The present invention relates to a restrictor element configured to provide a limitation and/or control in the gas flow used in the bearing formation between a piston and a cylinder of a gas compressor.
The present invention also relates to a gas compressor comprising at least one restrictor element as above.
Currently, it is quite common to use piston (plunger sets) and cylinders driven by electric motors for use in gas compressors and refrigeration equipment, such as domestic/commercial/industrial refrigerators, freezer and air conditioners.
In these types of compressors, the electric motor drives the piston which, in turn, moves within the cylinder in an axial reciprocating motion so as to compress the gas. Normally, in this cylinder head vales are positioned suction and gas discharge valves which regulate, respectively, the low pressure gas inlet and the high pressure gas outlet inside the cylinder. Thus, the axial movement of the piston within the cylinder of the compressor performs compression of the gas admitted by the suction valve, increasing its pressure in order to afford direction of gas flow through the discharge vale for a high pressure region.
One of the technical challenges noted in this type of gas compressor is avoiding direct contact between the piston and the cylinder. Thus, due to the relative motion between the piston and the cylinder, the bearing formation of the piston by means of a fluid disposed in the gap between these two parts to prevent their premature wear is necessary. The presence of the fluid between the piston and the cylinder also afford the reduction of friction between them, which allows a reduction of mechanical loss of the compressor.
The linear compressors frequently use a type of bearing formation, known as aerostatic bearing formation, which consists of implementing a gas cushion between the piston and the cylinder, avoiding contact between them. The use of aerostatic bearing formation is advantageous with respect to the other types of bearing formation, since, considering that the gas has a coefficient of viscous friction lower than the oil, the energy dissipated for the bearing formation is smaller, which contributes to a better compressor efficiency. Another additional advantage of using the gas itself as lubricant consists of the absence of the need to use an oil pumping system.
It should be noted that the gas used for the bearing formation may consist of a portion of the very gas pumped by the compressor and used in the refrigeration system, which is diverted, after its compression, towards the gap between the piston and the cylinder, forming a gas cushion that avoids contact between them. In this way, it is observed that all the gas used in the bearing formation represents a loss of efficiency of the compressor, since the main function of the compressed gas is its direct application in the refrigeration system to generate cold. Thus, the portion of the gas volume diverted to the bearing formation should be kept to a minimum so as not to significantly compromise the efficiency of the compressor.
Typically, in order to obtain an efficient operation of the aerostatic bearing, it is necessary to use a flow restrictor capable of limiting the flow of the compressed gas arising from a high pressure region of the compressor, so that the gas pressure present in the gap between the piston and cylinder is smaller and suitable for the application. In other words, such a constraint aims at allowing pressure reduction or control at the bearing formation region by restricting the flow of compressed gas arising from a high pressure region of the compressor.
Various constructive configurations have been developed to allow implementation of restrictors in order to afford the pressure reduction in the bearing formation region.
For example, the U.S. patent application US20040154468 describes a restrictor which comprises a porous medium, where a porous strip is used together with compression rings. A disadvantage of this type of configuration is the need for precision in the manufacture of the compression rings, which increases the cost of the production process, besides the difficulty of dimensional control.
The U.S. Pat. No. 6,293,684 discloses restrictors formed by micro channels disposed along the outer wall of the cylinder which, together with a sleeve in which said cylinder is inserted, form closed and isolated channels, yielding a plurality of restrictors. Analogous to the patent previously mentioned, a disadvantage of this type of configuration is the need for precision in the manufacture of sleeves, which increases manufacturing costs.
The international application WO/2008/055809 describes restrictors consisting of micro bores arranged in the cylinder wall, manufactured with the use of laser. Again, the manufacturing of the micro bores requires a lot of precision, which might impair the production of the compressor at competitive marker costs.
Thus, a satisfactory and efficient solution which presents good reliability and performance and whose cost is low is still not known for providing restriction in the gas flow used in the bearing formation between a piston and a cylinder of a gas compressor.
A first object of the present invention consists of providing a low cost flow restrictor configured to allow a limitation and/or flow/gas pressure control used in the bearing formation between a piston and a cylinder of a gas compressor, reducing or avoiding loss of efficiency of said gas compressor, so as to obtain optimum performance and execution.
A second object of the present invention consists of providing a flow restrictor capable of allowing the diversion of at least one portion of compressed gas flow through a gas compressor for a bearing formation region between its piston and cylinder, without significantly compromising the efficiency of said gas compressor.
A third object of the present invention consists of providing a flow restrictor capable of allowing a limiting of the gas flow used in the bearing formation between a piston and a cylinder of a gas compressor.
A fourth object of the present invention consists of providing a gas compressor that comprises a flow restrictor according any one of the objects above or a combination thereof.
A first manner of achieving the first, second and/or third object of the present invention is through the provision of a flow restrictor for use in bearing formation between a piston and a cylinder of a gas compressor. Such a gas compressor comprises at least a protective pad which externally surrounds the cylinder. In addition, the gas compressor further comprises at least one inner cavity, disposed between the protective pad and the cylinder, fluidly fed by a discharge flow from a compression movement exerted by the piston within the cylinder. Additionally, the gas compressor further comprises at least one bearing formation gap separating an outer wall of the piston and an inner wall of the cylinder. Further, the gas compressor also comprises at least one flow restrictor provided with a housing fluidly linking the inner cavity to the bearing formation gap. Such a flow restrictor comprises at least a limiting tube, associated with the housing, provided with at least one restraining portion having a cross section sized to restrict the gas flow flowing from the inner cavity to the bearing formation gap.
A second way to achieve the first, second and/or third object of the present invention is through the provision of a flow restrictor for use in bearing formation between a piston and a cylinder of a gas compressor. Such a gas compressor comprises at least one protective pad which externally surrounds the cylinder. In addition, the gas compressor further comprises at least one inner cavity, disposed between the protective pad and the cylinder, fluidly fed by a discharge flow from a compression movement exerted by the piston within the cylinder. Additionally, the gas compressor further comprises at least one bearing formation gap separating an outer wall of the piston and an inner wall of the cylinder. Additionally, the gas compressor further comprises at least one flow restrictor provided with a housing that fluidly associates the inner cavity to the bearing formation gap. Such a flow restrictor comprises at least a limiting tube, associated with housing, having at least one restraining portion provided with a cross section having a pre-established area. Said limiting tube has a pre-established length, where the relationship between the cross section area of the restraining portion and the length of the limiting tube is configured to optimally limit the gas flow flowing from the inner cavity to the bearing formation gap.
The fourth object of the present invention is achieved through the provision of a gas compressor comprising a cylinder, a piston reciprocally movable within the cylinder and a flow restrictor according to first or second manners described above.
The present invention will be described below in greater detail, with reference to the attached drawings:
FIG. 1—depicts a side sectional view of a gas compressor, object of the present invention, which comprises a first preferred embodiment of a flow restrictor, also object of the present invention, when its suction valve is in the open condition;
FIG. 2—depicts a side sectional view of the gas compressor shown in
FIG. 3—depicts a first detail of
FIG. 4—depicts a second detail of
FIG. 5A—depicts a side sectional view of a first preferred embodiment of the flow restrictor of the present invention;
FIG. 5B—depicts a side sectional view of a second preferred embodiment of the flow restrictor of the present invention;
FIG. 5C—depicts a side sectional view of a third preferred embodiment of the flow restrictor of the present invention;
FIG. 5D—depicts a side sectional view of a fourth preferred embodiment of the flow restrictor of the present invention;
FIG. 6—depicts a front sectional view of a fifth preferred embodiment of the flow restrictor of the present invention; and
FIG. 7A—depicts a side sectional view of a sixth preferred embodiment of the flow restrictor of the present invention;
FIG. 7B—depicts a side sectional view of a seventh preferred embodiment of the flow restrictor of the present invention;
FIG. 7C—depicts a side sectional view of an eighth preferred embodiment of the flow restrictor of the present invention;
FIG. 7D—depicts a side sectional view of a ninth preferred embodiment of the flow restrictor of the present invention; and
FIG. 7E—depicts a side sectional view of a tenth preferred embodiment of the flow restrictor of the present invention.
Such a gas compressor 4 comprises at least a piston 2, a cylinder 3 and a cylinder head 13 on its top or upper portion, forming, together with the piston 2 and the cylinder 3, a compression chamber 16, in that the axial and oscillating movement of piston 2 within the cylinder 3 affords the gas compression in the compression chamber 16.
As can be seen in
In other words, piston 2, driven by said linear motor, has the function to develop an alternative linear movement, enabling the movement of piston 2 within the cylinder 3, so as to afford an action of compressing the gas admitted by the suction valve 14, up to the point at which it may be discharged to the high pressure side through the discharge valve 15.
Gas compressor 4 is also provided with a discharge passageway 20 and a suction passageway 19, positioned in a cap 18, which connect gas compressor 4 with the other portions, parts and components of a refrigeration system.
In addition, gas compressor 4 also comprises at least one protective pad 5 that externally surrounds the cylinder 3.
Additionally, gas compressor 4 comprises at least one inner cavity 6, disposed between protective pad 5 and cylinder 3, fluidly fed by a discharge flow from the compression movement exerted by piston 2 within cylinder 3. Inner cavity 6 is formed by the outer diameter of cylinder 3 and the inner diameter of protective pad 5.
Further, gas compressor 4 comprises at least one bearing formation gap 7 that separates an outer wall of piston 2 and an inner wall of cylinder 3, as seen in
Gas compressor 4 comprises at least one flow restrictor 1, also object of the present invention, provided with a housing 12 that fluidly associates inner cavity 6 to bearing formation gap 7. The format of housing 12 may be substantially cylindrical or substantially conical.
As mentioned above, the function of the flow restrictor 1 is providing the bearing formation between piston 2 and cylinder 3 of gas compressor 4. In other words, flow restrictor 1, disposed between inner cavity 6 (high pressure region) and bearing formation gap 7, is capable of controlling the pressure in the bearing formation region and restricting gas flow.
From
When piston 2 suffers some axial force so as to approach cylinder wall 3, and consequently flow restrictor 1, bearing formation gap 7 in this region shrinks. (
On the other hand, in the opposite region of bearing formation gap 7 (
Flow restrictor 1 comprises at least one limiting tube 8 (or micro tube), associated with housing 12, provided with at least one restraining portion having a cross section sized to limit the gas flow that flows from inner cavity 6 to the bearing formation gap 7. Preferably, the restraining portion is positioned within housing 12. Thus, the gas flows through limiting tube 8 (or micro tube) towards the bearing formation gap 7, forming a gas cushion avoiding contact between piston 2 and cylinder 3. As can be seen in the preferred embodiments illustrated in
It should be noted that all of the gas used in bearing formation represents a loss of efficiency of the compressor, since the primary function of the gas is to be sent to the refrigeration system and provide temperature reduction. Thus, the gas diverted to the bearing formation should be kept at a minimum so as not to compromise the efficiency of the compressor. Therefore, the cross section of the restraining portion of limiting tube 8 has been designed to have a pre-established area and, moreover, limiting tube 8 has been designed to have a pre-established length, wherein the ration between the cross section area of the restraining portion and the length of limiting tube 8 is configured to limit gas flow that optimally flows from inner cavity 6 to bearing formation gap 7. Preferably, the substantially circular cross section has an inner diameter between 30 and 200 μm. The length of limiting tube 8 may vary in accordance with the preferred embodiment being implemented, as can be seen in
In other words, considering that the load loss imposed on the gas flow passing through limiting tube 8 is proportional to the length and diameter of its bore, it is possible to size said tube by varying these two measurements. For a given length, the greater the cross-sectional area to gas flow (i.e. the greater the inner diameter), the smaller the restriction imposed upon the flow. For a given inner diameter, the greater the length, the greater the restriction to gas flow. From these two variables—cross-sectional area to flow and length—it is possible to achieve the required load loss to any bearing of gas compressor 4.
For example, considering that piston 2 suffers with loss of support when it is in its top dead center due to the high pressure present at compression chamber 16, it is desirable that the bearings of this region of cylinder 3 provide greater gas flow than the bearing present in the inner portion of cylinder 3. In this case, one can act upon one of the two variables above in order to achieve a greater flow in flow restrictors 1 mounted in the region nearest the suction valve 14 and discharge vale 15.
Limiting tubes 8 may consist, for example, in micro tubes used in the manufacture of hypodermic needles or micro tubes used as electrodes in the process of electrical discharge machining (EDM) by penetration. Moreover, limiting tubes 8 are preferably made of metal, such as stainless steel (hypodermic needles), brass or copper (EDM tools).
Limiting tube 8 may be associated with housing 12 by an interference fit. Preferably, limiting tube 8 is fastened to housing 12 by adhesive or soldering, capable of filling a space between limiting tube 8 and housing 12.
Preferably, at least three flow restrictors 1 in a given section of cylinder 3 and at least two sections of flow restrictors 1 in cylinder 3 are implemented in the gas compressor 4, in order to maintain the balance of piston 2 within cylinder 3. Moreover, flow restrictors 1 are positioned such that, even with the oscillating movement of piston 2, they are never uncovered, i.e. piston 2 does not leave the work area of flow restrictors 1.
Preferably, limiting tube 8 is substantially cylindrical and has a substantially circular cross section, since the manufacturing of housing 12 can be made by a simple and inexpensive process such as piercing and, in addition, the micro tubes manufactured industrially are generally cylindrical. Naturally, limiting tubes 8 may present other forms of cross section.
Still preferably (first, second, sixth, eighth, ninth and tenth preferred embodiments, illustrated in
Alternatively, according to the third preferred embodiment of the present invention, limiting tube 8 has a substantially L-shaped profile, as illustrated in
In the fourth preferred embodiment of the present invention, shown in
According to the fifth preferred embodiment of the present invention, limiting tube 8 extends radially from housing 12 and is tangent to an outer wall of cylinder 3, as shown in
According to the seventh preferred embodiment of the present invention, limiting tube 8 comprises an end portion 23 configured in a substantially conical format, end portion 23 being insertible in housing 12, as can be seen in
According to an eighth embodiment of the present invention, illustrated in
According to a ninth preferred embodiment of the present invention, illustrated in
According to the tenth preferred embodiment of the present invention, illustrated in
Thus, limiting tube 8 may have a length of the same magnitude of the wall thickness, as well as it may be shorter or longer, or even have a length smaller than the outer diameter, taken on a disc shape, according to the first embodiment of the flow restrictor 1 of the present invention, illustrated in
Therefore, the present invention provides several ways of fixing limiting tube 8, so as to ensure the sealing between the outer wall of said limiting tube 8 and the inner wall of housing 12, forcing the gas to pass through the bore of limiting tube 8 to suffer the pressure drop required for the operation of the aerostatic bearing. In other words, the present invention allows the gas not to pass through an occasional gap between limiting tube 8 and cylinder wall 3. In sum, the preferred embodiments illustrated in
Having described examples of preferred embodiments, it should be understood that the scope of the present invention encompasses other possible variations, being limited solely by the content of the appended claims, where possible equivalents are included.
Number | Date | Country | Kind |
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PI1105480-8 | Nov 2011 | BR | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/BR2012/000449 | 11/14/2012 | WO | 00 | 5/15/2014 |