Swash plate compressor

Abstract

A swash plate compressor especially suited for automotive vehicles. The inner housing may be moved in the rear housing in the front and rear direction, as the occasion may demand, for adjusting the compression capacity or performance of the compressor. A partition wall is projectingly projected at the front side of the inner housing for defining an inner or discharge chamber and an outer or suction chamber. A plurality of clamp bolts for fixedly clamping together a rear cylinder block and the rear housing are passed through said suction chamber. The rear wall of the inner housing is formed with an annular thin-walled portion lesser in thickness than the valve plate on the front surface of said inner housing. By the function of said thin-walled portion, the inner housing may be flexed readily to absorb valve plate strain.

Description

FIELD OF THE INVENTION

This invention relates to a swash plate compressor especially suited for air-conditioning of automotive vehicles.

BACKGROUND OF THE INVENTION

In a certain conventional compressor used for air-conditioning of automotive vehicles, means are provided for adjusting the compression capacity or performance as a function of occasional cooling demand. The present inventor has proposed a compressor of this type in which, as shown in FIG. 9, an inner housing 62 movable axially of a rotary shaft is mounted in the rear housing 61 for providing a pressure chamber 63 between the inner surface of the rear housing 61 and the rear surface of the inner housing 62, a valve plate 64 is secured to the open front end face of the inner housing 62, and wherein a changeover valve 65 is provided for selective application of a high or discharge pressure or a low or suction pressure to said pressure chamber 63 to enable the compressor capacity to be switched between 100% value and 50% value to eliminate any unnecessary compression when the smaller compressor capacity is required.

However, with such swash plate compressor, a suction chamber 66 and a discharge chamber 67 are provided in the central and radially outward portions of the inner housing 62. Thus, when the front housing 68 and the rear housing 61 are secured to the front and rear cylinder blocks 69, 70 by through-bolts, the latter must be passed through the high-pressure discharge chamber 67, thus posing a serious sealing problem. Thus it is necessary, after securing the cylinder blocks 69, 70 to the front housing 68 by through-bolts 71, to fixedly clamp the rear cylinder block 70 and the rear housing 61 together by further clamp bolts 72, which are arranged radially outwardly of a sealing O-ring 73, as shown in FIG. 10, with consequent increase in the outside diameter of the compressor.

SUMMARY OF THE INVENTION

It is therefore an object of the present invention to provide a swash plate type compressor which can be switched between 100% operation and 50% operation as the occasion may require so that unnecessary compression may be dispensed with during low load operation for reducing the motive power and preventing undue heating of the compressor.

It is a further object of the present invention to provide a swash plate type compressor which may be reduced in size through reduction of the outside diameters of the rear cylinder block and the rear housing.

It is a further object of the present invention to provide a swash plate compressor wherein a portion of the inner housing is made flexible so as to absorb any strain experienced by a valve plate mounted to the front surface of the inner housing so that the valve plate may accurately and closely abut on the rear end face of the rear cylinder block for assuring fluid tightness.

It is a further object of the present invention to provide a swash plate compressor wherein the inner housing may have a simpler shape and the suction chamber positioned radially outwardly of the discharge chamber may be increased in volume.

It is a further object of the present invention to provide a swash plate compressor wherein the discharge pressure and the negative suction pressure developed in the compressor itself may be utilized as pressure sources for the pressure chamber which is disposed on the back surface of the inner housing.

Other objects of the present invention will be apparent from the following description of the preferred embodiments and the appended claims. Many advantages not specifically recited in the specificaton will readily be apparent to those engaged in the art upon execution of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a central longitudinal section of a swash plate compressor according to a first embodiment of the present invention.

FIG. 2 is a partial second showing the inner housing when moved in the fore direction.

FIG. 3 is a section taken along line III--III of FIG. 1.

FIG. 4 is a section taken along line IV--IV of FIG. 1.

FIG. 5 is a partial section showing a portion including the discharge passage of the swash plate compressor according to the first embodiment.

FIG. 6 is a partial section showing a swash plate compressor according to a second embodiment of the present invention.

FIG. 7 is a section taken along line VII--VII of FIG. 6.

FIG. 8 is a partial section showing a portion including a discharge passage of the swash plate compressor according to the second embodiment.

FIG. 9 is a section showing a conventional swash plate compressor.

FIG. 10 is a partial section showing the state of securing of the cylinder block and the rear housing in the conventional swash plate compressor.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to the first embodiment of the invention shown in FIGS. 1 through 5, the numerals 1 and 2 denote a fore cylinder block and an aft cylinder block constituting together a body member 3 of the compressor. Each of said cylinder blocks 1, 2 has for example five cylinder bores 1a, 2a, and a plurality of double-headed pistons 4 are slidably received in these cylinder bores 1a, 2 a. A rotary shaft 5 is inserted into a center bore 3a of the body member 3 of the compressor from the front side and is mounted for rotation by bearing members 6 and 7. An inclined or swash plate 8 is secured to the central portion of the rotary shaft 5 by a spring pins 9. The arrangement is so made that, when the inclined plate 8 is rotated, said piston 4 may be reciprocated in the cylinder bores 1a, 2a through the intermediary of two pairs of shoes 10 and balls 11. In the drawing, the numerals 12, 13 denote thrust bearings.

To the front end face of the fore cylinder block 1 is secured a front housing 17 through the intermediary of a suction valve seat 14, a valve plate 15 and a gasket 16. As shown in FIG. 3, this front housing 17 is divided by a substantially toroidal partition wall 17a, into an outwardly disposed suction chamber 100 and a centrally disposed dischage chamber 101. Five suction ports 15a are formed in the valve plate 15 in such positions as to suck refrigerant gas into each cylinder bore 1a from the common suction chamber 100 provided in said front housing 17, said suction ports 15a cooperating with valve plates, not shown, of the suction valve seat 14 for providing five suction valves 18. Said valve plate 15 also has five discharge ports 15b in such positions as to discharge the compressed refrigerant gas from each cylinder bore 1a into the common discharge chamber 101 provided in said front housing, said discharge ports 15b cooperating with valve plates 19a and retainers 19b for providing five discharge valves 19.

Four suction communication openings 20 are formed in said valve plate 15 for sucking refrigerant gas from a suction passage 1b of the front cylinder block 1 into the suction chamber 100. As shown in FIG. 3, the upper portion of the discharge chamber 101 of the front housing 17 is enlarged at 102, and a discharge communication opening 21 is provided in the valve plate 15 in register with the enlarged portion 102 for introducing the compressed refrigerant gas into a discharge passage 1c of the fore cylinder block 1 (see FIG. 5).

The foremost part of the rotary shaft 5 is passed through the center of the front housing 17 to be projected outwards and connected at the projected end to a drive source. Sealing means 22 are provided for sealing the rotary shaft 5 and the front housing 17 relative to one another.

A rear housing 23 is connected to the outer edge of the rear end face of the rear cylinder block 2. The rear housing 23, front housing 17 and the cylinder blocks 1, 2 are fixedly clamped to one another by five through-bolts 24 which are passed through the suction chamber 100 of the front housing 17, suction communication opening 20 of the valve plate 15 and suction passages 1b, 2b of the cylinder blocks 1, 2. A bottomed cylindrical inner housing 25 is slidably introduced onto the inner peripheral surface of the rear housing 23 in the axial direction of the rotary shaft 5. As shown in FIG. 4, this inner housing 25 is divided by a substantially circular partition wall 25a into the outwardly disposed suction chamber 100 and the centrally disposed discharge chamber 101. The outer peripheral wall 23a of the rear housing 23 is inscribed by the outer peripheral wall 25c of the inner housing 25. A gasket 28, valve plate 29 and a suction valve seat 30 are secured by a small screw 31 to the front end face of the inner housing 25. Five suction ports 29a are provided in the valve plate 29 in such positions as to such refrigerant gas into each cylinder bore 2a from the common suction chamber 100 provided in the inner housing 25, said suction ports 29a cooperating with valve plates, not shown, of the suction valve seat 30 for providing suction valves 32. Five discharge ports 29b are provided in the valve plate 29 in such positions as to discharge the compressed refrigerant gas from each of the cylinder bores 2a into the common discharge chamber 101 defined in the inner housing 25, said discharge ports 29b cooperating with the valve plates 26 and the retainers 27 for providing discharge valves 33.

The valve plate 29 is formed with a plurality of suction communication openings 34 for passage of said through-bolts 24 therethrough to permit the refrigerant gas to be sucked from suction passage 2b of the rear cylinder block 2 into the suction chamber 100 of the inner housing 25. As shown in FIG. 4, the upper portion of the discharge chamber 101 of the inner housing 25 is enlarged at 103, and a discharge communication opening 35 is provided in the valve plate 29 in register with the enlarged portion 103 for introducing the compressed refrigerant gas into a discharge passage 2c of the rear cylinder block 2 (see FIG. 5).

A spring retaining member 36 is axially reciprocable within the center bore 3a of the body member 3 of the compressor and fixedly clamped by small screw 31 to the front face of the suction valve plate 30 at the center thereof. A compression coil spring 38 is interposed between the spring retaining member 36 and a spring retaining plate 37 abutted against the rear end face of the bearing membr 7 so that the suction valve seat 30, valve plate 29 and the inner housing 25 are normally urged in a direction away from the rear end face of the rear cylinder block 2.

A gap is provided between the rear face of the inner housing 25 and the rear housing 23 for delimiting a pressure chamber 39. An O-ring 40 is fitted in an outer peripheral groove of the inner housing 25 for assuring air-tightness of the pressure chamber 39. An inlet opening 41 is formed through the rear housing 23 for communication with the pressure chamber 39. The rear surface of the inner housing 25 is formed with an annular reduced thickness portion 25b with thickness lesser than that of the valve plate 29. The arrangement is so made that, when the inner housing 25 and the valve plate 29 are clamped together by the small screw 31, the inner housing 25 may be deformed more readily so as to reduce the flexure imparted to the valve plate 29. Occasional strain caused by certain dimensional tolerances of the valve plates 26, retainers 27 and the gaskets 28 may also be absorbed by the reduced thickness portion 25b.

A suction flange 42 communicating with suction passages 1b, 2b of the cylinder blocks 1, 2 and a discharge flange 43 communicating with discharge passages 1c, 2c of the cylinder blocks 1, 2 are connected to the top of the body member 3 of the compressor. A check valve 44 is provided in the discharge passage 2c for preventing the reversed flow of the refrigerant gas into discharge chamber 101 of the inner housing 25. A discharge conduit 45 is connected to the discharge flange 43, an inlet conduit 46 is connected to the inlet opening 41, and a changeover valve 47 is connected to the conduits 45, 46, said changeover valve being operative when the suction pressure and temperature have exceeded their design valves. The numeral 48 denotes an inlet conduit interconnecting said suction flange 42 and the changeover valve 47.

The compressor so far shown and described operates as follows.

Upon starting the compressor, as shown in FIG. 1, the suction valve seat 30, valve plate 29, gasket 28 and the inner housing 25 are urged towards rear as one unit by the compression spring 38 so that the valve plate 29 clears the rear end face of the cylinder block 2 so as to permit the refrigerant to flow into and be discharged from all the cylinder bores 2a on the rear side. Thus the refrigerant does not meet any appreciable resistance thus causing no compression on the rear side. Since the compression occurs only on the front side, starting torque may be low.

With progress in the compression on the front side, when the pressure in the discharge chamber 101 has exceeded a predetermined value, a pressure switch, not shown, is energized. An electromagnet, not shown, provided in the changeover valve 47, is thereby turned on and, as shown in FIG. 2, the changeover valve 47 is switched to the side of the discharge flange 43. The discharge gas from the discharge flange 43 may thus be supplied through changeover valve 47 into pressure chamber 39. Under such discharge pressure, the inner housing 25 is pressed towards front against the compression spring 38 (FIG. 2) so that the suction valve seat 30 is closely abutted against the rear end face of the cylinder block 2. From this time on, compression occurs similarly on the side of the rear cylinder block 2.

When the compression has started on the rear side, the gas is supplied under pressure from discharge chamber 101 of the inner housing 25 through the discharge passage 2c and check valve 44 towards the discharge flange 43 to effect 100% operation of the compressor. During such compression operation, the cylinder bores 2a are placed sequentially under elevated pressure. Since the sectional area of the pressure chamber 39 is larger than the overall sectional area of the cylinder bores 2a occasionally placed under the elevated pressure acting on the valve plate 29 from the front side, the inner housing 25 is not floated during such compression operation. Since the back pressure acting on the back surface of the inner housing 25 corresponds to the differential sectional area between the inner and outer surfaces of the inner housing, there is no risk that the reduced thickness portion 25b may be destroyed due to abnormally increased back pressure.

Even supposing that the valve plate 29 is subjected to strain due to manufacturing and assembly tolerances and thus the suction valve seat 30 may not be contacted closely with the rear end face of the cylinder block 2, the inner housing 25 may be flexed under the back pressure applied to the inner housing 25 by virtue of the reduced thickness portion 25b so that the inner housing 25 is uniformly pressed at the front end face thereof against the valve plate 29 through the gasket 28. Thus the occasional strain to which valve plate 29 is subjected may be compensated, resulting in improved sealing between the gasket 28 and the rear end face of the cylinder block 2.

When the compressor may be switched in the course of its normal operation from 100% to 50% capacity, the changeover valve 47 is switched to the side of suction flange 42, as shown in FIG. 1, for establishing fluid communication between the inlet conduit 48 and the pressure chamber 39. The gas pressure in the pressure chamber 39 is now reduced and the inner housing 25 is shifted towards aft under the force of compression spring 38, thus making the action of compression at the rear side ineffective. At this time, reversed flow of the pressurized gas into the inner housing 25 may be prevented by the check valve 44.

A throttle valve, not shown, may be provided between the changeover valve 47 and the inlet opening 41 for preventing abrupt pressure rise in the pressure chamber 39 at the time of switching to 100% compressor operation and for reducing the torque as well as abrupt build-up of abnormally high pressure during start of the compressor. Alternatively, an intermediate pressure may be applied to the pressure chamber 39 during abnormally high pressure caused, for example, by liquid compression, for preventing the risk of destruction of the reduced thickness portion 25b of the inner housing 25.

The changeover valve 47 may be switched by automatic changeover device and thus without resorting to manual operation or pressure switch operation.

Thus, according to the first embodiment of the present invention, the compressor capacity may be switched between two stages, i.e. between 100% operation and 50% operation, as the occasion may require, and a sufficient relief area may be procured by only small displacement of the inner housing 25. Thus any undue compression may be dispensed with during low load operation resulting in the reduced motive power and prevention of undue heating of the compressor.

According to the first embodiment of the present invention, the discharge chamber 101 and the suction chamber 100 are defined in the central zone and the outer peripheral zone of the inner housing 25 respectively and thus the through-bolts 24 used for securing the rear cylinder block 2 and the rear housing 23 to each other may be provided in the low-pressure suction chamber 100 where fluid tightness is not of primary importance. Thus, the rear cylinder block 2 and the rear housing 23 may be reduced in their outside diameters for reducing the overall size.

Reference is made to FIGS. 6 through 8 for illustrating a second embodiment of the present invention. According to this embodiment, only the discharge chamber 101 is provided in the inner housing 25, whereas the suction chamber 100 is defined between the outer peripheral partition wall 25a of the inner housing 25 and the outer peripheral wall 23a of the rear housing 23. Thus the inner housing 25 may have a simpler shape, while the suction chamber 10 may be enlarged in volume. Other structure and effects of the present embodiment are similar to those already described in connection with the preceding embodiment. It is to be noted that, in this second embodiment, the partition wall 25a of the inner housing 25 and the discharge chamber 101 may be enlarged radially, and only the communicating portion of the discharge chamber 101 and the discharge passage 2c (i.e. discharge communication opening 35) may be provided in such radially enlarged portion.

It is evident that broadly different embodiments may be conceived within the spirit and scope of the present invention, and hence the present invention may not be restricted to the particular embodiment shown herein except as defined in the appended claims.

Claims

1. A swash plate compressor with two operating stages at front and rear sections, comprising

a cylinder body member with front and rear housings connected thereto, said cylinder body member having a plurality of cylinder bores therein,

a plurality of pistons situated in said cylinder bores to be reciprocally moved therein,

a rotary shaft rotationally disposed in said cylinder body member, said shaft having a swash plate so that when the shaft rotates, the pistons are reciprocally moved by means of said swash plate,

an inner housing situated between said rear housing and said cylinder body member to form a pressure chamber between said inner housing and said rear housing, said pressure chamber, when operated, being pressurized so that said inner housing is moved relative to said cylinder body member, said inner housing having a rear wall at a side adjacent to the rear housing,

a valve assembly connected to said inner housing at a side adjacent to the cylinder body member, a portion of the rear wall of the inner housing being thinner than the thickness of the valve assembly so as to permit the rear wall to flex under the pressure applied to the pressure chamber so that the inner housing is uniformly pressed against the valve assembly to thereby sealing press the valve assembly onto the cylinder body member,

a discharge chamber formed between said inner housing and said valve assembly at the center portion of said inner housing, whereby said discharge chamber, when said pressure chamber is in operating condition, receives pressurized fluid formed by the pistons in the cylinder body member and leads the fluid from the compressor, and

a suction chamber surrounded by at least the inner housing and said valve assembly and located outside said discharge chamber, whereby said suction chamber, when said pressure chamber is in operating condition, receives fluid to be pressurized and supplies the fluid to the pistons.

2. A swash plate compressor according to claim 1, in which said inner housing further includes a circular partition wall around the rear wall thereof and attached to the valve assembly, whereby said discharge chamber is defined by the partition wall, the rear wall and the valve assembly, and the suction chamber is located outside the discharge chamber and is defined by the partition wall, the valve assembly and the rear housing.

3. A swash plate compressor according to claim 2, in which said inner housing further includes an outer peripheral wall outside the partition wall so that the suction chamber is defined by the outer peripheral wall, the partition wall and the valve assembly.

4. A swash plate compressor according to claim 1 further comprising spring means situated between the cylindrical body member and the valve assembly and arranged on a line extending through the central axis of the cylinder body member for urging said inner housing and said valve assembly attached on said inner housing rearwardly, said inner housing and said valve assembly being moved rearwardly by means of said spring means when the pressure chamber is not operated, and said inner housing and said valve assembly being moved toward the cylinder body member against the force of said spring means when the pressure chamber is operated.

5. A swash plate compressor according to claim 4 further comprising changeover valve means connected to said pressure chamber for supplying pressure to said pressure chamber from one of a high pressure source and a low pressure source as desired, whereby when the high pressure is supplied to the pressure chamber, the pressure chamber is in operating condition, and when the low pressure is supplied to the pressure chamber, the pressure chamber is in non-operating condition.

6. A swash plate compressor according to claim 5 further comprising a discharge passage connected to said discharge chamber, and check valve means provided in said discharge passage for preventing a pressurized gas from the operating stage at the front section from entering into the discharge chamber when the pressure chamber is in non-operating condition.

7. A swash plate compressor according to claim 5 in which said high and low pressure sources are discharge pressure and the suction pressure, respectively.