Background of the Invention

The present invention relates to hermetically sealed compressor assemblies. More particularly, the present invention relates to hermetically sealed compresso

assemblies having a shell which is staked in place in a unique manner to resis excessive axial and circumferential loading.

Hermetically sealed motor compressors of various designs are well known i the art. These designs include both the piston/cylinder types and scroll types. Whil the present invention applies equally well to all of the various designs of moto

compressor units, it will be described for exemplary purposes embodied in hermetically sealed scroll type fluid machine.

A scroll type fluid machine has a compressor section and an electrical moto section mounted in a hermetic shell with fluid passages being formed through th walls of the hermetic shell. The fluid passages are normally connected through pipe to external equipment such as, for example, an evaporator and condenser when th machine is used in a refrigeration system.

The scroll type compressor section has a compressor which is comprised o a non-orbiting scroll member which is mated with an orbiting scroll member. Thes scroll members have spiral wraps formed in conformity with a curve usually close t an involute curve so as to protrude upright from end plates. These scroll member are assembled together such that their wraps mesh with each other to for therebetween compression chambers. The volumes of these compression chamber are progressively changed in response to an orbital movement of the orbiting scrol

member. A fluid suction port communicates with a portion of the non-orbiting scrol

member near the radially outer end of the outermost compression chamber, while a fluid discharge port opens in the portion of the non-orbiting scroll member close to the center thereof. An Oldham's ring mechanism is placed between the orbiting scroll member and the non-orbiting scroll member so as to prevent the orbiting scroll member from rotating about its own axis.

The non-orbiting scroll member is secured to the main bearing housing by means of a plurality of bolts extending therebetween which allow limited relative axial movement between the bearing housing and the non-orbiting scroll member.

The attachment for the non-orbiting scroll member is more fully disclosed in assignee's copending application Serial Number 07/591,444 entitled "Non-Orbiting Scroll Mounting Arrangements for a Scroll Machine" filed October 1, 1990, the disclosure of which is hereby incorporated herein by reference.

The orbiting scroll member is driven by a crankshaft so as to produce an orbiting movement with respect to the stationary scroll member. Consequently, the volumes of the previously mentioned chambers are progressively decreased to compress the fluid confined in these chambers, and the compressed fluid is

discharged from the discharge port as the compression chambers are brought into communication with the discharge port. The housing is fixedly attached to the hermetic shell. The attachment methods for connecting the housing to the hermetic shell include bolting, pin or plug welding and/or press or shrink fitting. While each of these methods offer certain advantages, they also come with individual disadvantages.

The press or shrink fit is the least expensive attachment method and it is

capable of withstanding most of the forces normally generated by the assembly. The

compressor assembly is capable, however, under certain conditions, of generatin forces which could exceed the holding capabilities of the press fit design. Whe these excessive forces are generated, the housing could slip either axially circumferentially with respect to the hermetic shell, adversely affecting the operatio

of the compressor assembly.

Welding of the housing resolves the issues of being able to withstand t forces in excess of the normal, but the cost of producing a welded assembly i volume production is relatively high.

Bolting the housing to the shell will also resolve the issue of being able t withstand the forces in excess of normal, but the cost involved in preparing both t shell and the internal components to be able to accommodate a bolt and st maintain the necessary hermetic seal makes the technique unsuitable to volu production. In addition, the problems of properly completing the fastening operati and the costs associated with the fastener make this an undesirable option. Accordingly, what is needed is a means of fixedly attaching the housing of motor compressor unit to the hermetic shell which is capable of withstanding bo the normal and the abnormal forces generated during the operation of t compressor. The means of fixedly attaching the housing should be both inexpensi and reliable, and suitable for high volume production. Summary of the Present Invention

The present invention provides the art with a means for attaching the housi to the hermetic shell of a motor compressor which is inexpensive, reliable a capable of withstanding both the normal and abnormal forces generated during t

operation of the motor compressor.

The hermetic shell of the present invention is plastically deformed into a plurality of apertures formed into the housing of the motor compressor unit. The deformation of the shell is such that material is displaced into the aperture without penetrating through the wall of the hermetic shell, thus maintaining the hermetic integrity of the sealed chamber. The shape of the displaced material of the shell and the aperture is such that a generally cylindrical load bearing interface is created which is capable of withstanding both axially and circumferentially directed forces.

Description of the Drawings

Further object, features and advantages of the present invention will become apparent from the analysis of the following written specification, the appended claims and the accompanying drawings in which:

Figure 1 is a side elevation view partially in cross section of a hermetically sealed compressor in accordance with the present invention.

Figure 2 is an enlarged view of the tool which is used to create the staking forming a part of the present invention.

Figure 3 is a further enlarged view of the shape of the staked area designated in Figure 1 by circle 3-3 in accordance with the present invention. Detailed Description of the Preferred Embodiment

The present invention is illustrated for exemplary purposes in conjunction with a hermetically sealed scroll compressor. It is to be understood that the invention is not limited to a scroll compressor and it is possible to utilize the staked configuration on virtually any type of motor compressor or similar machine.

Referring to the drawings, a scroll type fluid machine 10 in accordance with

the present invention, which is in this case a compressor of a refrigeration system,

is shown. The fluid machine 10 is comprised of a hermetic shell assembly 12, compressor section 14 and a motor drive section 16. The hermetic shell assembl

12 is comprised of lower shell 13, an upper cap 15, a bottom cover 17 and separation plate 19. The bottom cover 17, the lower shell 13, the separation plat 19 and the upper cap 15 are fixedly and sealingly attached in the manner shown b welding during assembly of the fluid machine 10 to form sealed suction chamber 2 and a discharge chamber 56. The hermetic shell 12 further has an inlet fitting 2 and an outlet fitting 25.

The compressor section 14 is comprised of a non-orbiting scroll member 1 an orbiting scroll member 20 and a bearing housing 22. The non-orbiting scro member 18 is comprised of an end plate and body 24 having a chamber 26 in whic is disposed a spiral wrap 28. The non-orbiting scroll has a plurality of embossmen 30 which are adapted to be attached to the bearing housing 22 by bolts 32.

The orbiting scroll member 20 is comprised of an end plate 34 and a spir wrap 36 which extends upright from the end plate 34 into chamber 26. The spir wrap 36 is meshed with the spiral wrap 28 of the non-orbiting scroll member 18 i the usual manner to form in combination with the bearing housing 22, a compress section 14 of the fluid machine 10. Closed chambers 52 are defined by the meshin wraps 28 and 36 and the arrangement is in communication with the usual discharg port 54 formed in the central position of the non-orbiting scroll 18. The discharg port 54 communicates with discharge chamber 56 formed by separation plate 19 an upper cap 15.

The bearing housing 22 has a plurality of (3 or 4) radially outwardly extendi

lobes 38 affixed to the hermetic shell assembly 12. The lobes 38 of the beari

housing align with the embossments 30 of the non-orbiting scroll member 18 and have threaded holes 40 for accepting bolts 32 to attach the non-orbiting scroll member 18 as described above. At its outer end, each lobe 38 has a cylindrical recess 42 disposed therein. The compressor section 14 further includes a crankshaft 46 having an eccentric shaft portion 48 coupled to the orbiting scroll member 20 through a drive bushing and bearing assembly 50. A counter-balance weight 60 is fixed to the crankshaft 46, which is supported at its lower end by lower bearing assembly 64. Lower bearing assembly 64 is fixedly secured to shell assembly 12 and has a center portion 66 having an elongated bore 68 in which is disposed a journal bearing 70 which is designed to receive the lower end of crankshaft 46.

The motor drive section 16 is comprised of a motor stator 80 securely mounted in the lower shell 13, preferably by press fitting, and a motor rotor 82 coupled to the crankshaft 46 of the compressor section 14. The lobes 38 of the bearing housing 22 are press fit into the inside diameter of the hermetic shell assembly 12. After proper positioning of the bearing housing 22 inside the lower shell 13, a staking tool 90, is forced radially inwardly against the shell to plastically deform the lower shell 13 in each of the areas of the recesses 42 to form a plurality of circular staked portions 92, as best shown in Figure 3. The lower shell 13 is deformed sufficiently to cause the edge 94 of recess 42 to bite into

the shell metal to form a cylinder retention surface 92, but the plastic deformation of the upper shell is not sufficient to affect the hermetic seal of the sealed chamber 21 by overly weakening or piercing through the shell material. During operation of the scroll type fluid machine, the forces generated by the operation of the

compressor in both the axial and circumferential directions must be accommodate by the joints between lobes 38 and lower shell 13. The recesses 42 are preferabl sufficient in size and number to support the maximum anticipated abnormal force which may be generated.

The staking tool 90 is shown in Figures 2 and 3 and comprises a generally fl annular circular surface 100 having a spherical surface 102 extending therefrom. radiused section 104 blends the area where spherical surface 102 meets the annula surface 100. The circular diameter 106 where these two surfaces meet is referred t as the base diameter. It has been found that with a shell material of draw quality hot rolled ste that very satisfactory results have been obtained when the base diameter 106 is equ to 1.30 to 1.35 times the diameter of the recess 42 formed in the bearing housing 2 The distance which spherical surface 102 extends from the flat circular surface 10 is termed the nose height. It has been found that the nose height should b

approximately equal to the thickness of the material used to manufacture the low shell 13 which is the material being staked. Finally, the radius of spherical surfac 102 is termed the nose radius and it should be equal to approximately 0.85 times th diameter of the recess 42. By following the above guidelines, a staked area simil to that shown in Figure 2 will be achieved. The width of the circular retentio surface 92 is equal to approximately one-third of the thickness of the material use to manufacture the lower shell 13 which is the material being staked.

Specifically, the scroll type fluid units 10 which were tested and found to b the most reliable had an lower shell 13 thickness of approximately 3.00 millimeter

The bearing housing 22 had four recesses 42 each having a diameter

approximately 12.70 millimeters. The bearing housing 22 was press fit into the lower sheE 13 having an interference fit of .20/.46 millimeters by a hydraulic press using approximately 2,000 pounds of force. This lower sheE 13 was then staked into the four 12.70 millimeter diameter recesses 42 with four staking tools 90 each having a base diameter 106 of approximately 16.764 millimeters, a nose height of approximately 3.045 millimeters and a nose radius of approximately 10.80 miEimeters. This produced the staking configuration shown in Figures 2 and 3 having a cylindrical retention surface 92 which was 1.0 to 1.3 millimeters in width.

WhEe it wEl be apparent that the preferred embodiment of the invention disclosed is weE calculated to provide the advantages above stated, it wiE be appreciated that the invention is susceptible to modification, variation and change without departing from the proper scope or fair meaning of the subjoined claims.