The present invention relates to a compressor having a valve port plate made of a steel.
In a piston type compressor, a piston is received in a cylinder bore which is formed in a cylinder block and a housing is connected to the end surface of the cylinder block through a valve port plate and has formed therein a suction chamber and a discharge chamber. The valve port plate has formed therethrough a suction port and a discharge port. The rotation of a rotary shaft of the compressor is converted through a drive mechanism into the reciprocation of the piston. The reciprocation of the piston causes refrigerant gas in the suction chamber to be introduced through the suction port into a compression chamber in the cylinder bore for compression therein, and the compressed refrigerant gas is discharged through the discharge port into the discharge chamber.
The discharge chamber in the housing is heated to a high temperature by the compressed refrigerant gas (discharged gas). Therefore, a low-temperature refrigerant gas flowing from external refrigerant circuit into the suction chamber is heated by heat transmitted through the wall surfaces of the housing and the valve port plate which cooperate to define the discharge chamber and the suction chamber. The refrigerant gas in the suction chamber is heated to expand before it is introduced into the compression chamber of the cylinder bore. This results in a decrease in the amount of refrigerant gas that substantially flows into the compression chamber and hence causes a decrease in volumetric efficiency of the compressor. If the suction refrigerant gas is thus heated, the temperature of the gas compressed in the compression chamber also increases, accordingly. Thus, there has been a problem that a seal member for the compressor or the refrigerant circuit tends to be degraded by the heat.
A solution for the above problem is disclosed by Unexamined Japanese Patent Publication No. 5-164042, according to which thermal insulation means is provided in a partition wall between suction chamber and discharge chamber of a piston type compressor. As shown in
A compressor disclosed in Unexamined Japanese Utility Model Publication No. 2-31382 is provided with a cylinder head which has formed therein a suction chamber and a discharge chamber on one end of a cylinder and is made of a material having a higher heat radiation, and the suction chamber in the cylinder head is formed by a thermal insulation material.
A rotary fluid compressor disclosed in Unexamined Japanese Patent Publication No. 5-33119 is provided with a vane-shaped steel material which has formed on the surface thereof an ion-nitriding layer for enhancing abrasion resistance of a vane used for the compressor.
The compressor in the above-cited Publication No. 5-164042 is disadvantageous in that the housing 53 is different in structure from a housing of conventional compressor because the thermal insulation groove 58a is formed in the partition wall 68, with the result that an existing housing is not usable in a compressor. Furthermore, the compressor disclosed in the above-cited Publication No. 2-31382, whose suction chamber is formed by a thermal insulation material, requires the structure of suction chamber to be changed accordingly if a conventional housing is to be used for the compressor.
Also, the compressor (vane compressor) disclosed in the above-cited Publication No. 5-33119, whose vane surface is ion-nitrided, is directed to enhance abrasion resistance of steel material, which is a conventional usage of the ion nitriding. Additionally, the above-cited Publication No. 5-33119 does not disclose or teach anything about nitriding for decreasing a thermal conductivity of steel material.
The present invention is directed to provide a compressor which prevents an increase in temperature of suction refrigerant gas while improving the compression efficiency thereof by providing an appropriate treatment to the low-cost ferrous material valve port plate without structural change to any part of the compressor.
In accordance with the present invention, a compressor has a valve port plate made of a steel. The valve port plate is nitrided or nitrocarburized.
Other aspects and advantages of the invention will become apparent from the following description, taken in conjunction with the accompanying drawings, illustrating by way of example the principles of the invention.
The features of the present invention that are believed to be novel are set forth with particularity in the appended claims. The invention together with objects and advantages thereof, may best be understood by reference to the following description of the presently preferred embodiments together with the accompanying drawings in which:
The following will describe a preferred embodiment of a variable displacement piston type compressor 10 according to the present invention which is used for a refrigerant circuit in a vehicle air conditioner with reference to
Referring to
The housing has formed therein a crank chamber 15 between the cylinder block 11 and the front housing 12. Between the cylinder block 11 and the front housing 12 is rotatably supported a drive shaft 16 for extension through the crank chamber 15. The drive shaft 16 is operatively connected to a vehicle engine (not shown) for rotation thereby in arrow direction R.
In the crank chamber 15, a substantially disc-shaped lug plate 17 is secured to the drive shaft 16 for integral rotation therewith. In the crank chamber 15, a swash plate or a cam plate 18 is accommodated. The swash plate 18 has formed at the center therethrough a through hole 18a, through which the drive shaft 16 is inserted. Between the lug plate 17 and the swash plate 18 is interposed a hinge mechanism 19. The swash plate 18 is connected to the lug plate 17 through the hinge mechanism 19 and supported by the drive shaft 16 through the through hole 18a. This permits the swash plate 18 to rotate integrally with the lug plate 17 and the drive shaft 16 and incline with respect to the drive shaft 16 while sliding in the direction of the axis T of the drive shaft 16.
The cylinder block 11 has formed therein a plurality of cylinder bores 20 (only one of them being shown in
The piston 21 engages with the outer periphery of the swash plate 18 through a pair of shoes 23. The housing has formed therein a suction chamber 24 and a discharge chamber 25 between the valve plate assembly 13 and the rear housing 14.
The valve plate assembly 13 includes a valve port plate 26, a suction valve plate 27 provided on one side of the valve port plate 26 adjacent to the cylinder block 11, and a discharge valve plate 28 provided on the other side of the valve port plate 26 adjacent to the rear housing 14. As shown in
The compressor 10 has a bleed passage 34, a supply passage 35 and a control valve 36 in the housing. The bleed passage 34 connects the crank chamber to the suction chamber 24. The supply passage 35 connects the discharge chamber 25 to the crank chamber 15. The control valve 36 which is a known electromagnetic valve is located in the supply passage 35.
The valve port plate 26 will now be described more in detail. The valve port plate 26 is made of steel (electromagnetic soft steel in the preferred embodiment) and nitrocarburized to have a thermal conductivity of 60 W/mK or less. The valve port plate 26 has nitride layers 26a formed on both front and rear surfaces thereof, as shown in
A thermal conductivity of the valve port plate 26 which has formed therein the nitride layers 26a depends on a method for forming the nitride layer 26a and a thickness of the nitride layer 26a, which will be described later. For example, the nitride layers 26a are formed by salt-bath nitriding to have a thickness of 20 μm or more. The valve port plate 26 is, for example, formed to have a thickness of 2 to 3 mm. An increase in temperature of suction refrigerant gas can be prevented more effectively by increasing the nitride layer thickness and, therefore, forming the thicker nitride layers 26a is preferable in terms of the prevention of an increase in temperature of suction refrigerant gas. However, the thicker nitride layers 26a require a longer time for nitrocarburizing and hence more treatment cost than the thinner one. The thickness of the nitride layers 26a in the preferred embodiment has been determined by the trade-off between the effectiveness to prevent temperature rise of the nitride layers and the treatment cost thereof.
The following will describe the relation between a thickness of the nitride layer formed by salt-bath nitriding and a thermal conductivity of a material for nitriding. The salt-bath nitriding was performed by a known method. The salt-bath mainly contains cyanate. Using sodium cyanate (or NaCNO) or potassium cyanate (or KCNO) as cyanate, a material for nitriding was nitrided at a temperature of 580 to 600 degrees C. The nitriding was performed using unpolished electromagnetic soft iron plate having a thickness of 1 mm as the material for nitriding. The results are shown in
A coefficient of thermal expansion of a nitrided product was measured, and it showed a substantially equivalent value to a non-nitrided product. This is because the thickness of the nitride layers is thin enough.
Surface hardness of the nitride layers was measured. The nitride layer having a thickness of 19 μm has a surface hardness of about 675 in salt-bath nitriding, while the nitride layer having a thickness of 20 μm has a surface hardness of about 580 in gas nitrocarburizing.
The following will describe the operation of the compressor.
As the drive shaft 16 is rotated, the swash plate 18 rotates therewith, and the rotation of the swash plate 18 is converted through a pair of the shoes 23 into the reciprocation of each piston 21 in its associated cylinder bore for a stroke length corresponding to the inclination angle of the swash plate 18 (which the swash plate 18 makes with a plane perpendicular to the axis T of the drive shaft 16). Thus, refrigerant gas is drawn from the suction chamber 24 into the compression chamber 22 for compression therein, and the compressed refrigerant gas is discharged into the discharge chamber 25, repeatedly. As the piston 21 moves from the top dead center toward the bottom dead center, the refrigerant gas in the suction chamber 24 (carbon dioxide in the preferred embodiment) flows into the compression chamber 22 through the suction port 29 while pushing open the suction valve 31. As the piston 21 moves from the bottom dead center toward the top dead center, on the other hand, the refrigerant gas introduced into the compression chamber 22 is compressed to a predetermined pressure and discharged into the discharge chamber 25 through the discharge port 30 while pushing open the discharge valve 32. The refrigerant gas discharged into the discharge chamber 25 is sent to the external refrigerant circuit through a discharge hole (not shown).
The control valve 36 is operable to control the opening degree thereof for adjustment of the balance between the amount of high-pressure discharged gas through the supply passage 35 into the crank chamber 15 and the amount of gas from the crank chamber 15 through the bleed passage 34, thus determining the pressure in the crank chamber 15. As the pressure in the crank chamber 15 is varied, the pressure difference between the crank chamber 15 and the compression chambers 22 across the pistons 21 is varied, accordingly, so that the inclination angle of the swash plate 18 is altered, thereby changing the stroke of the piston 21 and hence the displacement of the compressor 10.
For example, a decrease in the pressure in the crank chamber 15 increases the inclination angle of the swash plate 18, thereby increasing the stroke of the piston 21, resulting in an increase in the displacement of the compressor 10. On the other hand, an increase in the pressure in the crank chamber 15 reduces the inclination angle of the swash plate 18, thereby reducing the stroke of the piston 21, resulting in a reduction in displacement of the compressor 10.
In operation of the compressor 10, compressed refrigerant gas is temporarily reserved in the discharge chamber 25 under high pressure and temperature. If the valve port plate 26 is made of non-nitrided or non-nitrocarburized cold-rolled steel plate or made of non-nitrided or non-nitrocarburized electromagnetic soft iron having a thermal conductivity of about 80 W/mK, the heat of the refrigerant gas in the discharge chamber 25 is easily transmitted through the valve port plate 26. Accordingly, the refrigerant gas in the suction chamber 24 or passing through the suction port 29 is heated, resulting in a decrease in the amount of refrigerant gas substantially introduced into the compression chamber 22, thus reducing a volumetric efficiency of the compressor.
However, the valve port plate 26 of the preferred embodiment is so nitrided to have formed thereon the nitride layers 26a that the valve port plate 26 has a thermal conductivity of 60 W/mK or less as a whole, with the result that transmission of the heat of the refrigerant gas in the discharge chamber 25 through the valve port plate 26 to the refrigerant gas in the suction chamber 24 is prevented. Additionally, the suction refrigerant gas passing through the suction port 29 is prevented from being heated, so that the amount of the refrigerant gas substantially introduced into the compression chamber 22 is increased and the volumetric efficiency and compression efficiency of the compressor are improved, accordingly.
When the valve port plate 26 is nitrided (nitrocarburized), the valve port plate 26, that is, the base material 37, has formed on the surface thereof the nitride layer 26a, while having formed therein the diffusion layer 37a of nitrogen contiguously to the nitride layer 26a, as shown in
In the preferred embodiment, electromagnetic soft iron is used as a material for nitriding in both salt-bath nitriding and gas nitrocarburizing but low-carbon steel plate such as SPCC (or steel plate cold commercial), SPCD (or steel plate cold deep drawn), and SPCE (or steel plate cold deep drawn extra) may also be used.
According to the preferred embodiment, the following advantageous effects are achieved.
The present invention is not limited to the embodiments described above but may be modified into the following alternative embodiments.
In an alternative embodiment, the valve port plate 26 is nitrided or nitrocarburized to have a thermal conductivity of 60 W/mK or less. For example, as shown in
The present invention is not limited to the valve port plate 26 which is nitrided or nitrocarburized to have a thermal conductivity of about 60 W/mK or less, for which, for example, the valve port plate 26 needs to be salt-bath nitrided to have the nitride layer 26a having a thickness of about 20 μm or more. Alternatively, for example, the valve port plate 26 needs to be gas nitrocarburized to have the nitride layer 26a having a thickness of about 50 μm or more according to the results shown in
In an alternative embodiment, the suction chamber 24 is formed in radially outer region of the rear housing 13, while the discharge chamber 25 is formed in radially inner region, as shown in
The nitriding or nitrocarburizing is not limited to the salt-bath nitriding or gas nitrocarburizing. In an alternative embodiment, other nitriding processes are usable. Other nitriding processes include gas nitriding and ion nitriding (plasma nitriding). The relation between a thickness of the nitride layer 26a and a thermal conductivity of the valve port plate 26 depends on which nitriding or nitrocarburizing is performed for forming the nitride layer 26a. Therefore, a thickness of nitride layer 26a required for gaining a target thermal conductivity of the valve port plate 26 is determined adequately depending on which nitriding or nitrocarburizing is performed.
The material for the valve port plate 26 is not limited to cold-rolled steel plate and electromagnetic soft iron plate, but any ferrous material is usable. For example, hot-rolled mild steel plate or nitriding steel is usable. Additionally, the nitriding steel may be nitrided (nitrocarburized) easier than other ferrous material.
The present invention is not limited to the above-described swash plate type variable displacement compressor, but it is also applicable to a swash plate type compressor with a double-headed piston or a fixed displacement. Additionally, the compressor of the present invention may be of a wobble type in which the swash plate wobbles with the rotation of the drive shaft without making integral rotation with the drive shaft.
In an alternative embodiment, the housing of the compressor 10 is not limited to the structure that the front housing 12 and the rear housing 14 hold the cylinder block 11 therebetween. For example, the housing of the compressor includes a front housing and a rear housing, and either one of the front and rear housings has formed therein a crank chamber, while the other receives therein a cylinder that has formed therein a cylinder bore.
Alternatively, the present invention is applicable to a compressor having a piston which is operated by means other than the swash plate. Additionally, the present invention is not limited to a piston type compressor but is usable for a scroll type compressor.
The present invention is not limited to a compressor that uses carbon dioxide as refrigerant for vehicle air conditioner but is usable for a compressor that uses fluorocarbon refrigerant.
The present invention is not limited to a compressor whose drive shaft is rotated by the power of the engine, but the drive shaft of the compressor may be driven by a motor.
In an alternative embodiment, the compressor is not limited to be used for a vehicle air conditioner but may be a motor compressor that is used for a domestic air conditioner.
The present invention is not limited to a compressor used for air conditioning, but it is applicable to a compressor for other refrigerant circuits, such as a compressor used for a refrigerant circuit of a refrigerator or a freezer.
Therefore, the present examples and embodiments are to be considered as illustrative and not restrictive, and the invention is not to be limited to the details given herein but may be modified within the scope of the appended claims.
Number | Date | Country | Kind |
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2004-103539 | Mar 2004 | JP | national |