VANE COMPRESSOR

Abstract

There is provided a vane compressor with a plurality of vanes having a structure in which a rotor portion and a rotary shaft are unitarily formed so as to reduce bearing sliding loss of the rotary shaft and reduce gas leakage loss by narrowing a space formed between the rotor portion and the inner peripheral surface of a cylinder. In the vane compressor with the plurality of vanes according to the present invention, an angle α of a circular arc constituting the partial ring shape of each vane aligner satisfies a relationship of

Description

TECHNICAL FIELD

The present invention relates to a vane compressor.

BACKGROUND ART

Conventionally, a common vane compressor is proposed (refer to, e.g., Patent Literature 1). The vane compressor has a structure in which a vane is fitted in a vane groove formed at one location or each of a plurality of locations in a rotor portion of a rotor shaft (unitary formation of the columnar rotor portion that rotates within a cylinder and a shaft that transmits torque to the rotor portion being referred to as the rotor shaft), and a vane tip slides while contacting the inner peripheral surface of the cylinder.

A different vane compressor is proposed (refer to, e.g., Patent Literature 2). In the vane compressor, an inside of a rotor shaft is formed to be hollow, and a fixed shaft for vanes is disposed in the inside of the rotor shaft. The vanes are rotatably attached to the fixed shaft. Further, each vane is held rotatably with respect to a rotor portion through a pair of semicircular-bar-shaped supporting members in the vicinity of an outer peripheral part of the rotor portion.

CITATION LIST

Patent Literature

Patent Literature 1: JP 10-252675 A (Page 4 and FIG. 1)

Patent Literature 2: JP 2000-352390 A (Page 6 and FIG. 1)

SUMMARY OF INVENTION

Technical Problem

In the conventional common vane compressor (e.g., Patent Literature 1), the direction of the vane is restricted by the vane groove formed in the rotor portion of the rotor shaft. The vane is held to constantly have the same inclination with respect to the rotor portion. Therefore, an angle formed between the vane and the inner peripheral surface of the cylinder changes along with rotation of the rotor shaft. Thus, it is necessary to form the radius of a circular arc formed by the vane tip to be smaller than the radius of the inner peripheral surface of the cylinder in order for the vane tip to make contact with all around the inner peripheral surface of the cylinder.

In the vane compressor where the vane tip slides while contacting the inner peripheral surface of the cylinder, the vane tip having a greatly different radius from that of the inner peripheral surface slides. Thus, between the two components (the cylinder and the vane), a fluid lubrication state, in which an oil film is formed and the vane tip slides through the oil film, does not occur but rather a boundary lubrication state occurs. Generally, while a friction coefficient of a lubrication state is around 0.001 to 0.005 in the fluid lubrication state, the friction coefficient greatly increases to be approximately 0.05 or more in the boundary lubrication state.

In the structure of the conventional common vane compressor, the vane tip slides on the inner peripheral surface of the cylinder in the boundary lubrication state. Sliding resistance is therefore high, leading to a great reduction of the compressor efficiency due to an increase in machine loss. There is also a problem that the vane tip and the inner peripheral surface of the cylinder tend to abrade to make it difficult to ensure long life of the vane and the cylinder. Then, the conventional vane compressor has been so designed that a pressing force of the vane against the inner peripheral surface of the cylinder is reduced as much as possible.

As a mode for improving the above-mentioned problems, there has been proposed a method (e.g., Patent Literature 2). In this method, the inside of the rotor portion is formed to be hollow. Then, the fixed shaft for rotatably supporting the vanes at the center of the inner peripheral surface of the cylinder is provided in the inside. Further, each vane is held through the supporting members in the vicinity of the outer peripheral part of the rotor portion so that each vane is rotatable with respect to the rotor portion.

With this arrangement, the vanes are rotatively supported at the center of the inner peripheral surface of the cylinder. Therefore, the vane longitudinal direction constantly coincides with the normal direction of the inner peripheral surface of the cylinder. The radius of the inner peripheral surface of the cylinder and the radius of a circular arc formed by each vane tip may be therefore formed to be approximately equal to each other so that each vane tip portion is along the inner peripheral surface of the cylinder. Each vane tip and the inner peripheral surface of the cylinder may be therefore formed not to be in contact with each other. Alternatively, even if the vane tip and the inner peripheral surface of the cylinder contact with each other, a fluid lubrication state with a sufficient film may be produced. The sliding state of each vane tip portion, which is the problem of the conventional vane compressor, may be thereby improved.

In the method of Patent Literature 2, however, the inside of the rotor portion is formed to be hollow, thus making it difficult to provide torque to the rotor portion or to rotatively support the rotor portion. In Patent Literature 2, end plates are provided at both end surfaces of the rotor portion. As the end plate on one side needs to transmit power from the rotary shaft, the end plate on the one side is in the shape of a disk, and the rotary shaft is connected to the center of the end plate. The end plate on the other side needs to be formed not to interfere with rotation ranges of the vane fixed shaft and the vane axis support member. Thus, it is necessary to form the end plate on the other side to be in the shape of a ring with a hole opened at the center portion thereof. Therefore, it is necessary to form a portion for rotatively supporting each end plate to have a diameter larger than that of the rotary shaft, causing a problem that bearing sliding loss increases.

A space formed between the rotor portion and the inner peripheral surface of the cylinder is narrow so that compressed air does not leak. High precision is therefore required for the outer diameter and the rotation center of the rotor portion. The rotor portion and the end plates are, however, formed of separate components. Thus, there is a problem that a distortion which may occur by fastening the rotor portion to the end plates, a coaxial gap between the rotor portion and the end plates, or the like may lead to degradation of precision of the outer diameter or the rotation center of the rotor portion.

The present invention has been made in order to solve the problems as described above, and provides a vane compressor that, in order to reduce bearing sliding loss of a rotary shaft and reduce gas leakage loss by narrowing a space formed between a rotor portion and the inner peripheral surface of a cylinder, includes a plurality of vanes in which, a mechanism where the vanes rotate about the center of the cylinder, the mechanism being necessary for performing a compression operation such that the normal to a circular arc formed by each vane tip portion and the normal to the inner peripheral surface of the cylinder are constantly approximately coincident with each other, is implemented by unitarily forming the rotor portion and the rotary shaft. This mechanism is implemented without using, for the rotor portion, end plates that may degrade precision of the outer diameter or the rotation center of the rotor portion.

Solution to Problem

A vane compressor according to the present invention includes:

an approximately cylindrical cylinder whose both axial ends are open;

a cylinder head and a frame that close the both axial ends of the cylinder;

a rotor shaft including a columnar rotor portion that rotates in the cylinder and a shaft portion that transmits torque to the rotor portion; and

a plurality of vanes installed in the rotor portion, each of the plurality of vanes having a tip portion formed into a circular arc shape facing outward, wherein

a bush holding portion having an approximately circular cross-section and penetrating in an axial direction is formed in a vicinity of an outer peripheral portion of the rotor portion,

each of the plurality of vanes is supported through a pair of approximately semicolumnar bushes in the bush holding portion so as to be rotatable and movable with respect to the rotor portion in the rotor portion so that a compression operation is performed in a state where a longitudinal direction of each of the plurality of vanes and a normal direction of an inner peripheral surface of the cylinder are constantly approximately coincident with each other;

a pair of partial-ring-shaped vane aligners are attached to both ends of each of the plurality of vanes such that a center line of each of the plurality of vanes passes through an approximately central axis of a circular arc constituting a partial ring shape of each of the vane aligners,

a concave portion or a ring-shaped groove being concentric with an inner peripheral surface of the cylinder is formed in an end surface of each of the cylinder head and the frame on a side of the cylinder,

the vane aligners are fitted in the concave portion or the ring-shaped groove, and

an angle α of the circular arc constituting the partial ring shape of each of the vane aligners satisfies a relationship of

$\begin{array}{cc}\left[\mathrm{Equation}9\right]& \\ \alpha <2{\tan }^{-1}\left\{\frac{R\sin \left(\frac{\pi }{N}\right)}{R\cos \left(\frac{\pi }{N}\right)+e}\right\}& \left(1\right)\end{array}$

where R is a distance between the rotational central axis of the bushes and the rotational central axis of the rotor portion, e is a distance between the central axis of the inner peripheral surface of the cylinder and the rotational central axis of the rotor portion, and N (a natural number of two or greater) is the number of the plurality of vanes.

Advantageous Effects of Invention

In the vane compressor according to the present invention, by setting the angle of the circular arc constituting the partial ring of each vane aligner to be smaller than a predetermined value, a stable operation can be performed without contact between the vane aligners during rotation. By unitarily forming the rotor portion and the rotary shaft, a mechanism where the vanes rotate about the center of the cylinder, the mechanism being necessary for performing a compression operation such that the normal to a circular arc formed by each vane tip portion and the normal to the inner peripheral surface of the cylinder are constantly approximately coincident with each other, can be implemented. Bearing sliding loss can be therefore reduced by supporting the rotary shaft by bearings having a small diameter. Further, precision of the outer diameter or the rotation center of the rotor portion is improved. A space formed between the rotor portion and the inner peripheral surface of the cylinder can be thereby narrowed to reduce gas leakage loss.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 a diagram showing a first embodiment, which is a longitudinal sectional view of a vane compressor 200;

FIG. 2 a diagram showing the first embodiment, which is an exploded perspective view of a compression element 101 of the vane compressor 200;

FIG. 3 a diagram showing the first embodiment, which is a plan view of each of vane aligners 5, 6, 7, and 8;

FIG. 4 a diagram showing the first embodiment, which is a plan view (90-degree rotation angle) of the compression element 101 of the vane compressor 200;

FIG. 5 diagrams showing the first embodiment, which are plan views of the compression element 101 illustrating a compression operation of the vane compressor 200;

FIG. 6 diagrams showing the first embodiment, which are plan views illustrating rotation operations of the vane aligners 6 and 8 in a vane aligner holding portion 3a;

FIG. 7 a diagram showing the first embodiment, which is a plan view (90-degree angle) showing positional relationships between vanes and the vane aligners in the vane compressor 200;

FIG. 8 a diagram showing the first embodiment, which is a perspective view of each of a first vane 9 and a second vane 10;

FIG. 9 a diagram showing a different example of the first embodiment, which is a perspective view of the second vane 10 and the vane aligner 8;

FIG. 10 a diagram showing a different example of the first embodiment, which is a diagram showing a structure in which the second vane 10 and the vane aligner 8 are unitarily formed; and

FIG. 11 a diagram showing a second embodiment, which is a plan view showing a positional relationship between the first vane 9 and an Nth vane 16.

DESCRIPTION OF EMBODIMENTS

First Embodiment

FIG. 1 is a diagram showing a first embodiment, and is a longitudinal sectional view of a vane compressor 200. The vane compressor 200 (hermetic type) will be described, with reference to FIG. 1. This embodiment is, however, characterized by a compression element 101, and the vane compressor 200 (hermetic type) is an example. This embodiment is not limited to the hermetic type, and is also applied to a different type such as an engine-driven type and an open container type.

The compression element 101 and an electric motor element 102 for driving this compression element 101 are stored in a hermetic container 103 in the vane compressor 200 (hermetic type) shown in FIG. 1. The compression element 101 is located in the lower portion of the hermetic container 103 and guides refrigerant oil 25 stored in the bottom portion of the hermetic container 103 to the compression element 101 by a lubrication mechanism not shown, thereby lubricating each sliding portion of the compression element 101.

The electric motor element 102 for driving the compression element 101 is composed of a brushless DC motor, for example. The electric motor element 102 includes a stator 21 fixed to an inner periphery of the hermetic container 103 and a rotor 22 that is disposed inside the stator 21 and uses a permanent magnet. Electric power is supplied to the stator 21 from a glass terminal 23 fixed to the hermetic container 103 by welding.

The compression element 101 sucks a refrigerant of a low-pressure into a compression chamber from a suction portion 26 and compresses the sucked refrigerant. The compressed refrigerant is discharged in the hermetic container 103, passes through the electric motor element 102, and is then discharged to an outside (high-pressure side of a refrigerating cycle) from a discharge pipe 24 fixed to the upper portion of the hermetic container 103. The vane compressor 200 (hermetic type) may be either a high-pressure type compressor of high pressure inside the hermetic container 103, or a low-pressure type compressor of low pressure inside the hermetic container 103. This embodiment shows a case where the number of vanes is two.

Since this embodiment is characterized by the compression element 101, the compression element 101 will be described below in detail. Although a reference symbol is assigned to each component constituting the compression element 101 in FIG. 1 as well, the exploded perspective view of FIG. 2 is easier to understand, and thus a description will be given mainly with reference to FIG. 2. FIG. 2 is a diagram showing the first embodiment, and is the exploded perspective view of the compression element 101 of the vane compressor 200. FIG. 3 is a diagram showing the first embodiment, and is a plan view of each of vane aligners 5, 6, 7, and 8.

As shown in FIG. 2, the compression element 101 includes elements that will be described below.

• (1) Cylinder 1: The whole shape of the cylinder 1 is approximately cylindrical, and both axial end portions of the cylinder 1 are open. A suction port 1a is open in an inner peripheral surface 1b of the cylinder 1.
• (2) Frame 2: The frame 2 has a longitudinal section approximately in the shape of a letter T. A portion of the frame 2 contacting the cylinder 1 is approximately in the shape of a disk, and closes one opening portion (on the upper side of the cylinder 1 in FIG. 2) of the cylinder 1. A vane aligner holding portion 2a (shown in FIG. 1 alone), which is in the shape of a ring groove being concentric with the inner peripheral surface 1b of the cylinder 1, is formed in an end surface of the frame 2 on the side of the cylinder 1. The vane aligners 5 and 7, which will be described later, are fitted in this vane aligner holding portion 2a. The frame 2 has a cylindrically hollow central portion, at which a bearing portion 2b (shown in FIG. 1 alone) is provided. A discharge port 2c is formed in approximately the central portion of the frame 2.
• (3) Cylinder Head 3: The cylinder head 3 has a longitudinal section approximately in the shape of a letter T (refer to FIG. 1). A portion of the cylinder head 3 contacting the cylinder 1 is approximately in the shape of a disk, and closes the other opening portion (on the lower side of the cylinder 1 in FIG. 2) of the cylinder 1. A vane aligner holding portion 3a, which is in the shape of a ring groove being concentric with the inner peripheral surface 1b of the cylinder 1, is formed in an end surface of the cylinder head 3 on the side of the cylinder 1. The vane aligners 6 and 8 are fitted in this vane aligner holding portion 3a. The cylinder head 3 has a cylindrically hollow central portion, at which a bearing portion 3b (shown in FIG. 1 alone) is provided.
• (4) Rotor Shaft 4: The rotor shaft 4 has a structure in which a rotor portion 4a, upper and lower rotary shaft portions 4b and 4c are unitarily formed. The rotor portion 4a rotates inside the cylinder 1 about a central axis that is eccentric to the central axis of the inner peripheral surface 1b of the cylinder 1. The rotary shaft portions 4b and 4c are respectively supported by the bearing portion 2b of the frame 2 and the bearing portion 3b of the cylinder head 3. Bush holding portions 4d and 4e and vane relief portions 4f and 4g each having an approximately circular cross-section and penetrating in the axial direction are formed in the rotor portion 4a. The bush holding portion 4d and the vane relief portion 4f are communicated, and the bush holding portion 4e and the vane relief portion 4g are communicated. The bush holding portion 4d and the bush holding portion 4e are disposed at substantially symmetrical positions, and the vane relief portion 4f and the vane relief portion 4g are disposed at substantially symmetrical positions (refer to FIG. 4 as well, which will be described later).
• (5) Vane Aligners 5, 6, 7 and 8: Each of the vane aligners 5, 6, 7 and 8 is a partial-ring-shaped component. A vane holding portion 5a, which is a quadrangular plate-like projection, is installed upright on one of axial end surfaces of the vane aligner 5. A vane holding portion 6a, which is a quadrangular plate-like projection, is installed upright on one of axial end surfaces of the vane aligner 6. A vane holding portion 7a, which is a quadrangular plate-like projection, is installed upright on one of axial end surfaces of the vane aligner 7. A vane holding portion 8a, which is a quadrangular plate-like projection, is installed upright on one of axial end surfaces of the vane aligner 8. Each of the vane holding portions 5a, 6a, 7a, and 8a is formed in the normal direction of the circular arc of the partial ring (refer to FIG. 3). As shown in FIG. 3, α is the angle of the circular arc constituting the partial ring of each of the vane aligners 5, 6, 7 and 8.
• (6) First Vane 9: The first vane 9 is in the shape of an approximately quadrangular plate. A tip portion 9a located on the side of the inner peripheral surface 1b of the cylinder 1 is formed into a circular arc shape facing outward, and the radius of the circular arc shape is formed to be approximately equal to the radius of the inner peripheral surface 1b of the cylinder 1. Slit-like back side grooves 9b are formed in the back side of the first vane 9 which is opposite to the inner peripheral surface 1b of the cylinder 1, over the fitting length of the vane holding portion 5a of the vane aligner 5 and over the fitting length of the vane holding portion 6a of the vane aligner 6. The back side grooves 9b may be provided as one over the entire axial length of the first vane 9.
• (7) Second Vane 10: The second vane 10 is in the shape of an approximately quadrangular plate. A tip portion 10a located on the side of the inner peripheral surface 1b of the cylinder 1 is formed into a circular arc shape facing outward, and the radius of the circular arc shape is formed to be approximately equal to the radius of the circle formed by the inner peripheral surface 1b of the cylinder 1. Slit-like back side grooves 10b are formed in the back side of the second vane 10 which is opposite to the inner peripheral surface 1b of the cylinder 1, over the fitting length of the vane holding portion 7a of the vane aligner 7 and over the fitting length of the vane holding portion 8a of the vane aligner 8. The back side grooves 10b may be provided as one over the entire axial length of the second vane 10.
• (8) Bushes 11 and 12: A pair of the bushes 11 are each formed into an approximately semicolumnar shape. The pair of the approximately semicolumnar bushes 11 are fitted in the bush holding portion 4d of the rotor shaft 4. The plate-like first vane 9 is held inside the bushes 11 so that the first vane 9 may rotate and move in an approximately centrifugal direction (centrifugal direction from the center of the inner peripheral surface 1b of the cylinder 1) with respect to the rotor portion 4a. A pair of the bushes 12 are each formed into an approximately semicolumnar shape. The pair of the approximately semicolumnar bushes 12 are fitted in the bush holding portion 4e of the rotor shaft 4. The plate-like second vane 10 is held inside the bushes 12 so that the second vane 10 may rotate and move in the approximately centrifugal direction (centrifugal direction from the center of the inner peripheral surface 1b of the cylinder 1) with respect to the rotor portion 4a.

The vane holding portions 5a and 6a of the vane aligners 5 and 6 are fitted in the back side grooves 9b of the first vane 9, and the vane holding portions 7a and 8a of the vane aligners 7 and 8 are fitted in the back side grooves 10b of the second vane 10. The directions of the first vane 9 and the second vane 10 are thereby restricted such that the normal to the circular arc formed by the tip of each of the first vane 9 and the second vane 10 and the normal to the inner peripheral surface 1b of the cylinder 1 are constantly approximately coincident with each other.

Operations will now be described. The rotary shaft portion 4b of the rotor shaft 4 receives rotative power from a driving portion of the electric motor element 102 or the like (or engine in the case of the engine-driven type), so that the rotor portion 4a rotates in the cylinder 1. Along with rotation of the rotor portion 4a, the bush holding portions 4d and 4e disposed in the vicinity of the outer periphery of the rotor portion 4a move on the circumference of a circle centering on the rotary shaft portion 4b of the rotor shaft 4. Then, the pair of bushes 11 held in the bush holding portion 4d and the pair of bushes 12 held in the bush holding portion 4e, the first vane 9 rotatably held in the pair of bushes 11, and the second vane 10 rotatably held in the pair of bushes 12 also rotate together with the rotor portion 4a.

The plate-like vane holding portion 5a (projecting portion) of the partial-ring-shaped vane aligner 5 and the plate-like vane holding portion 6a (projecting portion) of the partial-ring-shaped vane aligner 6 are slidably fitted in the back side grooves 9b formed in the back side of the first vane 9, so that the orientation of the first vane 9 (the vane longitudinal orientation) is restricted approximately in the normal direction of the inner peripheral surface 1b of the cylinder 1. The vane aligner 5 is rotatably fitted in the vane aligner holding portion 2a (in FIG. 1) that is formed in the end surface of the frame 2 on the side of the cylinder 1, being concentric with the inner peripheral surface 1b of the cylinder 1. The vane aligner 6 is rotatably fitted in the vane aligner holding portion 3a (in FIGS. 1 and 2) that is formed in the end surface of the cylinder head 3 on the side of the cylinder 1, being concentric with the inner peripheral surface 1b of the cylinder 1.

The plate-like vane holding portion 7a (projecting portion) of the partial-ring-shaped vane aligner 7 and the plate-like vane holding portion 8a (projecting portion) of the partial-ring-shaped vane aligner 8 are slidably fitted in the back side grooves 10b formed in the back side of the second vane 10, so that the orientation of the second vane 10 (the vane longitudinal orientation) is restricted approximately in the normal direction of the inner peripheral surface 1b of the cylinder 1. The vane aligner 7 is rotatably fitted in the vane aligner holding portion 2a (in FIG. 1) that is formed in the end surface of the frame 2 on the side of the cylinder 1, being concentric with the inner peripheral surface 1b of the cylinder 1. The vane aligner 8 is rotatably fitted in the vane aligner holding portion 3a (in FIGS. 1 and 2) that is formed in the end surface of the cylinder head 3 on the side of the cylinder 1, being concentric with the inner peripheral surface 1b of the cylinder 1.

The first vane 9 is pressed in the direction of the inner peripheral surface 1b of the cylinder 1 due to a pressure difference between the tip portion 9a and the back side grooves 9b (when the vane compressor 200 has a structure in which the refrigerant of a high pressure or an intermediate pressure is guided to a back side space of the first vane 9), a spring (not shown), a centrifugal force, or the like. Then, the tip portion 9a of the first vane 9 slides along the inner peripheral surface 1b of the cylinder 1. During this sliding of the tip portion 9a, the radius of the circular arc formed by the tip portion 9a of the first vane 9 is approximately equal to the radius of the inner peripheral surface 1b of the cylinder 1, and the normal to the circular arc formed by the tip portion 9a of the first vane 9 and the normal to the inner peripheral surface 1b of the cylinder 1 are substantially coincident with each other. Thus, a sufficient oil film is formed between the tip portion 9a of the first vane 9 and the inner peripheral surface 1b of the cylinder 1 to produce a fluid lubrication state. The same also holds true for the second vane 10.

The compression principle of the vane compressor 200 in this embodiment is approximately similar to that of a conventional vane compressor. FIG. 4 is a diagram showing the first embodiment, and is a plan view (90-degree rotation angle) of the compression element 101 of the vane compressor 200. In FIG. 4, O is the rotational central axis of the rotor shaft 4, Oc is the central axis of the inner peripheral surface 1b of the cylinder, A is a point where the rotor portion 4a of the rotor shaft 4 and the inner peripheral surface 1b of the cylinder 1 are closest (which is the closest point A), B and C are respectively rotational central axes of the bushes 11 and 12. D is a point at which the tip portion 9a of the first vane 9 slides on the inner peripheral surface 1b of the cylinder 1.

Further, the first vane 9 slides on the inner peripheral surface 1b of the cylinder 1 at one location, and the second vane 10 slides on the inner peripheral surface 1b of the cylinder 1 at one location. Three spaces (which are a suction chamber 13, an intermediate chamber 14, and a compression chamber 15) are thereby formed in the cylinder 1. The suction port 1a (communicated with a low-pressure side of the refrigerating cycle) is open to the suction chamber 13. The compression chamber 15 is communicated with the discharge port 2c (which is formed in the frame 2, for example, but which may be formed in the cylinder head 3) that is closed by a discharge valve not shown except when discharging is performed. The intermediate chamber 14 is communicated with the suction port 1a up to a certain rotation angle range. Then, there is a rotation angle range where the intermediate chamber 14 is communicated with none of the suction port 1a and the discharge port 2c. Thereafter, the intermediate chamber 14 is communicated with the discharge port 2c.

FIG. 5 includes diagrams showing the first embodiment. FIG. 5 shows plan views of the compression element 101 illustrating a compression operation of the vane compressor 200. Referring to FIG. 5, a description will be given of how volumes of the suction chamber 13, the intermediate chamber 14, and the compression chamber 15 change along with rotation of the rotor shaft 4. First, referring to FIG. 5, a rotation angle at which the closest point where the rotor portion 4a of the rotor shaft 4 and the inner peripheral surface 1b of the cylinder 1 are closest (shown in FIG. 4) coincides with the location where the first vane 9 slides on the inner peripheral surface 1b of the cylinder 1 is defined as “0-degree angle”. FIG. 5 shows positions of the first vane 9 and the second vane 10 at the “0-degree angle”, “45-degree angle”, the “90-degree angle”, and “135-degree angle” and states of the suction chamber 13, the intermediate chamber 14, and the compression chamber 15 at those angles. The single-line arrow shown in the “0-degree angle” diagram of FIG. 5 indicates the rotation direction of the rotor shaft 4 (clockwise direction in FIG. 5). The arrow indicating the rotation direction of the rotor shaft 4 is omitted in the other diagrams. The reason why states at “180-degree angle” and more are not shown is that, at the “180-degree angle”, positions of the first vane 9 and the second vane 10 are exchanged from those of the first vane 9 and the second vane 10 at the “0-degree angle”, and then the compression operation is performed in the same manner as that at the rotation angles from the “0-degree angle” to the “135-degree angle”.

The suction port 1a is provided between the closest point A and a point D (shown in FIG. 4) where the tip portion 9a of the first vane 9 slides on the inner peripheral surface 1b of the cylinder 1 at the “90-degree angle” (e.g., at a location of approximately 45 degrees). The suction port 1a opens in the range from the closest point A to the point D. The suction port 1a is just denoted as “suck” in FIGS. 4 and 5.

The discharge port 2c is located in the vicinity of and at a predetermined distance leftward from the closest point A where the rotor portion 4a of the rotor shaft 4 and the inner peripheral surface 1b of the cylinder 1 are closest (e.g., at a location of approximately 30 degrees). The discharge port 2c is just denoted as “discharge” in FIGS. 4 and 5.

At the “0-degree angle” in FIG. 5, a right side space closed off by the closest point A and the second vane 10 is the intermediate chamber 14 and is communicated with the suction port 1a to suck in gas (refrigerant). A left side space closed off by the closest point A and the second vane 10 is the compression chamber 15 communicated with the discharge port 2c.

At the “45-degree angle” in FIG. 5, a space closed off by the first vane 9 and the closest point A is the suction chamber 13. The intermediate chamber 14 closed off by the first vane 9 and the second vane 10 is communicated with the suction port 1a, and the volume of the intermediate chamber 14 increases from that at the “0-degree angle”. Thus, the intermediate chamber 14 continues to suck in the gas. A space closed off by the second vane 10 and the closest point A is the compression chamber 15, and the volume of the compression chamber 15 is reduced from that at the “0-degree angle”. The refrigerant is therefore compressed, so that the pressure of the refrigerant gradually increases.

At the “90-degree angle” in FIG. 5, the tip portion 9a of the first vane 9 overlaps with the point D on the inner peripheral surface 1b of the cylinder 1. Thus, the intermediate chamber 14 is not communicated with the suction port 1a. This ends suction of the gas in the intermediate chamber 14. In this state, the volume of the intermediate chamber 14 reaches its approximately maximum level. The volume of the compression chamber 15 is further reduced from that at the “45-degree angle”. The refrigerant is therefore compressed, so that the pressure of the refrigerant increases. The volume of the suction chamber 13 increases from that at the “45-degree angle”, an the suction chamber 13 continues to suck in the gas.

At the “135-degree angle” in FIG. 5, the volume of the intermediate chamber 14 is reduced from that at the “90-degree angle”. The refrigerant is therefore compressed, so that the pressure of the refrigerant increases. The volume of the compression chamber 15 is also reduced from that at the “90-degree angle”. The refrigerant is therefore compressed, so that the pressure of the refrigerant increases. The volume of the suction chamber 13 increases from that at the “90-degree angle”. The suction chamber 13 therefore continues to suck in the gas.

Then, the second vane 10 approaches the discharge port 2c. When the pressure of the compression chamber 15 exceeds the high pressure (including a pressure necessary for opening the discharge valve not shown) of the refrigerating cycle, the discharge valve opens, so that the refrigerant in the compression chamber 15 is discharged in the hermetic container 103.

When the second vane 10 passes by the discharge port 2c, a small quantity of the high pressure refrigerant remains (becomes a loss) in the compression chamber 15. Then, when the compression chamber 15 disappears at the “180-degree angle” (not shown), this high pressure refrigerant changes to a low pressure refrigerant in the suction chamber 13. At the “180-degree angle”, the suction chamber 13 transitions to the intermediate chamber 14, and the intermediate chamber 14 transitions to the compression chamber 15. The compression operation is thereafter repeated.

As described above, the volume of the suction chamber 13 gradually increases due to rotation of the rotor shaft 4, so that the suction chamber 13 continues to suck in the gas. The suction chamber 13 thereafter transitions to the intermediate chamber 14. The volume of the intermediate chamber 14 gradually increases partway through the process of sucking in the gas, so that the intermediate chamber 14 continues to suck in the gas. Partway through the process of sucking in the gas, the volume of the intermediate chamber 14 reaches its maximum, and then the intermediate chamber 14 is not communicated with the suction port 1a. Suction of the gas in the intermediate chamber 14 is then finished. The volume of the intermediate chamber 14 thereafter gradually decreases, so that the gas is compressed. Then, the intermediate chamber 14 transitions to the compression chamber 15. The compression chamber 15 then continues to compress the gas. The gas, which has been compressed to a predetermined pressure, is discharged from a discharge port (e.g., the discharge port 2c (FIG. 2)) formed in the portion of the cylinder 1, the frame 2 or the cylinder head 3 opening to the compression chamber 15.

FIG. 6 includes diagrams showing the first embodiment, which are plan views illustrating rotation operations of the vane aligners 6 and 8 in the vane aligner holding portion 3a. The single-line arrow shown in the “0-degree angle” diagram of FIG. 6 indicates the rotation direction of the vane aligners 6 and 8 (clockwise direction in FIG. 6). The arrow indicating the rotation direction of the vane aligners 6 and 8 is omitted in the other diagrams. Due to rotation of the rotor shaft 4, the first vane 9 and the second vane 10 rotate about the central axis Oc of the inner peripheral surface 1b of the cylinder (in FIG. 5). The vane aligners 6 and 8 fitted with the first vane 9 and the second vane 10 thereby also rotate about the central axis Oc of the inner peripheral surface 1b of the cylinder 1, in the vane aligner holding portion 3a, as shown in FIG. 6. An operation similar to this operation is performed by the vane aligner 5 and the vane aligner 7 as well, which rotate in the vane aligner holding portion 2a.

In the above configuration, as is clear from FIG. 6, the vane aligner 6 and the vane aligner 8 rotate while changing their relative positions, and the circumferential ends of the vane aligner 6 and the vane aligner 8 come closest to each other on the side of the closest point A at the “90-degree angle”. This is because an angle φ (∠BOcC) between the first vane 9 and the second vane 10 on the side of the closest point A becomes smallest in FIG. 4 (at the 90-degree angle).

Thus, it is necessary to determine the angle α (shown in FIG. 3) of the circular arc constituting the partial ring of each of the vane aligners 5, 6, 7, and 8 in view of movements of the first vane 9, the second vane 10, and the vane aligners 5, 6, 7, and 8. When the angle α is set to be too large, the vane aligners are likely to contact with each other.

The angle φ between the first vane 9 and the second vane 10 on the side of the closest point A is obtained based on FIG. 4. In FIG. 4, where e is a distance between the point O and the point Oc and R is a distance between the point O and the point B, the angle φ is given by Equation (2).

$\begin{array}{cc}\left[\mathrm{Equation}2\right]& \\ \phi =2{\tan }^{-1}\left(\frac{R}{e}\right)& \left(2\right)\end{array}$

FIG. 7 is a diagram showing the first embodiment, and is a plan view (90-degree angle) showing positional relationships between the vanes and the vane aligners in the vane compressor 200. FIG. 7 shows a relationship between the angle α of the circular arc constituting the partial ring of each of the vane aligners 6 and 8 and the angle φ between the first vane 9 and the second vane 10 on the side of the closest point A at the “90-degree angle”. As is clear from the drawing, when the angle α of the circular arc constituting the partial ring of each of the vane aligners 6 and 8 is smaller than the angle φ, the vane aligners 6 and 8 can operate without contacting with each other during rotation. Thus, it is necessary to set the angle α of the circular arc constituting the partial ring of each of the vane aligners 6 and 8 to that given by the following Equation (3):

$\begin{array}{cc}\left[\mathrm{Equation}3\right]& \\ \alpha <2{\tan }^{-1}\left(\frac{R}{e}\right)& \left(3\right)\end{array}$

The above explanation may also be similarly applied to the vane aligners 5 and 7.

In this embodiment, a mechanism where the vanes (which are the first vane 9 and the second vane 10) rotate about the center of the cylinder 1, the mechanism being necessary for performing a compression operation such that the normal to the circular arc formed by each of the tip portion 9a of the first vane 9 and the tip portions 10a of the second vane 10, and the normal to the inner peripheral surface 1b of the cylinder 1 are constantly approximately coincident with each other, is implemented by a structure in which the rotary shaft portions 4b and 4c are unitarily formed with the rotor portion 4a. The mechanism is implemented without using, for the rotor portion 4a, end plates that may degrade precision of the outer diameter or the rotation center of the rotor portion 4a. That is, a pair of the partial-ring-shaped vane aligners 5 and 6 are fitted with and attached to both ends of the first vane 9 such that the center line of the first vane 9 passes through the central axis of the circular arc constituting the partial ring shape of each of the pair of the vane aligners 5 and 6. A pair of the partial-ring-shaped vane aligners 7 and 8 are fitted with and attached to both ends of the second vane 10 such that the center line of the second vane 10 passes through the central axis of the circular arc constituting the partial ring shape of each of the pair of the vane aligners 7 and 8. Then, the vane aligners 5 and 7 are fitted in the vane aligner 2a, which is the ring-shaped groove being concentric with the inner peripheral surface 1b of the cylinder 1 and being provided in the end surface of the frame 2 on the side of the cylinder 1. The vane aligners 6 and 8 are fitted in the vane aligner 3a, which is the ring-shaped groove being concentric with the inner peripheral surface 1b of the cylinder 1 and being provided in the end surface of the cylinder head 3 on the side of the cylinder 1. Then, the angle α of the circular arc constituting the partial ring shape of each of the vane aligners 5, 6, 7, and 8 is set to be smaller than a predetermined angle. With this arrangement, a stable operation such that the vane aligners 5 and 7 or the vane aligners 6 and 8 are unlikely to cause a damage or the like by getting contact with each other can be achieved. Bearing sliding loss can be reduced by supporting the rotary shaft portions 4b and 4c by the bearing portions 2b and 3b each having a small diameter. Further, the precision of the outer diameter or the rotation center of the rotor portion 4a is improved. A space formed between the rotor portion 4a and the inner peripheral surface 1b of the cylinder 1 can be thereby narrowed to reduce gas leakage loss. Thus, there is an effect of obtaining the vane compressor 200 with a high efficiency and high reliability.

In this embodiment, the vane holding portions 5a, 6a, 7a, and 8a are respectively provided approximately at the central portions of the vane aligners 5, 6, 7, and 8, as shown in FIG. 3. The vane holding portions 5a, 6a, 7a, and 8a do not need to be provided at the central portions of the vane aligners 5, 6, 7, and 8, respectively, if the vane holding portions 5a, 6a, 7a and 8a are attached to the vane aligners 5, 6, 7, and 8 such that the center line of each of the vanes (which are the first vane 9 and the second vane 10) passes through approximately the center axes of the circular arcs constituting the partial ring shapes of corresponding ones of the vane aligners 5, 6, 7, and 8. When the angle α of the circular arc constituting the partial ring shape of each of the vane aligners 5, 6, 7, and 8 satisfies Equation (3), the vane aligners 5 and 7 and the vane aligners 6 and 8 may operate without contacting with each other during rotation.

In this embodiment, the vane aligner holding portions 2a and 3a formed in the frame 2 and the cylinder head 3 are shaped into ring grooves. The vane aligners 5, 6, 7, and 8 slide on cylindrical surfaces on the outer peripheral sides of the ring grooves. The vane aligner holding portions 2a and 3a therefore do not necessarily need to be in the shape of the ring grooves. The vane aligner holding portions 2a and 3a may be concave portions with grooves each having an outer diameter substantially equal to the outer diameter of each of the vane aligners 5, 6, 7, and 8.

Though not shown in the drawings, it is also possible to further reduce the sliding resistances of the vane tip portions by applying to the configuration of this embodiment a conventional technique. In this conventional technique, a pressure to be acted on the back side of each vane is controlled, thereby reducing a pressing force between the vane tip portions and the inner peripheral surface of the cylinder.

This embodiment shows a method of restricting the directions of the first vane 9 and the second vane 10 by fitting the vane holding portions 5a, 6a, 7a, and 8a of the vane aligners 5, 6, 7, and 8 in the back side grooves 9b of the first vane 9 and the back side grooves 10b of the second vane 10. The vane holding portions 5a, 6a, 7a, and 8a, the back side grooves 9b of the first vane 9, and the back side grooves 10b of the second vane 10 each include a thin-walled portion.

Since the vane holding portions 5a, 6a, 7a, and 8a are the quadrangular plate-like projections as shown in FIG. 2, the vane holding portions 5a, 6a, 7a, and 8athemselves are low in strength.

FIG. 8 is a diagram showing the first embodiment, and is a perspective view of each of the first vane 9 and the second vane 10. The first vane 9 includes thin-walled portions 9c at both sides of each back side groove 9b. The second vane 10 includes thin-walled portions 10c at both sides of each back side groove 10b.

Therefore, in order to apply the method of this embodiment, it is preferable that a refrigerant with a small force to be acted on the vanes (which are the first vane 9 and the second vane 10), that is, with a low operating pressure be used. The refrigerant with a normal boiling point of minus 45 degrees Celsius or higher is suitable. The refrigerant such as R600a (isobutane), R600 (butane), R290 (propane), R134a, R152a, R161, R407C, R1234yf, and R1234ze can be used without causing any problem in terms of the strength of the vane holding portions 5a, 6a, 7a, and 8a, the back side grooves 9b of the first vane 9, and the back side grooves 10b of the second vane 10.

In the above configuration, the projecting portions (which are the vane holding portions 5a, 6a, 7a, and 8a) are provided at the vane aligners 5, 6, 7, and 8, and the groove portions (which are the back-side grooves 9b and 10b) are provided in the vanes (which are the first vane 9 and second vane 10). Then, the vanes (which are the first vane 9 and the second vane 10) and the vane aligners 5, 6, 7, and 8 are fitted together. Projecting portions may be provided at the vanes (which are the first vane 9 and the second vane 10), and groove portions may be provided in the vane aligners 5, 6, 7, and 8 to fit together the vanes (which are the first vane 9 and the second vane 10) and the vane aligners 5, 6, 7, and 8.

FIG. 9 is a diagram showing a different example of the first embodiment, and is a perspective view of the second vane 10 and the vane aligner 8. Projecting portions 10d are provided at the second vane 10, in place of the back side grooves 10b. A slit-like vane holding groove 8b is provided in the vane aligner 8, in place of the vane holding portion 8a, which is a plate-like projection. Though not illustrated, similarly, a slit-like vane holding groove 7b is provided in the vane aligner 7, in place of the vane holding portion 7a. Then, the projecting portions 10d provided at an end surface of the second vane 10 are fitted in the vane holding grooves 7b and 8b, thereby restricting the direction such that the normal to the circular arc formed by the tip portion 10a of the second vane 10 and the normal to the inner peripheral surface 1b of the cylinder 1 are constantly approximately coincident with each other. Alternatively, excessive movement of the second vane 10 in a direction opposite to the side of the inner peripheral surface 1b of the cylinder 1 may be restricted by closing, instead of opening, each of the vane holding groove 7b of the vane aligner 7 and the vane holding groove 8b of the vane aligner 8 on the internal diameter side. The same configuration may also be applied to the first vane 9 and the vane aligners 5 and 6.

In the above configuration, it is so arranged that the vanes (which are the first vane 9 and the second vane 10) are movable with respect to the vane aligners 5, 6, 7, and 8. The vane aligners 5 and 6 may be unitarily formed with one of the vanes (the first vane 9) and the vane aligners 7 and 8 may be unitarily formed with another one of the vanes (the second vane 10). FIG. 10 is a diagram showing a different example of the first embodiment, and is a diagram showing a structure in which the second vane 10 and the vane aligner 8 are unitarily formed. FIG. 10 shows the case where the second vane 10 and the vane aligner 8 are unitarily formed. Similarly, the second vane 10 and the vane aligner 7 may be unitarily formed. The same also holds true for the first vane 9 and the vane aligners 5 and 6. In this configuration, an approximately similar operation to that described above is performed. Movements of the first vane 9 and the second vane 10 in the rotor normal direction are, however, fixed. Consequently, the tip portion 9a of the first vane 9 and the tip portion 10a of the second vane 10 do not slide on the inner peripheral surface 1b of the cylinder 1, so that the first vane 9 and the second vane 10 rotate without contacting to and with maintaining a minute space from the inner peripheral surface 1b of the cylinder 1.

Second Embodiment

In the first embodiment, constraint of the angle α of the circular arc constituting the partial ring shape of each of the vane aligners 5, 6, 7, and 8 is given by Equation (3). The constraint is imposed not to let the vane aligners 5 and 7 or the vane aligners 6 and 8 contact with each other when the number of the vanes is two. In a second embodiment, when the number of vanes is an arbitrary number of two or more, an angle α of the circular arc constituting the partial ring shape of each of vane aligners is given not to let the vane aligners contact with each other.

FIG. 11 is a diagram showing the second embodiment, and is a plan view showing a positional relationship between the first vane 9 and an Nth vane 16. FIG. 11 shows states of two vanes (which are the first vane 9 and the Nth vane 16) in the vicinity of the closest point A when the number of the vanes is N (which is a natural number of two or more). Referring to FIG. 11, a bush 17 holds the Nth vane 16 so that the Nth vane 16 is rotatable with respect to the rotor portion 4a and movable in approximately the normal direction. B and C are respectively rotational central axes of the bushes 11 and 17, θ is a rotation angle of the rotor portion 4a, which is ∠AOB, φ is an angle between the first vane 9 and the Nth vane 16, which is ∠BOcC. Due to the geometric relationship in FIG. 11, a relationship expressed by the following Equation (4) holds between φ and θ:

$\begin{array}{cc}\left[\mathrm{Equation}4\right]& \\ \phi =2{\tan }^{-1}\left\{\frac{R\sin \left(\theta \right)}{R\cos \left(\theta \right)+e}\right\}& \left(4\right)\end{array}$

There is a relationship between θ and the number of the vanes expressed by the following Equation (5):

$\begin{array}{cc}\left[\mathrm{Equation}5\right]& \\ \theta =\frac{\pi }{N}& \left(5\right)\end{array}$

φ can be expressed by the following Equation (6) from Equations (4) and (5):

$\begin{array}{cc}\left[\mathrm{Equation}6\right]& \\ \phi =2{\tan }^{-1}\left\{\frac{R\sin \left(\frac{\pi }{N}\right)}{R\cos \left(\frac{\pi }{N}\right)+e}\right\}& \left(6\right)\end{array}$

When the angle α of the circular arc constituting the partial ring of each vane aligner is smaller than the angle φ, irrespective of the number of the vanes, the vane aligners can operate without contacting with each other during rotation. Thus, the angle α of the circular arc constituting the partial ring of each vane aligner needs to satisfy Equation (1) when the number of the vanes is N.

$\begin{array}{cc}\left[\mathrm{Equation}7\right]& \\ \alpha <2{\tan }^{-1}\left\{\frac{R\sin \left(\frac{\pi }{N}\right)}{R\cos \left(\frac{\pi }{N}\right)+e}\right\}& \left(1\right)\end{array}$

In this embodiment, when the number of the vanes is N (which is an arbitrary number), the angle of the circular arc constituting the partial ring of each vane aligner is set such that the vane aligners do not contact with each other. A similar effect to that in the first embodiment can be therefore obtained.

REFERENCE SIGNS LIST

1: cylinder

1 a: suction port

1 b: inner peripheral surface

2: frame

2 a: vane aligner holding portion

2 b: bearing portion

2 c: discharge port

3: cylinder head

3 a: vane aligner holding portion

3 b: bearing portion

4: rotor shaft

4 a: rotor portion

4 b: rotary shaft portion

4 c: rotary shaft portion

4 d: bush holding portion

4 e: bush holding portion

4 f: vane relief portion

4 g: vane relief portion

5: vane aligner

5 a: vane holding portion

6: vane aligner

6 a: vane holding portion

7: vane aligner

7 a: vane holding portion

7 b: vane holding groove

8: vane aligner

8 a: vane holding portion

8 b: vane holding groove

9: first vane

9 a: tip portion

9 b: back side groove

9 c: thin-walled portion

10: second vane

10 a: tip portion

10 b: back side groove

10 c: thin-walled portion

10 d: projecting portion

11: bush

12: bush

13: suction chamber

14: intermediate chamber

15: compression chamber

16: Nth vane

17: bush

21: stator

22: rotor

23: glass terminal

24: discharge pipe

25: refrigerant oil

26: suction portion

101: compression element

102: electric motor element

103: hermetic container

200: vane compressor

Claims

1-3. (canceled)

4. A vane compressor comprising: an approximately cylindrical cylinder;a frame that closes one axial end of the cylinder;a cylinder head that closes the other axial end of the cylinder;a rotor shaft including a rotary shaft portion supported by the frame and the cylinder head and being eccentric to a center of an inner peripheral surface of the cylinder, and a rotor portion that rotates about the rotary shaft portion in the cylinder;vanes installed in the rotor portion and each having a tip portion that moves in the cylinder along with rotation of the rotor portion; anda partial-ring-shaped vane aligner attached to an end surface of each of the frame and the cylinder head on a side of the cylinder to rotate about an axis concentric with the inner peripheral surface of the cylinder, the vane aligners supporting the vanes such that the vanes are rotatable with respect to the rotor portion, whereinan angle α of a circular arc constituting a partial ring shape of the vane aligner satisfies a relationship of

5. The vane compressor according to claim 4, wherein a concave portion whose inner peripheral surface is concentric with the inner peripheral surface of the cylinder is formed in the end surface of each of the frame and the cylinder head on the side of the cylinder, andthe vane aligner is provided to slide along the inner peripheral surface of the concave portion of each of the frame and the cylinder head.

6. The vane compressor according to claim 5, wherein the concave portion of each of the frame and the cylinder head is a ring-shaped groove.

7. The vane compressor according to claim 4, wherein a bush holding portion penetrating axially is formed in the rotor portion,the vane compressor further comprising:a pair of approximately semicolumnar bushes inserted in the bush holding portion to support the vanes by sandwiching the vanes, whereinthe vane aligner supports the vanes such that the vanes are rotatable about a central axis of the bush holding portion.

8. The vane compressor according to claim 4, wherein the vane aligner supports axial ends of each of the vanes such that the tip portion of each of the vanes moves along the inner peripheral surface of the cylinder along with rotation of the rotor portion while maintaining a space between the tip portion of each of the vanes and the inner peripheral surface of the cylinder.

9. The vane compressor according to claim 4, wherein the vane aligner is unitarily attached to one of the vanes, or the vane aligner is unitarily formed with one of the vanes.

10. The vane compressor according to claim 4, wherein the tip portion of each of the vanes is a longitudinal tip portion of each of the vanes, andthe vane aligner supports the vanes such that each of the vanes is movable in a longitudinal direction of each of the vanes.

11. The vane compressor according to claim 10, wherein a concave portion or a convex portion is formed in each of axial ends of each of the vanes, anda convex portion fitted in the concave portion of each of the vanes or a concave portion in which the convex portion of each of the vanes is fitted is formed at one axial end of the vane aligner.

12. The vane compressor according to claim 4, wherein an outer peripheral surface of the tip portion of each of the vanes is formed to curve into a circular arc shape having approximately a same radius as the inner peripheral surface of the cylinder.

13. The vane compressor according to claim 4, the vane compressor compressing a refrigerant having a normal boiling point of minus 45 degrees Celsius or higher.