EP1775472A1

EP1775472A1 - Seal structure of compressor

Info

Publication number: EP1775472A1
Application number: EP05719891A
Authority: EP
Inventors: Hiroshi Valeo Thermal System Japan Corp. KANAI; Shunichi Valeo Thermal System Japan Corp FURUYA
Original assignee: Valeo Thermal Systems Japan Corp
Current assignee: Valeo Thermal Systems Japan Corp
Priority date: 2004-06-21
Filing date: 2005-03-03
Publication date: 2007-04-18
Also published as: JP2006002716A; WO2005124152A1; EP1775472A4

Abstract

The sealability in a compressor is improved without increasing the number of required parts and the number of assembly steps or increasing the dimensions of the compressor. In the compressor which includes an intake valve 11 and a valve plate 10 disposed adjacent to each other, a seal member 65 is formed through printing as an integrated part at least at either of contact surfaces 11a and 10a of the intake valve 11 and the valve plate 10 respectively. In addition, a lead portion 55 at the intake valve 11 is formed so that the lead portion 55 in a free state leans toward the valve plate 10 by an extent greater than the thickness d1 of the seal member 65 printed at the intake valve 11 and/or the valve plate 10.

Description

Technical Field

The present invention relates to a seal structure that may be adopted in a compressor used in an automotive air-conditioning system or the like.

Background Art

In a compressor in the related art, an intake valve 102 and a gasket 103 are held between a cylinder block 100 having formed therein a plurality of bores 104 and a valve plate 101 and the valve plate 101 and the intake valve 102 are set in tight contact with each other during the assembly process, as shown in FIG. 11. Since the valve plate 101 and the intake valve 102 are each normally constituted of metal, the seal between the valve plate 101 and the intake valve 102 is achieved by placing the metals constituting these members in tight contact with each other. In addition, an outlet valve 111 and a gasket 112 are held between the valve plate 101 and a rear head 110 having defined therein intake chambers 113 and an outlet chamber 114 and the valve plate 101 is set in tight contact with the outlet valve 111 during the assembly process, as shown in FIG. 12. As in the case of the seal between the intake valve 102 and the valve plate 101, the seal between the valve plate 101 and the outlet valve 111, each normally constituted of metal, is achieved by placing the metals constituting these members in tight contact with each other as well.
In a method disclosed in the related art for manufacturing gaskets used to prevent fluid leakage, a metal body to be coated is made to travel between the rotary screen surfaces facing opposite each other, each belonging to one of a pair of rotary screen coaters disposed so as to allow their rotary screen surfaces to rotate while facing opposite each other. In this method, as the metal body travels between the rotary screen surfaces facing opposite each other, an organic high polymer coating material is applied onto areas of the two surfaces of the metal body (see patent reference literature 1). This method is assumed to assure low-cost production of high-quality metal gaskets at a high line speed.
Patent reference literature 1: Japanese Unexamined Patent Publication No. H10-96473

Disclosure of the Invention

Problems to be Solved by the Invention

In the compressor in the related art shown in FIGS. 11 and 12, the seal between the valve plate 101 in the intake valve 102 is through tight metal-to-metal contact as described above and the level of the seal thus achieved tends to be insufficient, particularly between the bores 104, and coolant leakage occurs readily as indicated by the arrows in FIG. 11. Likewise, the level of seal between the valve plate 101 and the outlet valve 111 also tends to be insufficient, particularly between the intake chambers 113 and the outlet chamber 114, allowing the coolant to leak readily, as indicated by the arrows in FIG. 12. Such a leakage phenomenon is more pronounced in a compressor used in a refrigeration cycle in which a high-pressure coolant such as CO2 is used. While a gasket such as that disclosed in patent reference literature 1 may be inserted between the valve plate 101 and the intake valve 102 or between the valve plate 101 and the outlet valve 111 in order to address the problem described above, the solution will lead to increases in the number of required parts and the number of assembly steps and also an increase in the dimension of the compressor along the axial direction.
Accordingly, an object of the present invention is to improve sealability in a compressor without increasing the number of required parts and the number of assembly steps or increasing the dimensions of the compressor.

Means for Solving the Problems

The object described above is achieved in the present invention by providing a compressor that includes an intake valve and a valve plate disposed adjacent to each other, characterized in that a seal member is formed through printing as an integrated part at least at either of the contact surfaces of the intake valve and the valve plate (claim 1).
It is desirable that a lead portion of the intake valve be formed so that the lead portion in a free state leans toward the valve plate by an extent greater than the thickness of the seal member printed at the intake valve and/or the valve plate (claim 2).
In addition, assuming that the seal member is printed at the intake valve in the compressor according to claim 1 or claim 2, the seal member may be printed on both surfaces of the intake valve (claim 3).
It is desirable that assuming that the seal member is printed at the intake valve in the compressor according to any of claims 1 through 3, the seal member be not printed at a lead portion of the intake valve (claim 4).
The object described above is also achieved in the present invention by providing a compressor that includes an outlet valve and a valve plate disposed adjacent to each other, characterized in that a seal member is formed through printing as an integrated part at least at either of contact surfaces of the outlet valve and the valve plate (claim 5).
It is desirable that a lead portion of the outlet valve be formed so that the lead portion in a free state leans toward said valve plate by an extent greater than the thickness of the seal member printed at the outlet valve and/or the valve plate (claim 6).
In addition, assuming that the seal member is printed at the outlet valve in the compressor according to claim 5 or claim 6, the seal member may be printed on both surfaces of the outlet valve (claim 7).
It is desirable that assuming that the seal member is printed at the outlet valve in the compressor according to any of claims 5 through 7, the seal member be not printed at a lead portion of the outlet valve (claim 8).
Furthermore, it is desirable that assuming that the seal member is printed at the valve plate in the compressor according to any of claims 1 through 8, the seal member not be printed over an area of the valve plate facing opposite the lead portion of the intake valve and/or the lead portion of the outlet valve (claim 9).
It is also desirable that the seal member in the compressor according to any of claims 1 through 9 be printed through screen printing.
It is desirable that the seal member in the compressor according to claims 1 through 10 be an elastic film constituted of rubber or the like, so as to effectively prevent coolant leakage (claim 11).
Moreover, it is desirable that the structure disclosed in any of claims 1 through 11 be adopted in a compressor constituting part of a refrigeration cycle in which CO2 is used as a coolant (claim 12).

Effect of the Invention

The structure disclosed in claim 1 achieves a reliable seal at the contact surfaces of the intake valve and the valve plate, which are set in metal-to-metal contact in the related art without requiring a separate gasket. In addition, since the surface regularity of the contact surfaces of the valve plate and the intake valve does not need to be controlled as rigorously as in the related art, productivity can be improved.
The structure disclosed in claim 2 prevents formation of a gap between the lead portion of the intake valve and the valve plate during the assembly process.
The structure disclosed in claim 3 eliminates the need to use a gasket to seal the areas between the bores formed in the cylinder block.
The structure disclosed in claim 4, prevents the seal member from becoming worn as the lead portion at the intake valve opens/closes.
The structures disclosed in claims 5, 6 and 8 achieve advantages with regard to the relationship between the valve plate and the outlet valve, which are similar to the advantages achieved by adopting the structures according to claims 1 through 3 for the relationship between the valve plate and the intake valve. In addition, the structure disclosed in claim 7 eliminates the need to use a gasket to seal the areas between the intake chambers and the outlet chamber defined at the rear head.
The structure disclosed in claim 9 prevents a seal member printed on the valve plate side from becoming worn as the lead portion of the intake valve or the outlet valve opens/closes.
The structure disclosed in claim 10 assures efficient production of the product according to the present invention.
The structure disclosed in claim 11 reliably improves the sealability between the valve plate and the intake valve or between the valve plate and the outlet valve.
By adopting the structure disclosed in claim 12 in a compressor constituting part of a CO2 cycle engaged in operation under high pressure conditions, coolant leakage is effectively prevented and the compression efficiency is improved.

Brief Description of the Drawings

(FIG. 1) A sectional view showing the structure adopted in the compressor achieved in embodiment 1 of the present invention.
(FIG. 2) A partially enlarged sectional view of the structure adopted in the connecting area between the cylinder block and the rear head in embodiment 1.
(FIG. 3) An illustration showing how the valve plate and the intake valve are set in contact with each other.
(FIG. 4) The structures adopted in the valve plate and the intake valve in embodiment 1.
(FIG. 5) The structure adopted in the intake valve in embodiment 1 at the contact surface thereof, which is set in contact with the valve plate.
(FIG. 6) The structures adopted in the valve plate and the intake valve in embodiment 2.
(FIG. 7) The structure adopted in the valve plate in embodiment 2 at the contact surface thereof, which is set in contact with the intake valve.
(FIG. 8) The structures adopted in the valve plate and the outlet valve in embodiment 3.
(FIG. 9) The structures adopted in the valve plate and the outlet valve in embodiment 4.
(FIG. 10) A partially enlarged sectional view of the structure adopted in the connecting area between the cylinder block and the rear head in embodiment 5.
(FIG. 11) The structures adopted in the valve plate and the intake valve in a compressor in the related art.
(FIG. 12) The structures adopted in the valve plate and the outlet valve in a compressor in the related art.

Explanation of Reference Numerals

1: compressor
2: cylinder block
3: front head
4: rear head
10: valve plate
10a: contact surface (to contact the intake valve)
10b: contact surface (to contact the outlet valve)
11: intake valve
11a: contact surface (to contact the valve plate)
12: outlet valve
12a: contact surface (to contact the valve plate)
13, 14: gasket
20: bore
21: compression space
25: intake chamber
26: outlet chamber
41, 47, 60: intake port
42, 48, 56: outlet port
45: communicating hole
50: intake passage
51: outlet passage
55: (intake valve) lead portion
59: (outlet valve) lead portion
65, 66, 68, 70, 75, 76, 77, 78: elastic film (seal member)

Best Mode for Carrying Out the Invention

The following is an explanation of the embodiments of the present invention, given in reference to the attached drawings.

Embodiment 1

A compressor 1 in FIG. 1, constituting part of a refrigeration cycle in an automotive air-conditioning system in which CO2 is used as a coolant, comprises a cylinder block 2, a front head 3, a rear head 4, a drive shaft 5, a swashplate mechanism 6, pistons 7, a valve plate 10, an intake valve 11, an outlet valve 12 and the like.
The cylinder block 2 is a substantially cylindrical member with a plurality of bores 20 arrayed circumferentially. Inside each bore 20, a compression space 21 where the coolant is compressed is formed. The front head 3 is a member that seals off one end surface of the cylinder block 2, with and the front head 3 in the embodiment is mounted so as to cover the cylinder block 2. The rear head 4 with intake chambers 25 and an outlet chamber 26 formed therein seals off another end surface of the cylinder block 2, with the intake chambers 25 separated from the outlet chamber 26 by a barrier wall 27. The drive shaft 5 is a member assuming a substantially rod-like shape. It is rotatably held at bearings 30 and 31 and a seal member 32 disposed at the cylinder block 2 and the front head 3, and its portion 5a projecting beyond the front head 3 is connected to a pulley 33 that is caused to rotate by a drive source such as an engine or a motor. The pulley 33 is rotatably fitted on the outside of a boss portion 3a of the front head 3 via a bearing 34. The swashplate mechanism 6, which is disposed inside the crankcase 35 defined by the front head 3 and the cylinder block 2, includes a swashplate 36, shoes 37, an angle adjustment mechanism 38, a thrust flange 39 and the like. It converts the rotational force of the drive shaft 5 to a reciprocal motion of the pistons 7 and the angle of the swashplate 36 is adjusted in conformance to predetermined conditions. The pistons 7 are each linked to the shoes 37 so as to be allowed to move reciprocally and are also each slidably fitted inside one of the bores 20.
As shown in FIG. 2, a gasket 13, the intake valve 11, the valve plate 10, the outlet valve 12 and a gasket 14 disposed in this order starting from the cylinder block side are held between the cylinder block 2 and the rear head 4. The gaskets 13 and 14 are of the known art, each formed by covering the two surfaces of a metal plate with rubber or the like. At the gasket 13, communicating holes 45 communicating between the compression spaces 21 and the intake chambers 25 and the outlet chamber 26, are formed, whereas intake ports 47 each constituting part of an intake passage 50 communicating between the intake chambers 25 and the compression spaces 21 and holes 48 large enough to house retainers 61 are formed at the gasket 14. The gasket 13 disposed between the cylinder block 2 and the intake valve 11 prevents the coolant from leaking over the areas between the individual compression spaces 21 (bores 20) and the areas between the compression spaces 21 and the outside (atmosphere side), whereas the gasket 14 disposed between the outlet valve 12 and the rear head 4 prevents the coolant from leaking over the areas between the intake chambers 25 and the outlet chamber 26 and also over the areas between the intake chambers 25 and the atmosphere side.
At the valve plate 10, which is a disk-shaped member constituted of metal, intake ports 41 each constituting part of one of the intake passages 50 and outlet ports 42 each constituting part of an outlet passage 51 communicating between a compression space 21 and the corresponding outlet chamber 26 are formed. The valve plate 10 is disposed adjacent to the intake valve 11 and the outlet valve 12.
The intake valve 11 is constituted with a metal plate having formed therein lead portions 55 each used for opening/closing the corresponding intake passage 50 and outlet ports 56 each constituting part of one of the outlet passages 51. The intake valve 11 is disposed adjacent to the gasket 13 and the valve plate 10. The lead portions 55 at the intake valve 11 become displaced in correspondence to the difference between the pressure in the compression spaces 21 which changes as the pistons 7 slide and the pressure in the intake chambers 25. As the lead portions curve toward the cylinder block 2, the intake passages 50 are opened and as they come in contact with the valve plate 10, the intake passages 50 are closed.
The outlet valve 12 is constituted with a metal plate having formed therein lead portions 59 each used for opening/closing the corresponding outlet passage 51 and intake ports 60 each constituting part of one of the intake passages 50. The outlet valve 12 is disposed adjacent to the valve plate 10 and the gasket 14. The lead portions 59 at the outlet valve 12 become displaced in correspondence to the difference between the pressure in the compression spaces 21 which changes as the pistons 7 slide and the pressure in the outlet chamber 26. As the lead portions curve toward the rear head 4, the outlet passages 51 are opened and as they come in contact with the valve plate 10, the outlet passages 51 are closed. In addition, a retainer 61 which regulates the displacement of the lead portion 59 into an open state is installed within each outlet chamber 26.
As shown in FIG. 3, the valve plate 10 and the intake valve 11 are set so as to place their contact surfaces 10a and 11 a in contact with each other (FIG. 3 does not include an illustration of the gasket 13 inserted between the cylinder block 2 and the intake valve 11). An elastic film (seal member) 65 is formed through printing at the contact surface 11 a of the intake valve 11 as an integrated part thereof in the embodiment, as shown in FIGS. 4 and 5. The elastic film 65 is formed by coating the surface (contact surface 11 a) of the intake valve 11 constituted with a metal plate with a thin film constituted of rubber (high polymer) or the like through screen printing. In addition, the elastic film 65 is not printed over the areas where the lead portions 55 are formed, i.e., over the moving portion, as shown in FIG. 5. Also, as shown in FIG. 4, the lead portions 55 in a free state assumes a shape leaning toward the valve plate. 10, and are designed so as to satisfy a relationship expressed as d2 > d1 with d1 representing the thickness of the elastic film 65 and d2 representing the extent to which the lead portions 55 lean toward the valve plate. It is desirable that the thickness d1 be approximately 0.1 mm.
In the compressor 1 achieved in the embodiment described above, having the elastic film 65 constituted of rubber or the like formed through screen printing as an integrated part of the contact surface 11a of the intake valve 11, which comes in contact with the valve plate 10, the contact surfaces of the intake valve 11 and the valve plate 10 sealed through metal to metal contact in the related art, can be sealed with a higher level of reliability without requiring a separate gasket. In addition, since the surface profile regularity at the metal surfaces (contact surfaces 10a and 11a) at the valve plate 10 and the intake valve 11 does not need to be controlled as rigorously as in the related art, productivity can be improved. Since the elastic film 65 is not formed over the lead portions 55 at the intake valve 11, the elastic film 65 does not become worn as the lead portions 55 are displaced. Moreover, since the lead portions 55 in the free state lean toward the valve plate 10, no gap is formed between the lead portions 55 and the valve plate 10 during the assembly process.

Embodiment 2

In the following explanation of other embodiments of the present invention given in reference to the drawings, the same reference numerals are assigned to components identical to those in embodiment 1 described above to preclude the necessity for a repeated explanation thereof. In embodiment 2, shown in FIGS. 6 and 7, an elastic film 66 constituted of rubber or the like is formed through screen printing as an integrated part of the contact surface 10a of the valve plate 10 which comes in contact with the intake valve 11. The elastic film 66 is not printed over an area 67, which faces opposite the corresponding lead portion 55 of the intake valve 11, as shown in FIG. 7. In addition, as shown in FIG. 6, the lead portions 55 in the free state lean toward the valve plate 10, and are designed so as to achieve a relationship expressed as d2 > d1 with d1 representing the thickness of the elastic film 66 and d2 representing the extent to which the lead portions 55 lean toward the valve plate. As a result, advantages similar to those of the embodiment 1 are achieved.

Embodiment 3

In the structure achieved in embodiment 3 in FIG. 8, the intake chambers 25 are defined toward the center within the rear head 4, the outlet chamber 26 is defined further toward the outside and an elastic film 68 constituted of rubber or the like is formed through screen printing as an integrated part of the contact surface 12a of the outlet valve 12, which comes in contact with the valve plate 10. The elastic film 68 is not printed over the lead portions 59 at the outlet valve 12. In addition, the lead portions 59 in the free state lean toward the valve plate 10, and are designed so as to achieve a relationship expressed as d2 > d1 with d 1 representing the thickness of the elastic film 68 and d2 representing the extent to which the lead portions 59 lean toward the valve plate. As a result, the contact surfaces of the valve plate 10 in the outlet valve 12, sealed through metal to metal contact in the related art, can be sealed with a higher level of reliability without using a separate gasket. In addition, since the surface profile regularity at the metal surfaces (contact surfaces 10b and 12a) at the valve plate 10 and the outlet valve 12 does not need to be controlled as rigorously compared to the related art, the productivity can be improved. Since the elastic film 68 is not formed over the lead portions 59 at the outlet valve 12, the elastic film 68 does not become worn as the lead portions 59 are displaced. Moreover, since the lead portions 59 in the free state lean toward the valve plate 10, no gap is formed between the lead portions 59 and the valve plate 10 during the assembly process.

Embodiment 4

In the structure achieved in embodiment 4 in FIG. 9, the intake chambers 25 and the outlet chamber 26 are each disposed at positions identical to those assumed in embodiment 3 and an elastic film 70 constituted of rubber or the like is formed through screen printing as an integrated part at the contact surface 10b at the valve plate 10, which comes in contact with the outlet valve 12. The elastic film 70 is not printed over an area 71, which faces opposite the corresponding lead portion 59 at the outlet valve 12. In addition, the lead portions 59 in the free state lean toward the valve plate 10, and are designed so as to achieve a relationship expressed as d2 > d1 with d1 representing the thickness of the elastic film 70 and d2 representing the extent to which the lead portions 59 lean toward the valve plate. As a result, advantages similar to those of the embodiment 3 are achieved.

Embodiment 5

In the structure achieved in embodiment 5 in FIG. 10, elastic films 75 and 76 are each formed through screen printing at one of the two surfaces of the intake valve 11 and elastic films 77 and 78 are formed through screen printing each at one of the two surfaces of the outlet valve 12. This structure eliminates the need for the gasket 13 and the gasket 14 respectively used on the cylinder block side and the rear head side in the other embodiments and still assures a sufficient level of sealability. As a result, a further reduction in the number of required parts and further device miniaturization are achieved.

Industrial Applicability

As described above, the present invention provides a compressor with improved sealability between the valve plate and the intake valve or between the valve plate and the outlet valve without leading to increases in the number of required parts and the number of assembly steps or increasing the dimensions of the compressor.

Claims

A seal structure adopted in a compressor that includes an intake valve (11) and a valve plate (10) disposed adjacent to each other, characterized in:
that a seal member (65) is formed through printing as an integrated part at least at either of contact surfaces (10a, 11a) of said intake valve (11) and the valve plate (10).
A seal structure adopted in a compressor according to claim 1, characterized in:
that a lead portion (55) at said intake valve (11) is formed so that said lead portion (55) in a free state leans toward said valve plate (10) by an extent greater than a thickness of said seal member (65) printed at said intake valve (11) and/or said valve plate (10).
A seal structure adopted in a compressor according to claim 1 or claim 2, characterized in:
that if said seal member (65) is printed at said intake valve (11), said seal member (65) is printed on both surfaces of said intake valve (11).
A seal structure adopted in a compressor according to any of claims 1 through 3, characterized in:
that if said seal member (65) is printed at said intake valve (11), said seal member (65) is not printed at a lead portion (55) of said intake valve (11).
A seal structure adopted in a compressor that includes an outlet valve (12) and a valve plate (10) disposed adjacent to each other, characterized in:
that a seal member (68) is formed through printing as an integrated part at least at either of contact surfaces (10a, 12a) of said outlet valve (12) and said valve plate (10).
A seal structure adopted in a compressor according to claim 5, characterized in:
that a lead portion (59) at said outlet valve (12) is formed so that said lead portion (59) in a free state leans toward said valve plate (10) by an extent greater than a thickness of said seal member (68) formed at said outlet valve (12) and/or said valve plate (10).
A seal structure adopted in a compressor according to claim 5 or claim 6, characterized in:
that if said seal member (68) is printed at said outlet valve (12), said seal member (68) is printed on both surfaces of said outlet valve (12).
A seal structure adopted in a compressor according to any of claims 5 through 7, characterized in:
that if said seal member (68) is printed at said outlet valve (12), said seal member (68) is not printed at a lead portion (59) of said outlet valve (12).
A seal structure adopted in a compressor according to any of claims 1 through 8, characterized in:
that if said seal member (70) is printed at said valve plate (10), said seal member (70) is not printed over an area of said valve plate (10) facing opposite a lead portion (55) of said intake valve (11) and/or a lead portion (59) of said outlet valve (12).
A seal structure adopted in a compressor according to any of claims 1 through 9, characterized in:
that said seal member (65, 68, 70) is printed through screen printing.
A compressor according to any of claims 1 through 10, characterized in:
that said seal member (65, 68, 70) is constituted with an elastic film.
A seal structure according to any of claims 1 through 11, adopted in a compressor (1) constituting part of a refrigeration cycle in which CO2 is used as a coolant.