Abstract:
Scrolls made from one or more near-net shaped powder metal processes either wholly or fabricated together from sections and comprising a sealing polymer disposed in pores of the sintered powder. Both "conventional" press and sinter methods and metal injection molding methods will be described.
Abstract:
Methods of forming scroll compressor components are provided. The methods include forming at least one component of a scroll member from a powder metallurgy technique and joining the component with another distinct component via a sinter-brazing process. For example, a baseplate having a spiral scroll involute is joined to a hub via a joint interface having brazing material to form a braze joint with superior quality. At least one component is formed from a powder metal material including carbon and at least one species that reacts with or binds carbon to prevent migration during brazing of the sinter-brazing heat process. Optionally, during the powder metallurgy process, an alloy with a lower concentration of carbon is selected, which may be incorporated into a crystal structure with the species that prevents carbon migration.
Abstract:
Scroll members for scroll compressors made from one or more near-net shaped powder metal processes, either wholly or partially fabricated together from sections. In certain variations, the involute scroll portion of the scroll member has a modified terminal end region. The terminal end region may include an as-sintered coupling feature comprising a tip component that forms a contact surface for contacting an opposing scroll member during compressor operation. The tip component can be a tip seal or a tip cap received by the as-sintered coupling feature. The tip cap may be sinter-bonded or otherwise coupled to the terminal end region. In other variations, a terminal end region may comprise a second material including a tribological material that forms a contact surface. Methods of making such scroll members for scroll compressors are also provided.
Abstract:
Methods for improving bearing performance in compressors, especially for those that use high energy refrigerants or that have a high-side design, are provided. The compressor comprises a bearing that is substantially free of lead. The bearing comprises copper and at least one lubricant particle type selected from a group consisting of: molybdenum disulfide (MoS2), calcium fluoride (CaF2), tungsten disulfide (WS2), zinc sulfide (ZnS), hexagonal boron nitride, polytetrafluoroethylene (PTFE), carbon fiber, graphite, graphene, carbon nanotubes, carbon particles, thermoset polyimide, and combinations thereof. The compressor processes a high energy refrigerant and a lubricant oil comprising a sulfur-based additive. The sulfur-based additive reacts with the copper in the bearing to enhance lubricity and improve performance of the bearing in the compressor machine. Compressors having such features and improved bearing performance are also contemplated.