Compressor Having Capacity Modulation System

This application claims the benefit of U.S. Provisional Application No. 63/635,270, filed on Apr. 17, 2024. The entire disclosure of the above application is incorporated herein by reference.

The present disclosure relates to a compressor having a capacity-modulation system.

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

A climate-control system (e.g., 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. The one or more compressors can include a capacity-modulation system operable to modulate the capacity of the one or more compressors.

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

The present disclosure provides a compressor that may include a first scroll, a second scroll, and a capacity-modulation system. 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 second end plate. The first and second spiral wraps may cooperate to define a plurality of fluid pockets. During operation of the compressor, the fluid pockets move from a radially outer position to radially intermediate positions to a radially inner position. The capacity-modulation system may be operable in a high-capacity mode and a low-capacity mode. The second end plate may define a suction inlet, a discharge passage, a modulation port, and a vent passage. The modulation port may communicate with one of the fluid pockets at one of the radially intermediate positions. The vent passage may extend from and is in communication with the suction inlet defined by the second scroll. The capacity-modulation system may include a control valve and a piston. The control valve is movable between a first position and a second position. The piston may be disposed within a recess in the second end plate. The vent passage may extend from the recess to the suction inlet. The piston may be movable in the recess between an open position in which fluid communication between the modulation port and the vent passage is allowed and a closed position in which fluid communication between the modulation port and the vent passage is prevented. Movement of the control valve to the first position may cause movement of the piston to the closed position. Movement of the control valve to the second position may cause movement of the piston to the open position.

In some configurations of the compressor of the above paragraph, the second end plate includes another modulation port that communicates with another one of the fluid pockets at another one of the radially intermediate positions.

In some configurations of the compressor of the above paragraph, the piston blocks both of the modulation ports in the closed position and opens both of the modulation ports in the open position.

In some configurations of the compressor of any one or more of the above paragraphs, the piston includes a recess formed in an axially-facing surface of the piston, wherein the axially-facing surface sealingly contacts a surface of the non-orbiting scroll when the piston is in the closed position.

In some configurations of the compressor of any one or more of the above paragraphs, the recess in the piston is vented to the vent passage.

In some configurations of the compressor of any one or more of the above paragraphs, a spring is disposed within the recess.

In some configurations of the compressor of any one or more of the above paragraphs, when the control valve is in the first position, the control valve allows intermediate-pressure working fluid to flow to an actuation chamber defined by the piston and the second end plate.

In some configurations of the compressor of any one or more of the above paragraphs, when the control valve is in the second position, the control valve prevents intermediate-pressure working fluid from flowing to the actuation chamber.

In some configurations of the compressor of any one or more of the above paragraphs, the intermediate-pressure working fluid is at a pressure higher than a suction pressure and less than a discharge pressure.

In some configurations of the compressor of any one or more of the above paragraphs, when the control valve is in the first position, the intermediate-pressure working fluid flows from an axial biasing chamber, through the control valve to the actuation chamber via a passage in the second end plate.

In some configurations of the compressor of any one or more of the above paragraphs, the axial biasing chamber is defined by the second end plate and a floating seal assembly.

In some configurations of the compressor of any one or more of the above paragraphs, a plug is disposed within the recess in the second end plate. The actuation chamber may be disposed between the plug and the piston.

In some configurations of the compressor of any one or more of the above paragraphs, the second end plate includes a first portion and a second portion that is attached to the first portion by fasteners. The second portion may define a closed end of the actuation chamber.

In some configurations of the compressor of any one or more of the above paragraphs, the control valve includes a body, a housing, and a valve member.

In some configurations of the compressor of any one or more of the above paragraphs, the body is received in a valve passage in the second end plate.

In some configurations of the compressor of any one or more of the above paragraphs, the body includes a first passage, a second passage, and a third passage.

In some configurations of the compressor of any one or more of the above paragraphs, the housing is fixed relative to the second end plate and the body.

In some configurations of the compressor of any one or more of the above paragraphs, the valve member is disposed within the housing and is movable therein between the first and second positions.

In some configurations of the compressor of any one or more of the above paragraphs, a portion of the valve member is movably received in the first passage of the body.

In some configurations of the compressor of any one or more of the above paragraphs, when the valve member is in the first position, the valve member allows fluid communication between the second and third passages and prevents fluid communication between the first passage and a suction chamber of the compressor.

In some configurations of the compressor of any one or more of the above paragraphs, when the valve member is in the second position, the valve member prevents fluid communication between the second and third passages and allows fluid communication between the first passage and the suction chamber of the compressor.

In some configurations of the compressor of any one or more of the above paragraphs, the control valve includes a solenoid coil and a spring.

In some configurations of the compressor of any one or more of the above paragraphs, the spring biases the valve member toward the first position.

In some configurations of the compressor of any one or more of the above paragraphs, when the solenoid coil is energized, the valve member moves toward the second position.

In another form, the present disclosure provides a compressor that may include a first scroll, a second scroll, and a capacity-modulation system. 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 second end plate. The first and second spiral wraps may cooperate to define a plurality of fluid pockets. During operation of the compressor, the fluid pockets move from a radially outer position to radially intermediate positions to a radially inner position. The second end plate may include a first modulation port, a second modulation port, a first recess, a second recess, and a discharge passage. The first and second modulation ports may fluidly communicate with respective fluid pockets at the radially intermediate positions. The capacity-modulation system may be operable to switch the compressor between a high-capacity mode, an intermediate-capacity mode, and a low-capacity mode. The capacity-modulation system may include a first piston, a second piston, a first control valve, and a second control valve. The first and second control valves may be movable between a first position and a second position. The first and second pistons may be disposed within the first and second recesses, respectively, and are movable therein between an open position and a closed position. When the first and second pistons are in the open position, fluid communication is allowed between the first and second modulation ports and a suction-pressure region of the compressor. When the first and second pistons are in the closed position, fluid communication is prevented between the first and second modulation ports and the suction-pressure region of the compressor. Movement of the first control valve to the first position causes movement of the first piston to the closed position, and movement of the first control valve to the second position causes movement of the first piston to the open position. Movement of the second control valve to the first position causes movement of the second piston to the closed position, and movement of the second control valve to the second position causes movement of the second piston to the open position.

In some configurations of the compressor of the above paragraph, the suction-pressure region of the compressor is a suction inlet defined by the second scroll.

In some configurations of the compressor of either of the above paragraphs, the compressor is in the high-capacity mode when the first and second pistons are in the closed position and the first and second control valves are in the first position.

In some configurations of the compressor of any one or more of the above paragraphs, the compressor is in the intermediate-capacity mode when one of the first and second pistons is in the closed position, one of the first and second pistons is in the open position, one of the first and second control valves is in the first position, and one of the first and second control valves is in the second position.

In some configurations of the compressor of any one or more of the above paragraphs, the compressor is in the low-capacity mode when the first and second pistons are in the open position and the first and second control valves are in the second position.

In some configurations of the compressor of any one or more of the above paragraphs, the second end plate includes a connecting passage that extends from the first recess to the second recess. The connecting passage may be in fluid communication with the first and second recesses when the first and second pistons are in the open position.

In some configurations of the compressor of any one or more of the above paragraphs, each of the first and second control valves includes a body, a housing, and a valve member.

In some configurations of the compressor of any one or more of the above paragraphs, the body is received in a respective valve passage in the second end plate.

In some configurations of the compressor of any one or more of the above paragraphs, the body includes a first passage, a second passage, and a third passage.

In some configurations of the compressor of any one or more of the above paragraphs, the housing is fixed relative to the second end plate and the body.

In some configurations of the compressor of any one or more of the above paragraphs, the valve member is disposed within the housing and is movable therein between the first and second positions.

In some configurations of the compressor of any one or more of the above paragraphs, a portion of the valve member is movably received in the first passage of the body.

In some configurations of the compressor of any one or more of the above paragraphs, when the valve member is in the first position, the valve member allows fluid communication between the second and third passages and prevents fluid communication between the first passage and a suction chamber of the compressor.

In some configurations of the compressor of any one or more of the above paragraphs, when the valve member is in the second position, the valve member prevents fluid communication between the second and third passages and allows fluid communication between the first passage and the suction chamber of the compressor.

In some configurations of the compressor of any one or more of the above paragraphs, each of the first and second control valves includes a solenoid coil and a spring.

In some configurations of the compressor of any one or more of the above paragraphs, the spring biases the valve member toward the first position.

In some configurations of the compressor of any one or more of the above paragraphs, when the solenoid coil is energized, the valve member moves toward the second position.

In another form, the present disclosure provides a compressor that may include a first scroll, a second scroll, and a capacity-modulation system. 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 second end plate. The first and second spiral wraps may cooperate to define a plurality of fluid pockets. During operation of the compressor, the fluid pockets move from a radially outer position to radially intermediate positions to a radially inner position. The second end plate may include a first modulation port, a second modulation port, a first recess, a second recess, and a discharge passage. The first and second modulation ports may fluidly communicate with respective fluid pockets at the radially intermediate positions. The capacity-modulation system may include a first piston, a second piston, and a control valve. The first and second pistons may be disposed within the first and second recesses, respectively, and are movable therein between an open position and a closed position. When the first and second pistons are in the open position, fluid communication is allowed between the first and second modulation ports and a suction-pressure region of the compressor. When the first and second pistons are in the closed position, fluid communication is prevented between the first and second modulation ports and the suction-pressure region of the compressor. Movement of the control valve to a first position causes movement of the first and second pistons to the closed position, and movement of the control valve to a second position causes movement of the first and second pistons to the open position.

In some configurations of the compressor of the above paragraph, the suction-pressure region of the compressor is a suction inlet defined by the second scroll.

In some configurations of the compressor of any one or more of the above paragraphs, the second end plate includes a connecting passage that extends from the first recess to the second recess.

In some configurations of the compressor of any one or more of the above paragraphs, the connecting passage is in fluid communication with the first and second recesses when the first and second pistons are in the open position.