Patent Application
20120174617
The present invention relates to a refrigerant compressor and a refrigeration cycle apparatus.
In a compression unit for compressing refrigerant in a refrigerant compressor, slide members (such as vanes and pistons) are used for compressing refrigerant. A refrigerant compressor disclosed in PLT 1 listed below is known as one that improves anti-wear characteristics of its slide members.
The slide members (vanes) in the refrigerant compressor disclosed in the PLT 1 is constructed by forming a nitrided layer on a surface of a base member (core material), then hardening the base member, and further forming an intermediate layer and a single-layered or double-layered amorphous carbon layer(s) thereon. In a case where two of the amorphous carbon layers are formed, a lower layer (on a side of the base member) is made as a hydrogen-containing amorphous carbon layer and an upper layer is made as a metal-containing amorphous carbon layer.
In the slide member disclosed in PLT 1, adherence between the base member and the intermediate layer becomes superior because deformation of the base member is restricted due to the formation of the nitrided layer on the surface of the base member for hardening the base member. However, there are problems in the adherence between the intermediate layer and the amorphous carbon layer or between the two amorphous carbon layers in a case where two of the amorphous carbon layers are provided. When repeatedly stressed, separation or crack may occur between the intermediate layer and the amorphous carbon layer or between the two amorphous carbon layers as mentioned above.
An object of the present invention is to provide a refrigerant compressor that restricts deformation of base members of vanes used in the refrigerant compressor and improves adherence of a film formed on a surface of the base member, and further can restrict wearing of vanes and members that slidably contact with the vanes, and to provide a refrigeration cycle apparatus that uses the refrigerant compressor.
A first aspect of the present invention provides a refrigerant compressor that includes a compression unit for compressing refrigerant used in a refrigeration cycle, a vane that is slidably provided in the compression unit hand has a base member made of metallic material, a film formed by sequentially layering first to fourth layers on the base member, and a roller that is rotatably provided in the compression unit and slidably contacts with an end edge with the vane. The first layer is a single layer of chromium, the second layer is an alloyed layer of chromium and tungsten carbide, the third layer is a metal-containing amorphous carbon layer containing at least one of tungsten and tungsten carbide, and the fourth layer is an amorphous carbon layer containing carbon and hydrogen without containing metal. In the second layer, a content rate of chromium on a side of the first layer is made larger than on a side of the third layer, and a content rate of tungsten carbide on a side of the third layer is made larger than on a side of the first layer. In the third layer, a content rate of the at least one of tungsten and tungsten carbide on a side of the second layer is larger than on a side of the fourth layer. The roller is made of flake graphite cast iron containing molybdenum, nickel and chromium.
A second aspect of the present invention provides a refrigeration cycle apparatus that includes the above refrigerant compressor, a condenser connected with the compressor for condensing refrigerant compressed by the compressor, an expansion device connected with the condenser for expanding refrigerant condensed by the condenser, and an evaporator connected with the condenser and the expansion device for evaporating refrigerant expanded by the expansion device and then recirculating the refrigerant to the compressor.
Hereinafter, embodiments will be explained with reference to the drawings.
A first embodiment will be explained with reference to
A hermetically-sealed rotary-type refrigerant compressor 2, a four-way valve 3, an outdoor heat exchanger 4 that functions as a condenser at a cooling operation and functions as an evaporator at a heating operation, an expansion device 5, an indoor heat exchanger 6 that functions as an evaporator at the cooling operation and functions as a condenser at the heating operation, and an accumulator 7 are connected to configure the refrigeration cycle apparatus 1. Refrigerant circulates above components in the refrigeration cycle apparatus 1.
In the refrigeration cycle apparatus 1, at its cooling operation, refrigerant discharged from the refrigerant compressor 2 is supplied to the outdoor heat exchanger (condenser) 4 through the four-way valve 3 as shown by solid arrows, and condensed by heat exchanging with outside air. The condensed refrigerant flows out from the outdoor heat exchanger 4, and flows into the indoor heat exchanger (evaporator) 6 through the four-way valve 3. The refrigerant flowing into the indoor heat exchanger 6 is evaporated by heat exchanging with inside air to cool inside air. The refrigerant flowing out from the indoor heat exchanger 6 is suctioned into the refrigerant compressor 2 through the four-way valve 3 and the accumulator 7°.
On the other hand, at its heating operation, refrigerant discharged from the refrigerant compressor 2 is supplied to the indoor heat exchanger (condenser) 6 through the four-way valve 3 as shown by dotted arrows, and condensed by heat exchanging with outside air to heat inside air. The condensed refrigerant flows out from the indoor heat exchanger 6, and flows into the outdoor heat exchanger (evaporator) 4 through the expansion device 5. The refrigerant flowing into the outdoor heat exchanger 4 is evaporated by heat exchanging with outside air. The evaporated air flows out from the outdoor heat exchanger 4, and is suctioned into the refrigerant compressor 2 through the four-way valve 3 and the accumulator 7.
Subsequently, the refrigerant flows sequentially in a similar way, so that the operation of the refrigeration cycle apparatus 1 is continued. As the refrigerant, HFC refrigerant, HC (hydrocarbons) refrigerant, carbon dioxide refrigerant and so on may be used.
The refrigerant compressor 2 is a 2-cylinder type and includes a sealed case 2a, as shown in
The electrical motor 8 is comprised of a rotor 8a and a stator 8b. The electrical motor 8 may be any of a brush-less DC synchronous motor, an AC motor, a motor driven by a commercial electric power source, and so on.
Refrigerant oil 11 for lubricating the rotational compression unit 9 is accumulated at a bottom of the sealed case 2a. POE (polyol esther), PVE (polyvinyl ether), PAG (polyalkylene glycol), and so on are used as the refrigerant oil 11.
The rotational compression unit 9 is comprised of a first compression unit 9a and a second compression unit 9b. The first compression unit 9a includes a cylinder 13a that forms a cylinder chamber 12a, and the second compression unit 9b includes a cylinder 13b that forms a cylinder chamber 12b. As shown in
The roller 14a is engaged to the eccentric portion 10a of the rotary shaft 10, and eccentrically rotates within the cylinder chamber 12a along with the rotation of the rotary shaft 10. The roller 14b is engaged to the eccentric portion 10b of the rotary shaft 10, and eccentrically rotates within the cylinder chamber 12b along with the rotation of the rotary shaft 10. The rollers 14a and 14b are made of flake graphite cast iron containing molybdenum, nickel and chromium. Note that the first compression unit 9a and the second compression unit 9b have an identical configuration, as shown in
As shown in
Both end faces of the cylinder 13a of the first compression unit 9a are covered by a primary bearing 17 and a partition plate 18, respectively, and the cylinder chamber 12a is formed therewithin. Both end faces of the cylinder 13b of the first compression unit 9b are covered by a secondary bearing 19 and the partition plate 18, respectively, and the cylinder chamber 12b is formed therewithin. A discharge port 20a for communicating the cylinder chamber 12a with an inner space of the sealed case 2a and a discharge valve 21a for opening and closing the discharge port 20a are provided in the primary bearing 17. A discharge port 20b for communicating the cylinder chamber 12b with the inner space of the sealed case 2a and a discharge valve 21b for opening and closing the discharge port 20b are provided in the secondary bearing 19.
A discharge pipe 22 for discharging compressed refrigerant within the sealed case 2a toward the four-way valve 3 is connected to an upper portion of the sealed case 2a. Suction pipes 23 for introducing refrigerant from the accumulator 7 into the cylinder chambers 12a and 12b are connected to a lower side of the sealed case 2a.
Further, a film 29 in which first to fourth layers 25 to 28 are layered sequentially is formed on the surface of the base member 24 that has been treated with the a surface-hardening process. The first layer 25 is a single layer of chromium (Cr). The second layer 26 is an alloyed layer of chromium and tungsten carbide (WC). The third layer 27 is an amorphous carbon layer containing tungsten (W). The fourth layer 28 is an amorphous carbon layer containing carbon and hydrogen without containing metal. Note that the third layer 27 may be an amorphous carbon layer containing tungsten carbide instead of tungsten, or an amorphous carbon layer containing both tungsten and tungsten carbide.
In the second layer 26, formed is a content gradient such that a content rate of chromium on its side of the first layer 25 is made larger than that on its side of the third layer 27 and a content rate of tungsten carbide on its side of the third layer 27 is made larger than that on its side of the first layer 25.
In the third layer 27, formed is a content gradient such that a content rate of tungsten on its side of the second layer 26 is made larger than that on its side of the fourth layer 28.
With respect to each thickness of the layers 25 to 28, the first layer 25 has 0.1 μm, the second layer 26 has 0.2 μm, the third layer 27 has 0.5 μm, and the fourth layer 28 has 2.2 μm, so that total thickness of the film 29 is 3 μm.
A graph chart in
In the above measurements, relative wear depths are measured under conditions shown below.
Vane: the film 29 is formed on the surface-hardened base member 24 (the vanes 15a and 15b shown in
Roller: made of flake graphite cast iron containing molybdenum, nickel and chromium (the rollers 14a and 14b)
Vane: made of high-speed steel (SKH51)
Roller: made of flake graphite cast iron containing molybdenum, nickel and chromium (similarly to the rollers 14a and 14b)
Vane made of high-speed steel (SKH51)
Roller: made of flake graphite cast iron
Vane: the film 29 is formed on the surface-hardened base member 24 (similarly to the vanes 15a and 15b shown in
Roller: made of flake graphite cast iron
Further, in the above measurements, the vanes and the rollers of the Applied Example 1 or the Comparative Example 1 to 3 are installed in the rotational compression unit 9 of the refrigerant compressor 2, and the vanes are subject to be heavily impacted to the rollers by forcibly operating the rotational compression unit 9 so as to suction fluid refrigerant intermittently and repeatedly. Note that condensation temperature is set to 65° C. in the above measurements.
According to the measurement results shown in
In this manner, elastic deformation of the base member 24 to which a large load applies can be restricted by treating the metallic base member 24 of the vanes 15a and 15b with a surface-hardening process by carburized quenching. Therefore, deformation of the film 29 to which a large load applies can be restricted, so that the adherence between the base member 24 and the film 29 and the adherences between the layers 25 to 28 in the film 29 can improve.
With respect to the four layers 25 to 28 that constitutes the film 29, the first layer 25 is a single layer of chromium, the second layer is an alloyed layer of chromium and tungsten carbide, the third layer 27 is a metal-containing amorphous carbon layer containing at least one of tungsten and tungsten carbide, the fourth layer 28 is an amorphous carbon layer containing carbon and hydrogen without containing metal. In addition, in the second layer 26, formed is a content gradient such that a content rate of chromium on its side of the first layer 25 is made larger than that on its side of the third layer 27 and a content rate of tungsten carbide on its side of the third layer 27 is made larger than that on its side of the first layer 25. Further, in the third layer 27, formed is a content gradient such that a content rate of tungsten on its side of the second layer 26 is made larger than that on its side of the fourth layer 28.
Therefore, differences of hardness between the first layer 25 and the second layer 26, between the second layer 26 and the third layer 27 and between the third layer 27 and the fourth layer 28 become deduced, respectively, and thereby the adherences between the layers 25 to 28 improves, so that cracks in the film 29 can be restricted.
In addition, since the fourth layer 28 located outermost in the film 29 is an amorphous carbon layer containing carbon and hydrogen without containing metal, it can be more hardened than in a case where a metal-containing amorphous carbon layer is located outermost, so that anti-wear characteristics of the vanes 15a and 15b can improve.
Further, as shown in the measurement results of
Note that, if hardness of a base member of a vane is sufficiently high (for example, high-speed tool steel refined to HRC63), the same advantage as the advantage achieved by the above-mentioned Applied Example 1 can be obtained without a surface-hardening process.
In addition, tests are done under the same condition as the condition of the measurements shown in
A second embodiment will be explained with reference to
In the second embodiment, the cylinders 13a and 13b are made of flake graphite cast iron or made of sintered metal whose surface is treated with a porosity sealing process.
In the above measurements, the vanes 15a and 15b in which the films 29 are also formed on their side surfaces are used in all Examples A to D. In addition, the cylinders 13a and 13b made of spheroidal graphite cast iron are used in the Example A, the cylinders 13a and 13b made of flake graphite cast iron are used in the Example B, the cylinders 13a and 13b made of flake graphite cast iron with addition of vanadium and phosphorus are used in the Example C, and the cylinders 13a and 13b made of the sintered metal 30 with the film 32 shown in
Further, the above measurements, the vanes on which the film 29 is formed and the cylinder of the Example A to D are installed in the rotational compression unit 9 of the refrigerant compressor 2, and the vanes are subject to be heavily impacted to the rollers by forcibly operating the rotational compression unit 9 so as to suction fluid refrigerant intermittently and repeatedly, similarly to the measurement in the first embodiment.
According to the measurement results, the wear depth is large in the case where the cylinders are made of spheroidal graphite cast iron (Example A), so that it can be found that the configuration in the Example A is not adequate for being used in the refrigerant compressor 2. However, the wear depths are small in the cases of the Examples B to D, so that it can be found that their configurations are adequate for being used in the refrigerant compressor 2.
A third embodiment will be explained based on a Table 1 shown below. In the present embodiment, the above-explained film 29 composed of the first layer 25 to the fourth layer 28 is formed on a surface of the rotary shaft 10.
The Table 1 shows measurement results of relationships of material of the rotary shaft 10, with-or-without the film 29 on the rotary shaft 10 and burnout characteristics of the shaft. In the Table 1, the burnout characteristics become better in order of rank C, B and A.
According to the measurement results, it can be found that the burnout characteristics improve due to the formation of the film 29 with any material of the rotary shaft 10 and thereby burnouts can be restricted.
For the refrigerant compressor 2, expansion of variable rotational speed of the rotational compression unit 9 is required. Especially, a low frequency rotation brings a lubricating condition wherein oil film pressure by shaft rotational speed cannot raise sufficiently, so that the rotary shaft 10 may directly contact with its bearing(s) (the primary bearing 17 and the secondary bearing 19) without interposing an oil film. Therefore, formation of the film 29 on the surface of the rotary shaft 10 can restricts burnouts under a operational state at a low frequency rotation, and thereby wears at slidably contact portion can be reduced.
A fourth embodiment will be explained based on a Table 2.
In the fourth embodiment, end faces of the bearings (the primary bearing 17 and the secondary bearing 19) slidably contact with side surfaces of the vanes 15a and 15b, respectively. The primary bearing 17 and the secondary bearing 19 are made of flake graphite cast iron and their surfaces are made of the sintered metal 30 (
Anti-wear characteristics of the bearings 17 and 19 are measured, using the vanes 15a and 15b in which the films 29 are formed also on their side surfaces, with the bearings 17 and 19 made of flake graphite cast iron and with the bearings 17 and 19 made of sintered metal 30 with the film 32. The measurement results are shown in the Table 2 below.
In the above measurements, the bearings 17 and 19 whose material is different from that of the vanes on which the film 29 is formed are installed in the rotational compression unit 9 of the refrigerant compressor 2, and the vanes 15a and 15b are subject to be heavily impacted to the rollers 14a and 14b by forcibly operating the rotational compression unit 9 so as to suction fluid refrigerant intermittently and repeatedly, similarly to the measurement in the first embodiment.
According to the measurement results, it can be found that the bearings 17 and 19 can achieve superior anti-wear characteristics (rank A) in any case of the bearings 17 and 19 made of flake graphite cast iron and the bearings 17 and 19 made of sintered metal 30 with the film 32.
Note that flake graphite cast iron has a feature of minute graphite structure, so that its oil-retaining characteristics are superior under usage environment of concern for oil-shortage and thereby can improve anti-wear characteristics.
In addition, by using the sintered metal 30, the above-explained dent 34 improves the oil-retaining characteristics, so that the anti-wear characteristics can be enhanced.
A fifth embodiment will be explained. The fifth embodiment relates to a combination of types of the refrigerant oil 11 accumulated in the sealed case 2a and types of the refrigerant.
In the fifth embodiment, HFC refrigerant is used as the refrigerant, and POE (polyol esther) or PVE (polyvinyl ether) is used as the refrigerant oil 11.
HFC refrigerant without containing chlorine has no lubrication characteristics, so that lubrication performance at slidably contact portions depends only on the refrigerant oil 11. Namely, lubrication performance when using refrigerant without containing chlorine may degrade compared to when using chlorine-containing refrigerant. Therefore, lubrication performance can be improved by using POE (polyol esther) or PVE (polyvinyl ether) as the refrigerant oil 11.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2009-217840 | Sep 2009 | JP | national |
This application is a National Stage of International Application No. PCT/JP2010/065441 (not published in English), filed Sep. 8, 2010, which, in turn, claims the benefit of Japanese Patent Application No. 2009-217840, filed Sep. 18, 2009.
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2010/065441 | 9/8/2010 | WO | 00 | 3/16/2012 |
