U.S. patent application number 15/373102 was filed with the patent office on 2017-06-22 for variable-capacity compressor control valve.
This patent application is currently assigned to Fujikoki Corporation. The applicant listed for this patent is Fujikoki Corporation. Invention is credited to Hisashi Asano, Masaharu Itoh, Yoshiyuki Kume, Masaki Tomaru.
Application Number | 20170175725 15/373102 |
Document ID | / |
Family ID | 57206136 |
Filed Date | 2017-06-22 |
United States Patent
Application |
20170175725 |
Kind Code |
A1 |
Kume; Yoshiyuki ; et
al. |
June 22, 2017 |
VARIABLE-CAPACITY COMPRESSOR CONTROL VALVE
Abstract
Provided is a variable-capacity compressor control valve where a
decrease in the sealability or the operability due to shaft
misalignment can be effectively suppressed without requiring high
dimensional accuracy. The dimensions and the shape of each part are
designed such that when the sub valve element closes the in-valve
release passage, the tapered portion (sub valve element portion)
provided at the lower end portion of the sub valve element enters
the release through-hole of the in-valve release passage, and the
sub valve element is thus aligned with the main valve element by
the tapered portion.
Inventors: |
Kume; Yoshiyuki; (Tokyo,
JP) ; Asano; Hisashi; (Tokyo, JP) ; Tomaru;
Masaki; (Tokyo, JP) ; Itoh; Masaharu; (Tokyo,
JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Fujikoki Corporation |
Tokyo |
|
JP |
|
|
Assignee: |
Fujikoki Corporation
Tokyo
JP
|
Family ID: |
57206136 |
Appl. No.: |
15/373102 |
Filed: |
December 8, 2016 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F04B 2027/1859 20130101;
F04B 27/1804 20130101; F04B 2027/1813 20130101; F04B 2027/1827
20130101; F04B 2027/1818 20130101; F04B 2027/1831 20130101; F04B
2027/1845 20130101 |
International
Class: |
F04B 27/18 20060101
F04B027/18 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 16, 2015 |
JP |
2015-245030 |
Claims
1. A variable-capacity compressor control valve comprising: a valve
body including a valve chamber with a valve orifice, a Ps
inlet/outlet port communicating with a suction chamber of a
compressor, a Pd introduction port arranged upstream of the valve
orifice and communicating with a discharge chamber of the
compressor, and a Pc inlet/outlet port arranged downstream of the
valve orifice and communicating with a crank chamber of the
compressor; a main valve element adapted to open or close the valve
orifice; an electromagnetic actuator with a plunger for moving the
main valve element in a direction to open or close the valve
orifice; a pressure-sensitive chamber adapted to receive a suction
pressure Ps from the compressor via the Ps inlet/outlet port; a
pressure-sensitive reaction member adapted to urge the main valve
element in the direction to open or close the valve orifice in
accordance with a pressure in the pressure-sensitive chamber; an
in-valve release passage provided in the main valve element, the
in-valve release passage being adapted to release a pressure Pc in
the crank chamber to the suction chamber of the compressor via the
Ps inlet/outlet port; and a sub valve element adapted to open or
close the in-valve release passage, wherein the sub valve element
has a sub valve element portion with a tapered portion, and
dimensions and a shape of each part are designed such that when the
sub valve element closes the in-valve release passage, the tapered
portion enters the in-valve release passage, and the sub valve
element is thus aligned with the main valve element by the tapered
portion.
2. The variable-capacity compressor control valve according to
claim 1, wherein part of the tapered portion is located in the
in-valve release passage when the sub valve element is at the
highest elevated position with respect to the main valve
element.
3. The variable-capacity compressor control valve according to
claim 1, wherein the sub valve element is supported by the
pressure-sensitive reaction member at an end portion on a side
opposite to the sub valve element portion, and is pressed against
the plunger by a plunger spring such that the sub valve element
moves up or down with the plunger.
4. The variable-capacity compressor control valve according to
claim 1, wherein the tapered portion has a protrusion that extends
toward the in-valve release passage.
Description
CLAIM OF PRIORITY
[0001] The present application claims priority from Japanese patent
application JP 2015-245030 filed on Dec. 16, 2015, the content of
which is hereby incorporated by reference into this
application.
BACKGROUND
[0002] Technical Field
[0003] The present invention relates to a variable-capacity
compressor control valve for use in an automotive air conditioner
or the like.
[0004] Background Art
[0005] Conventionally, a variable-capacity swash plate compressor
such as the one schematically shown in FIG. 9 has been used as a
compressor for an automotive air conditioner. The variable-capacity
swash plate compressor 100 includes a rotating shaft 101 that is
rotationally driven by an on-vehicle engine, a swash plate 102 that
is attached to the rotating shaft 101, a crank chamber 104 in which
the swash plate 102 is disposed, a piston 105 that is reciprocated
by the swash plate 102, a discharge chamber 106 for discharging
refrigerant compressed by the piston 105, a suction chamber 107 for
sucking refrigerant, an in-compressor release passage (fixed
orifice) 108 for releasing a pressure Pc in the crank chamber 104
to the suction chamber 107, and the like.
[0006] Meanwhile, a control valve 1' used for the aforementioned
variable-capacity compressor receives the discharge pressure Pd
from the discharge chamber 106 of the compressor 100 and is
configured to control the pressure Pc in the crank chamber 104 by
controlling the discharge pressure Pd in accordance with the
suction pressure Ps of the compressor 100. Such a control valve 1'
has, as the basic configuration, a valve body that includes a valve
chamber with a valve orifice, a Ps introduction port communicating
with the suction chamber 107 of the compressor 100, a Pd
introduction port arranged upstream of the valve orifice and
communicating with the discharge chamber 106 of the compressor 100,
and a Pc outlet port arranged downstream of the valve orifice and
communicating with the crank chamber 104 of the compressor 100; a
valve element (valve stem) for opening or closing the valve
orifice; an electromagnetic actuator with a plunger for moving the
valve element in the direction to open or close the valve orifice
(in the vertical direction); a pressure-sensitive chamber that
receives the suction pressure Ps from the compressor 100 via the Ps
introduction port; and a pressure-sensitive reaction member that
urges the valve element in the direction to open or close the valve
orifice in accordance with the pressure in the pressure-sensitive
chamber. The valve element and the valve orifice form a valve unit
indicated by reference numeral 11' in FIG. 9 (for example, see
Patent Document 1 below).
[0007] In the control valve 1' with such a configuration, when
current is flowed through a solenoid portion including a coil, a
stator, an attractor, and the like of the electromagnetic actuator,
the plunger is attracted by the attractor, and along with this, the
valve element is moved in the direction to close the valve such
that it follows the plunger by the urging force of a valve closing
spring. Meanwhile, the suction pressure Ps introduced from the
compressor 100 via the Ps introduction port is introduced into the
pressure-sensitive chamber from an inlet/outlet chamber via a gap
formed between the plunger and a guide pipe arranged around the
outer periphery of the plunger or the like. Then, the
pressure-sensitive reaction member (e.g., a bellows device) is
expansively or contractively displaced in accordance with the
pressure (suction pressure Ps) in the pressure-sensitive chamber
(contracts if the suction pressure Ps is high, and expands if it is
low), and the displacement (urging force) is then transmitted to
the valve element, whereby the valve element portion of the valve
element moves up or down with respect to the valve orifice to
regulate the valve opening of the valve unit 11'. That is, the
valve opening is determined by the force of attracting the plunger
with the solenoid portion, the urging force (expansion or
contraction force) that acts with the expansive or contractive
displacement of the pressure-sensitive reaction member, the urging
force of a plunger spring (valve opening spring) and the valve
closing spring. The pressure Pc in the crank chamber 104
(hereinafter also referred to as a crank chamber pressure Pc or
simply referred to as a pressure Pc) is controlled in accordance
with the valve opening.
[0008] In response to the aforementioned variable-capacity
compressor, an improved variable-capacity swash plate compressor,
such as the one schematically shown in FIGS. 10A and 10B, for
example, has already been proposed that is intended to reduce the
time required to increase the discharge capacity at the compressor
actuation time, and suppress or reduce a decrease in the operation
efficiency of the compressor at the normal control time.
[0009] A control valve 2' used for such an improved
variable-capacity swash plate compressor 200 has a valve element
(valve stem) including a main valve element and a sub valve
element, and has an in-valve release passage 16' in the main valve
element. The control valve 2' basically has a valve body that
includes a valve chamber with a valve orifice, a Ps inlet/outlet
port communicating with a suction chamber 107 of the compressor
200, a Pd introduction port arranged upstream of the valve orifice
and communicating with a discharge chamber 106 of the compressor
200, and a Pc inlet/outlet port arranged downstream of the valve
orifice and communicating with a crank chamber 104 of the
compressor 200; a main valve element for opening or closing the
valve orifice; an electromagnetic actuator with a plunger for
moving the main valve element in the direction to open or close the
valve orifice; a pressure-sensitive chamber that receives the
suction pressure Ps from the compressor 200 via the Ps inlet/outlet
port; and a pressure-sensitive reaction member that urges the main
valve element in the direction to open or close the valve orifice
in accordance with the pressure in the pressure-sensitive chamber.
Further, the in-valve release passage 16' for releasing the
pressure Pc in the crank chamber 104 to the suction chamber 107 of
the compressor 200 via the Ps inlet/outlet port is provided in the
main valve element, and the sub valve element for opening or
closing the in-valve release passage 16' is also provided so that
when the plunger is continuously moved upward from the lowest
position by the attraction force of the electromagnetic actuator,
the sub valve element moves upward together with the plunger while
closing the in-valve release passage 16', and the main valve
element is also moved upward so as to follow the sub valve element.
Then, after the valve orifice is closed by the main valve element,
if the plunger is further moved upward, the sub valve element is
configured to open the in-valve release passage 16'. The main valve
element and the valve orifice form a main valve unit indicated by
reference numeral 11' in FIGS. 10A and 10B, while the sub valve
element and the in-valve release passage form a sub valve unit
indicated by reference numeral 12' (for example, see Patent
Document 2 below).
[0010] At the normal control time (Pd.fwdarw.Pc control time) of
the control valve 2' with such a configuration, when current is
flowed through a solenoid portion including a coil, a stator, an
attractor, and the like of the electromagnetic actuator, the
plunger is attracted by the attractor, and along with this, the sub
valve element moves upward integrally with the plunger, and
following the movement of the sub valve element, the main valve
element is moved in the direction to close the valve by the urging
force of a valve closing spring. Meanwhile, the suction pressure Ps
introduced from the compressor 200 via the Ps inlet/outlet port is
introduced into the pressure-sensitive chamber from an inlet/outlet
chamber via a horizontal hole in the plunger or the like, and the
pressure-sensitive reaction member (e.g., a bellows device) is
expansively or contractively displaced in accordance with the
pressure (suction pressure Ps) in the pressure-sensitive chamber
(contracts if the suction pressure Ps is high, and expands if it is
low), and the displacement (urging force) is then transmitted to
the main valve element, whereby the main valve element portion of
the main valve element moves up or down with respect to the valve
orifice to regulate the valve opening of the main valve unit 11'.
That is, the valve opening is determined by the force of attracting
the plunger with the solenoid portion, the urging force (expansion
or contraction force) that acts with the expansive or contractive
displacement of the pressure-sensitive reaction member, the urging
force of a plunger spring (valve opening spring) and the valve
closing spring, and force that acts on the main valve element in
the valve opening direction and in the valve closing direction. The
pressure Pc in the crank chamber 104 is controlled in accordance
with the valve opening. In such a case, the main valve element is
always urged upward by the urging force of the valve closing
spring, while the sub valve element is always urged downward by the
urging force of the valve opening spring. Thus, the sub valve unit
12' is closed and the in-valve release passage 16' is blocked in
the main valve element. Therefore, there is no possibility that the
crank chamber pressure Pc may be released to the suction chamber
107 via the in-valve release passage 16'.
[0011] In contrast, at the compressor actuation time, current is
flowed through the solenoid portion so that the plunger is
attracted by the attractor and the sub valve element moves upward
together with the plunger. Following the upward movement of the sub
valve element, the main valve element is moved in the direction to
close the valve by the urging force of the valve closing spring,
and after the valve orifice is closed by the main valve element
portion of the main valve element, the plunger is further moved
upward, whereby the sub valve element opens the in-valve release
passage 16'. Then, the crank chamber pressure Pc is released to the
suction chamber 107 via two passages that are an in-compressor
release passage 108 and the in-valve release passage 16' (for
details, see Patent Document 2 below and the like).
RELATED ART DOCUMENTS
Patent Documents
[0012] Patent Document 1: JP 2010-185285 A [0013] Patent Document
2: JP 2013-130126 A
SUMMARY
[0014] By the way, in the variable-capacity compressor control
valve 2' descried above, a sub valve element portion of the sub
valve element that opens or closes the in-valve release passage has
a flat shape, and the sub valve element is guided so as not to be
tilted by a predetermined amount or more upon insertion into an
insertion hole of a latch member that is fixed to the inner
peripheral portion of the plunger.
[0015] However, in the control valve with the aforementioned
configuration, it follows that the sub valve element is guided by
the plunger that is a movable part (or the latch member fixed
thereto). Therefore, a decrease in the sealability or the
operability due to shaft misalignment is concerned, and there has
also been a problem that the cost would increase if the dimensional
accuracy of the guide portion is increased.
[0016] The present invention has been made in view of the
foregoing, and it is an object of the present invention to provide
a variable-capacity compressor control valve where a decrease in
the sealability or the operability due to shaft misalignment can be
effectively suppressed without requiring high dimensional
accuracy.
[0017] In order to achieve the aforementioned object, a
variable-capacity compressor control valve in accordance with the
present invention basically includes a valve body including a valve
chamber with a valve orifice, a Ps inlet/outlet port communicating
with a suction chamber of a compressor, a Pd introduction port
arranged upstream of the valve orifice and communicating with a
discharge chamber of the compressor, and a Pc inlet/outlet port
arranged downstream of the valve orifice and communicating with a
crank chamber of the compressor; a main valve element adapted to
open or close the valve orifice; an electromagnetic actuator with a
plunger for moving the main valve element in a direction to open or
close the valve orifice; a pressure-sensitive chamber adapted to
receive a suction pressure Ps from the compressor via the Ps
inlet/outlet port; a pressure-sensitive reaction member adapted to
urge the main valve element in the direction to open or close the
valve orifice in accordance with a pressure in the
pressure-sensitive chamber; an in-valve release passage provided in
the main valve element, the in-valve release passage being adapted
to release a pressure Pc in the crank chamber to the suction
chamber of the compressor via the Ps inlet/outlet port; and a sub
valve element adapted to open or close the in-valve release
passage. The sub valve element has a sub valve element portion with
a tapered portion, and dimensions and a shape of each part are
designed such that when the sub valve element closes the in-valve
release passage, the tapered portion enters the in-valve release
passage, and the sub valve element is thus aligned with the main
valve element by the tapered portion.
[0018] In a preferred aspect, part of the tapered portion is
located in the in-valve release passage when the sub valve element
is at the highest elevated position with respect to the main valve
element.
[0019] The sub valve element is preferably supported by the
pressure-sensitive reaction member at an end portion on a side
opposite to the sub valve element portion, and is pressed against
the plunger by a plunger spring such that the sub valve element
moves up or down with the plunger.
[0020] In another preferred aspect, the tapered portion has a
protrusion that extends toward the in-valve release passage.
[0021] According to the variable-capacity compressor control valve
in accordance with the present invention, a sub valve element has a
sub valve element portion with a tapered portion, and the
dimensions and the shape of each part are designed such that when
the sub valve element closes the in-valve release passage, the
tapered portion enters the in-valve release passage, and the sub
valve element is thus aligned with the main valve element by the
tapered portion. Therefore, in comparison with the conventional art
in which a sub valve element portion of a sub valve element has a
flat shape, it is possible to effectively suppress a decrease in
the sealability or the operability due to shaft misalignment
without requiring high dimensional accuracy.
[0022] Further, as part of the tapered portion is located in the
in-valve release passage even when the sub valve element is at the
highest elevated position with respect to the main valve element,
the tapered portion surely enters the in-valve release passage when
the sub valve element closes the in-valve release passage. Thus,
further relaxation of the dimensional accuracy can also be
achieved.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a longitudinal sectional view showing the first
embodiment of the variable-capacity compressor control valve in
accordance with the present invention in which the main valve
element is in the open position and the sub valve element is in the
closed position (at the normal control time).
[0024] FIG. 2 is a longitudinal sectional view showing the first
embodiment of the variable-capacity compressor control valve in
accordance with the present invention in which the main valve
element is in the closed position and the sub valve element is in
the closed position (at the time of transition to compressor
actuation).
[0025] FIG. 3 is a longitudinal sectional view showing the first
embodiment of the variable-capacity compressor control valve in
accordance with the present invention in which the main valve
element is in the closed position and the sub valve element is in
the open position (at the compressor actuation time).
[0026] FIGS. 4A to 4E are views each showing a plunger used for the
variable-capacity compressor control valve in accordance with the
present invention; specifically, FIG. 4A is a front view, FIG. 4B
is a left-side view, FIG. 4C is a bottom view, FIG. 4D is a
sectional view along the direction of the arrows X-X in FIG. 4A,
and FIG. 4E is a sectional view along the direction of the arrows
Y-Y in FIG. 4B.
[0027] FIG. 5 is an enlarged sectional view of the main part
showing a variation of a sub valve element portion of a sub valve
element in the first embodiment.
[0028] FIG. 6 is a longitudinal sectional view showing the second
embodiment of the variable-capacity compressor control valve in
accordance with the present invention in which the main valve
element is in the open position and the sub valve element is in the
closed position (at the normal control time).
[0029] FIG. 7 is a longitudinal sectional view showing the second
embodiment of the variable-capacity compressor control valve in
accordance with the present invention in which the main valve
element is in the closed position and the sub valve element is in
the closed position (at the time of transition to compressor
actuation).
[0030] FIG. 8 is a longitudinal sectional view showing the second
embodiment of the variable-capacity compressor control valve in
accordance with the present invention in which the main valve
element is in the closed position and the sub valve element is in
the open position (at the compressor actuation time).
[0031] FIG. 9 is a view showing the circulation state of a
refrigerant pressure between a compressor and a control valve of
the first conventional art.
[0032] FIGS. 10A and 10B are views each showing the circulation
state of a refrigerant pressure between a compressor and a control
valve of the second conventional art; specifically, FIG. 10A is a
view at the normal operation time and FIG. 10B is a view at the
compressor actuation time.
DETAILED DESCRIPTION
[0033] Hereinafter, embodiments of the present invention will be
described with reference to the drawings.
First Embodiment
[0034] FIGS. 1 to 3 are longitudinal sectional views each showing
the first embodiment of the variable-capacity compressor control
valve in accordance with the present invention. Specifically, FIG.
1 is a view in which the main valve element is in the open position
and the sub valve element is in the closed position (at the normal
control time), FIG. 2 is a view in which the main valve element is
in the closed position and the sub valve element is in the closed
position (at the time of transition to compressor actuation), and
FIG. 3 is a view in which the main valve element is in the closed
position and the sub valve element is in the open position (at the
compressor actuation time).
[0035] It should be noted that in the present specification,
descriptions indicating the positions or directions, such as upper,
lower, top, bottom, left, right, front, and rear, are used for the
sake of convenience in accordance with the drawings to avoid
complexity in the description, but such descriptions do not
necessarily indicate the actual positions or directions when the
control valve of the present invention is incorporated into a
compressor.
[0036] In addition, in each drawing, a gap formed between members,
a clearance between members, and the like may be depicted larger or
smaller than their actual dimensions to help understand the present
invention and also for the sake of convenience to create the
drawing.
[0037] A control valve 1 in the shown embodiment has a valve body
20 with a valve orifice 22; a valve element 10 with a main valve
element 15 for opening or closing the valve orifice 22; an
electromagnetic actuator 30 for moving the valve element 10 (main
valve element 15) in the direction to open or close the valve
orifice (in the vertical direction); and a bellows device 40 that
serves as a pressure-sensitive reaction member.
[0038] The electromagnetic actuator 30 includes a bobbin 38, an
energization coil 32 wound around the bobbin 38, a connector head
31 attached to the upper side of the bobbin 38 with an attachment
plate 39 interposed therebetween, a stator 33 and an attractor 34
arranged on the inner peripheral side of the coil 32, a guide pipe
35 whose upper end portion is joined by welding to the outer
periphery of the lower end portion (a step portion) of the stator
33 and the attractor 34, a plunger 37 having a recessed cross
section and arranged vertically slidably on the inner peripheral
side of the guide pipe 35 below the attractor 34, a cylindrical
housing 60 externally arranged around the coil 32, and a holder 29
arranged between the lower end portion of the housing 60 and the
guide pipe 35 and adapted to fix them to the top of the valve body
20. In the present example, the attractor 34 with a recessed cross
section is integrally molded with the inner periphery of the bottom
of the cylindrical stator 33. Herein, a portion of the
electromagnetic actuator 30 including the coil 32, the stator 33,
the attractor 34, and the like and excluding the plunger 37 is
referred to as a solenoid portion 30A.
[0039] A stator 65 in a short columnar shape is attached to the top
of the stator 33 by press fitting or the like, and a
pressure-sensitive chamber 45, which receives a suction pressure Ps
in a compressor 100, is formed between the stator 65 and the
attractor 34 on the inner peripheral side of the stator 33. The
pressure-sensitive chamber 45 has arranged therein the bellows
device 40 that serves as a pressure-sensitive reaction member and
includes bellows 41, an upper stopper 42 in an inverted projection
shape, a lower stopper 43 in an inverted recessed shape, and a
compression coil spring 44. Further, a top small-diameter portion
17d (an end portion on the side opposite to a sub valve element
portion 17a) of a sub valve element 17 described below is fitted
and inserted in and supported by the recess of the lower stopper
43, and a compression coil spring 46, which urges the bellows
device 40 in the direction to contract the bellows device 40, is
provided in a compressed state between the lower stopper 43 and the
attractor 34.
[0040] The plunger 37 has a cylindrical upper half portion 37A and
a columnar lower half portion 37B. Provided in the center of the
columnar lower half portion 37B is an insertion hole 37b through
which a waist portion 17b of the sub valve element 17 that extends
downward through the attractor 34 and a top small-diameter portion
15f (described in detail below) of the main valve element 15 are
inserted. The outer peripheral portion of the insertion hole 37b on
the upper surface of the columnar lower half portion 37B serves as
a latch portion 37a to which an intermediate large-diameter latch
portion 17c of the sub valve element 17 is latched.
[0041] In addition, a plunger spring (valve opening spring) 47
constructed from a cylindrical compression coil spring, which urges
the sub valve element 17 and the plunger 37 downward (in the
direction to open the valve), is provided in a compressed state
between the attractor 34 and the intermediate large-diameter latch
portion 17c of the sub valve element 17 (plunger 37) so that the
sub valve element 17 (or the intermediate large-diameter latch
portion 17c thereof) is pressed against the plunger 37 by the
plunger spring 47 and thus is caused to move up or down with the
plunger 37.
[0042] Further, as can be understood well from FIGS. 4A to 4E, the
bottom of the columnar lower half portion 37B of the plunger 37 (a
portion that is above the lower end portion by a predetermined
distance) has a cut-in 37t with an approximately semicircular shape
in plan view (in the horizontal direction) that is formed so as to
overlap the insertion hole 37b. On the side below the cut-in 37t
(i.e., at a portion between the cut-in 37t and the lower end
portion of the columnar lower half portion 37B), a slit 37s with
approximately the same width as the hole diameter of the insertion
hole 37b is formed that extends linearly from the edge portion at
the lower end of the columnar lower half portion 37B to the
insertion hole 37b. The height (in the vertical direction) of the
cut-in 37t is slightly larger than the height of a flanged latch
portion 15k of the main valve element 15, and the height (in the
vertical direction) of the slit 37s is slightly smaller than the
height of the top small-diameter portion 15f of the main valve
element 15. The main valve element 15 is movable in the vertical
direction with respect to the plunger 37 (which will be described
in detail below). The width (in the horizontal direction) of the
slit 37s is set slightly larger than the outside diameter of the
top small-diameter portion 15f of the main valve element 15 and
smaller than the outside diameter of the flanged latch portion 15k
of the main valve element 15 taking into consideration the
assembling properties and the like.
[0043] The valve element 10 has the main valve element 15 and the
sub valve element 17 arranged in the vertical direction (along the
direction of the axial line O).
[0044] The main valve element 15 arranged on the lower side has,
sequentially arranged from the bottom side, a bottom fit-insertion
portion 15b, a lower small-diameter portion 15c, a main valve
element portion 15a, an intermediate small-diameter portion 15d, a
top fit-insertion portion 15e, the top small-diameter portion 15f,
and the flanged latch portion 15k. A stepped release through-hole
16A forming part of an in-valve release passage 16 is provided in
the center of the main valve element 15 such that it penetrates the
center of the main valve element 15 in the vertical direction, and
the upper end portion of the release through-hole 16A serves as a
sub valve seat portion 23 with/from which the lower end portion
(sub valve element portion) 17a of the sub valve element 17 is
moved into contact or away. The intermediate small-diameter portion
15d of the main valve element 15 has a plurality of horizontal
holes 16s.
[0045] The top small-diameter portion 15f of the main valve element
15 is loosely fitted in the insertion hole 37b (or a portion below
the cut-in 37t thereof), and the flanged latch portion 15k of the
main valve element 15 has a larger diameter than that of the
insertion hole 37b so that when the plunger 37 is moved upward with
respect to the main valve element 15, the flanged latch portion 15k
is latched to an inner flanged latch portion 37k that is formed by
the outer peripheral portion of the insertion hole 37b, and thus,
latching is achieved and slippage is prevented.
[0046] The sub valve element 17 arranged above the main valve
element 15 has, sequentially arranged from the bottom side, an
inverted conical tapered portion 17a, which is moved into contact
with or away from the sub valve seat portion 23 that is the edge
portion at the upper end of the release through-hole 16A, the waist
portion 17b having the intermediate large-diameter latch portion
17c formed thereon, a truncated conical portion 17e, and a top
small-diameter portion 17d that is inserted in and supported by the
recess of the lower stopper 43. The tapered portion 17a serves as
the sub valve element portion that opens or closes the in-valve
release passage 16. Herein, the sub valve seat portion 23 and the
sub valve element portion 17a form the sub valve unit 12. In the
present example, a portion below the intermediate large-diameter
latch portion 17c of the waist portion 17 is inserted into the
insertion hole 37b of the plunger 37 with a small gap therebetween,
and a portion above the intermediate large-diameter latch portion
17c and below the attractor (a portion arranged inside the
cylindrical upper half portion 37A) has a slightly larger diameter
than those of the other portions.
[0047] The dimensions and the shape of each part around the sub
valve element 17 (e.g., a gap between the waist portion 17b and the
insertion hole 37b) are designed such that even when the sub valve
element 17 is slightly tilted at a position where it has been moved
upward with respect to the main valve element 15 (i.e., a position
where the in-valve release passage 16 is open), the lower end
portion of the sub valve element portion (a tapered portion) 17a in
an inverted conical shape enters the release through-hole 16A, and
the sub valve element 17 is thus aligned with the main valve
element 15 by the sub valve element portion 17a as the sub valve
element 17 moves closer to the main valve element 15 (i.e., when
the sub valve element 17 closes the in-valve release passage 16).
More specifically, the dimensions and the shape of each part are
designed such that part of the sub valve element portion 17a in an
inverted conical shape is located in the release through-hole 16A
when the sub valve element 17 is at the highest elevated position
with respect to the main valve element 15 (see FIG. 3, in
particular).
[0048] When the valve element 10 (the main valve element 15 and the
sub valve element 17) and the plunger 37 are assembled, for
example, the main valve element 15 is moved horizontally with
respect to the plunger 37 so that the flanged latch portion 15k and
the top small-diameter portion 15f of the main valve element 15,
which has been assembled in advance to the valve body 20 (or a
guide hole 19 thereof), are inserted into the cut-in 37t and the
slit 37s of the plunger 37, respectively, and the top
small-diameter portion 15f is fitted and inserted into the
insertion hole 37b provided in the center of the plunger 37, and
thereafter, the sub valve element 17 (or a portion below the
intermediate large-diameter latch portion 17c thereof) may be
inserted into the insertion hole 37b from above.
[0049] Meanwhile, the valve body 20 has a two-split structure that
includes a body member 20A having a fit recess hole 20C in the
center at the top thereof, and a support member 20B that is fixedly
inserted into the recess hole 20C by press fitting or the like.
[0050] The support member 20B is produced from a material with
relatively high hardness, such as stainless steel (SUS), and has a
protruding stopper portion 24A for defining the lowest position of
the plunger 37, on the upper side of a fit-insertion portion 24
that is fitted and inserted in the recess hole 20C. In addition,
the guide hole 19 (an upper guide hole 19A) into which the top
fit-insertion portion 15e of the main valve element 15 is slidably
fitted and inserted is formed in the center of the support member
20B such that it penetrates the support member 20B in the vertical
direction, and the lower end portion of the upper guide hole 19A
serves as the valve orifice 22 (a valve seat portion) that is
opened or closed by the main valve element portion 15a of the main
valve element 15. Herein, the main valve element portion 15a and
the valve orifice 22 form a main valve unit 11. As the support
member 20B is produced from a material with high hardness, such as
stainless steel, as described above, the specific gravity of the
support member 20B is also high.
[0051] The body member 20A is produced from a material, such as
aluminum, brass, or resin, that has relatively low specific gravity
(a material with relatively low hardness) as compared to stainless
steel and the like. An inlet/outlet chamber 28 for the suction
pressure Ps in the compressor 100 is formed around the outer
periphery of the stopper portion 24A, and a plurality of Ps
inlet/outlet ports 27 are formed around the outer peripheral side
of the inlet/outlet chamber 28 in a state in which the support
member 20B (or the fit-insertion portion 24 thereof) is inserted in
the recess hole 20C of the body member 20A. The suction pressure Ps
introduced into the inlet/outlet chamber 28 from the Ps
inlet/outlet ports 27 is introduced into the pressure-sensitive
chamber 45 via the slit 37s and the cut-in 37t formed at the bottom
of the plunger 37, a gap formed between the waist portion 17b of
the sub valve element 17 and the insertion hole 37b of the plunger
37, a gap 36 formed between the outer periphery of the plunger 37
and the guide pipe 35, and the like.
[0052] A reception hole 18, which has a larger diameter than those
of the guide hole 19 and the main valve element portion 15a and has
a smaller diameter than that of the recess hole 20C and is adapted
to store the main valve element portion 15a of the main valve
element 15, is provided continuously with the center of the bottom
of the recess hole 20C of the body member 20A, and the guide hole
19 (a lower guide hole 19B) into which the bottom fit-insertion
portion 15b of the main valve element 15 is slidably fitted and
inserted is formed in the center of the bottom of the reception
hole 18. A valve closing spring 50 constructed form a conical
compression coil spring is provided in a compressed state between
the corner on the outer periphery of the bottom of the reception
hole 18 and a stepped portion (terrace portion) 15g provided on the
outer periphery of the bottom of the main valve element portion 15a
of the main valve element 15. Thus, with the urging force of the
valve closing spring 50, the main valve element 15 (or a step
portion between the top fit-insertion portion 15e and the top
small-diameter portion 15f thereof) is pressed against the plunger
37.
[0053] The inside of the reception hole 18 (a portion below the
valve orifice 22 of the support member 20B) is the valve chamber
21. The valve chamber 21 has a plurality of Pd introduction ports
25 communicating with a discharge chamber 106 of the compressor
100. A ring-like filter member 25A is arranged around the outer
periphery of the Pd introduction ports 25 of the body member
20A.
[0054] The lower end portion of the body member 20A has a lid-like
member 48, which functions as a filter, fixed thereto by
engagement, press fitting, or the like. A Pc inlet/outlet chamber
(inlet/outlet port) 26, which communicates with a crank chamber 104
of the compressor 100, is provided on the side above the lid-like
member 48 below the main valve element 15. The Pc inlet/outlet
chamber (inlet/outlet port) 26 communicates with the Pd
introduction ports 25 via the release through-hole 16A.fwdarw.the
horizontal holes 16s.fwdarw.a gap between the bottom of the upper
guide hole 19A and the intermediate small-diameter portion
15d.fwdarw.a gap between the valve orifice 22 and the main valve
element portion 15a.fwdarw.the valve chamber 21.
[0055] In addition, in this embodiment, the in-valve release
passage 16 for releasing the pressure Pc in the crank chamber 104
to a suction chamber 107 of the compressor 100 via the Ps
inlet/outlet ports 27 is formed by the release through-hole 16A
formed in the main valve element 15, the cut-in 37t and the slit
37s provided in the plunger 37, the inlet/outlet chamber 28, and
the like. The in-valve release passage 16 is adapted to be opened
or closed as the sub valve element portion 17a of the sub valve
element 17 is moved into contact with or away from the sub valve
seat portion 23 that is the upper end portion of the release
through-hole 16A of the main valve element 15.
[0056] Herein, in the control valve 1 in this embodiment, when the
plunger 37, the main valve element 15, and the sub valve element 17
are at the lowest position (when the bottom end surface of the
plunger 37 abuts the stopper portion 24A, the main valve unit 11 is
in the fully open position, and the sub valve unit 12 is in the
fully closed position) as shown in FIG. 1, the clearance in the
vertical direction between the main valve element portion 15a of
the main valve element 15 and the valve orifice 22 (valve seat
portion) is represented by a first lift amount Lv, and the
clearance between the inner flanged latch portion 37k of the
plunger 37 and the flanged latch portion 15k of the main valve
element 15 is represented by a predetermined amount La. The maximum
lift amount (second lift amount) Lp of the plunger 37 (the lift
amount of from the lowest position to the highest position of the
plunger 37) corresponds to the first lift amount Lv+the
predetermined amount La.
[0057] Next, the operation of the control valve 1 with the
aforementioned configuration will be generally described.
[0058] At the normal control time (Pd.fwdarw.Pc control time), the
lift amount of the plunger 37 is slightly greater than the first
lift amount Lv at the maximum, and at the compressor actuation time
(Pc.fwdarw.Ps control time), the lift amount of the plunger 37 is
the second lift amount Lp.
[0059] That is, at the normal control time (Pd.fwdarw.Pc control
time), when the solenoid portion 30A including the coil 32, the
stator 33, the attractor 34, and the like is supplied with current
and energized, the plunger 37 is attracted by the attractor 34, and
along with this, the intermediate large-diameter latch portion 17c
of the sub valve element 17 is latched to the latch portion 37a of
the plunger 37. Thus, the sub valve element 17 moves upward
integrally with the plunger 37, and following the movement of the
sub valve element 17, the main valve element 15 is moved upward (in
the direction to close the valve) by the urging force of the valve
closing spring 50. Meanwhile, the suction pressure Ps introduced
into the Ps inlet/outlet ports 27 from the compressor 100 is
introduced into the pressure-sensitive chamber 45 from the
inlet/outlet chamber 28 via the slit 37s and the cut-in 37t of the
plunger 37 and the like, and the bellows device 40 (the inside
thereof is at a vacuum pressure) is expansively or contractively
displaced in accordance with the pressure (suction pressure Ps) in
the pressure-sensitive chamber 45 (contracts if the suction
pressure Ps is high, and expands if it is low), and the
displacement is then transmitted to the main valve element 15 via
the plunger 37 and the sub valve element 17, whereby the valve
opening (the clearance between the valve orifice 22 and the main
valve element portion 15a) is regulated, and the pressure Pc in the
crank chamber 104 is controlled in accordance with the valve
opening. Along with this, the inclination angle of the swash plate
102 and the stroke of the piston 105 in the compressor 100 are
controlled to increase or decrease the discharge capacity.
[0060] In this case, the main valve element 15 is always urged
upward by the urging force of the valve closing spring 50, while
the sub valve element 17 is always urged downward by the urging
force of the valve opening spring 47. Therefore, the sub valve
element portion 17a is in a state of being pressed against the sub
valve seat portion 23 (the sub valve unit 12 is closed), and the
in-valve release passage 16 is blocked in the main valve element
15. Therefore, there is no possibility that the crank chamber
pressure Pc may be released to the suction chamber 107 via the
in-valve release passage 16.
[0061] In contrast, at the compressor actuation time, the solenoid
portion 30A is supplied with current and energized, and the plunger
37 is attracted by the attractor 34 so that the sub valve element
17 moves upward together with the plunger 37. Following such
vertical movement of the sub valve element 17, the main valve
element 15 is also moved upward and the valve orifice 22 is closed
by the main valve element portion 15a of the main valve element 15.
After that, the plunger 37 is further moved upward, whereby the sub
valve element 17 is caused to open the in-valve release passage 16.
Thus, the pressure Pc in the crank chamber 104 is released into the
suction chamber 107 via two passages that are an in-compressor
release passage 108 and the in-valve release passage 16.
[0062] Specifically, until the upward movement amount of the
plunger 37 reaches the first lift amount Lv, the main valve element
15 moves in the direction to close the valve such that it follows
the upward movement of the plunger 37 and the sub valve element 17
by the urging force of the valve closing spring 50. Then, when the
upward movement amount reaches the first lift amount Lv, the valve
orifice 20 is closed by the main valve element portion 15a of the
main valve element 15 (the state shown in FIG. 2), and the plunger
37 is further moved upward by the predetermined amount La with the
main valve unit 11 in the closed valve state (the state shown in
FIG. 3). In other words, after the upward movement amount of the
plunger 37 has reached the first lift amount Lv, the sub valve
element 17 is elevated by the predetermined amount La until the
inner flanged latch portion 37k of the plunger 37 is latched to the
flanged latch portion 15k of the main valve element 15 (the first
lift amount Lv+the predetermined amount La=the second lift amount
Lp). In such a case, the main valve element 15 remains still in the
closed valve state. Thus, the sub valve element portion 17a of the
sub valve element 17 is lifted from the sub valve seat portion 23
by the predetermined amount La, whereby the in-valve release
passage 16 is opened. When the inner flanged latch portion 37k of
the plunger 37 is latched to the flanged latch portion 15k of the
main valve element 15, neither the plunger 37 nor the sub valve
element 17 is lifted any further even if the solenoid portion 30A
generates an attraction force.
[0063] As described above, in the control valve 1 in this
embodiment, the dimensions and the shape of each part are designed
such that when the sub valve element 17 closes the in-valve release
passage 16, the tapered portion (sub valve element portion) 17a
provided at the lower end portion of the sub valve element enters
the release through-hole 16A of the in-valve release passage 16,
and the sub valve element 17 is thus aligned with the main valve
element 15 by the tapered portion 17a. Therefore, in comparison
with the conventional art in which a sub valve element portion of a
sub valve element has a flat shape, it is possible to effectively
suppress a decrease in the sealability or the operability due to
shaft misalignment without requiring high dimensional accuracy.
[0064] Further, as part of the tapered portion 17a is located in
the release through-hole 16A of the in-valve release passage 16
even when the sub valve element 17 is at the highest elevated
position with respect to the main valve element 15 (the state shown
in FIG. 3), the tapered portion 17a surely enters the release
through-hole 16A of the in-valve release passage 16 when the sub
valve element 17 closes the in-valve release passage 16. Thus,
further relaxation of the dimensional accuracy can also be
achieved.
[0065] It should be noted that as shown in FIG. 5, a protrusion
17t, which extends downward (toward the release through-hole 16A of
the in-valve release passage 16), may also be provided at the tip
end portion of the sub valve element portion 17a of the sub valve
element 17 for guiding purposes to allow the lower end portion of
the sub valve element portion 17a of the sub valve element 17 to
easily enter the release through-hole 16A.
Second Embodiment
[0066] FIGS. 6 to 8 are longitudinal sectional views each showing
the second embodiment of the variable-capacity compressor control
valve in accordance with the present invention. Specifically, FIG.
6 is a view in which the main valve element is in the open position
and the sub valve element is in the closed position (at the normal
control time); FIG. 7 is a view in which the main valve element is
in the closed position and the sub valve element is in the closed
position (at the time of transition to compressor actuation), and
FIG. 8 is a view in which the main valve element is in the closed
position and the sub valve element is in the open position (at the
compressor actuation time).
[0067] The control valve 2 in the second embodiment basically
differs from the control valve 1 in the aforementioned first
embodiment only in the configurations of the valve body and the
main valve element of the valve element. Thus, configurations with
the same functions as those in the first embodiment are denoted by
the same reference numerals and the detailed description thereof
will thus be omitted. Hereinafter, only the differences will be
discussed in detail.
[0068] In the control valve 2 in this embodiment, the top
fit-insertion portion 15e and the intermediate small-diameter
portion 15d of the main valve element 15 are formed longer than
those of the control valve 1 in the first embodiment, while the
lower small-diameter portion 15c and the bottom fit-insertion
portion 15b on the lower side of the main valve element portion 15a
are omitted.
[0069] In addition, the fit-insertion portion 24 of the support
member 20B of the valve body 20 has a step formed thereon, and at a
position below an upper large-diameter portion 24a (an outer shape
corresponding to the fit-insertion portion 24 in the first
embodiment), a lower small-diameter portion 24b, which is longer
than the upper large-diameter portion 24a in the vertical
direction, is provided, and at a lower end of the lower
small-diameter portion 24b, a flanged abutment portion 24c adapted
to abut the stepped portion (terrace portion) between the recess
hole 20C and the reception hole 18 of the body member 20A is
provided such that it protrudes outward.
[0070] Meanwhile, the recess hole 20C of the body member 20A of the
valve body 20 also has a step formed thereon, and has an upper
large-diameter hole 20Ca (an outer shape corresponding to the
recess hole 20C in the first embodiment) into which the upper
large-diameter portion 24a is fitted and inserted, and a lower
small-diameter hole 20Cb into which the lower small-diameter
portion 24b is fitted and inserted, and further has a stepped
reception hole 18 for storing the main valve element portion 15a of
the main valve element 15 in a manner continuous with the center of
the bottom of the lower small-diameter hole 20Cb. A valve closing
spring 50 constructed from a conical compression coil spring is
provided in a compressed state between the stepped portion provided
on the inner periphery of the reception hole 18 and the stepped
portion (terrace portion) 15g provided on the outer periphery of
the bottom of the main valve element portion 15a of the main valve
element 15.
[0071] The inside of the reception hole 18 (a portion below the
valve orifice 22 of the support member 20B) is the valve chamber
21. Herein, the lower small-diameter hole 20Cb in the recess hole
20C has a plurality of Pd introduction ports 25 communicating with
the discharge chamber 106 of the compressor 100. A ring-like filter
member 25A is arranged around the outer periphery of the Pd
introduction ports 25 thereof, and the lower small-diameter portion
24b of the fit-insertion portion 24 (instead of the intermediate
small-diameter portion 15d of the main valve element 15) has a
plurality of horizontal holes 25a communicating with the Pd
introduction ports 25. The Pc inlet/outlet chamber (inlet/outlet
port) 26, which communicates with the crank chamber 104 of the
compressor 100, communicates with the Pd introduction ports 25 via
the valve chamber 21.fwdarw.a gap between the valve orifice 22 and
the main valve element portion 15a.fwdarw.a gap between the bottom
of the guide hole 19 (upper guide hole 19A) and the intermediate
small-diameter portion 15d.fwdarw.the horizontal holes 25 in the
lower small-diameter portion 24b.fwdarw.a gap between the lower
small-diameter portion 24b and the lower small-diameter hole 20Cb
(which will be discussed in detail below).
[0072] In addition, in this embodiment, the outer periphery of the
upper large-diameter portion 24a abuts the inner periphery of the
upper large-diameter hole 20Ca (that is, the upper large-diameter
portion 24a is fitted into (fits snugly inside) the upper
large-diameter hole 20Ca), and the support member 20B is fixedly
inserted into the recess hole 20C of the body member 20A in a
posture in which a small gap is provided between the outer
periphery of the lower small-diameter portion 24b and the inner
periphery of the lower small-diameter hole 20Cb.
[0073] Needless to say, the control valve 2 in the second
embodiment with the aforementioned configuration can also obtain
operational effects that are similar to those of the control valve
1 in the first embodiment.
DESCRIPTION OF SYMBOLS
[0074] 1 Variable-capacity compressor control valve (First
Embodiment) [0075] 2 Variable-capacity compressor control valve
(Second Embodiment) [0076] 10 Valve element [0077] 11 Main valve
unit [0078] 12 Sub valve unit [0079] 15 Main valve element [0080]
15a Main valve element portion [0081] 15k Flanged latch portion
[0082] 16 In-valve release passage [0083] 17 Sub valve element
[0084] 17a Sub valve element portion (tapered portion) [0085] 19
Guide hole [0086] 19A Upper guide hole [0087] 19B Lower guide hole
[0088] 20 Valve body [0089] 20A Body member [0090] 20B Support
member [0091] 20C Recess hole [0092] 21 Valve chamber [0093] 22
Valve orifice [0094] 23 Sub valve seat portion [0095] 25 Pd
introduction port [0096] 26 Pc inlet/outlet port [0097] 27 Ps
inlet/outlet port [0098] 30 Electromagnetic actuator [0099] 30A
Solenoid portion [0100] 37 Plunger [0101] 37k Inner flanged latch
portion [0102] 37s Slit [0103] 37t Cut-in [0104] 40 Bellows device
(pressure-sensitive reaction member) [0105] 45 Pressure-sensitive
chamber [0106] 50 Valve closing spring [0107] Lv First lift amount
[0108] La Predetermined amount [0109] Lp Second lift amount
* * * * *