Multi-stage scroll vacuum pumps and related scroll devices

Abstract

A multi-stage vacuum pump, expander, or compressor, that incorporates one or more stages of a fixed scroll(s) and orbiting scroll(s) that operates simultaneously. The motor drives the orbiting scroll(s) within the structure, and the various fixed and orbiting scrolls are arranged for either parallel generation of a vacuum or high pressure gas, or arranged in series for generating of a significantly high vacuum or gaseous pressure, or a combination of parallel arranged and series arranged fixed and orbiting scrolls may be embodied within the structure, operated by a single motor means, in order to attain the high efficiencies of operation as a vacuum pump, or a gaseous compressor, during its functioning. The various combinations of orbiting and fixed scrolls, when arranged as aforesaid, can be reduced in size, or miniaturized, and used in conjunction with small appliances, or even in hand-held instruments, as for example, for use in conducting mass spectrometry, or for other purposes. The actual structure of the multi-stage devices can include the fixed and orbiting scrolls adjacent the motor, or the singular motor may be located intermediate various stages of the formed vacuum pump/compressor, in its assembly.

Claims

1. A three-stage scroll device comprising: a housing; three fixed scrolls fixedly secured to the housing; three orbiting scrolls, each configured to interface with and orbit relative to a separate one of the three fixed scrolls, each pair of one fixed scroll and one orbiting scroll defining a stage; an eccentric drive shaft operably connected to at least one of the three orbiting scrolls, the eccentric drive shaft extending through at least one of the three fixed scrolls; and wherein two of the three stages are configured to receive a gas at a first pressure and discharge the gas at a second pressure higher than the first pressure, and a separate one of the three stages is configured to receive the gas at the second pressure and discharge the gas at a third pressure higher than the second pressure.

2. The three-stage scroll device of claim 1, further comprising a motor in force-transmitting communication with the three orbiting scrolls.

3. The three-stage scroll device of claim 2, wherein the eccentric drive shaft extends from the motor to one of the three orbiting scrolls, and further comprising a counterweight fixedly secured to the drive shaft.

4. The three-stage scroll device of claim 1, wherein two of the orbiting scrolls extend in opposite directions from a single orbiting plate, and the single orbiting plate is connected to another of the orbiting scrolls via a plurality of idler shafts.

5. A multi-stage vacuum pump comprising: a first fixed scroll; a second fixed scroll opposite from, spaced from, and facing the first fixed scroll, the first fixed scroll fixedly secured to the second fixed scroll; an orbiting plate positioned in between the first fixed scroll and the second fixed scroll, the orbiting plate having a first involute extending toward and interfacing with the first fixed scroll to form a first stage, and a second involute extending toward and interfacing with the second fixed scroll to form a second stage; a third fixed scroll fixedly secured to the second fixed scroll; and an orbiting scroll facing the third fixed scroll and having a third involute extending toward and interfacing with the third fixed scroll to form a third stage; wherein a first inlet of the first stage is in fluid communication with a second inlet of the second stage, and a first outlet of the first stage is in fluid communication with a second outlet of the second stage and a third inlet of the third stage via a chamber enclosed by a housing of the pump; wherein the first and second stages are configured to receive a gas at a first pressure and discharge the gas at a second pressure distinct from the first pressure, and the third stage is configured to receive the gas at the second pressure and discharge the gas at a third pressure higher than the second pressure.

6. The multi-stage vacuum pump of claim 5, wherein the orbiting plate and the orbiting scroll are connected via at least one eccentric idler shaft.

7. The multi-stage vacuum pump of claim 6, wherein the orbiting plate and the orbiting scroll are connected via three eccentric idler shafts.

8. The multi-stage vacuum pump of claim 5, wherein the housing contains the first fixed scroll, the second fixed scroll, the orbiting plate, the third fixed scroll, and the orbiting scroll, and the chamber comprises a discharge plenum adjacent to the first outlet and adjacent to the second outlet and further comprises an inlet plenum adjacent to the third inlet.

9. The multi-stage vacuum pump of claim 5, further comprising a motor secured to the third fixed scroll; and an eccentric drive shaft extending from the motor to the orbiting scroll, the eccentric drive shaft configured to cause the orbiting scroll to orbit relative to the third fixed scroll when the motor is in operation.

10. The multi-stage vacuum pump of claim 9, further comprising at least one counterweight affixed to the drive shaft to balance the orbital motion of the orbiting scroll when the motor is in operation.

11. The multi-stage vacuum pump of claim 5, wherein the each of the first fixed scroll, the second fixed scroll, the third fixed scroll, the first involute, the second involute and the orbiting scroll comprises a tip seal.

12. The multi-stage vacuum pump of claim 11, wherein the tip seal has a trapezoidal cross-section.

13. A multi-stage scroll compressor comprising: a first stage compressor comprising: a first fixed scroll, a first orbiting scroll configured to interface with and orbit relative to the first fixed scroll; a first gas inlet; and a first gas outlet; a second stage compressor comprising: a second fixed scroll fixedly secured to the first fixed scroll; a second orbiting scroll configured to interface with and orbit relative to the second fixed scroll; a second gas inlet; and a second gas outlet; a third stage compressor comprising: a third fixed scroll fixed secured to the second fixed scroll; a third orbiting scroll configured to interface with and orbit relative to the fixed scroll; a third gas inlet; and a third gas outlet; wherein the first gas inlet is in fluid communication with the second gas inlet, and the first gas outlet is in fluid communication with the second gas outlet and the third gas inlet, and wherein an eccentric drive shaft extends third orbiting scroll to orbit relative to the third fixed scroll and is configured to cause the third orbiting scroll to orbit relative to the third fixed scroll; wherein the first and second stages are configured to receive a gas at a first pressure and discharge the gas at a second pressure distinct from the first pressure, and the third stage is configured to receive the gas at the second pressure and discharge the gas at a third pressure higher than the second pressure.

14. The multi-stage scroll compressor of claim 13, wherein the first fixed scroll is positioned opposite from and facing the second fixed scroll.

15. The multi-stage scroll compressor of claim 14, wherein the first orbiting scroll and the second orbiting scroll extend from opposites sides of an orbiting plate positioned in between the first fixed scroll and the second fixed scroll.

16. The multi-stage scroll compressor of claim 15, wherein the orbiting plate is connected to the third orbiting scroll by at least one eccentric idler shaft such that orbiting movement of the third orbiting scroll causes orbiting movement of the orbiting plate.

17. The multi-stage scroll compressor of claim 16, further comprising: a motor secured to the third fixed scroll wherein the eccentric drive shall extends from the motor to the third orbiting scroll, and the motor rotates the eccentric drive shaft to cause the third orbiting scroll to orbit relative to the third fixed scroll.

18. The multi-stage scroll compressor of claim 13, further comprising: a housing, wherein the second fixed scroll is fixedly secured to the first fixed scroll via the housing, and the third fixed scroll is fixedly secured to the second fixed scroll via the housing.

19. The multi-stage scroll compressor of claim 13, wherein each of the first, second, and third fixed scrolls and each of the first, second, and third orbiting scrolls comprises a tip seal.

20. The multi-stage scroll compressor of claim 13, wherein the first stage and the second stage are configured to compress a gas by a first amount, and the third stage is configured to further compress the gas by a second amount.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In referring to the drawings,

(2) FIG. 1 provides a cross sectional view of the single stage spinning or co-rotating scroll vacuum pump/compressor design of this invention;

(3) FIG. 1A provides a right end view of the design of FIG. 1;

(4) FIG. 1B is a left end view of the design of FIG. 1;

(5) FIG. 2 shows a cross sectional view of the two stage spinning scroll vacuum pump or compressor design of this invention;

(6) FIG. 3 shows a cross sectional view of the three stage scroll vacuum pump or compressor design of this invention;

(7) FIG. 4 shows a cross sectional view of the four stage vacuum pump or compressor design of this Invention;

(8) FIGS. 5A through 5C shows a new compact clamping method and apparatus for the bellows of FIG. 1 and FIG. 2, which allows for clamping of the bellows within the same outer diameter of the bellows structure;

(9) FIG. 6 discloses an innovative alignment method for maintaining the phase relationship and running clearances for the scrolls of this invention, when assembled as the spinning scroll type or an orbiting scroll type where idler shafts are not present for alignment, with FIG. 6 being a section taken along the line 6-6 of FIG. 7;

(10) FIG. 7 shows an alignment method for maintaining the phased relationship and running clearances for the scrolls used in this invention, FIG. 7 taken along the line 7-7 of FIG. 1;

(11) FIGS. 8A and 8B show an enlarged view of the tip seals used in the structure of the compressors/pump scrolls of this invention, generally as can be noted as located in FIG. 6 of this disclosure; and

(12) FIG. 9 shows a cross section of a two stage pump or compressor of this invention.

(13) Identification of the various components parts of the pump/compressor designs of this invention are as follows:

(14) Referring to FIG. 1 and FIG. 5, the major component parts are: 1. Driven scroll housing 2. Shaft seal 3. Driven scroll 4. Bellows 5. Drive scroll housing 6. Drive scroll 7. Drive Shaft 8. Motor 9. Back motor bracket 10. Inlet port 11. Port 12. Cross hole 13. Inlet plenum 15. O-rings 16. Port 17. Hole or Passage 18. Clamp 19. Screws

(15) Referring to FIG. 2, the major component parts are: 29. Cross hole 30. Outlet 31. Bellows 32. Second stage inlet plenum

(16) Referring to FIG. 3, the major component parts are: 33. Fixed scroll first stage 34. Orbiting scroll first and second stage 35. Fixed scroll second stage 36. Orbiting scroll third stage 37. Fixed scroll third stage 38. Crankshaft 39. Motor housing 40. Motor 41. Counterweight 42. Idler shafts 43. Inlet port 44. Second stage location port 45. Discharge plenum 46. Port 47. Third stage inlet plenum 48. Annular air movement space 49. Counterweight 50. Eccentric

(17) Referring to FIG. 4, the major components are: 51. Fixed scroll first stage 52. Orbiting scroll first and second stage 53. Fixed scroll second stage 54. Drive housing 55. Motor housing 56. Motor 57. Fixed scroll third stage 58. Orbiting scroll third and fourth stage 59. Fixed scroll fourth stage 60. Crankshaft and counterweight 61. Motor drive shaft 62. Idler shaft first stage 63. Idler shaft third stage 64. Crankshaft and counterweight 65. Inlet port 66. First and second stage inlet plenum 67. Scroll passage 68. Passage 69. Annular air passage area 70. Opening 71. Port 72. Third stage discharge plenum 73. Fourth stage discharge port 74. Cover 75. Cover

(18) Referring to FIGS. 6 and 7, the major components are: 3. Driven scroll 6. Drive scroll 18. Bellows clamp 19. Screws 20. Hole 21. Hole 22. Hole 23. Hole 24. Plugs 25. Plugs 26. Fit

(19) Referring to FIGS. 8A and 8B, the major components are: 101. Involute 100. Tip seal 102. Tip seal 103. Groove for o-ring

DESCRIPTION OF THE PREFERRED EMBODIMENT

(20) In referring to the drawings, FIG. 1 shows a cross-sectional view of the single stage spinning or co-rotating scroll vacuum pump/compressor design of this invention. It includes the various components as previously identified, such as the driven scroll housing 1, provided with a shaft seal 2, and a driven scroll 3. Item 4 provides a bellows that surrounds the driven scroll, that seals the generated pressures, whether it be derived from a vacuum pump, or a compressor that generates high pressure, in its operations: A drive scroll housing 5 surrounds these operative components. The drive scroll 6 has its various scrolls interconnected with the driven scroll 3, as shown. A drive shaft 7, connects with the drive scroll 6, to provide for its rotation relative to the driven scroll, and the drive shaft 7 is rotated by means of the motor 8, as can be noted. There is a back motor bracket 9 that is provided for mounting of the motor, and its pump/compressor, in its configured assembly.

(21) Gas to be evacuated or compressed enters the spinning scroll pump through the inlet port 10, in the driven scroll housing 1, as noted. The gas is sealed from leaking to the atmosphere through the rotary shaft seal 2, as disclosed. In this figure, two lip seals are shown, however, other type seals such as a labyrinth or mechanical seal can also be utilized. The gas enters the driven scroll 3 through the central port 11, as noted. The port 11 intersects a cross path 12, that directs the gas to the inlet plenum 13, on the peripheries of the arranged scrolls. The Inlet plenum 13 is bounded on the outside by the identified flexible bellows 4, which is sealed on its ends by use of the various o-rings 15, as can be noted. The gas then enters the scrolls, and is compressed, through the operations of said scrolls, and then discharged at the center of the drive scroll 6, as at its port 16. The gas then flows through the aperture 17, within the shaft 7, and is discharged to its site of usage. Obviously, the shaft 7 is turned by the motor 8. The bellows 4 performs the function of sealing the inlet chamber 13 from the atmosphere, and also maintains the phase relationship between the drive scroll 6, and the driven scroll 3, in its operations. The driven scroll 3 is driven by the bellows 4. The clamps 18 are designed so that the bellows 4 is retained without increasing the diameter of the assembly, thus keeping the entire pump very compact. As previously summarized, the concept of this invention is to provide for either a parallel arrangement of a series of scroll pump/compressors, or series arranged pump/compressors, or a combination of the two, which can provide for a very high generation of a pressure, or evacuation of a vacuum, within a small scale apparatus, that may even be accommodative of a hand-held type of device, during its usage and application.

(22) The phase relationship between the two scrolls 3 and 6, and their alignment within its assembly is achieved by the alignment pins fixture as shown in FIG. 6, as subsequently described.

(23) As previously described, FIG. 1A provides a left end view of the pump housing, as noted in FIG. 1, while FIG. 1B provides a right end view of the housing, particularly its back motor bracket 9, as previously defined.

(24) FIG. 2 discloses a further modifications to the single stage scroll vacuum pump/compressor design of FIG. 1, but in this particular instance, it includes, in series, a second scroll vacuum pump or compressor design, as noted. In this particular Instance, the back motor bracket is integrally extended rearwardly, and mounts a second scroll vacuum pump or compressor design. As can be seen, the motor or drive shaft 7 further turns a driven scroll 27, which is held into position for eccentrically shifting by means of the clamps 18, that secure the o-rings 15 in position around the perimeter of the scroll plate. The high pressure or vacuum that is transferred through the passage 17, within the drive shaft 7, exits into the cross hole 29, then into the second stage Inlet plenum 32. At this point the gas is subjected to the operations of the movable scroll 27 and the driven scroll 28, and further increases in pressure, or generates further vacuum pressure, which then exits out of the passage 30, for use for purposes of such generated vacuum or compressed gas, as a result of operations of the scroll vacuum pump or compressor design of this invention. Once again, a bellows means 31 is provided between the clamps 18, to assure the hermetic sealing of the scroll compressor, therein, during its functioning. The various screws 19 cooperating with the clamps 18 secure the bellows 31 to the assembly.

(25) This is an example of how a pair of co-rotating scrolls, maintained in series, can provide for a high efficiency in generating a vacuum, or a high pressure gas, in a fairly reduced dimensioned design, as noted and described herein.

(26) The phase relationship between the two scrolls 3 and 6, as previously explained, as positioned within the assembly is achieved through usage of the alignment pin fixture, in the manner as to be subsequently described in FIGS. 6 and 7.

(27) In FIG. 6, in addition to FIG. 7, the apertures 20 and 21 are precision located into the driven scroll 3. Likewise, the apertures 22 and 23 are precision located in the drive scroll 6. There are four such apertures 20-23, that are located such that when a close fitting pin is inserted into the apertures 20, thereby engaging the aperture 22, and another close fitting pin is inserted into the aperture 21, engaging the aperture 23, the alignment between the two scrolls will be precisely as desired so that the fit between the two scrolls will be maintained, and also so that the “phase” relationship between the scrolls is as required and desired for precise operation. In FIG. 7, the scroll and position of the drive scroll 6 relative to the drive scroll 3 must be properly aligned or “phased” for proper operation of the unit.

(28) While the alignment pins are engaged, the bellows clamp 18 is positioned and bolted into place through usage of the screw 19, as previously described, so that the positioning of the scrolls 3 and 6 will be maintained after the alignment pins are removed. The final step is to seal the apertures 20 and 21 with plugs 24 and 25, so there will be no leakage of the vacuum generated gas or compressed gas to the atmosphere.

(29) FIG. 8 shows the enlarged view of the tip seals located at the end of each scroll, generally as shown in the enlarged view identified at 8, in FIG. 6. This shows the enlarged views of two different tip seal designs for use in the spinning type scroll devices, vacuum pumps, compressors, or expanders. In describing the schematics as shown in FIGS. 8A and 8B, the centrifugal forces are shown as “R” and their direction of force as noted in said figure. This will cause the tip seals to jam in a traditional tip seal sense where the angle α is zero. By making the tip seal slides slightly tapered with an angle α greater than zero, the centrifugal forces in the “R” direction will cause a component of force in the axial direction “A”, thus forcing the tip seal to move in the “A” direction and engage the inner surface of the adjacent scroll, thereby effectively enhancing the sealing of any leakage from any pressure differential that exists across the involute, during its functioning.

(30) FIG. 8A shows one embodiment of the invention where the tip seal 100 is trapezoidal of shape, and has the same a angle as the groove in the involute 101. FIG. 8B is the same as FIG. 8A, except the tip seal 102 has a groove 103 for placement of an o-ring cord stock therein, to further enhance the sealing activity of the scrolls, during their functioning.

(31) In referring to FIG. 3, and as previously summarized, this design is shown in a three stage vacuum pump. The design incorporates its first and second stage pumping sections, that operate in parallel, providing for the transfer of its compressed gas for flow into a third pumping stage, arranged in a series, with the first and second stages. The design is of the orbiting scroll type, as known in the art. The advantage of this design is that large displacements, or flow, are possible in a compact package due to the first and second stages being arranged in parallel, while the high vacuums are achievable through the use of the third stage, arranged in series.

(32) During its functioning, the gas to be evacuated or compressed enters the first stage fixed scroll 33, at its inlet port 43. The gas also enters the second stage at the location 44, in the orbiting scroll 34. The gas is then expanded in these first and second stages to the first and second stage discharge plenum 45. The gas then travels through the port 46, in the second stage fixed scroll 35, and into the third stage inlet plenum 47. The gas then enters into the third stage formed by the third stage fixed and orbiting scrolls 36 and 37, respectively. The gas is then compressed in the third stage and is discharged through the annular space 48 between the third stage fixed scroll and the crank shaft 37 and 38. The gas is then discharged through the housing 39, for further usage.

(33) Counterweights are located at 49 and 41, to balance the orbital motion of the orbiting scrolls 34 and 36. The eccentric 50, located on the crank shaft 38, drives the orbiting scroll 36. Three idler shafts 42 are arranged and positioned approximately 120° apart from each other, around the second stage fixed scroll 35, and the third stage orbiting scroll 36, in addition to the orbiting scroll 34, that locate the orbiting scrolls 34 and 36 relative to the fixed scrolls 33, 35, and 37. The idler shafts 42 are supported by their ball bearings, as shown. The idler shafts 42 also serve to maintain the relative “phase” relationship between the fixed and orbiting scrolls, and also serve to drive the second stage orbiting scroll 34.

(34) As noted in FIG. 4, this particular design is of a four stage orbital type Scroll vacuum pump. This design has the first and second stages in parallel, for high displacement, or flow, and then includes a third and fourth stage in series, for generating ultra-high vacuums. This results in a relatively compact unit, for this design, that generates ultra-high vacuums. It may also be structured as a pump or compressor.

(35) In this four stage orbital type scroll vacuum pump or compressor, the gas to be evacuated enters the fixed scroll first stage 51, at the inlet port 65. The gas then travels into the first and second stage inlet plenum 66. The first and second stages are in parallel to increase the displacement of the pump while keeping the unit of compact design. After compression, the gas in the first stage travels through the port 71, and then into the passage 68 into the second stage. From there, the combined flow from the first and second stages travels through the annular area 69, as noted, formed by the crank shaft 60 and the fixed scroll second stage 53. The gas then travels past the motor 56 and into the opening 70. The gas enters the center of the third stage through the annular area formed by the crank shaft 64, and the fixed scroll third stage 57. After expansion, the gas enters the plenum 72, and is then compressed in the fourth stage, and exits the unit through the port 73, in the fixed scroll fourth stage. From there, the gas exits out of the port 73, as can be noted, after passing through the fourth compression stage.

(36) There are three idler shafts 62 and 63 at each scroll pair, that are positioned so that any axial forces can be counteractive and for maintaining the axial positioning of the orbiting scrolls 52 and 58, and for attaining the “phase” relationship between the identified scrolls. The covers 74 and 75 are used to seal the openings in the fixed scrolls 51 and 57. The two orbiting scrolls 52 and 58 are driven by the motor 56, generally in the manner as previously described in earlier designs. The motor rotor turns the shaft 61, which has eccentric crank shafts 60 and 64, with their counterweights for balancing of the unit, during operations. These counterweights are noted at 60 and 64.

(37) FIGS. 5A-5C show the various types of compact clamping means that are used for holding the ends of the bellows sealed in place, as previously shown and described in FIGS. 1 and 2.

(38) In referring to FIG. 9, this shows a two stage orbital style scroll vacuum pump, but it may also be a pump, compressor, or expander. This design has first and second stages in series, but could have said stages in parallel, for generating ultra-high vacuums, pressures, and the like, as can be understood. This structure results in a very compact unit, for this design, and therefore may be made to much lessor dimensions. As noted, the pump 80 includes its structured orbital pump or compressor 81, rendered operative from its motor 82, and its first stage orbital type structures is noted at 83, while the second stage is defined at 04. The gas to be evacuated or pressurized enters the inlet 85 is conveyed past the motor 82 and its crank shaft 86 into the plenum 87 for processing by the first stage or the device. The processed air then passes to the second stage, for further pressuring or evacuation, or expansion, and is discharged through the outlet 88. An alternative inlet 89 may be provided for entering gas directly into the first stage, as can be noted. There are a series of idler shafts 90 that are located within the structure of the device and positioned so that the axial forces can be counteractive and for maintaining the axial positioning of the orbiting scrolls of the stages, for obtaining that phased relationship between the various scrolls. The covers 91 and 92 form the housing and are provided to seal the various scrolls, in their operations, within the said first and second stages, and the orbiting scrolls are rendered operative by the identified motor 82, as stated.

(39) As reviewed throughout this discussion, while the description generally is made for a vacuum pump, formed of the designs of the structure as shown and identified herein, the units can just as easily be made into a compressor; and thus the terms “vacuum pump” and “compressor” are used interchangeably, to mean either type of multi-stage pumps or compressors. Essentially, it is the combination of the various scrolls either in parallel, or in series, or a combination of such, that form the multi-stage scroll devices of this invention.

(40) Variations of modifications to the subject matter of this invention may occur to those skilled in the art upon review of the summary of the invention as provided herein, and upon undertaking a study of the description of its preferred embodiments in view of the drawings. Such variations, if within the spirit of this invention, are intended to be encompassed within the scope of any claims to patent protection issuing hereon. The description of the preferred embodiment, and its depiction in the drawings, are generally set forth for illustrative purposes only.