Abstract:
A device for automatic processing of contaminated refrigerant from an air conditioning system, said device comprising a compressor for compressing refrigerant. Said device further comprising an oil separator, said oil separator receiving compressed refrigerant from said compressor; said oil separator further including means for draining oil separated from said compressed refrigerant. Said device further comprising a storage tank, said storage tank receiving and temporarily containing said compressed refrigerant from said oil separator. Said storage tank including a vapor port and a liquid port. Said device further comprising a vacuum pump for creating low pressure within said device during evacuation of refrigerant. Said device further comprising a low pressure service hose for connecting said device to said air conditioning system. Said device further comprising a high pressure service hose for connecting said device to said air conditioning system. Said device further comprising at least one automatic multi-position ball valve. Said at least one automatic multi-position ball valve controlling flow of said refrigerant through said device.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The device relates to equipment used for air conditioning refrigerant recovery, recycling, evacuation, and/or recharge with particular use on commercial and automotive refrigerant containing systems. 
         [0003]    2. Description of Related Art 
         [0004]    Refrigerant Recovery, Recycling, Evacuation, and/or Recharge equipment (commonly referred to as R/R/R Equipment) is designed for use on Commercial and Automotive Refrigerant containing systems. Since it is illegal to vent CFC, HCFC and HFC refrigerants into the atmosphere, equipment has been developed to recover or extract, recycle, evacuate, flush and/or recharge refrigerants such as R-12, R-22, R-134a and R-410a. The equipment comes in many forms. 
         [0005]    R/R/R Equipment has been designed around components such as solenoid valves, check valves, compressors, vacuum pumps, oil separators, and filtration devices. The refrigerant flow through these devices are controlled by electro-mechanical or electronic controls. The following is a brief description on how these components are used in the R/R/R Equipment. Electro-Magnetic Solenoid valves are the current valve of choice to control the flow on R/R/R Equipment. Manufacturers add check valves (to prevent back flow), filters, and other preventive devices to protect solenoid valves used in their equipment. 
         [0006]    The solenoid valves (SV) are designed with a small orifice, stem, tightly fitting plunger/core, and electrical coil. The small orifice in the SV is required to meet activation and non-activation pressure differential requirements. The tight spacing between the stem, coil and plunger/core are required for proper electro-magnetic operation. SV&#39;s are placed within the R/R/R Equipment plumbing circuit for the desired operation of each mode. This allows for flow control between recovery, recycle, evacuation, flush and/or recharge modes. 
         [0007]    The physical design of a typical SV currently used in R/R/R Equipment incorporates a small orifice, plunge/core, spring, shell and electrical inductive coil. The smaller the orifice, the greater the holding power of the solenoid valve plunger/core. If the orifice diameter is too big, the plunger/core spring will not be strong enough to prevent back flow. Also note the electro-magnetic field may not be strong enough to open the plunger/core to the open position due to the differential operation pressures. The direct effect of the small orifice of the SV on the R/R/R Equipment is reduced flow rates during all operational modes. 
         [0008]    Other problems associated with the SV are due to the presence of contaminates such as refrigerant system sealers, metal filings, chemical additives, oil, air, and moisture. Metal filings and other particles can lodge and jam between the tight space between the plunger/core and stem assembly making the SV inoperable. Refrigerant scaler, on the other hand, is in the liquid form until air/moisture makes direct contact with it. When the sealer activates, it will harden into a solid form. If the hardening takes place in the stem and plunger/core area, the SV will become inoperable. Excessive oil or liquid in the solenoid stem on the back side of the plunger can cause a delay or even prevent activation. This is called hydraulic lock. Another problem with the SV is that any contaminates on the surface of the orifice will cause the SV to not properly seal. The lack of the seal will cause internal leakage which will lead to overcharging, incomplete recovery, and loss of vacuum. 
         [0009]    Compressors (CMP) are used to create a pressure differential during the recovery, recycling, flush and/or recharge operation. The CMP will suck refrigerant from one vessel and compress it into another vessel. 
         [0010]    Vacuum Pumps (VP) are used to create a very low pressure area in a vessel during the evacuation mode. This is needed to remove (boil) any existing contaminates such as moisture and/or air before recharging. The presence of air and moisture will cause a refrigeration system to prematurely fail. 
         [0011]    Oil separators and other filtration devices are placed in the R/R/R equipment plumbing circuit to meet recycling requirements. 
         [0012]    Several attempts have been made to improve Refrigerant Recovery technology. For example, U.S. Pat. No. 5,479,788 issued to Roegner on Jan. 2, 1996 entitled “Refrigerant Recovery System” teaches a new refrigerant recovery system, but does not contemplate the recycling and evacuation of the refrigerant. The &#39;788 patent contemplates the use of a ball valve for regulating flow of refrigerant as well as flare ball valves for service hoses, which are commonly found on solely recovery units. The &#39;788 patent contemplates tank shut off ball valves that are required to disconnect a tank from the system. All of the ball valves in the &#39;788 patent are only two-way valves. 
         [0013]    U.S. Pat. No. 6,832,491 issued to Ramachandran et al. on Dec. 21, 2004 entitled “Compressor, Head, Internal Discriminator, External Discriminator, and Manifold Design for Refrigerant Recovery Apparatus” teaches the use of ball valves on the suction and discharge of a cylinder head in the recovery of refrigerant liquid and/or vapor. U.S. Pat. No. 6,779,350 issued to Ramachandran et al. on Aug. 24, 2004 entitled “Compressor Head, Internal Discriminator, External Discriminator, Manifold Design for Refrigerant Recovery Apparatus and Vacuum Sensor” teaches the same technology as the &#39;491 patent. However, the type of ball valve contemplated by the &#39;491 patent and &#39;350 patent is a ball/spring valve, not a rotational ball valve. The spring holds a ball against a seat. When certain conditions occur, the ball will push against the spring allowing flow through. The ball is completely solid and has no holes. This structure is distinctly different from a rotational ball valve. 
         [0014]    U.S. Pat. No. 6,371,440 issued to Genga et al. on Apr. 16, 2002 entitled “Electronic Motorized Zone Valve” teaches a valve actuator including a motor for changing the position of a valve, a switch for switching power to the motor, and a sensor for detecting the arrival of the valve at a desired position and for stopping the motor without using a mechanical stop. The ball valve contemplated in the &#39;440 patent is for a two way ball valve which uses only one optical valve switch to estimate the valve position. 
         [0015]    U.S. Pat. No. 5,875,638 issued to Tinsler on Mar. 2, 1999 entitled “Refrigerant Recovery System” teaches a system of refrigerant recovery very similar to that described in the &#39;788 patent. The &#39;638 patent is a refrigerant recovery only unit. The &#39;638 patent contemplates the use of ball valves to connect hoses to removable tanks, manifolds, or the valves located on the removable tank. The &#39;638 patent contemplates the use of solenoid valves for its normal operation. All of the valves mentioned in the &#39;638 patent are two way valves. 
         [0016]    U.S. Pat. No. 4,398,562 issued to Saarem et al. on Aug. 16, 1983 entitled “Motorized Diverter Valve” teaches a motor driven valve that diverts fluid flow from a single inlet port to either one of two outlet ports, or vice versa. The &#39;562 patent teaches a three way valve that uses mechanical means to determine its position through Cams and micro-switches. 
         [0017]    U.S. Pat. No. 5,099,867 issued to Emery on Mar. 31, 1992 entitled “Sealed Valve and Control Means Therefore” teaches a ball valve rotated by a spindle connected to a disc. The &#39;867 patent covers a 2 way valve using magnetic pulse to determine the position. When the valve is moved, pulses are created. 
         [0018]    U.S. Pat. No. 5,226,454 issued to Cabalfin on Jul. 13, 1993 entitled “DC Motor Actuated Flow Diversion Valve” teaches a three way valve using a DC motor, cam and micro switches to determine the position. 
         [0019]    U.S. Pat. No. 4,299,251 issued to Dugas on Nov. 10, 1981 entitled “Optical Valve Position Sensing” teaches an apparatus for indicating the position of a rotary valve. The &#39;251 patent covers a three light source light reflecting sensor to determine position of a valve. The light is reflected by mirrors to determine the position of the valve. 
         [0020]    U.S. Pat. No. 6,843,070 issued to Suharno on Jan. 18, 2005 entitled “Refrigerant Recycling System With Single Ball Valve” teaches a system with a single manual ball valve can be used to connect a common port to either high or low service hoses. The flow through the system is controlled by solenoid valves. 
         [0021]    U.S. Patent Application 2006/0070672 filed by Martins et al. entitled “Control Valve for an Engine Cooling Circuit” teaches a structure of a control valve for fluid circulation. 
         [0022]    The desire remains for an automatic refrigerant recovery, recycler, recharging or evacuation equipment for the mobile air conditioning market. 
       SUMMARY OF THE INVENTION 
       [0023]    It is contemplated that the present patent application will address a solution to the above stated problems by using ball valves in conjunction with R/R/R Equipment. Said ball valves are automatically operated by electromechanical controls. 
         [0024]    In accordance with these and other objects which will become apparent hereinafter, the instant invention will now be described with particular reference to the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0025]      FIG. 1  shows an automatic motorized ball valve in plan view as viewed from the front. 
           [0026]      FIG. 2  shows a ball valve in plan view from the side. 
           [0027]      FIG. 3  shows a plan view of the ball valve from the back side. 
           [0028]      FIG. 4  shows a top plan view of the ball valve. 
           [0029]      FIG. 5  shows a cross section view of a ball valve as taken from the front. 
           [0030]      FIG. 6  shows a cross section view of a ball valve as taken from the side. 
           [0031]      FIG. 7  shows a cross section view of a ball valve as taken from the back. 
           [0032]      FIG. 8  shows a cross section view of a ball valve as taken from the top. 
           [0033]      FIG. 9  shows an isolated view of the optical sensor and ball position wheel. 
           [0034]      FIG. 10  shows a block diagram of the R/R/R Equipment which comprises the subject matter of this application. 
           [0035]      FIGS. 11   a - 13   d  show an enlarged view of a three way ball valve in its different forms and positions. 
       
    
    
     DETAILED DESCRIPTION 
       [0036]    The subject matter in the present application pertains to the use of automatic motorized ball valves used in automatic automotive refrigerant recovery, recycling, and recharging or evacuation equipment for the mobile air conditioning markets. The ball valves are not on/off valves, but are control valves. 
         [0037]    With reference to  FIG. 1 , an automatic motorized ball valve  10  is shown in plan view as viewed from the front. The ball valve  10  has a motor  12  which turns a handle or ball position wheel  16 . It is contemplated that the motor may be a high torque 12 volt direct current motor, however it is contemplated that alternative motors may be effective. A ball valve  10  is opened by turning the ball position wheel  16  attached to stem  50  which is engaged to a ball  13  inside the valve. The position of the handle  16  is determined by a position system  14 . It is contemplated that the position system  14  is exacted through two optical sensors. The optical sensors use direct transmissive infrared signals each aimed toward a sensing device that will produce a digital signal of open or closed. The infrared signals must pass through two position holes in order to produce a digital signal of open. Further shown is one of two apertures  18  located on either side of the valve  10 . Each aperture  18  provides an opening for either end of a central flow canal. The ball  13  is contained within the canal. The ball  13  has a hole, or port, through the middle so that when the port is in line with both ends of the valve, flow of refrigerant is permitted. When the valve is closed, the hole is perpendicular to the ends of the valve, and flow is blocked. The handle position allows you to view the valve&#39;s position. The body of ball valves may be made of metal, ceramic, or plastic. The ball valve  10  is a three-way valve, as it is commonly called in the marketplace. Three-way ball valves have an L- or T-shaped hole through the middle. 
         [0038]    With reference to  FIG. 2 , the ball valve  10  is shown in plan view from the side. One of possible multiple apertures  20  located on this side of ball valve  10 . One possible aperture is on the bottom and one possible aperture opposite side of the ball valve  10 . A minimum of One or more of these aperatures can exist on. Additional aperatures are used to minimize connection fittings. As further displayed, the two oppositely located apertures  18  are located at a point higher on the ball valve  10 . 
         [0039]    With reference to  FIG. 3 , a plan view of the ball valve  10  is shown from the back side. The motor  12  is shown mounted onto the motor bracket  30 . There is a square aperture  32  in the side of the motor bracket  30  through which the ball position wheel  16  slightly extends. 
         [0040]    With reference to  FIG. 4 , a top plan view of the ball valve  10  is shown. As shown, the ball position wheel  16  exits the motor bracket  30  slightly. 
         [0041]    With reference to  FIG. 5 , a cross section view of the ball valve  10  as taken from the front is shown. As shown, the motor  12  is connected to a stem  50 . The stem  50  sits atop the ball  13  and controls the direction of the ball  13 . As shown, the ball  13  is located within the channel  52 . 
         [0042]    With reference to  FIG. 6 , a cross section view of the ball valve  10  as taken from the side is shown. 
         [0043]    With reference to  FIG. 7 , a cross section view of the ball valve  10  as taken from the back is shown. As shown, the stem  50  has one or two O ring seals  70  around its circumference. With reference to  FIG. 8 , a cross section view of the ball valve  10  as taken from the top is shown. As shown, the ball position wheel  16  is secured around the stem  50 . The position of the ball position wheel  16  is determined by shining the optical sensors  14  through the pair of sensor holes  80  located on the wheel  16 . 
         [0044]    With reference to  FIG. 9 , an isolated view of the optical sensor  14  and ball position wheel  16  is shown. As shown, the optical sensor  14  has a pair of optical sensor lights  90  which are spaced equally as the sensor holes  80  located on the ball position wheel  16 . The ball position wheel  16  will be rotated by the motor  12  until one or both optical sensor lights  90  are aligned with one or both sensor holes  80  on the ball position wheel  16 . 
         [0045]    With reference to  FIG. 10 , a block diagram of the R/R/R Equipment which comprises the subject matter of this application is shown. As shown, a low side service hose snap coupling  100  and a high side service hose snap coupling  102  extend outwardly from the R/R/R Equipment. The low side service hose snap coupling  100  and the high side service hose snap coupling  102  connect to the R/R/R Equipment through service hoses  104 ,  106 . The service hose snap couplings  100 ,  102  connect to an external air conditioning device in order to recycle and recharge the refrigerant. The low side service hose  104  is equipped with a low side pressure gauge  108  and the high side service hose  106  is equipped with a high side pressure gauge  110 . The R/R/R Equipment contains a vacuum pump  114  which is connected to a vacuum pump hose  132 . A motorized automatic ball valve  112  controls flow between the low side service hose  104  and the vacuum pump  114 . This ball valve  112  is a three way valve. The ball valve  112  also controls flow into the compressor  138 . The compressor suction hose  136  connects to a compressor  138 . The compressor  138  compresses the refrigerant before it exits the compressor  138  through the compressor discharge hose  140  to an oil separation chamber  116 . The refrigerant enters the oil separation chamber  116  through an inlet port  120  and exits though an outlet port  124 . The separated oil is drained out of the oil separation chamber  116  through a drain port  118  into a drain bottle  130 . A motorized automatic ball valve  128  controls flow between the oil separation chamber  116  and the oil drain bottle  130 . This ball valve  128  is a three way valve. When the R/R/R cycle is complete, a user may remove the drain bottle  130  and empty the separated oil. The ball valve  128  is also used to purge Non-Condensable Gases (NCGs) from the storage tank  150 . This ball valve  128  controls the flow of pressurized gases through a port  168  and hose  166  from the storage tank  150 . The purged NCGs flows from the ball valve  128  into the drain bottle  130 . 
         [0046]    A discharge hose  126  is connected between the outlet port  124  of the oil drain separator  116  and the automatic motorized ball valve  146 . This ball valve  146  controls the flow through hose  126  to moisture filter drier  134  which removes moisture from the refrigerant flow. The automatic motorized ball valve  146  can also bypass flow to port  154  of the storage tank  150 . The dry refrigerant flow exits the moisture filter drier  134  through a hose  148 . The hose  148  connects between compressor  138  and vapor port  152  of the storage tank  150 . 
         [0047]    A tank liquid hose  156  is connected to the liquid port  154 . The tank liquid hose  156  transports the refrigerant back towards the high side service hose  102 . A motorized automatic three way ball valve  160  controls the flow of refrigerant between the storage tank  150  and the high side service hose  102 . 
         [0048]    In addition, the R/R/R Equipment may have a discharge line temperature thermistor  144  and an ambient temperature thermistor  158  used to determine NCG purging algorithms. The R/R/R Equipment may have high pressure safety cutout switch  142  and pressure transducer  162  on monitoring compressor and vacuum pump conditions. 
         [0049]    Oil re-injection is done by placing oil in oil injection bottle  164  and using the negative pressure differential created during the vacuum pump mode. The oil will flow from oil injection bottle  164   
         [0050]    With reference to  FIGS. 11   a - 11   d  and  12   a - 12   d , an enlarged view of a three way “L-shaped” ball valve  112 ,  128 ,  146 ,  160  is shown in different positions.  FIGS. 11   a - 11   d ,  12   a - 12   d and  13   a - 13   d  are shown with the common port “C” with a perpendicular perspective to ports “1” and “2”.  FIGS. 12   a - 12   d  are also representative of an “L shaped” ball valve but shown in a different planar view from  FIGS. 11   a - 11   d .  FIGS. 13   a - 13   d  represents a “T shaped” valve. It is contemplated that the L-shaped valve and T-shaped valves may be used with the R/R/R process. These ball valves  112 ,  128 ,  146 ,  160  are turned to different positions by an electromechanical motor  12 . The position is exacted by the two optical sensors  14 . 
         [0051]    The automatic ball valves  112 ,  128 ,  146 ,  160  aid in the performance of three distinct functions in the R/R/R process: recovery, vacuum, and charge. In the recovery operation, two automatic ball valves  112 ,  160  are used to control the incoming flow of refrigerant to the compressor  138  and automatic ball valve  146  is used to control the discharge flow from the compressor  138 . Automatic ball valve  160  is used to connect the high side service hose  106  to the low side service hose  104 . Automatic ball valve  112  directs the refrigerant flow to the compressor  138 . Automatic ball valve  146  opens just before the compressor  138  is started. Both automatic ball valves  112 ,  160  remain closed until the compressor  138  is started. Once started, both automatic ball valves  112 ,  160  are opened allowing the incoming refrigerant to flow to the compressor  138 . The compressor  138  then compresses the refrigerant vapor into a storage vessel  150 . The compressed refrigerant passes through several filtration devices on its journey to the storage vessel  150 . The R/R/R Equipment continues to be operated until the pressure in the service hoses  104 ,  106  decreases into a slight negative pressure. Once desired negative pressure is achieved and recorded by the pressure transducer  162 , the automatic ball valves  112 ,  160 ,  146  close and the compressor  138  shuts off. 
         [0052]    In the vacuum operation, two automatic ball valves  160 ,  112  are used to control the vacuum flow to the vacuum pump  114 . Automatic ball valve  160  is used to connect the high side service hose  106  to the low side service hose  104 . The other automatic ball valve  112  directs the vacuum flow to the vacuum pump  114 . The automatic ball valves  112 ,  160  remain closed until the vacuum pump  114  is started. Once the vacuum pump  114  is started, both automatic ball valves  112 ,  160  are opened allowing the vacuum flow to be applied to both the high  106  and low  104  side service hoses. The vacuum operation will continue until the desired amount of time has expired. 
         [0053]    In the charge operation, automatic ball valve  160  controls the refrigerant flow. The automatic ball valve  160  is opened allowing liquid refrigerant from the storage tank  150  to flow out of the high side service hose  106  and into the air conditioning device. Once the desired amount of refrigerant is dispensed, the automatic ball valve  160  is closed. 
         [0054]    It is further contemplated that a separate battery provides a backup power source to the automatic ball valves. A typical solenoid valve uses a physical return spring on the plunger to stop flow of refrigerant in situations where power is removed from the electrical coil. A similar function is necessary with the use of ball valves in case of a power interruption or failure. Thus, if the primary power source were to fail, the battery would provide enough power to immediately close all of the automatic ball valves and stop flow. 
         [0055]    R/R/R Equipment with automatic ball valves operated by electromechanical controls. Said ball valves wipe themselves clean every time they open and close. The shearing action of the ball against the Teflon seals during the action of opening and closing prevents hardened sealant from making it inoperable. Due to the ball valve construction, contaminates and particles which affect solenoid valves do not affect the effectiveness of the ball valve. 
         [0056]    Due to a ball valve&#39;s large porting, an increase in refrigerant flow will be achieved in both recovery and evacuation. Testing has proven that the use of ball valves instead of solenoid valves can reduce vacuum time by 50% to achieve the same vacuum level or performance. Thus, smaller vacuum pumps can be used in conjunction with ball valves to get the same performance as a larger vacuum pump used in conjunction with a solenoid valve. This may lead to a reduction in material cost and energy usage. 
         [0057]    Testing has proven that the use of ball valves instead of solenoid valves can reduce recovery time by 30%. Typical recovery time through a solenoid valve on an automobile air conditioning system takes about 12 to 14 minutes. Tests run have proven that the same process run with ball valves can be completed in 8 to 10 minutes. Thus, smaller compressors could be used in conjunction with ball valves to get the same performance as a larger compressor used in conjunction with a solenoid valve. This may lead to a reduction in material cost and energy usage. 
         [0058]    Testing has proven that the use of ball valves instead of solenoid valves can reduce charge time by 30%. Typical charge time through a solenoid valve on an automobile air conditioning system takes about 1.5 minutes. Tests run have proven that the same process run with ball valves can be completed in 1 minute. 
         [0059]    The instant invention has been shown and described herein in what is considered to be the most practical and preferred embodiment. It is recognized, however, that departures may be made there from within the scope of the invention and that obvious modifications will occur to a person skilled in the art.