Reciprocating Compressor and Fluid Injection System

The present disclosure relates to a reciprocating compressor and particularly to a reciprocating compressor incorporating a fluid injection system.

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

Reciprocating compressors typically include a compressor body housing a drive motor and one or more piston-cylinder arrangements. In operation, the drive motor imparts a force on each piston to move the pistons within and relative to respective cylinders. During operation of the reciprocating compressor, pressure of working fluid disposed within the cylinders is increased. For example, a reciprocating compressor may receive fluid at a suction pressure and may increase the pressure from the suction pressure to a discharge pressure. The fluid at the discharge pressure may then exit the compressor.

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 reciprocating compressors circulating a working fluid (e.g., refrigerant or carbon dioxide) between the indoor and outdoor heat exchangers. Efficient and reliable operation of the compressor is desirable to ensure that the climate-control system in which the compressor is installed is capable of effectively and efficiently providing a cooling and/or heating effect on demand. It is advantageous to have a reciprocating compressor that minimizes energy consumption during operation while providing sufficient discharge-pressure refrigerant to the system to satisfy a cooling and/or heating demand. Moreover, in compressors including more than one compression mechanism (i.e., one or more pairs of reciprocating piston-cylinder arrangements), it is advantageous to inject fluid at an intermediate pressure into each compression mechanism from a single external source.

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 includes a housing, a first compression mechanism and a second compression mechanism disposed in the housing, and a housing cover fixed to the housing. Both the first compression mechanism and the second compression mechanism are configured to compress a working fluid from a suction pressure to a discharge pressure. The first compression mechanism includes a first cylinder housing having a first cylinder, a second cylinder, and a first fluid storage plenum. The second compression mechanism includes a second cylinder housing having a third cylinder, a fourth cylinder, and a second fluid storage plenum. The housing cover defines an intermediate-fluid port therein. The intermediate-fluid port is in fluid communication with the first fluid storage plenum via a first intermediate-fluid passage and the second fluid storage plenum via a second intermediate-fluid passage. Working fluid at an intermediate pressure enters the intermediate-fluid port. The intermediate pressure is greater than the suction pressure and less than the discharge pressure. The first fluid storage plenum and the second fluid storage plenum are configured to store the fluid at the intermediate pressure therein.

In some configurations of the compressor of the above paragraph, the housing cover includes a body defining an outer diameter and an inner diameter spaced radially inward from the outer diameter. The housing cover includes a first surface and a second surface opposite the first surface. The first surface and the second surface define a thickness therebetween. The housing cover includes a third surface that protrudes axially from the second surface. The second surface and the third surface cooperate to define a cavity therebetween.

In some configurations of the compressor of either of the above paragraphs, the cavity is in fluid-communication with the intermediate-fluid port.

In some configurations of the compressor of any of the above paragraphs, the second surface of the housing cover defines a plurality of apertures positioned between the outer diameter and the inner diameter. Each of the plurality of apertures extend partially through the body to a depth that is less than the thickness.

In some configurations of the compressor of any of the above paragraphs, a channel extends radially inward from each of the plurality of apertures to the inner diameter. Each of the channels are in fluid communication with the cavity.

In some configurations of the compressor of any of the above paragraphs, each of the channels includes an intermediate-fluid inlet proximate to the inner diameter and an intermediate-fluid outlet proximate to one of the plurality of apertures. The fluid at the intermediate pressure flows through the channel from the intermediate-fluid inlet to the intermediate-fluid outlet.

In some configurations of the compressor of any of the above paragraphs, a length of the channel is greater than a diameter of the channel.

In some configurations of the compressor of any of the above paragraphs, each of the plurality of apertures are in fluid communication with the cavity via the channel.

In some configurations of the compressor of any of the above paragraphs, the plurality of apertures includes a first aperture in fluid communication with the first intermediate-fluid passage and a second aperture in fluid communication with the second intermediate-fluid passage.

In some configurations of the compressor of any of the above paragraphs, fluid at the intermediate pressure flows from the intermediate-fluid port, through the cavity, through the plurality of apertures, and through the first intermediate-fluid passage and the second intermediate-fluid passage to the respective first storage plenum and second storage plenum.

In some configurations of the compressor of any of the above paragraphs, the first fluid storage plenum is in selective fluid communication with the first cylinder and the second cylinder, and the second fluid storage plenum is in selective fluid communication with the third cylinder and the fourth cylinder.

In some configurations of the compressor of any of the above paragraphs, each of the first cylinder second cylinder, third cylinder, and fourth cylinder include a sleeve assembly disposed therein. The sleeve assembly including a sleeve and a collar.

In some configurations of the compressor of any of the above paragraphs, the sleeve includes a hollow body including an annular wall. The annular wall extends between a first end and a second end. The hollow body includes an inner surface and an outer surface opposite the inner surface. A flange extends radially outward from the first end of the annular wall. A step is positioned between a first portion of the hollow body and a second portion of the hollow body. A diameter of the outer surface of the first portion is greater than a diameter of the outer surface of the second portion. A plurality of recesses is defined in the first portion. A plurality of apertures is defined in the second portion.

In some configurations of the compressor of any of the above paragraphs, the collar includes an annular member extending between a first end and a second end and including an outer surface and an inner surface opposite the outer surface. A first plurality of protrusions extend axially from the second end. A second plurality of protrusions extend axially from the first end. A plurality of depressions is defined in the inner surface. Each of the plurality of depressions is positioned between each of the first plurality of protrusions.

In some configurations of the compressor of any of the above paragraphs, the first end of the collar is in contact with the first step of the sleeve. The second plurality of protrusions of the collar are received in the plurality of recesses of the sleeve. The plurality of depressions of the collar are aligned with and spaced apart from the plurality of apertures of the sleeve.

In some configurations of the compressor of any of the above paragraphs, the plurality of depressions of the collar and the plurality of apertures of the sleeve cooperate to define a plurality of ports therebetween.

In some configurations of the compressor of any of the above paragraphs, each of the first cylinder, the second cylinder, the third cylinder, and the fourth cylinder receive a piston therein. The piston is movable between a first position and a second position. The piston and the sleeve assembly cooperate to selectively permit the fluid at the intermediate pressure to enter the respective cylinder.

In some configurations of the compressor of any of the above paragraphs, when the piston is in the first position, the fluid at the intermediate pressure enters the cylinder through the plurality of ports.

In some configurations of the compressor of any of the above paragraphs, when the piston is in the second position, the fluid at the intermediate pressure is restricted from entering the cylinder.

In another form, the present disclosure provides a compressor that includes a housing, a compression mechanism disposed in the housing, and a housing cover attached to the housing. The compression mechanism is configured to compress a working fluid from a suction pressure to a discharge pressure. The housing cover includes a circular body defining an outer diameter and an inner diameter spaced radially inward from the outer diameter. The circular body includes a first surface and a second surface opposite the first surface. A third surface protrudes axially from the second surface along at least a portion of the inner diameter. The second surface and the third surface cooperate to define a cavity therebetween. An intermediate-fluid port extends between the first surface and the second surface. The intermediate-fluid port is configured to receive working fluid at an intermediate pressure and to provide the fluid at the intermediate pressure to the compression mechanism. The intermediate pressure is greater than the suction pressure and less than the discharge pressure.

In some configurations of the compressor of the above paragraph, the second surface defines a plurality of apertures positioned between the outer diameter and the inner diameter. Each of the plurality of apertures extend partially through the circular body.

In some configurations of the compressor of either of the above paragraphs, a channel extends radially inward from each of the plurality of apertures to the inner diameter. The channel is in fluid communication with the cavity.

In some configurations of the compressor of any of the above paragraphs, the channel includes an intermediate-fluid inlet proximate to the inner diameter. The channel also includes an intermediate-fluid outlet proximate to one of the plurality of apertures. Fluid at the intermediate pressure flows through the channel from the intermediate-fluid inlet to the intermediate-fluid outlet.

In some configurations of the compressor of any of the above paragraphs, at least one of the plurality of apertures is in fluid communication with the compression mechanism via an intermediate-fluid passage.

In another form, the present disclosure provides a compressor that includes a housing, a first compression mechanism and a second compression mechanism disposed in the housing, a valve, and an intermediate-fluid port. The first compression mechanism and the second compression mechanism are configured to compress a working fluid from a suction pressure to a discharge pressure. The first compression mechanism includes a first cylinder housing having a first cylinder, a second cylinder, and a first fluid storage plenum. The second compression mechanism includes a second cylinder housing having a third cylinder, a fourth cylinder, and a second fluid storage plenum. The intermediate-fluid port is in selective communication with the valve. The intermediate-fluid port is in fluid communication with the first fluid storage plenum via a first intermediate-fluid passage. The intermediate-fluid port is also in fluid communication with the second fluid storage plenum via a second intermediate-fluid passage. Working fluid at an intermediate pressure enters the intermediate-fluid port from the valve. The intermediate pressure is greater than the suction pressure and less than the discharge pressure. The first fluid storage plenum and the second fluid storage plenum are configured to store the fluid at the intermediate pressure therein.

In some configurations of the compressor of the above paragraph, the first fluid storage plenum is in selective fluid communication with the first cylinder and the second cylinder. The second fluid storage plenum is in selective fluid communication with the third cylinder and the fourth cylinder.

In some configurations of the compressor of either of the above paragraphs, each of the first cylinder, second cylinder, third cylinder, and fourth cylinder include a sleeve assembly disposed therein. The sleeve assembly includes a sleeve and a collar.

In some configurations of the compressor of any of the above paragraphs, the sleeve includes a hollow body including an annular wall. The annular wall extends between a first end and a second end. The hollow body includes an inner surface and an outer surface opposite the inner surface. A flange extends radially outward from the first end of the annular wall. A step is positioned between a first portion of the hollow body and a second portion of the hollow body. A diameter of the outer surface of the first portion is greater than a diameter of the outer surface of the second portion. A plurality of recesses is defined in the first portion. A plurality of apertures is defined in the second portion.

In some configurations of the compressor of any of the above paragraphs, the collar includes an annular member extending between a first end and a second end and including an outer surface and an inner surface opposite the outer surface. A first plurality of protrusions extend axially from the second end. A second plurality of protrusions extend axially from the first end. A plurality of depressions is defined in the inner surface. Each of the plurality of depressions is positioned between each of the first plurality of protrusions.

In some configurations of the compressor of any of the above paragraphs, the first end of the collar is in contact with the step of the sleeve. The second plurality of protrusions of the collar are received in the plurality of recesses of the sleeve. The plurality of depressions of the collar are aligned with and spaced apart from the plurality of apertures of the sleeve.

In some configurations of the compressor of any of the above paragraphs, the plurality of depressions of the collar and the plurality of apertures of the sleeve cooperate to define a plurality of ports therebetween.

In some configurations of the compressor of any of the above paragraphs, each of the first cylinder, the second cylinder, the third cylinder, and the fourth cylinder receive a piston therein. The piston is movable between a first position and a second position. The piston and the sleeve assembly cooperate to selectively permit fluid at the intermediate pressure to enter the respective first, second, third, or fourth cylinder.

In some configurations of the compressor of any of the above paragraphs, when the piston is in the first position, the fluid at the intermediate pressure enters the respective cylinder through the plurality of ports.

In some configurations of the compressor of any of the above paragraphs, when then piston is in the second position, the fluid at the intermediate pressure is restricted from entering the respective cylinder.

In another form, the present disclosure provides a compressor that includes a cylinder, a sleeve assembly disposed in the cylinder, and a piston disposed within the sleeve assembly. The sleeve assembly includes a sleeve and a collar. The sleeve and the collar cooperate to define a plurality of ports. The piston is movable between a first position and a second position. The piston is configured to compress a working fluid from a suction pressure at the first position to a discharge pressure at the second position. The piston and the sleeve assembly cooperate to selectively permit working fluid at an intermediate pressure to enter the cylinder. The intermediate pressure is greater than the suction pressure and less than the discharge pressure.

In some configurations of the compressor of the above paragraph, the sleeve includes a hollow body including an annular wall. The annular wall extends between a first end and a second end. The hollow body includes an inner surface and an outer surface opposite the inner surface. A flange extends radially outward from the first end of the annular wall. A step is positioned between a first portion of the hollow body and a second portion of the hollow body. A diameter of the outer surface of the first portion is greater than a diameter of the outer surface of the second portion. A plurality of recesses is defined in the first portion. A plurality of apertures is defined in the second portion.

In some configurations of the compressor of either of the above paragraphs, the collar includes an annular member extending between a first end and a second end and including an outer surface and an inner surface opposite the outer surface. A first plurality of protrusions extend axially from the second end. A second plurality of protrusions extend axially from the first end. A plurality of depressions is defined in the inner surface. Each of the plurality of depressions is positioned between each of the first plurality of protrusions.

In some configurations of the compressor of any of the above paragraphs, a shape of the second plurality of protrusions of the collar is complimentary to a shape of the plurality of recesses of the sleeve.

In some configurations of the compressor of any of the above paragraphs, the first end of the collar is in contact with the step of the sleeve. The second plurality of protrusions of the collar are received in the plurality of recesses of the sleeve.

In some configurations of the compressor of any of the above paragraphs, the plurality of depressions of the collar are aligned with and spaced apart from the plurality of apertures of the sleeve.

In some configurations of the compressor of any of the above paragraphs, the plurality of depressions of the collar and the plurality of apertures of the sleeve cooperate to define the plurality of ports.

In some configurations of the compressor of any of the above paragraphs, the piston includes a hollow cylindrical body including a top wall and a side wall extending perpendicularly from the top wall. The top wall defines a plurality of chamfered recesses.

In some configurations of the compressor of any of the above paragraphs, the plurality of chamfered recesses extend radially inward from a perimeter of the top wall at an angle relative to the side wall.

In some configurations of the compressor of any of the above paragraphs, the angle is greater than or equal to about 15 degrees to less than or equal to about 45 degrees.

In some configurations of the compressor of any of the above paragraphs, the plurality of chamfered recesses are aligned with the plurality of ports.