Method of making a two-piece counterweight for a scroll compressor

Patent metadata

Field	Value
Publication number	US-10697454-B2
Application number	US-201615064408-A
Country	US
Kind code	B2
Filing date	Mar 8, 2016
Priority date	Mar 8, 2016
Publication date	Jun 30, 2020
Grant date	Jun 30, 2020

Abstract

A method of manufacturing a two-piece counterweight for a scroll compressor is provided. The method includes molding an outer plate, and molding a base having a first opening configured to receive a scroll compressor drive shaft having a longitudinal axis, and configuring the base for assembly and attachment to the drive shaft. The method also includes attaching the outer plate to the base such that the outer plate is axially offset from the base. In a particular embodiment of this method, the base and outer plate are molded from powdered metal. In certain embodiments, the base and outer plate include one or more openings aligned to permit attachment by inserting a mechanical fastener through the aligned openings. In alternate embodiments, the base and outer plate are attached via brazing or welding.

First claim

What is claimed is:

1. A method of manufacturing a two-piece counterweight for a scroll compressor, the method comprising:
molding an outer plate;
molding a base separately from the molding of the outer plate, the base having a first opening configured to receive a scroll compressor drive shaft having a longitudinal axis, and configuring the base for assembly and attachment to the drive shaft;
attaching the outer plate directly to the base such that the outer plate extends radially outward from a perimeter portion of the base, and wherein the outer plate is offset axially, with respect to the longitudinal axis of the scroll compressor drive shaft when the base is assembled to the drive shaft, from the base
wherein molding the base comprises molding the base having:
a central hub portion configured to completely encircle the drive shaft; and
the perimeter portion located radially outward, with respect to the longitudinal axis of the drive shaft when the base is assembled to the drive shaft, from the central hub portion, the perimeter portion only partially encircling the drive shaft;

wherein molding the outer plate comprises molding the outer plate with an inner radial portion and an outer radial portion disposed radially outward, with respect to the longitudinal axis of the drive shaft when the base is assembled to the drive shaft, from the inner radial portion;
wherein molding the base comprises molding the base such that a stepped segment extends axially, with respect to the longitudinal axis of the drive shaft when the base is assembled to the drive shaft, from the perimeter portion of the base, the stepped segment having a first straight radially-inward-facing surface; and
wherein molding the outer plate comprises molding the outer plate such that the inner radial portion of the outer plate has a notched segment with a first straight radially-outward-facing surface that abuts the first straight radially-inward-facing surface to help position the outer plate with respect to the base;
wherein molding the base comprises molding the base such that the stepped segment has a second straight surface perpendicular to the first straight radially-inward-facing surface, the second straight surface facing a direction of rotation for the two-piece counterweight; and
wherein molding the outer plate comprises molding the outer plate such that the notched segment has a second straight surface perpendicular to the first straight radially-outward-facing surface, the second straight surface abutting the second straight radially-inward-facing surface.

2. The method of claim 1 , wherein attaching the outer plate to the base comprises attaching the outer plate to the base by brazing to form a brazing attachment, or by welding to form a welding attachment.

3. The method of claim 2 , wherein the welding attachment or brazing attachment is located along the perimeter portion of the base, and along the inner radial portion of the outer plate where it abuts the perimeter portion.

4. The method of claim 3 , configuring the base and the outer plate such that the perimeter portion and the inner radial portion are arcuate.

5. The method of claim 2 , wherein attaching the outer plate to the base comprises attaching the outer plate to the base by one of MIG welding, TIG, welding, and resistance welding.

6. The method of claim 1 , further comprising configuring the base for attachment to multiple different outer plates.

7. The method of claim 6 , further comprising configuring the outer plate for removable attachment to the base.

8. The method of claim 7 , wherein configuring the outer plate for removable attachment comprises configuring the outer plate for removable attachment to the base via one or more mechanical fasteners.

9. The method of claim 1 , further comprising configuring the base with one or more second openings which are located in the perimeter portion, and configuring the outer plate with one or more outer plate openings which are located in the inner radial portion, which abuts the perimeter portion of the base, wherein each of the one or more second openings is aligned with the one or more outer plate openings; and
wherein attaching the outer plate directly to the base comprises attaching the outer plate to the base by inserting a mechanical fastener through the aligned one or more openings in the base and outer plate.

10. The method of claim 9 , wherein each of the one or more second openings in the base is threaded, or wherein each of the one or more outer plate openings is threaded.

11. The method of claim 1 , wherein molding the base comprises molding the base such that the perimeter portion of the base has a first axial thickness, with respect to the longitudinal axis of the drive shaft when the base is assembled to the drive shaft, and having the central hub portion with a second axial thickness that is less than the first axial thickness such that there is a step at an interface of the perimeter portion and central hub portion.

12. The method of claim 11 , wherein molding the outer plate comprises molding the outer plate with an arcuate inner radial portion that includes a stepped portion configured to abut the step on the base to help position the outer plate with respect to the base.

13. The method of claim 1 , wherein molding the outer plate comprises molding a powdered metal outer plate, and wherein molding the base comprises molding a powdered metal base.

14. The method of claim 1 , wherein molding the base, separately from the molding of the outer plate, comprises molding the base such that the central hub portion and the perimeter portion are substantially flat;
wherein molding the outer plate comprises molding the outer plate such that the inner radial portion extends axially more than the outer radial portion, and such that the outer radial portion extends radially outward from the inner radial portion; and
wherein the inner radial portion is directly attached to the perimeter portion.

15. The method of claim 1 , wherein molding the outer plate comprises molding the outer plate such that the inner radial portion and the outer radial portion are substantially flat;
wherein molding the base comprises molding the base such that the perimeter portion extends axially more than the central hub portion, and extends radially outward from the central hub portion; and
wherein the perimeter portion is directly attached to the inner radial portion.

16. A method of manufacturing a two-piece counterweight for a scroll compressor, the method comprising:
molding an outer plate;
molding a base separately from the molding of the outer plate, the base having a first opening configured to receive a scroll compressor drive shaft having a longitudinal axis, and configuring the base for assembly and attachment to the drive shaft;
attaching the outer plate directly to the base such that the outer plate extends radially outward from a perimeter portion of the base, and wherein the outer plate is offset axially, with respect to the longitudinal axis of the scroll compressor drive shaft when the base is assembled to the drive shaft, from the base
wherein molding the base comprises molding the base having:
a central hub portion configured to completely encircle the drive shaft; and
the perimeter portion located radially outward, with respect to the longitudinal axis of the drive shaft when the base is assembled to the drive shaft, from the central hub portion, the perimeter portion only partially encircling the drive shaft;

wherein molding the outer plate comprises molding the outer plate with an inn

Assignees

• Stephens Carl F
• Markley Lauren A
• Bitzer Kuehlmaschinenbau Gmbh

Inventors

• Stephens Carl F
• Markley Lauren A

Classifications

• F04C23/008

  Hermetic pumps · CPC title

• F04C2230/60

  Assembly methods · CPC title

• F04C2240/807

  Balance weight, counterweight · CPC title

• F04C2210/26

  Refrigerants with particular properties, e.g. HFC-134a · CPC title

• F04C2230/20

  essentially without removing material · CPC title