Methods of forming modulated capacity scrolls

Abstract

Methods of forming modulated capacity scroll compressors are provided, where at least two distinct mold shapes are formed of foam material and then joined together to form a mold assembly. The mold assembly defines one or more substantially horizontal features, such as a horizontally oriented fluid passage or a weight-reduction recess in a solid wall. In certain aspects, the mold assembly defines a junction between a portion of a horizontal fluid passage and a portion of a vertical fluid passage. A molten metal displaces the foam material of the mold assembly to solidify and form the scroll component.

1 . A method of manufacturing a scroll component having a fluid passage, the method comprising:
 forming a plurality of distinctly shaped molds with a foam material;   forming a mold assembly defining a scroll component shape by adhering said plurality of molds together, wherein said scroll component shape comprises a body portion comprising a substantially vertical feature and a substantially horizontal feature, wherein at least a portion of said substantially horizontal feature intersects with at least a portion of said substantially vertical feature to form the fluid passage; and   molding said scroll component by displacing said foam material of said mold assembly with molten metal that solidifies to form the scroll component.   
   
   
       2 . The method of  claim 1 , wherein after said forming of said mold assembly, substantially coating said mold assembly with a slurry material; and
 substantially surrounding said slurry-coated mold assembly with a refractory material comprising a material selected from the group: mullite sand, olivine sand, silica sand, and mixtures thereof.   
   
   
       3 . The method of  claim 1 , wherein said adhering comprises applying an adhesive to at least one surface of said plurality of molds, wherein said adhesive comprises a material selected from the group consisting of polypropylene, polyethylene, isoprene, butadiene, isobutylene, ethylene-vinyl acetate, polymers, copolymers, and mixtures thereof. 
   
   
       4 . The method of  claim 1 , wherein said forming of said plurality of distinctly shaped molds comprises filling a pattern with a plurality of beads and exposing said plurality of beads in said pattern to a fusing treatment to fuse said beads together, wherein said beads comprise a material selected from the group consisting of polystyrene, expanded polystyrene, polymethylmethacrylate, expanded methylmethacrylate, polyalkylene carbonate, copolymers and mixtures thereof. 
   
   
       5 . The method of  claim 1 , wherein said substantially horizontal feature is a horizontal fluid injection port and said substantially vertical feature is a vertical fluid injection passage formed in the scroll component, said horizontal fluid injection port and said vertical fluid injection passage permitting fluid communication therebetween. 
   
   
       6 . The method of  claim 1 , wherein said substantially horizontal feature is a horizontal capacity bypass passage, wherein a first opening in an end plate of the scroll component shape is connected to said substantially vertical passage and a second opening in said body portion is connected to said horizontal capacity bypass passage, thus permitting fluid communication between said first opening and said second opening through said substantially vertical passage and said horizontal capacity bypass passage. 
   
   
       7 . The method of  claim 1 , wherein said portion of said substantially horizontal feature that intersects with said portion of said substantially vertical feature forms a T-shaped junction or L-shaped junction therebetween. 
   
   
       8 . The method of  claim 1 , wherein said forming of said mold assembly further comprises positioning a core within the scroll component shape to define a portion of said substantially horizontal feature. 
   
   
       9 . The method of  claim 1 , wherein said core is formed of a casting material capable of dissolving and/or disintegrating upon exposure to water. 
   
   
       10 . A method of manufacturing a modulated capacity scroll component comprising:
 forming a mold assembly defining a capacity modulating scroll component shape by adhering a first foam mold having a first shape to a second foam mold having a second distinct shape, wherein said scroll component shape comprises a body portion having at least one capacity modulating feature formed therein having a shape defined by a combining a first portion of said first foam mold and a second portion of said second foam mold, wherein said first and said second portions are adhered together with an adhesive; and   molding the scroll component by displacing said first and second foam molds with molten metal, which solidifies to form the modulated capacity scroll component.   
   
   
       11 . The method of  claim 10 , wherein said scroll component shape has a major axial axis and said first portion of said first mold and said second portion of said second mold are adhered along respective surfaces to define a plane that is transverse to said major axial axis. 
   
   
       12 . The method of  claim 10 , wherein said at least one capacity modulating feature comprises a substantially horizontal fluid passage and a substantially vertical fluid passage formed in the scroll component, wherein said substantially horizontal fluid passage and said substantially vertical fluid passage permit fluid communication therebetween. 
   
   
       13 . The method of  claim 12 , wherein said portion of said substantially horizontal fluid passage that intersects with said portion of said substantially vertical fluid passage forms a T-shaped junction or L-shaped junction therebetween. 
   
   
       14 . The method of  claim 12 , wherein said capacity modulating feature is a capacity bypass fluid passage comprising said substantially horizontal fluid passage and said substantially vertical fluid passage. 
   
   
       15 . The method of  claim 10 , wherein after said forming of said mold assembly, substantially coating said mold assembly with a slurry material; and
 substantially surrounding said slurry-coated mold assembly with a refractory material comprising a material selected from the group: mullite sand, olivine sand, silica sand, and mixtures thereof.   
   
   
       16 . The method of  claim 10 , wherein said forming of said plurality of distinctly shaped molds comprises filling a first mold pattern defining an upper portion of the scroll component shape with a plurality of beads to form said first mold and filling a second mold pattern defining a lower portion of the scroll component shape to form said second mold, wherein said lower portion comprises an involute scroll form; and exposing said plurality of beads in each of said first and said second mold patterns to a stream treatment to fuse said beads together, wherein said plurality of beads comprise a material selected from the group consisting of polystyrene, expanded polystyrene, polymethylmethacrylate, expanded methylmethacrylate, polyalkylene carbonate, copolymers and mixtures thereof. 
   
   
       17 . A method of manufacturing a modulated capacity fixed scroll component, the method comprising:
 forming a mold assembly defining a scroll component shape by adhering a plurality of distinctly shaped expendable foam molds together via an adhesive, wherein said scroll component shape comprises a body portion comprising a capacity modulating feature defining a first opening in a base plate of said scroll component shape connected to a substantially vertical fluid passage and a second opening in a solid wall of said body portion connected to a substantially horizontal fluid passage opening, wherein a portion of said substantially vertical passage intersects with a portion of said substantially horizontal passage to provide fluid communication between said first opening to said second opening; and   molding the modulated capacity fixed scroll component by displacing said mold assembly with molten metal that solidifies to form the modulated capacity fixed scroll component.   
   
   
       18 . A method of manufacturing a scroll component comprising:
 forming a mold assembly defining a scroll component shape by disposing a core comprising a material that dissolves and/or disintegrates in water in a mold pattern and filling said mold pattern with a plurality of beads comprising an expendable material;   exposing said plurality of beads to fusing treatment to fuse the beads to one another;   substantially surrounding said mold assembly with a refractory material;   molding the scroll component by displacing said expendable material of said mold assembly with a molten metal that solidifies to form the scroll component; and   removing said core from the solidified scroll component by exposing said core to an aqueous solution.   
   
   
       19 . The method of  claim 18 , further comprising machining the solidified scroll component to remove any remaining core materials after said removing.