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

Patent metadata

Field	Value
Publication number	US-11598336-B2
Application number	US-202016887745-A
Country	US
Kind code	B2
Filing date	May 29, 2020
Priority date	Mar 8, 2016
Publication date	Mar 7, 2023
Grant date	Mar 7, 2023

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. The method further includes 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 to the base, wherein the outer plate is axially offset from the base, with respect to the longitudinal axis; and
configuring the outer plate for removable attachment to the base;
wherein molding the base comprises molding the base having:
a central hub portion configured to completely encircle the drive shaft;
a perimeter portion located radially outward from the central hub portion with respect to the longitudinal axis, the perimeter portion only partially encircling the drive shaft; and
a first axially-extending step with a first radially-inward facing surface;

wherein molding the outer plate comprises molding the outer plate with a second axially-extending step with a second radially-outward facing surface that abuts the first radially-inward facing surface to locate the outer plate with respect to the base, and to absorb some of the centrifugal force generated when the attached base and outer plate spin with the rotating drive shaft.

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

3. The method of claim 1 , wherein the step of molding the base comprises molding the base with the first axially-extending step on the perimeter portion.

4. The method of claim 1 , wherein the first axially-extending step and the second axially-extending step are arcuate.

5. The method of claim 1 , wherein the first axially-extending step and the second axially-extending step are straight.

6. The method of claim 1 , wherein each of the first axially-extending step and the second axially-extending step includes two angled portions.

7. The method of claim 6 , wherein each of the two angled portions are perpendicular to each other.

8. The method of claim 1 , wherein the step of molding the base comprises molding the perimeter portion with a first axial thickness, and molding the central hub portion with a second axial thickness that is less than the first axial thickness such that the first axially-extending step is at an interface of the perimeter portion and central hub portion.

9. The method of claim 8 , wherein the step of molding the outer plate comprises molding an inner radial portion of the outer plate, where it abuts the base perimeter portion, with a third axial thickness, and molding an outer radial portion with a fourth axial thickness that is less than the third axial thickness such that the second axially-extending step is at an interface of the perimeter portion and central hub portion.

10. The method of claim 1 , further comprising configuring the base for attachment to the outer plate, wherein multiple different embodiments of the outer plate are attachable to the base.

11. The method of claim 1 , 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.

12. The method of claim 11 , wherein molding the base comprises molding the base with one or more openings located in the perimeter portion, and wherein molding the outer plate comprises molding the outer plate with one or more outer plate openings located in an inner radial portion of the outer plate, which abuts the base perimeter portion, wherein each of the one or more base openings is aligned with the one or more outer plate openings, and wherein attaching the outer plate to the base comprises inserting the one or more mechanical fasteners through each of the aligned one or more openings in the base and outer plate.

13. 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 to the base, wherein the outer plate is axially offset from the base, with respect to the longitudinal axis;
wherein the step of molding the base comprises molding the base having:
a central hub portion configured to completely encircle the drive shaft;
a perimeter portion located radially outward from the central hub portion with respect to the longitudinal axis, the perimeter portion only partially encircling the drive shaft; and
a first axially-extending step with a first radially-inward facing surface;

wherein the step of molding the outer plate comprises molding the outer plate with a second axially-extending step with a second radially-outward facing surface that abuts the first radially-inward facing surface to locate the outer plate with respect to the base, and to absorb some of the centrifugal force generated when the attached base and outer plate spin with the rotating drive shaft;
wherein molding the outer plate comprises molding the outer plate with an inner radial portion, and with an outer radial portion disposed radially outward from the inner radial portion, wherein the second axially-extending step is on the inner radial portion.

14. 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 to the base, wherein the outer plate is axially offset from the base, with respect to the longitudinal axis;
wherein the step of molding the base comprises molding the base having:
a central hub portion configured to completely encircle the drive shaft;
a perimeter portion located radially outward from the central hub portion with respect to the longitudinal axis, the perimeter portion only partially encircling the drive shaft; and
a first axially-extending step with a first radially-inward facing surface;

wherein the step of molding the outer plate comprises molding the outer plate with a second axially-extending step with a second radially-outward facing surface that abuts the first radially-inward facing surface to locate the outer plate with respect to the base, and to absorb some of the centrifugal force generated when the attached base and outer plate spin with the rotating drive shaft;
wherein the step of 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.

15. The method of claim 14 , 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.

16. The method of claim 14 , wherein the welding attachment or brazing attachment is located along the base perimeter portion, and along an inner radial portion, of the outer plate where it abuts the base perimeter portion.

Assignees

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

Inventors

• Stephens Carl F
• Markley Lauren A

Classifications

• F04C2240/807

  Balance weight, counterweight · CPC title

• F04C2230/60

  Assembly methods · CPC title

• F04C18/0215 Primary

  where only one member is moving · CPC title

• F04C2230/20

  essentially without removing material · CPC title

• F04C2240/40

  Electric motor · CPC title