98 and an inner diametrical surface of the cavity 90. The stem portion 100 of each valve member 94 may extend from the corresponding head portion 98 into a corresponding one of the first, second and third capacity-modulation apertures 62, 64, 66. Each spring 96 may be disposed around a corresponding stem portion 100 between the corresponding head portion 98 and corresponding shoulder 67 of the capacity-modulation apertures 62, 64, 66.

The valve members 94 are movable relative to the capacity-modulation apertures 62, 64, 66 and cavities 90 between a first position (FIG. 10) and a second position (FIG. 11). In the first position, the head portion 98 may contact a top face 55 of the end plate 54, and a distal end 101 of the stem portion 100 may sealingly engage (directly or indirectly via a thin layer of lubricant) a tip 47 of the spiral wrap 46 of the orbiting scroll 40. In some embodiments, a minimal gap may be provided between the distal end 101 and the tip 47 in the first position. The springs 96 may bias the valve members 94 toward the second position. In the second position, the head portion 98 may be spaced apart from the top face 55 and a leakage path may be formed between the distal end 101 of the stem portion 100 and the tip 47 of the spiral wrap 46.

The actuation valve 78 (shown schematically in the figures) may be attached to the end portion 88 of the first leg 81 of the manifold 74 and may include an outlet passage 102, a first inlet passage 104 (FIGS. 5 and 7) and a second inlet passage 106 (FIG. 8). The outlet passage 102 may be fluidly coupled with the first passageway 86 of the first leg 81. The first inlet passage 104 may be fluidly coupled to the L-shaped passageway 89 in the end portion 88 of the first leg 81 (as shown in FIGS. 5 and 7). While FIG. 8 depicts the second inlet passage 106 in fluid communication with the internal volume 26, in some embodiments, the second inlet passage 106 may be in fluid communication with a pocket containing intermediate-pressure working fluid.

The actuation valve 78 may be actuated by a solenoid or any other suitable device may move the actuation valve 78 between a first configuration (FIG. 5) in which the outlet passage 102 is fluidly coupled with the first inlet passage 104 and fluidly isolated from the second inlet passage 106 and a second configuration (FIG. 8) in which the outlet passage 102 is fluidly coupled with the second inlet passage 106 and fluidly isolated from the first inlet passage 104. Accordingly, when the actuation valve 78 is in the first configuration, a fluid pathway is formed that extends between the fluid chambers 79 and the suction-inlet opening 58 (i.e., through the suction-communication aperture 68, the L-shaped passageway 89, the first inlet passage 104, the outlet passage 102 and the first and/or second passageways 86, 87) so that fluid within the fluid chambers 79 are at the same pressure as the suction-inlet conduit 30 (i.e., suction pressure). When the actuation valve 78 is in the second configuration, a fluid pathway is formed that extends between the fluid chambers 79 and the internal volume 26 (i.e., through the second inlet passage 106, the outlet passage 102 and the first and/or second passageways 86, 87) so that fluid within the chambers 79 are at the same pressure as the internal volume 26. The actuation valve 78 may be controlled by a control module (not shown) that moves the actuation valve 78 between the first and second configurations based on compressor operating parameters, system operating parameters and/or demand for heating or cooling, for example.

In some embodiments, the actuation valve 78 may be pulse-width-modulated to achieve a desired operating capacity for the compressor 10. In some embodiments, the compressor 10 may include a plurality of actuation valves 78, each of which may actuate a corresponding one of the capacity-modulation valve assemblies 76. In this manner, each of the capacity-modulation valve assemblies 76 may be independently actuated to provide further control and levels of capacities at which the compressor 10 may operate.

It will be appreciated that the number, shape and locations of the capacity-modulation apertures 62, 64, 66 and capacity-modulation valve assemblies 76 can be varied from the configuration shown in the figures. In some configurations, the orbiting scroll 40 may include capacity-modulation apertures 62, 64, 66 and capacity-modulation valve assemblies 76 (instead of or in addition to the capacity-modulation apertures 62, 64, 66 and capacity-modulation valve assemblies 76 of the non-orbiting scroll 42) that open and close to selectively allow leakage around a tip of the spiral wrap 56 of the non-orbiting scroll.

With continued reference to FIGS. 1-15, operation of the compressor 10 will be described in detail. As described above, orbital motion of the orbiting scroll 40 relative to the non-orbiting scroll 42 may draw suction-pressure working fluid into the compression mechanism 16 through the suction-inlet conduit 30 and suction-inlet opening 58. The compression mechanism 16 may compress the working fluid and discharge the compressed working fluid to the internal volume 26. The capacity-modulation assembly 18 may be selectively operable in a full-capacity mode and in a reduced-capacity mode.

In the full capacity mode, the actuation valve 78 may be in the second configuration (FIG. 8), which allows the fluid chambers 79 to communicate with the internal volume 26. When the fluid chambers 79 are in communication with the internal volume 26, relatively high pressure fluid in the chambers 79 forces the valve members 94 downward to the first position shown in FIG. 10 (i.e., pressure differentials are created between the fluid chambers 79 and one or more pockets 110 that forces the valve members 94 downward to the first position). In this position, the valve members 94 restrict or prevent fluid from the pockets 110 (FIGS. 10 and 12) from leaking to a suction-pressure zone 112 (i.e., a zone in communication with the suction-inlet opening 58 and suction-inlet conduit 30).

In the reduced-capacity mode, the actuation valve 78 may be in the first position (FIG. 5), which allows the fluid chambers 79 to communicate with the suction-inlet opening 58. When the fluid chambers 79 are in communication with the suction-inlet opening 58, relatively low pressure fluid in the chambers 79 allows the springs 96 to force the valve members 94 upward to the second position shown in FIG. 11. In this position, leakage paths are formed between the tip 47 of the spiral wrap 46 of the orbiting scroll 40 and the distal ends 101 of the valve members 94 that allows fluid from the pocket 110 to leak to the suction-pressure zone 112.

In the reduced-capacity mode, the fluid in a given pocket 110 may only begin to be compressed once that pocket 110 has advanced far enough radially inward (toward the discharge passage 60) that the pocket 110 is sealed off from all of the capacity-modulation apertures 62, 64, 66. Because the start of compression is delayed until after the pocket 110 is sealed off from the capacity-modulation apertures 62, 64, 66 (i.e., at the position shown in FIG. 15), the working fluid in the pocket 110 is subjected to less compression before the pocket 110 reaches the discharge passage 60 and the fluid therein is discharged to the internal volume 26.

By contrast, in the full-capacity mode, compression of the fluid within the pocket 110 begins earlier in the compression cycle (i.e., as soon as the pocket 110 is sealed off from the suction-inlet open 58 and communication aperture 68 (at the position shown in FIG. 12). Because there is no leakage of fluid out of the pockets 110 in the full-capacity mode, the fluid within the pockets 110 undergoes additional compression as is moves from the position shown in FIG. 12 to the position shown in FIG. 15 that the fluid is not subjected to in the reduced-capacity mode. Therefore, the fluid in the compression pockets 110 undergoes additional compression (i.e., the volume ratio is higher in the full-capacity mode than in the reduced-capacity mode) by the time it reaches the discharge passage 60 and is discharged to the internal volume 26.

With reference to FIGS. 16 and 17, another capacity-modulation assembly 218 and non-orbiting scroll 242 are provided. The capacity-modulation assembly 218 and non-orbiting scroll 242 can replace the capacity-modulation assembly 18 and non-orbiting scroll 42 in the compressor 10 described above. The structure and function of the capacity-modulation assembly 218 and non-orbiting scroll 242 may be substantially similar to that of the capacity-modulation assembly 18 and non-orbiting scroll 42, apart from the exceptions described below and shown in the figures. Therefore, similar features will not be described again in detail.

As shown in FIGS. 16 and 17, capacity-modulation apertures 264 in the non-orbiting scroll 242 may be formed so that a counterbore 267 has the same diameter or a larger that the cavities 290 of manifold 274. Accordingly, top face 255 of end plate 254 of the non-orbiting scroll 242 does not act as a hard stop that contacts head portions 298 of valve members 294 when the valve members 294 are in the first position (i.e., the position corresponding to the full-capacity mode shown in FIG. 16). Rather, distal ends 301 of the stem portions 300 of the valve members 294 may directly contact the tip 47 of the spiral wrap 46 of the orbiting scroll 40 in the full-capacity mode. A fluid chamber 279 may be defined by the cavity 290 and the valve member 294 (e.g., between an end wall 297 of the cavity 290 and an end 299 of the head portion 298).

With reference to FIGS. 18-20, another capacity-modulation assembly 318 and non-orbiting scroll 342 are provided. The capacity-modulation assembly 318 and non-orbiting scroll 342 can replace the capacity-modulation assembly 18 and non-orbiting scroll 42 in the compressor 10 described above. The structure and function of the capacity-modulation assembly 318 and non-orbiting scroll 342 may be substantially similar to that of the capacity-modulation assembly 18 and non-orbiting scroll 42, apart from the exceptions described below and shown in the figures. Therefore, similar features will not be described again in detail.

The non-orbiting scroll 342 may include first, second and third capacity-modulation apertures 362, 364, 366 that may each include a first recess 368, a second recess 370 and a plurality of openings 372. The first and second recesses 368, 370 may be substantially concentric with each other and may receive valve members 394 that are movable therein between a first position corresponding to the full-capacity mode (FIG. 19) and a second position corresponding to the reduced-capacity mode (FIG. 20). The first recess 368 may include a larger diameter than the second recess 370 and may include an annular shoulder 374 engaging a spring 396. Stem portions 400 of the valve members 394 may seal against a bottom face 376 of the second recess 370 in the first position to restrict or prevent fluid from pocket 410 flowing through one or more of the opening 372 into the second recess 370 and into a suction-pressure zone 412 through one or more other openings 372. In the second position, the stem portions 400 may be spaced apart from the bottom face 376 to allow fluid from pocket 410 to flow through one or more of the opening 372 into the second recess 370 and into a suction-pressure zone 412 through one or more other openings 372.

With reference to FIGS. 21 and 22, another capacity-modulation assembly 418 is provided. The capacity-modulation assembly 418 can replace the capacity-modulation assembly 18 in the compressor 10 described above. The structure and function of the capacity-modulation assembly 418 may be substantially similar to that of the capacity-modulation assembly 18, apart from the exceptions described below and shown in the figures. Therefore, similar features will not be described again in detail.

The capacity-modulation assembly 418 may include a manifold 474, valve members 494, springs 496, and an actuation valve 478. The valve members 494 and springs 496 may be similar or identical to the valve members 94 and springs 96 described above. The manifold 474 may be similar to the manifold 74 described above, except that the manifold 474 may include an end portion 480 including a recess 482. The recess 482 may include an open end 484, an outlet 486 and an inlet 488. The outlet 486 may be fluidly coupled to fluid passageways 489 extending through the legs 490 of the manifold 474. The inlet 488 may be fluidly coupled with the suction-communication aperture 68 in the non-orbiting scroll 42.

The actuation valve 478 may include a valve body 491, a valve member 493 and a solenoid coil 495. The valve body 491 may be a hollow, generally tubular member that may extend through an opening 498 in the shell assembly 12. The valve body 491 may include an internal cavity 500 having a first inlet 502, a second inlet 504 and an outlet 506. The first inlet 502 may provide fluid communication between the internal cavity 500 and the internal volume 26 of the compressor 10. The second inlet 504 may be fluidly coupled with the inlet 488 of the recess 482 of the manifold 474. The outlet 506 may be fluidly coupled with the outlet 486 of the recess 482. The valve body 491 may also include first and second valve seats 508, 510 disposed within the internal cavity 500. The first valve seat 508 may surround a passage 512 that provides fluid communication between the first inlet 502 and the outlet 506. The second valve seat 510 may surround the second inlet 504.

The valve member 493 may be disposed within the internal cavity 500 and may be movable therein between a first position corresponding to the full-capacity mode (FIG. 21) and a second position corresponding to the reduced-capacity mode (FIG. 22). The valve member 493 may include a base portion 514, a stem portion 516 and a head portion 518. The base portion 514 may be disposed in the internal cavity 500 of the valve body 491 adjacent a distal end 520 of the internal cavity 500. In this manner, the base portion 514 is at least partially surrounded by the solenoid coil 495 so that energizing the solenoid coil with electrical current magnetically forces the valve member 493 upward toward the second position. A spring 522 may engage the base portion 514 and the distal end 520 of the internal cavity 500 and may bias the valve member 493 toward the first position so that when the solenoid coil 495 is not energized, the spring 522 forces the valve member 493 into the first position.

The stem portion 516 of the valve member 493 may extend between the base portion 514 and the head portion 518 and through the passage 512 of the internal cavity 500. The head portion 518 may include first and second ends 524, 526. When the valve member 493 is in the first position (FIG. 21), the first end 524 may be spaced apart from the first valve seat 508 and the second end 526 may sealingly engage the second valve seat 510. In this manner, when the valve member 493 is in the first position, fluid passageways 489 of the manifold 474 are sealed off from the suction-communication aperture 68, but are allowed to communicate with the internal volume 26 through the first inlet 502, the passage 512 and the outlet 506. When the valve member 493 is in the second position (FIG. 22), the first end 524 may sealingly engage the first valve seat 508 and the second end 526 may be spaced apart from the second valve seat 510. In this manner, when the valve member 493 is in the second position, fluid passageways 489 of the manifold 474 are sealed off from the internal volume 26, but are allowed to communicate with the suction-inlet opening 58 through the suction-communication aperture 68, the inlet 488 of the recess 482, the second inlet 504 of the valve body 491 and the outlet 506 of the valve body 491.

While the solenoid coil 495 and a portion of the valve body 491 are described above and shown in FIGS. 21 and 22 as being disposed outside of the shell assembly 12, it will be appreciated that the entire actuation valve 478 could be disposed within the shell assembly 12. However, the configuration depicted in FIGS. 21 and 22 may allow the solenoid coil 495 to be more easily accessed by a user or service technician in the event that the solenoid coil 495 needs to be replaced or serviced, for example. Furthermore, configurations in which the solenoid coil 495 is disposed outside of the shell assembly 12 provide a cooler operating environment for the solenoid coil 495, which may improve the longevity of the solenoid coil 495.

With reference to FIG. 23, another capacity-modulation assembly 618 is provided. The capacity-modulation assembly 618 can replace the capacity-modulation assembly 18 in the compressor 10 described above. The structure and function of the capacity-modulation assembly 618 may be substantially similar to that of the capacity-modulation assembly 18, apart from the exceptions described below and shown in the figures. Therefore, similar features will not be described again in detail.

The capacity-modulation assembly 618 may include a manifold 674, a plurality of capacity-modulation valve assemblies 676, and an actuation valve (not shown). The manifold 674 and actuation valve may be similar or identical to any of the manifolds 74, 274, 474 and actuation valves 78, 478 described above. Each of the capacity-modulation valve assemblies 676 may include a valve member 694 and a spring 696. The valve member 694 may include a head portion 700 and a stem portion 702. In some embodiments, the head portion 700 and the stem portion 702 may be initially formed as separate pieces and/or from different materials. For example, the stem portion 702 may be formed from a softer material that will wear relatively quickly in response to friction between a distal end 704 of the stem portion 702 and the tip 47 of the spiral wrap 46 of the orbiting scroll 40 during operation of the compressor 10. Accordingly, the stem portion 702 may be manufactured to include an axial length that causes a gap to exist between the top face 55 of the end plate 54 of the non-orbiting scroll 42 and a bottom face 706 of the head portion 700 when the capacity-modulation assembly 618 is in the full-capacity mode.

After assembly of the compressor 10, operating the compressor 10 will cause the tip 47 of the spiral wrap 46 to wear material off of the distal end 704 of the stem portion 702 until the axial length of the stem portion 702 is reduced to an extent at which the bottom face 706 of the head portion 700 contacts the top face 55 of the end plate 54 when the capacity-modulation assembly 618 is in the full-capacity mode (as shown in FIG. 23). Once the stem portion 702 has worn down to this length, minimal contact may exist between the stem portion 702 and the tip 47 of the spiral wrap 46 that will provide sufficient sealing therebetween without unnecessary loading on the tip 47. This process of wearing-in the valve member 694 may eliminate the need to tightly control tolerances on the axial length of the valve member 694, while still providing optimal engagement between the valve member 694 and the tip 47.

With reference to FIG. 24, another capacity-modulation assembly 818 is provided. The capacity-modulation assembly 818 can replace the capacity-modulation assembly 18 in the compressor 10 described above. The structure and function of the capacity-modulation assembly 818 may be substantially similar to that of the capacity-modulation assembly 18, apart from the exceptions described below and shown in the figures. Therefore, similar features will not be described again in detail.

The capacity-modulation assembly 818 may include a manifold 874, a plurality of capacity-modulation valve assemblies 876, and an actuation valve (not shown). The manifold 874 and actuation valve may be similar or identical to any of the manifolds 74, 274, 474, 674 and actuation valves 78, 478 described above. Each of the capacity-modulation valve assemblies 876 may include a valve member 894 and a spring 896. The valve member 894 may include a body 900 and a cap 902. The body 900 may include a head portion 904 and a stem portion 906. The cap 902 may be cup-shaped member having a generally U-shaped cross section. The stem portion 906 may be fixedly received within the cap 902.

In some embodiments, the body 900 and the cap 902 may be initially formed as separate pieces and/or from different materials. For example, the cap 902 may be formed from a softer material that will wear relatively quickly in response to friction between the cap 902 and the tip 47 of the spiral wrap 46 of the orbiting scroll 40 during operation of the compressor 10. Accordingly, the cap 902 may be manufactured so that an axial end 908 of the cap 902 includes an thickness that causes a gap to exist between the top face 55 of the end plate 54 of the non-orbiting scroll 42 and a bottom face 910 of the head portion 904 when the capacity-modulation assembly 818 is in the full-capacity mode.

After assembly of the compressor 10, operating the compressor 10 will cause the tip 47 of the spiral wrap 46 to wear material off of the axial end 908 of the cap 902 until the overall axial length of the valve member 894 is reduced to an extent at which the bottom face 910 of the head portion 904 contacts the top face 55 of the end plate 54 when the capacity-modulation assembly 818 is in the full-capacity mode (as shown in FIG. 24). Once the cap 902 has worn down to this thickness, minimal contact may exist between the cap 902 and the tip 47 of the spiral wrap 46 that will provide sufficient sealing therebetween without unnecessary loading on the tip 47. This process of wearing-in the valve member 894 may eliminate the need to tightly control tolerances on the axial length of the valve member 894, while still providing optimal engagement between the valve member 894 and the tip 47.

In some embodiments, the cap 902 could be a coating that is applied to the bottom of the body 900 of the valve member 894. Such a coating could be applied to form the cup shape of the cap 902 shown in FIG. 24 or the coating could be applied only to the axial end of the stem portion 906

In this application, the term “module” may be replaced with the term “circuit.” The term module may refer to, be part of, or include an Application Specific Integrated Circuit (ASIC); a digital, analog, or mixed analog/digital discrete circuit; a digital, analog, or mixed analog/digital integrated circuit; a combinational logic circuit; a field programmable gate array (FPGA); a processor (shared, dedicated, or group) that executes code; memory (shared, dedicated, or group) that stores code executed by a processor; other suitable hardware components that provide the described functionality; or a combination of some or all of the above, such as in a system-on-chip.

The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. For example, the principles of the present disclosure are applicable to low-side compressors. Further, individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Claims

1. A compressor comprising:

a shell defining an internal volume;

a first scroll disposed within said internal volume and including a first spiral wrap;

a second scroll disposed within said internal volume and including a second spiral wrap engaged with said first spiral wrap to form a pocket between said first and second spiral wraps, said second scroll including a suction inlet opening, a discharge passage and a capacity-modulation aperture, said suction inlet opening receiving said fluid at a first pressure and being isolated from said internal volume, said discharge passage discharging said fluid to said internal volume at a second pressure that is higher than said first pressure; and

a valve member at least partially disposed within said capacity-modulation aperture and movable between a first position in which said valve member restricts fluid to flow around a tip of said first spiral wrap to restrict fluid communication between said suction inlet opening and said pocket and a second position in which said valve member allows fluid-flow around said tip of said first spiral wrap to provide fluid communication between said suction inlet opening and said pocket.

2. The compressor of claim 1, wherein an end of said valve member is exposed to fluid within a fluid chamber, said fluid chamber communicating with said internal volume when said valve member is in said first position and communicating with said suction inlet opening when said valve member is in said second position.

3. The compressor of claim 2, further comprising an actuation valve movable between a first position allowing fluid communication between said fluid chamber and said internal volume and restricting fluid communication between said fluid chamber and said suction inlet opening and a second position restricting fluid communication between said fluid chamber and said internal volume and allowing fluid communication between said fluid chamber and said suction inlet opening.

4. The compressor of claim 3, wherein moving said actuation valve into said second position allows said fluid chamber to fluidly communicate with said suction inlet opening through an aperture of an end plate of said second scroll.

5. The compressor of claim 2, wherein said valve member moves between said first position and said second position responsive to a change in a pressure differential between said fluid chamber and said pocket.

6. The compressor of claim 1, wherein said valve member includes a first portion and a second portion, said first portion contacting said first spiral wrap and disposed between said second portion and said first spiral wrap, said first portion being formed from a material that allows said first portion to wear faster than said second portion.

7. A compressor comprising:

a first scroll including a first end plate and a first spiral wrap extending from said first end plate;

a second scroll including a second end plate and a second spiral wrap extending from said first end plate and engaged with said first spiral wrap, said second end plate including a suction inlet opening and first and second capacity-modulation apertures;

first and second valve members at least partially disposed within said first and second capacity-modulation apertures, respectively, and movable to selectively provide first and second leakage paths around a tip of said first spiral wrap;

a manifold including first and second chambers and a fluid passageway fluidly connecting said first and second chambers, said first and second chambers being aligned with said first and second capacity-modulation apertures, respectively, and portions of said first and second valve members are exposed to said first and second chambers; and

an actuation valve in fluid communication with said fluid passageway and movable between a first position providing fluid communication between said fluid passageway and said suction inlet opening and a second position providing fluid communication between said fluid passageway and a fluid source having a fluid pressure that is greater than a fluid pressure of said suction inlet opening.

8. The compressor of claim 7, wherein said first and second capacity-modulation apertures are positioned so that said first and second leakage paths fluidly connect said suction inlet opening with one or more pockets defined by said first and second spiral wraps.

9. The compressor of claim 7, further comprising first and second pockets defined by said first and second spiral wraps, said first and second pockets being sealed off from said suction inlet opening when said first scroll is in a first orbital position, wherein said first and second capacity-modulation apertures are positioned so that when said first scroll is in said first orbital position and said actuation valve is in said first position, said first leakage path allows leakage from said first pocket to said second pocket and said second leakage path allows leakage from said second pocket to said suction inlet opening.

10. The compressor of claim 9, wherein said second scroll includes a third capacity-modulation aperture disposed between said first and second capacity-modulation apertures.

11. The compressor of claim 10, further comprising a third valve member at least partially disposed within said third capacity-modulation aperture and movable therein to selectively provide a third leakage path around a tip of said first spiral wrap, and wherein said manifold includes a third chamber in communication with said fluid passageway and aligned with said third capacity-modulation aperture.

12. The compressor of claim 7, further comprising a shell defining an internal volume in which said first and second scrolls are disposed, and wherein said fluid source is said internal volume.

13. The compressor of claim 7, wherein said fluid passageway is in communication with said suction inlet opening through an aperture formed in said second end plate when said actuation valve is in said first position.

14. A high-side compressor including a shell defining an internal volume containing compressed working fluid and first and second scrolls, said first scroll including a first spiral wrap, said second scroll including a second spiral wrap, a suction inlet opening and a capacity-modulation aperture, said second spiral wrap meshingly engaging said first spiral wrap to define a pocket therebetween, said suction inlet opening being sealed off from said internal volume, said capacity-modulation aperture receiving a valve member that is movable therein between a first position allowing leakage of fluid from said pocket to said suction inlet opening and a second position restricting leakage of fluid from said pocket.

15. The high-side compressor of claim 14, wherein said valve member allows leakage of fluid from said pocket around a tip of said first spiral wrap to said suction inlet opening.

16. The high-side compressor of claim 14, further comprising another valve member movable within another capacity-modulation aperture formed in said second scroll between a first position allowing leakage of fluid from said pocket to said suction inlet opening and a second position restricting leakage of fluid from said pocket.

17. The high-side compressor of claim 16, wherein said valve members are independently controllable and independently movable between said first and second positions.

18. The high-side compressor of claim 16, further comprising a manifold and an actuation valve operable in a first position to supply fluid to said valve members at a first pressure to move the valve members to said first position and operable in a second position to supply fluid to said valve members at a second pressure that is higher than said first pressure to move said valve members to said second position.

19. The high-side compressor of claim 18, wherein an end plate of said second scroll includes a fluid passageway in communication with said suction inlet opening, and wherein said actuation valve is in communication with a fluid passageway in said first position.

20. The high-side compressor of claim 19, wherein said actuation valve is in communication with said internal volume in said second position.

21. The high-side compressor of claim 20, wherein said valve members allow leakage of fluid around a tip of said first spiral wrap to said suction inlet opening.