U.S. patent application number 11/903750 was filed with the patent office on 2008-03-27 for expansion valve.
This patent application is currently assigned to DENSO Corporation. Invention is credited to Shin Honda, Kazuto Kobayashi, Takashi Mogi.
Application Number | 20080073441 11/903750 |
Document ID | / |
Family ID | 39223881 |
Filed Date | 2008-03-27 |
United States Patent
Application |
20080073441 |
Kind Code |
A1 |
Honda; Shin ; et
al. |
March 27, 2008 |
Expansion valve
Abstract
An expansion valve for a refrigerant cycle has an orifice
passage portion, a valve body, a spring member and a deformation
portion. The orifice passage portion is configured for
decompressing and expanding a high pressure refrigerant into a low
pressure refrigerant. The valve body is disposed to open and close
the orifice passage portion so that a flow rate of the low pressure
refrigerant flowing into a low pressure passage portion is
controlled in accordance with a valve opening degree. The spring
member is disposed between the valve body and the deformation
portion for applying a biasing force to the valve body. The
deformation portion is plastically deformable in a direction
parallel to an expansion and contraction direction of the spring
member by applying an external force.
Inventors: |
Honda; Shin; (Nagoya-city,
JP) ; Kobayashi; Kazuto; (Tokyo, JP) ; Mogi;
Takashi; (Tokyo, JP) |
Correspondence
Address: |
HARNESS, DICKEY & PIERCE, P.L.C.
P.O. BOX 828
BLOOMFIELD HILLS
MI
48303
US
|
Assignee: |
DENSO Corporation
Kariya-city
JP
|
Family ID: |
39223881 |
Appl. No.: |
11/903750 |
Filed: |
September 24, 2007 |
Current U.S.
Class: |
236/92B |
Current CPC
Class: |
F25B 41/31 20210101;
F25B 2341/0683 20130101 |
Class at
Publication: |
236/92.B |
International
Class: |
F25B 41/06 20060101
F25B041/06 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 25, 2006 |
JP |
2006-259438 |
Claims
1. An expansion valve for a refrigerant cycle, comprising: a high
pressure passage portion that allows a high pressure refrigerant to
flow; an orifice passage portion disposed to communicate with the
high pressure passage portion for decompressing and expanding the
high pressure refrigerant, which flows from the high pressure
passage portion, into a low pressure refrigerant; a low pressure
passage portion disposed to communicate with the orifice passage
portion for allowing the low pressure refrigerant to flow; a valve
body disposed to open and close the orifice passage portion such
that a flow rate of the low pressure refrigerant flowing into the
low pressure passage portion is controlled in accordance with an
opening degree of the valve body; a spring member disposed to apply
a biasing force to the valve body; and a deformation portion
disposed on an opposite side of the valve body with respect to the
spring member such that the spring member is interposed between the
deformation portion and the valve body, wherein the deformation
portion is plastically deformable in a direction parallel to an
expansion and contraction direction of the spring member by an
external force.
2. The expansion valve according to claim 1, further comprising: a
main body block, wherein the spring member is housed in the main
body block, and the deformation portion is provided by a wall of
the main body block, the wall having a thickness that is smaller
than a thickness of a peripheral area thereof in the main body
block with respect to the direction parallel to the expansion and
contraction direction of the spring member.
3. The expansion valve according to claim 1, further comprising: a
main body block that houses the spring member therein, the main
body block having an opening portion at a position opposite to the
valve body; and a deformation plate member having a shape
corresponding to the opening portion, wherein the deformation plate
member is disposed in the opening portion and fixed to the main
body block, and the deformation portion is provided by the
deformation plate member.
4. The expansion valve according to claim 3, wherein the opening
portion has an inner diameter that is greater than an outer
diameter of the spring member, the outer diameter of the spring
member being defined in a direction perpendicular to the expansion
and contraction direction of the spring member.
5. The expansion valve according to claim 1, wherein the
deformation portion has a first surface to which the external force
is applied and a second surface that receives the spring member,
and an area of the first surface is equal to or greater than that
of the second surface.
6. The expansion valve according to claim 5, wherein the thickness
of the deformation portion is at least 0.5 mm and at most 2 mm, and
the second surface has an outer diameter that is at least 7 mm and
at most 20 mm.
7. The expansion valve according to claim 5, wherein the main body
block has a peripheral wall portion that coaxially extends from the
first surface of the wall.
8. The expansion valve according to claim 7, wherein the peripheral
wall portion has a thread portion so that an adjustment jig for
applying the external force is capable of being screwed into the
peripheral wall portion.
9. The expansion valve according to claim 2, wherein the main body
block has a tubular projection projecting from the deformation
portion, and the tubular projection includes a thread portion so
that an adjustment jig for applying the eternal force is capable of
being screwed into the tubular projection.
10. An expansion valve for a refrigerant cycle, comprising: a main
body block having a high pressure passage portion, a low pressure
passage portion and a communication passage portion between the
high pressure passage portion and the low pressure passage portion;
a valve element disposed in the communication passage portion so
that an orifice passage is defined for decompressing and expanding
a high pressure refrigerant, which flows from the high pressure
passage portion, into a low pressure refrigerant and for
controlling a flow rate of the low pressure refrigerant flowing
into the low pressure passage portion in accordance with an opening
degree of the orifice passage; a spring member disposed in the
communication passage portion for applying a biasing force to the
valve element; and a deformation portion disposed on a side
opposite to the valve element with respect to the spring member to
define an end of the communication passage portion, wherein the
spring member is disposed between the valve element and the
deformation portion and a set value of the spring member is
adjusted by deforming the deformation portion by a predetermined
amount in a direction parallel to an expansion and contraction
direction of the spring member.
11. The expansion valve according to claim 10, wherein the
deformation portion is integrally formed into the main body block,
and has a predetermined thickness in the direction parallel to the
expansion and contraction direction of the spring member.
12. The expansion valve according to claim 10, wherein the main
body block has a recessed portion on its outer wall and at a
position opposite to the communication passage portion with respect
to the deformation portion for receiving an adjustment jig when the
deformation portion is deformed.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is based on Japanese Patent Application No.
2006-259438 filed on Sep. 25, 2007, the disclosure of which is
incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to an expansion valve for a
refrigerant cycle.
BACKGROUND OF THE INVENTION
[0003] An expansion valve for a refrigerant cycle generally
controls a valve opening degree by detecting at least of
temperature and pressure of a refrigerant, thereby to control the
flow of the refrigerant in the refrigerant cycle. For example, a
thermal-type expansion valve that controls a refrigerant to a
predetermined condition by detecting the temperature and the
pressure of low pressure-side refrigerant is generally known. Also,
an expansion valve that controls the refrigerant by detecting a
condition of high pressure-side refrigerant is generally known as a
pressure control valve.
[0004] For example, Japanese Unexamined Patent Publication No.
2002-310538 (U.S. Pat. No. 6,560,982 B2) discloses a thermal-type
expansion valve having a ball valve. In the disclosed expansion
valve, a high pressure passage and a low pressure passage are
offset in a longitudinal direction of a main body block and are
communicated with each other through an orifice passage. Namely,
the disclosed expansion valve has a crank-shaped refrigerant
passage in the main body block. The orifice passage extends in the
longitudinal direction, and an operation rod, which has a diameter
smaller than an inner diameter of the orifice passage, is disposed
in the orifice passage. The operation rod is provided with a ball
valve at its end for controlling the orifice passage. Namely, as
the operation rod is moved in the orifice passage in the
longitudinal direction, the orifice passage is opened or closed by
the ball valve.
[0005] The orifice passage is in communication with an opening
formed at a top portion of the main body block. When the expansion
valve is assembled, the operation rod with which the ball valve is
integrated is inserted into the orifice passage from the opening of
the main body block. Specifically, in a condition that a valve
seating member is placed on a periphery of the operation rod, the
ball valve is integrated with the end of the operation rod, such as
by welding. Then, the operation rod with the valve seating member
and the ball valve is inserted into the orifice passage. At this
time, the valve seating member is press-fitted in the orifice
passage by a large diameter portion of the operation rod.
[0006] In such an expansion valve in which an operation rod and
other members are inserted through an opening of a main body block,
the number of component parts is reduced and the component parts
are easily assembled. Thus, it is easy to improve assembling
accuracy. However, the length of the operation rod will be varied
when the ball valve is welded. Also, the operation rod will be
deformed when the valve seating member is press-fitted. If the
above situations occur, it is difficult to maintain the
characteristic of the valve opening degree within a predetermined
characteristic range.
SUMMARY OF THE INVENTION
[0007] In an expansion valve, it is proposed to adjust the
characteristic of the valve opening degree by using an adjustment
mechanism before shipment. Further, an adjustment mechanism that
enables simple adjustment of the characteristic of the valve
opening degree without increasing costs and the number of component
parts is desired.
[0008] The present invention is made in view of the foregoing
matter, and it is an object of the present invention to provide an
expansion valve in which a characteristic of a valve opening degree
is adjustable by a simple structure.
[0009] According to an aspect of the present invention, an
expansion valve for a refrigerant cycle has a high pressure passage
portion through which a high pressure refrigerant flows, an orifice
passage portion that is in communication with the high pressure
passage portion, and a low pressure passage portion that is in
communication with the orifice passage. The high pressure
refrigerant flowing from the high pressure passage portion is
decompressed and expanded into a low pressure refrigerant in the
orifice passage, and the low pressure refrigerant flows into the
low pressure passage portion. The expansion valve further has a
valve body, a spring member and a deformation portion. The valve
body is disposed to open and close the orifice passage such that a
flow rate of the low pressure refrigerant flowing into the low
pressure passage portion is controlled in accordance with an
opening degree thereof. The spring member is disposed between the
valve member and the deformation portion for applying a biasing
force to the valve body. The deformation portion is plastically
deformable in a direction parallel to an expansion and contraction
direction of the spring member by an applied force.
[0010] The deformation portion is plastically deformed in the
expansion and contraction direction of the spring member by
applying an external force. By deforming the deformation portion
such that a distance between the valve body and the deformation
portion reduces, that is, in a contraction direction of the spring
member, the biasing force of the spring member to the valve body
increases. On the other hand, by deforming the deformation portion
such that the distance between the valve body and the deformation
portion increases, that is, in an expansion direction of the spring
member, the biasing force of the spring member to the valve body
reduces. Namely, by deforming the deformation portion in the
expansion and contraction direction of the spring member, the
biasing force of the spring member is adjusted. Therefore, the
opening degree of the valve body is adjusted to have a
predetermined characteristic. In this way, the characteristic of
the valve opening degree is properly adjusted by such a simple
structure.
[0011] For example, the deformation portion is integrally formed
into a main body block that houses the spring member therein.
Namely, the deformation portion is formed at the same time as the
main body block is formed. Alternatively, the deformation portion
is provided by a deformation plate member, which is separately
formed from a main body block. The deformation plate member is
fixed in an opening portion of the main body block, and is deformed
so that the spring member has a predetermined biasing force.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Other objects, features and advantages of the present
invention will become more apparent from the following detailed
description made with reference to the accompanying drawings, in
which like parts are designated by like reference numbers and in
which:
[0013] FIG. 1 is a schematic cross-sectional view of a thermal-type
expansion valve for a refrigerant cycle according to a first
embodiment of the present invention;
[0014] FIG. 2 is an enlarged cross-sectional view of a part of the
expansion valve according to the first embodiment;
[0015] FIG. 3 is a graph showing a relationship between the amount
of movement of an adjustment jig and the amount of change of a set
value according to the first embodiment;
[0016] FIG. 4 is an enlarged cross-sectional view of a part of an
expansion valve having a tubular projection according to a second
embodiment of the present invention;
[0017] FIG. 5 is an enlarged cross-sectional view of a part of an
expansion valve having a peripheral wall with a female thread
according to a third embodiment of the present invention;
[0018] FIG. 6 is an enlarged cross-sectional view of a part of an
expansion valve having a deformable plate as a deformation portion
according to a fourth embodiment of the present invention; and
[0019] FIG. 7 is a schematic cross-sectional view of an expansion
valve having a ball valve according to a fifth embodiment of the
present invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0020] A first embodiment of the present invention will now be
described with reference to FIGS. 1 to 3. FIG. 1 shows an example
of a thermal-type expansion valve 1 (hereafter, simply referred to
as the expansion valve 1). The expansion valve 1 is generally
employed in a refrigerant cycle for decompressing and expanding a
liquid-phase, high pressure refrigerant, which flows out from a
condenser 2, into a low pressure refrigerant and introducing the
low pressure refrigerant into an evaporator 3. Also, the expansion
valve 1 adjusts an opening degree of a valve thereof in accordance
with a degree of superheat of the refrigerant that flows out from
the evaporator 3, thereby to control a flow rate of the low
pressure refrigerant to be introduced into the evaporator 3.
[0021] In the refrigerant cycle, the refrigerant flows in the
following manner. First, a high pressure refrigerant that has been
compressed in a compressor 4 passes through the condenser 2. While
passing through the condenser 2, the high pressure refrigerant
becomes the liquid-phase, high pressure refrigerant due to heat
exchange.
[0022] Then, the liquid-phase, high pressure refrigerant is
decompressed and expanded in the expansion valve 1 and becomes a
gas and liquid two-phase, low pressure refrigerant. Thereafter, the
two-phase, low pressure refrigerant becomes a gas-phase, low
pressure refrigerant in the evaporator 3 due to heat exchange, and
then the gas-phase, low pressure refrigerant is drawn into the
compressor 4.
[0023] The expansion valve 1 generally has a main body block 100
and a power element 400. The main body block 100 includes a
superheat detection passage 200 and a decompression passage 300.
Each of the superheat detection passage 200 and the decompression
passage 300 extends through the main body block 100 in a direction
generally perpendicular to a longitudinal direction of the main
body block 100. The superheat detection passage 200 and the
decompression passage 300 are aligned with each other in a
longitudinal direction of the main body block 100.
[0024] In the superheat detection passage 200, which is located
above the decompression passage 300 in FIG. 1, the gas-phase, low
pressure refrigerant flowing from the evaporator 3 flows toward the
compressor 4. The superheat detection passage 200 is provided to
detect the degree of superheat of the gas-phase, low pressure
refrigerant flowing therein.
[0025] In the decompression passage 300, the liquid-phase, high
pressure refrigerant, which has flowed from the condenser 2, flows.
The decompression passage 300 is provided to decompress and expand
the liquid-phase, high pressure refrigerant into the low pressure
refrigerant, and discharge the low pressure refrigerant toward the
evaporator 3.
[0026] The main body block 100 has an opening 110 on an end
adjacent to the superheat detection passage 200. The opening 110 is
in communication with the superheat detection passage 200. The
power element 400 is mounted to the opening 110. The power element
400 is configured to control the valve opening degree of a spool
valve 600 as a valve body in accordance with the degree of
superheat detected in the superheat detection passage 200.
[0027] The power element 400 generally has a case 410 and a
diaphragm 420. The diaphragm 420 is housed in the case 410 such
that an inner space of the case 410 is divided into two chambers in
the longitudinal direction of the main body block 100. One of the
chambers, which is adjacent to the main body block 100, is referred
to as a lower pressure chamber 440, and the other chamber, which is
farther away than the lower pressure chamber 440 with respect to
the main body block 100, is referred to as an upper pressure
chamber 430.
[0028] The upper pressure chamber 430 is filled with a saturated
refrigerant and is sealed by a plug 431. The temperature of the
refrigerant passing through the superheat detection passage 200 is
detected by the refrigerant in the first pressure chamber 430, and
a saturation pressure according to the detected temperature is
exerted to the diaphragm 420. In the lower pressure chamber 440, a
stopper member 441 is housed in a condition that an outer
peripheral portion thereof is interposed between the case 410 and
the diaphragm 420.
[0029] The case 410 has a tubular part at its lower end. A male
thread portion 411 is formed on an outer surface of the tubular
part. The male thread portion 411 engages a female thread portion
111 that is formed on a wall defining the opening 110 of the main
body block 100.
[0030] The tubular part of the case 410 has an opening 412. The
case 410 is arranged on the main body block 100 such that the
opening 412 of the case 410 is in communication with the opening
110 of the main body block 100. Thus, the refrigerant passing
through the superheat detection passage 200 can reach the stopper
member 441 through the openings 110, 412. Namely, the stopper
member 441 can receive the pressure of the refrigerant passing
through the superheat detection passage 200.
[0031] Accordingly, the saturation pressure of the refrigerant of
the upper pressure chamber 430 and the refrigerant pressure applied
to the stopper member 441 are exerted to the diaphragm 420. Thus,
the diaphragm 420 moves up and down, that is, in the longitudinal
direction of the main body block 100 in response to the difference
between the saturation pressure and the refrigerant pressure. The
position of the stopper member 441 is determined by the movement of
the diaphragm 420.
[0032] Thus, when the difference between the saturation pressure
and the refrigerant pressure increases, the stopper member 441
moves downward, that is, toward the main body block 100. On the
other hand, when the difference reduces, the stopper member 441
moves upward, that is, in a direction opposite to the main body
block 100. As a result, when the degree of superheat increases, the
stopper member 441 moves downward. When the degree of superheat
reduces, the stopper member 441 moves upward.
[0033] An operation rod 450 is coupled to the stopper member 441
for transmitting the movement of the stopper member 441 to the
spool valve 600 that is disposed in the decompression passage 300.
The operation rod 450 extends across the superheat detection
passage 200 and connects to the spool valve 600. The operation rod
450 is movable with the movement of the stopper member 441. Thus,
the operation rod 450 applies a biasing force to the spool valve
600 in a downward direction, that is, in a valve opening
direction.
[0034] The decompression passage 300 includes a high pressure
passage portion 310, a low pressure passage portion 320, and a
small diameter passage portion 330 as a communication passage
portion. The high pressure passage portion 310 and the low pressure
passage portion 320 are offset from each other in the longitudinal
direction of the main body block 100. The high pressure passage
portion 310 and the low pressure passage portion 320 are
communicated with each other through the small diameter passage
portion 330 that extends in the longitudinal direction of the main
body block 100.
[0035] The high pressure passage portion 310 is provided to allow
the liquid-phase, high pressure refrigerant flowing from the
condenser 2 to flow into the small diameter passage portion 330. In
the small diameter passage portion 330, the high pressure,
liquid-phase refrigerant is decompressed and expanded. The low
pressure passage portion 320 is located at a position higher than
the high pressure passage portion 310. The low pressure passage
portion 320 is provided to allow the low pressure refrigerant
flowing from the small diameter passage portion 330 to flow toward
the evaporator 3.
[0036] The spool valve 600 is disposed in the small diameter
passage portion 330. Also, a spring member 700 is disposed in the
small diameter passage portion 330 for applying a force to the
spool valve 600 in the upward direction. In the example shown in
FIG. 1, the upward direction corresponds to a valve closing
direction for closing the valve, and the downward direction
corresponds to the valve opening direction for opening the valve.
The upward and downward direction, that is, the longitudinal
direction of the main body block 11 corresponds to an expansion and
contraction direction of the spring member 700.
[0037] In this embodiment, the spring member 700 is disposed in the
small diameter passage portion 330 in an compressed condition, that
is, in a pre-stressed condition. Here, the valve closing direction
corresponds to the expansion direction of the spring member 700.
The valve opening direction corresponds to the contraction
direction of the spring member 700. An outer diameter of the spool
valve 600 and an outer diameter of the spring member 700 are
substantially equal to an inner diameter of the small diameter
passage portion 330.
[0038] The spool valve 600 is formed with an orifice passage 610.
The orifice passage 610 has a substantially T-shape and allows
communication between the high pressure passage portion 310 and the
low pressure passage portion 320. The orifice passage 610 is
provided to decompress and expand the high pressure, liquid-phase
refrigerant flowing from the high pressure passage portion 310
therein and discharge the decompressed and expanded low pressure
refrigerant into the low pressure passage portion 320. Also, the
spool valve 600 is formed with an outer peripheral groove 620 on a
periphery of a top portion (refrigerant discharge portion) 611 of
the T-shaped orifice passage 610.
[0039] The spool valve 600 is movable in the small diameter passage
330 in the upward and downward direction. As the spool valve 600
moves in the upward and downward direction, a communication area
between the outer peripheral groove 620 and the low pressure
passage 320 varies. By this mechanism, the amount of the low
pressure refrigerant flowing into the low pressure passage portion
320 is controlled.
[0040] Namely, when the spool valve 610 is moved in the valve
opening direction, that is, in the downward direction, the
communication area between the outer peripheral groove 620 and the
low pressure passage 320 is increased. That is, the valve opening
degree is increased. As such, the amount of the low pressure
refrigerant flowing into the low pressure passage portion 320
increases.
[0041] On the other hand, when the spool valve 610 is moved in the
valve closing direction, that is, in the upward direction, the
communication area is reduced. That is, the valve opening degree is
reduced. As such, the amount of the low pressure refrigerant
flowing into the low pressure passage portion 320 reduces.
Accordingly, the amount of the low pressure refrigerant flowing
into the low pressure passage portion 320 is controlled by
controlling the valve opening degree of the spool valve 600.
[0042] The spring member 700 is disposed under the spool valve 600
in the small diameter passage portion 330 for applying the force to
the spool valve 600 in the upward direction. The spring member 700
is, for example, a coil spring. Further, in the small diameter
passage portion 330, a spring seating member 710 is disposed at the
lower end of the spring member 700. The spring seating member 710
is provided to improve the stability of the spring member 700 and
to restrict the main body block 110 from being cut or damaged by
rotation of the spring member 700.
[0043] The main body block 100 has a deformation portion 120 at a
lower position of the small diameter passage portion 330. The
deformation portion 120 is plastically deformable in the upward
direction, that is, in the valve closing direction by an external
force. The deformation portion 120 is a thin wall that is thinner
than a peripheral portion thereof in the main body block 100 with
respect to the upward and downward direction, that is, in the valve
opening and closing direction.
[0044] The spring member 700 is disposed between the spool valve
600 and the deformation portion 120. Thus, the deformation portion
120 serves as a seating for receiving a load from the spring member
700. The deformation portion 120 has predetermined thickness and
size (e.g., area) such that the deformation portion 120 is
displaceable in the upward and downward direction, that is, in a
direction parallel to the expansion and contraction direction of
the spring member 700. Also, the deformation portion 120 is
displaceable in such a range that an initial load, such as a
pre-stress, applied to the spring member 700 can be changed.
[0045] Further, the deformation portion 120 is displaceable in such
a range that the characteristic of the expansion valve 1 is
adjusted in a manufacturing process. The deformation portion 120 is
formed at a position where an adjustment jig 800 as a tool for the
deformation can easily reach in a condition that the main block
body 100 is securely held. The deformation portion 120 is much
thinner than the peripheral portion thereof in the main body block
100.
[0046] The main body block 100 has a substantially polyhedral
shape. The deformation portion 120 is located in a recess that is
formed at a substantially middle portion of one of sides of the
polyhedral shape. For example, the deformation portion 120 is
located in the recess that is formed on the bottom wall of the main
body block 100. The recess is defined by a peripheral wall 130 and
an outer surface of the deformation portion 120.
[0047] An inner surface of the deformation portion 120, that is, an
upper surface of the deformation portion 120 serves as a receiving
surface 120A that receives a load from the spring member 700. In
other words, the receiving surface 120A serves to apply the force
of the spring member 700 toward the spool valve 600. The outer
surface of the deformation portion 120, that is, a lower surface of
the deformation portion 120 serves as a working surface 120B that
receives the external force by the adjustment jig 800 such as a
plunger. Each of the receiving surface 120A and the working surface
120B has a circular shape, for example.
[0048] The peripheral wall 130 is coaxial with the deformation
portion 120. The diameter of the peripheral wall 130 is larger than
an outer diameter of the receiving surface 120A. Namely, the
working surface 120B is relatively larger than the receiving
surface 120A.
[0049] The above described expansion valve 1 is assembled in the
following manner. First, the spring seating member 710, the spring
member 700, and the spool valve 600 are placed in the small
diameter passage portion 330 through the opening 100 in this order.
Then, the power element 400 is screwed into the opening 110 of the
main body block 100.
[0050] After the component parts are assembled in the above manner,
the deformation portion 120 is deformed so as to adjust a control
characteristic of the spool valve 600. In the first embodiment,
this adjustment step is performed after all the component parts
associated with a movable section of the expansion valve 1 are
assembled.
[0051] In the expansion valve 1, the valve opening degree of the
spool valve 600 is controlled in the following manner. When the
degree of the superheat of the refrigerant flowing from the
evaporator 3 increases, the pressure difference in the power
element 400 increases. As such, the operation rod 450 is urged in
the downward direction by the stopper member 441. Namely, the
operation rod 450 biases the spool valve 600 in the downward
direction.
[0052] Therefore, the spool valve 600 moved in the downward
direction in the small diameter passage portion 330 against the
spring member 700. As a result, the communication area between the
low pressure passage portion 320 and the outer peripheral groove
620 of the orifice passage 610 increases. That is, the valve
opening degree increases. Therefore, the amount of the low pressure
refrigerant flowing into the low pressure passage portion 320
increases.
[0053] On the other hand, when the degree of superheat of the
refrigerant flowing out from the evaporator 3 reduces, the pressure
difference in the power element 400 reduces. As such, the operation
rod 450 is urged in the upward direction with the stopper member
441. Therefore, the biasing force for biasing the spool valve 600
in the downward direction is reduced. As a result, the spool valve
600 is moved in the upward direction in the small diameter passage
portion 330 by the force of the spring member 700. With this, the
communication area between the low pressure passage portion 320 and
the outer peripheral groove 620, that is, the valve opening degree
reduces. Therefore, the amount of the low pressure refrigerant
flowing into the low pressure passage portion 320 reduces.
[0054] In this embodiment, spring-back force (biasing force) of the
spring member 700 is adjusted such that the characteristic of the
valve opening degree is in a predetermined characteristic range.
The adjustment of the biasing force of the spring member 700 is
performed by plastically deforming the deformation portion 120 in
the upward direction using the adjustment jig 800.
[0055] First, the adjustment jig 800 is aligned with the working
surface 120B of the deformation portion 120. At this time, because
the adjustment jig 800 is inserted within the peripheral wall 130,
the adjustment jig 800 is properly positioned with respect to the
deformation portion 120.
[0056] In a condition that the adjustment jig 800 is in contact
with the working surface 120B of the deformation portion 120, the
adjustment jig 800 is moved in the upward direction. As such, the
deformation portion 120 is deformed in the upward direction by the
force generated by the adjustment jig 800, and thus the receiving
surface 120A is moved upward. Since the working surface 120B is
relatively larger than the receiving surface 120A, the deformation
of the deformation portion 120 is exerted entirely over the
receiving surface 120A. Thus, the receiving surface 120A is
entirely moved in the upward direction.
[0057] As a result, a distance between the receiving surface 120A
and the spool valve 600 is reduced. Thus, the biasing force of the
spring member 700 for biasing the spool valve 600 in the valve
closing direction is adjusted to increase. In this way, the
characteristic of the valve opening degree of the spool valve 600
is adjusted.
[0058] Here, the characteristic of the spring member 700 to be set
is predetermined. Also, the amount of movement of the receiving
surface 120A, which is required to set the characteristic, is
predetermined. Therefore, in the adjustment step, the adjustment
jig 800 is moved by a predetermined amount in accordance with the
predetermined amount of movement of the receiving surface 120A.
[0059] For example, a thickness t1 of the deformation portion 120
is 1 mm, and a diameter .phi. of the deformation portion 120 is 14
mm. FIG. 3 shows a relationship between the amount of movement of
the adjustment jig 800 and the amount of change of a set value
(initial spring-back force) of the spring member 700 for the
deformation portion 120 having the above thickness and
diameter.
[0060] As shown in FIG. 3, when the amount of movement of the
adjustment jig 800 is smaller than 0.8 mm, the amount of change of
the set value is substantially in proportion to the amount of
movement. Therefore, when the set value needs to be changed in a
range between 0 and 40 kPa, the adjustment jig 800 is moved by the
corresponding amount.
[0061] The thickness t1 and the diameter .phi. of the deformation
portion 120 are not limited to the above values, but may be varied
in a thickness range between 0.5 mm and 2 mm and in a diameter
range between 7 mm and 20 mm, respectively. In these thickness
range and diameter range, the movement of the adjustment jig 800
and the set value have the similar relationship as the relationship
shown in FIG. 3.
[0062] When the thickness t1 is larger than 2 mm, that is, when the
thickness t1 is large relative to the diameter .phi., the
deformation portion 120 does not substantially deform even if the
amount of movement of the adjustment jig 800 is increased. In this
case, therefore, it is difficult to adjust the set value of the
spring member 700 to a desired set value.
[0063] On the other hand, when the thickness t1 is smaller than 0.5
mm, that is, when the thickness t1 is small relative to the
diameter .phi., rigidity of the deformation portion 120 reduces.
Therefore, even when the deformation portion 120 is deformed by the
adjustment jig 800, the deformation portion 120 is likely to be
pushed back in the downward direction due to such as the biasing
force of the spring member 700 and the pressure of the refrigerant
in the small diameter passage portion 330. As such, even when the
deformation portion 120 is deformed by the predetermined amount, it
is difficult to maintain the set value in a desired set value.
[0064] When the thickness t1 and the diameter .phi. of the
deformation portion 120 are in the above ranges, the set value of
the spring member 700 is appropriately set in accordance with the
amount of movement of the adjustment jig 800.
[0065] As described above, the biasing force of the spring member
700 in the valve closing direction is increased by deforming the
deformation portion 120 in the upward direction using the
adjustment jig 800. Since the biasing force of the spring member
700 is adjusted by the deformation of the deformation portion 120,
the characteristic of the valve opening degree is adjusted to the
predetermined characteristic.
[0066] Further, since the set value of the spring member 700 is
adjusted by deforming the deformation portion 120, a structure
required for adjusting the set value is simplified. Also, even by
the simple structure, the adjustment of the set value is
appropriately performed.
[0067] The deformation portion 120 is provided by the thin wall
portion of the main body block 100. Namely, it is not necessary to
provide the deformation portion 120 separately. As such, the
structure is further simplified.
[0068] Also, since the working surface 120B is relatively larger
than the receiving surface 120A, the receiving surface 120A is
entirely deformed in the upward direction. That is, it is less
likely that the receiving surface 120A will be partly deformed.
[0069] The main body block 100 has the peripheral wall 130 that is
coaxial with the deformation portion 120. Therefore, the adjustment
jig 800 is easily and properly positioned with respect to the
deformation portion 120. Accordingly, the deformation portion 120
is properly deformed.
Second Embodiment
[0070] A second embodiment will be described with reference to FIG.
4. In this embodiment, the deformation portion 120 is formed on the
bottom wall of the main body block 100. The working surface 120B is
provided by a portion of the bottom surface of the main body block
100. The main body block 100 has a tubular projection 140 that
extends from the working surface 120B. The tubular projection 140
has a female thread portion 140A on its inner surface, so that the
adjustment jig 800 is screwed into the tubular projection 140. The
tubular projection 140 is integrally formed with the main body
block 100 when the main body block 100 is formed.
[0071] The tubular projection 140 serves an operation portion for
displacing the deformation portion 120 in at least one of the
upward direction and the downward direction. For example, the
tubular projection 140 is located at a center of the deformation
portion 120. The tubular projection 140 extends in a direction
parallel to the displacement direction of the deformation portion
120. The deformation portion 120 can be displaced in one of or both
of the expansion direction and the contraction direction of the
spring member 700.
[0072] The adjustment jig 800 is formed with a male thread portion
800A on its outer surface so that the adjustment jig 800 is screwed
with the female thread portion 140A of the tubular projection 140.
In a condition that the adjustment jig 800 is engaged with the
tubular projection 140, the adjustment jig 800 is moved in at least
one of the upward direction and the downward direction.
[0073] When the adjustment jig 800 is moved upward, the deformation
portion 120 deforms in the upward direction. Thus, the receiving
surface 120A moves in the upward direction. On the other hand, when
the adjustment jig 800 is moved downward, the deformation portion
120 deforms in the downward direction. Thus, the receiving surface
120A moves in the downward direction.
[0074] Accordingly, since the receiving surface 120A can be
deformed in both of the upward direction and the downward
direction, the biasing force of the spring member 700 is adjusted
in both direction, that is, adjusted in an increase manner and a
decrease manner.
Third Embodiment
[0075] A third embodiment of the present invention will be
described with reference to FIG. 5. In this embodiment, the main
body block 100 has the recessed portion on its bottom, and the
deformation portion 120 is provided by the wall that defines the
recessed portion. As shown in FIG. 5, the peripheral wall 130 is
formed with a female thread portion 130A to which the male thread
portion 800A of the adjustment jig 800 is screwed.
[0076] Here, the depth of the recessed portion is greater than that
of the first embodiment. Further, the depth of the recessed portion
is greater than the diameter of the deformation portion 120.
[0077] The deformation portion 120 is deformed in the upward
direction by screwing the adjustment jig 800 into the recessed
portion. In this case, the deformation portion 120 can be deformed
by a force that is smaller than the force required to simply moving
the adjustment jig 800 as the first embodiment. As such, the
deformation portion 120 is easily deformed by a small device
without requiring a large apparatus such as a pressing machine.
Fourth Embodiment
[0078] A fourth embodiment will be described with reference to FIG.
6. As shown in FIG. 6, the main body block 100 is formed with an
opening portion 150 on its bottom end. The opening portion 150 is
located at the bottom of the small diameter passage portion 330 and
is in communication with the small diameter passage portion 330.
The opening portion 150 is coaxial with the small diameter passage
portion 330 and has an inner diameter larger than the inner
diameter of the small diameter passage portion 330. Namely, the
opening portion 150 is formed at a position opposite to the spool
valve 600 and the inner diameter of the opening portion 150 is
larger than the outer diameter of the spring member 700.
[0079] Further, a deformation plate member 160 having a shape
corresponding to an inner shape of the opening portion 150 is fixed
in the opening portion 150 such as in a pressed manner. For
example, the deformation plate member 160 has a substantially cup
shape. The deformation plate member 160 is fixed to the main body
block 100 such that an opening of the cup-shaped deformation plate
member 160 faces the spring member 700.
[0080] Namely, the opening portion 150 is formed as the recessed
portion, and the deformation plate member 160 is fixed in the
recessed portion. Thus, the deformation plate member 160 serves as
the deformation portion 120. Accordingly, the set value of the
spring member 700 is adjusted by deforming the deformation plate
member 160 using the adjustment jig 800. As such, the
characteristic of the valve opening degree is adjusted.
[0081] In this structure, it is easy to increase the diameter of
the deformation plate member 160. Thus, this structure is adaptable
to increase the amount of deformation, that is, to increase the
adjustment range.
Fifth Embodiment
[0082] A fifth embodiment will be described with reference to FIG.
7. In the fifth embodiment, the expansion valve 1 has a ball valve
900 in place of the spool valve 600. Hereafter, structures
different from the above embodiments will be mainly described.
[0083] As shown in FIG. 7, a first valve seating member 910 is
disposed above the spring member 700 within the small diameter
passage portion 330 for supporting the ball valve 900. Also, a
second valve seating member 920 is disposed above the first valve
seating member 910 in the small diameter passage portion 330, such
as in a pressed manner.
[0084] The second valve seating member 920 is formed with a through
hole 921. The through hole 921 extends in the axial direction of
the small diameter passage portion 330. The operation rod 450
passes through the through hole 921 and contacts the ball valve
900, which is disposed between the first valve seating member 910
and the second valve seating member 920. The second valve seating
member 920 is further formed with a communication opening 922 that
extends perpendicular to the through hole 921. The communication
opening 922 is disposed to communicate with the low pressure
passage portion 320.
[0085] A lower area of the through hole 921, which allows
communication between the high pressure passage portion 310 and the
communication opening 922, provides an orifice passage 921A for
decompressing and expanding the high pressure refrigerant. The ball
valve 900 is configured to open and close an inlet opening of the
orifice passage 921A. Namely, the flow rate of the low pressure
refrigerant flowing into the low pressure refrigerant passage 320
is adjusted by controlling an opening degree of the inlet opening
of the orifice passage 921A by the ball valve 900.
[0086] Also in this embodiment, the main body block 100 is formed
with the deformation portion 120 and the peripheral wall 130 at the
bottom of the small diameter passage portion 330, similar to the
first embodiment. As such, the characteristic of the valve opening
degree is adjusted in the similar manner as the first embodiment.
Alternatively, the deformation portion 120 and the peripheral wall
130 can be provided in the similar manner as one of the second to
fourth embodiments.
Other Embodiments
[0087] The various exemplary embodiments of the present invention
are described hereinabove. However, the present invention is not
limited to the above described exemplary embodiments, but may be
implemented in various other ways without departing from the spirit
of the invention.
[0088] For example, the above embodiments will be modified in the
following manners. In the first embodiment, the peripheral wall 130
is formed coaxially with the deformation portion 120. However, the
peripheral wall 130 may be eliminated. That is, the working surface
120B may be formed to be aligned with the bottom wall of the main
body block 100.
[0089] In the first embodiment, the working surface 120B is
relatively larger than the receiving surface 120A. Alternatively,
the working surface 120B may be the same size as the receiving
surface 120A or be smaller than the receiving surface 120A.
[0090] In the first embodiment, the deformation portion 120 is
deformed by moving the adjustment jig 800 such as by the pressing
device. However, the deformation portion 120 may be deformed by
other means. For example, the deformation portion 120 can be
deformed by hitting with another tool such as a hammer.
[0091] In the second embodiment, the inner diameter of the tubular
projection 140 is smaller than the inner diameter of the small
diameter passage portion 330. Alternatively, the inner diameter of
the tubular projection 140 may be the same as the inner diameter of
the small diameter passage portion 330. In this case, the
deformation portion 120 is entirely deformed in the upward and
downward direction.
[0092] In the fourth embodiment, the inner diameter of the opening
portion 150 is larger than the inner diameter of the small diameter
passage portion 330. Alternatively, the inner diameter of the
opening portion 150 may be the same as or smaller than the inner
diameter of the small diameter passage portion 330.
[0093] In the above embodiments, the expansion valve 1 is
configured such that the valve opening degree is controlled by
detecting the condition of the low pressure refrigerant using the
valve operation device such as the power element 400. However, the
present invention may be employed to an expansion valve that
controls a valve opening degree based on a condition of high
pressure refrigerant detected by a valve operation device. Further,
the present invention may be implemented by combining the above
embodiments in various ways.
* * * * *