Patent Publication Number: US-2017363080-A1

Title: Control valve for compressor

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a control valve for compressor, and more particularly to an internally and externally controlled control valve for a variable displacement compressor of a refrigeration system including an improved and simplified structure or configuration for allowing the compressor of the refrigeration system to be effectively actuated or operated by the internally and externally controlled control valve. 
     2. Description of the Prior Art 
     Typical refrigerating systems, such as the automotive air conditioning systems comprise a refrigerant circuit having a condenser, an evaporator, and a wobble plate type or slant plate type compressor with a variable displacement mechanism, in which the variable displacement mechanisms may be controlled either internally or externally. 
     For example, U.S. Pat. No. 5,071,321 to Skinner et al., U.S. Pat. No. 5,092,741 to Taguchi, U.S. Pat. No. 5,152,673 to Pettitt et al., and U.S. Pat. No. 5,167,492 to Kent et al. disclose several of the typical variable displacement mechanisms for wobble plate type or slant plate type compressors controlled internally with bellow devices or the like, and controlled by a suction chamber pressure and in response to a discharge chamber pressure and a crankcase pressure formed inside a crankcase chamber. 
     A “bellow” device, such as a sylphon bellow is a thin-walled cylindrical metal bellow consisting of elements arranged responding to external or internal fluid pressure, and used in a pressure-governing system. The control mechanism comprises a passage way communication between the crankcase chamber and discharge chamber. A control valve is in response to a pressure difference between the crankcase chamber and the discharge chamber and provides a fluid path between the crankcase chamber and the discharge chamber to allow refrigerant from the discharge chamber to be injected into the crankcase chamber through the fluid path provided by the control valve under the influence of the pressure of the pressure difference inside the suction chamber. The “bellow” device is responsive by a suction pressure connected to the suction chamber for allowing the wobble plate type or slant plate type compressors to be controlled internally with bellow devices or the like. 
     However, the typical variable displacement mechanisms for wobble plate type or slant plate type compressors should normally be actuated or operated at a rate ranging between 6-100%, and may not be shut off completely while in use, without an outside of compressor control device, such as a clutch device or a solenoid device. 
     U.S. Pat. No. 5,240,385 to Nashiro et al., U.S. Pat. No. 5,586,870 to Kawaguchi et al., U.S. Pat. No. 6,241,484 to Hiltemann, and U.S. Pat. No. 6,250,891 to Kawaguchi et al. disclose the other typical variable displacement mechanisms for wobble plate type or slant plate type compressors controlled externally with vehicle electrical control unit (ECU) or vehicle electrical control module (ECM), including a “solenoid” inside the control valve and disposed between a discharge chamber and a crankcase chamber, for controlling a crankcase pressure in response to a signal generated outside of the compressor, such as the vehicle electrical control unit (ECU) or vehicle electrical control module (ECM). 
     However, the typical variable displacement mechanisms for wobble plate type or slant plate type compressors may only be controlled externally with the signals from the vehicle electrical control unit (ECU) or vehicle electrical control module (ECM), and should normally be actuated or operated at a fast speed such that the working life of the typical variable displacement mechanisms will be greatly reduced or decreased. 
     U.S. Pat. No. 5,025,636 to Terauchi discloses a further typical variable displacement mechanism for wobble plate type or slant plate type compressor that may be controlled both internally with such as a bellow device and externally with such as a solenoid device. 
     However, the typical variable displacement mechanisms include a complicated structure or configuration that may not be easily and quickly made or manufactured and that may include a complicated making or manufacturing procedure and that may include a greatly increased manufacturing cost or the like. The internally controlled mechanism and the externally controlled mechanism are spaced or separated from each other, but not in one control body unit. 
     The present invention has arisen to mitigate and/or obviate the afore-described disadvantages of the conventional control valves for compressors. 
     SUMMARY OF THE INVENTION 
     The primary objective of the present invention is to provide a control valve for compressor including an improved and simplified structure or configuration for allowing the compressor of the refrigeration system to be effectively actuated or operated by the internally and externally controlled control valve. 
     The other objective of the present invention is to provide a control valve for compressor including an improved and simplified structure or configuration having both internally controlled mechanism and externally controlled mechanism in one control body unit. 
     In accordance with one aspect of the invention, there is provided a control valve for compressor, the compressor comprising a cylinder housing including a number of piston casings provided in the cylinder housing, the cylinder housing including a control chamber formed therein and communicating with the piston casings of the cylinder housing, a suction chamber and a discharge chamber formed in the cylinder housing and communicating with the piston casings, and arranged for allowing an air to be drawn from the suction chamber into the piston casings of the cylinder housing, and for allowing a pressurized air to be discharged into the discharge chamber of the cylinder housing selectively, a compartment formed in the cylinder housing, a channel formed in the cylinder housing and communicating with the compartment and the suction chamber of the cylinder housing, a conduit formed in the cylinder housing and communicating with the compartment and the discharge chamber of the cylinder housing, a pathway formed in the cylinder housing and communicating with the compartment and the control chamber of the cylinder housing, a number of pistons slidably received and engaged in the piston casings of the cylinder housing respectively, a swash plate rotatably received and engaged in the control chamber of the cylinder housing with a spindle and adjustable relative to the spindle to different angles, and engaged with the pistons for changing and determining a moving stroke of the pistons, and a control valve including a receptacle engaged in the compartment of the cylinder housing, the control valve includes a valve member engaged in the receptacle for controlling the pressurized air to flow from the discharge chamber and the conduit of the cylinder housing through the receptacle and into the pathway and the control chamber of the cylinder housing, and a valve element for controlling a bypass of the pressurized air through the receptacle and for controlling the pressurized air to flow from the discharge chamber to the control chamber of the cylinder housing in order to control or adjust the swash plate relative to the spindle to different angles. 
     The receptacle includes a control space formed in the receptacle and communicating with the pathway of the cylinder housing for allowing the air with a control pressure (Pc) to flow from the control space of the receptacle into the control chamber of the cylinder housing, a discharge space formed in the receptacle and communicating with the conduit of the cylinder housing for allowing the air with a discharge pressure (Pd) to flow from the discharge chamber and the conduit of the cylinder housing through the discharge space of the receptacle and into the control space of the receptacle, the valve member is provided between the discharge space and the control space of the receptacle for controlling the pressurized air to flow from the discharge space to the control space of the receptacle. 
     The receptacle includes a sliding member slidably received and engaged in the control space of the receptacle, and the sliding member includes a valve piece for selectively engaging with a primary valve seat of the receptacle and for forming the valve member between the receptacle and the sliding member. The sliding member includes a bore formed therein and communicating with the control space of the receptacle for forming a bypass from the discharge passage of the receptacle into the bore of the sliding member and into the control space of the receptacle, and the valve element is provided in the bore and the bypass of the sliding member for controlling the pressurized air to flow from the discharge space of the receptacle into the bore of the sliding member. 
     The sliding member includes an aperture formed therein and communicating with the bore of the sliding member and communicating with the control space of the receptacle. The sliding member includes a secondary valve seat formed therein, and a valve part slidably engaged in the bore of the sliding member for selectively engaging with the secondary valve seat of the sliding member and for forming the valve element in the sliding member. The receptacle includes a bellow device connected to the valve part for actuating the valve part to selectively engage with the secondary valve seat of the sliding member and to be selectively disengaged from the secondary valve seat of the sliding member. 
     The receptacle includes a suction space formed in the receptacle and communicating with the channel of the cylinder housing for allowing the air with a suction pressure (Ps) to flow from the suction space of the receptacle into the piston casings of the cylinder housing selectively, and the bellow device is disposed in the suction space of the receptacle. The receptacle includes a suction passage formed therein and communicating with the suction space of the receptacle for allowing the air to flow into the suction space of the receptacle. 
     The receptacle includes a solenoid device engaged with the sliding member for selectively actuating the sliding member to engage with or disengage from the primary valve seat of the receptacle. The solenoid device includes a coil attached to the receptacle, and a plunger slidably engaged in the coil and engaged with the sliding member for selectively actuating the sliding member to close and open the valve member. The receptacle includes a discharge passage formed therein and communicating with the discharge space of the receptacle, and a control passage formed in the receptacle and communicating with the control space of the receptacle for allowing the pressurized air to flow from the control space to the control passage of the receptacle, and then into the control chamber of the cylinder housing. 
     Further objectives and advantages of the present invention will become apparent from a careful reading of the detailed description provided hereinbelow, with appropriate reference to the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a partial cross sectional view of a compressor having a control valve in accordance with the present invention; 
         FIG. 2  is an enlarged partial perspective view illustrating the control valve for the compressor; 
         FIG. 3  is a partial cross sectional view of the control valve for compressor, taken along lines  3 - 3  of  FIG. 2 ; and 
         FIGS. 4, 5  are partial cross sectional views similar to  FIG. 3 , illustrating the operation of the control valve for compressor. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to the drawings, and initially to  FIG. 1 , a compressor in accordance with the present invention comprises an outer receptacle or cylinder housing  10 , and a number of pistons  11  slidably received or engaged in piston casings  12  that are formed and provided in the cylinder housing  10 , and actuated or operated to move in a reciprocating action in the cylinder housing  10  for generating a pressurized air, the cylinder housing  10  includes a crank case chamber or control chamber  13  formed therein and communicating with the piston casings  12 , and a swash plate  14  is rotatably received or engaged in the control chamber  13  of the cylinder housing  10  with a spindle  15  and connected or coupled to and engaged with the pistons  11  for changing and determining the moving stroke of the pistons  11 , in which the spindle  15  is substantially parallel to the pistons  11 . A driven pulley  16  is connected or coupled to the spindle  15  and rotated in concert with the spindle  15 . 
     When the swash plate  14  is tilted or adjusted relative to the spindle  15  to a substantially upright angle that is substantially perpendicular to the spindle  15 , the moving stroke of the pistons  11  is decreased to the smallest; but when the swash plate  14  is tilted or adjusted relative to the spindle  15  to a substantially flat angle that is substantially parallel to the spindle  15 , the moving stroke of the pistons  11  will be increased to the greatest moving stroke, for example, and the pressurized air will be generated in the greatest efficiency. The cylinder housing  10  further includes a suction chamber  17  and a discharge chamber  18  formed therein and communicating with the piston casings  12  and arranged for allowing the air to be drawn from the suction chamber  17  into the piston casings  12 , and for allowing the pressurized air to be discharged into the discharge chamber  18  when or after the pressurized air is generated by or with the pistons  11 . 
     The cylinder housing  10  further includes a receiving chamber or compartment  19  formed therein and communicating with the suction chamber  17  and the discharge chamber  18  and the control chamber  13  of the cylinder housing  10  with a channel  20 , a conduit  21  and a pathway  22  respectively, and the compartment  19  of the cylinder housing  10  may be provided for receiving or engaging with a control valve  3  that is provided for actuating or operating the compressor in accordance with the present invention. The compressor in accordance with the present invention further comprises a refrigerant circuit including at least an evaporator  23 , an expansion valve  24  and a condenser  25  connected or coupled in series between the suction chamber  17  and the discharge chamber  18  of the cylinder housing  10  for air conditioning purposes. The above-described structure or configuration for the pistons  11  and the swash plate  14  and the evaporator  23  and the expansion valve  24  and the condenser  25  is typical and will not be described in further details. 
     Referring next to  FIGS. 2-5 , the control valve  3  for the compressor in accordance with the present invention includes a control valve body or receptacle  30  having a suction space  31  formed therein, such as formed in the upper portion thereof, a suction passage  32  formed therein, such as formed in the upper portion thereof and communicating with the suction space  31  of the receptacle  30  and also communicating with the channel  20  of the cylinder housing  10  for allowing the air with a suction pressure (Ps) to be flown from the suction space  31  of the receptacle  30  and through the channel  20  and into the piston casings  12  of the cylinder housing  10  selectively, and the suction space  31  of the receptacle  30  is provided for receiving or engaging with a bellow device  40 , such as a thin-walled cylindrical metal bellow consisting of elements arranged responding to external or internal fluid pressure, and used in a pressure-governing system, and responsive by the suction pressure (Ps) connected to the suction chamber  17  of the cylinder housing  10 . 
     For example, when the temperature and/or the pressure in the outer environment and/or the suction pressure (Ps) reach a predetermined value, such as 40 psi, the bellow device  40  will be compressed or actuated or operated by the suction pressure (Ps) in order to actuate or operate the control valve  3  to work the compressor, this is the so-called internally controlled wobble plate type or slant plate type or swash plate type compressors. The compressor will be continuously actuated or operated by the suction pressure (Ps) that is ranged between 30 and 40 psi, for example, and the compressor will be idled or the like when the suction pressure (Ps) is lower than 30 psi, for example. The above-described structure or configuration for the bellow device  40  is also typical and will not be described in further details. 
     The receptacle  30  further includes a crank case or control space  33  formed in the middle or intermediate portion of the receptacle  30 , and a crank case or control passage  34  is also formed in the middle or intermediate portion of the receptacle  30  and communicating with the control space  33  of the receptacle  30  and also communicating with the pathway  22  of the cylinder housing  10  for allowing the air with a control pressure (Pc) to be flown from the control space  33  of the receptacle  3  and through the pathway  22  and into the control chamber  13  of the cylinder housing  10  in order to control or tilt or adjust the swash plate  14  relative to the spindle  15  of the cylinder housing  10 . The receptacle  30  further includes an orifice or discharge space  35  formed therein and communicating with the suction space  31  and the control space  33  of the receptacle  30 , and a discharge passage  36  also formed in the middle or intermediate portion of the receptacle  30  and communicating with the discharge space  35  of the receptacle  30  and also communicating with the conduit  21  of the cylinder housing  10  for allowing the pressurized air generated by or with the pistons  11  with a discharge pressure (Pd) to flow into the discharge passage  36  and/or the control space  33  of the receptacle  30 . 
     A container or sliding member  41  is slidably received or engaged in the control space  33  and/or the discharge space  35  of the receptacle  30 , and includes a shoulder or valve piece  42  for selectively contacting or engaging with a primary valve seat  37  of the receptacle  30  and for forming or defining a primary valve member  43  between the receptacle  30  and the sliding member  41  and for controlling the pressurized air (Pd) to flow from the discharge passage  36  into the control space  33  of the receptacle  30 . The sliding member  41  includes an inner bore  44  and an aperture  45  formed therein and communicating with each other and also communicating with the control space  33  of the receptacle  30  for forming a manifold or bypass  440  of the pressurized air from the discharge passage  36  of the receptacle  30  into the bore  44  and the aperture  45  of the sliding member  41  and into the control space  33  of the receptacle  30 , and the aperture  45  of the sliding member  41  is communicating with the control space  33  of the receptacle  30 , and the inner bore  44  of the sliding member  41  is partially communicating with the discharge passage  36  of the receptacle  30  for allowing the pressurized air to partially flow from the discharge passage  36  of the receptacle  30 , through the manifold or bypass  440  and into the bore  44  and the aperture  45  of the sliding member  41  selectively. 
     The sliding member  41  further includes an inner socket or secondary valve seat  46  formed or provided therein, and another valve ball or piece or part  47  is slidably received or engaged in the bore  44  of the sliding member  41  and attached or mounted or secured to the bellow device  40  and moved in concert with the bellow device  40  and arranged for allowing the valve part  47  to be actuated or operated or moved by the bellow device  40  to selectively contact or engage with the secondary valve seat  46  of the sliding member  41  in order to form or define a secondary valve element  48  within the sliding member  41 , and to control the pressurized air (Pd) to flow from the discharge passage  36  into the bore  44  and the aperture  45  of the sliding member  41  and then into the control space  33  of the receptacle  30  and then to selectively flow out through the control passage  34  of the receptacle  30 , such that the bypass of the pressurized air (Pd) from the discharge passage  36  of the receptacle  30  into the bore  44  of the sliding member  41  and then into the control space  33  of the receptacle  30  may be controlled with the valve part  47  and the secondary valve seat  46  of the valve element  48  and thus may be controlled internally with the valve part  47  and the bellow device  40 . 
     The control valve  3  further includes a solenoid device  5  having a coil  50  disposed or attached or mounted or secured in the lower or bottom portion of the receptacle  30 , and a plunger  51  slidably received or engaged in the coil  50  and contacted or engaged with the sliding member  41 , for being actuated or operated by the coil  50  and for selectively actuating or forcing or moving the sliding member  41  to contact or engage with the primary valve seat  37  of the receptacle  30  ( FIGS. 4, 5 ) and for closing or opening the valve member  43  selectively. A spring biasing member  52  is provided and engaged between the receptacle  30  and the sliding member  41  for biasing and forcing or moving the valve piece  42  of the valve member  43  from the primary valve seat  37  of the receptacle  30  or of the valve member  43  ( FIG. 3 ) and thus for allowing the pressurized air (Pd) to freely flow from the discharge passage  36  into the control space  33  of the receptacle  30 . 
     In operation, as shown in  FIG. 3 , when the coil  50  of the solenoid device  5  is not actuated or operated or when it is not required to be air conditioned, or when the suction pressure (Ps) is lower than a predetermined low value, such as 30 psi, the pressurized air (Pd) may freely flow from the discharge passage  36  into the control space  33  of the receptacle  30  through the valve member  43 , and then into the control chamber  13  of the cylinder housing  10  in order to tilt or adjust the swash plate  14  relative to the spindle  15  of the cylinder housing  10  to the substantially upright angle that is substantially perpendicular to the spindle  15 , the moving stroke of the pistons  11  is decreased to the smallest and the work done by the compressor is decreased to almost zero. 
     As shown in  FIGS. 4 and 5 , when it is required to be air conditioned, the coil  50  of the solenoid device  5  may be actuated or operated or energized with a signal generated outside of the compressor, such as the vehicle electrical control unit (ECU) or vehicle electrical control module (ECM), and the sliding member  41  may be actuated or operated or moved by the plunger  51  and/or the coil  50  of the solenoid device  5  to contact or engage with the primary valve seat  37  of the receptacle  30  and for closing the valve member  43  selectively and for preventing the pressurized air (Pd) from directly flow from the discharge passage  36  through the valve member  43  that is formed by the primary valve seat  37  of the receptacle  30  and the valve piece  42  of the valve member  43 , and then into the control space  33  of the receptacle  30 . 
     As also shown in  FIG. 4 , when it is required to be air conditioned and when the temperature and/or the pressure in the outer environment and/or the suction pressure (Ps) reach the predetermined high value, such as 40 psi, the bellow device  40  will be compressed or actuated or operated by the suction pressure (Ps) in order to actuate or operate or move the valve part  47  to contact or engage with the secondary valve seat  46  of the sliding member  41  in order to close the valve element  48 , at this moment, no pressurized air (Pd) may flow from the discharge passage  36  into the control space  33  of the receptacle  30  and no pressurized air (Pd) may be supplied into the control chamber  13  of the cylinder housing  10 , and the swash plate  14  may be tilted or adjusted relative to the spindle  15  of the cylinder housing  10  to the substantially flat that is substantially parallel to the spindle  15 , the moving stroke of the pistons  11  will be increased to the greatest moving stroke, and the pressurized air will be generated in the greatest efficiency. 
     As also shown in  FIG. 5 , when the suction pressure (Ps) is ranged between 30 and 40 psi, for example, the valve part  47  of the bellow device  40  or of the valve element  48  will be compressed or actuated or operated by the suction pressure (Ps) in order to partially open the valve element  48  and thus for allowing the pressurized air (Pd) to bypass and to partially flow from the discharge passage  36  of the receptacle  30  into the bore  44  of the sliding member  41  and then into the control space  33  of the receptacle  30 , and thus for allowing the compressor will be continuously actuated or operated by the suction pressure (Ps) internally with the bellow device  40 . It is to be noted that the valve member  43  is closed at this moment, and will not be further moved or opened by the plunger  51  and/or the coil  50  of the solenoid device  5 . It is further to be noted that the valve element  48  and the valve member  43  are formed or provided within the receptacle  30 , and the valve element  48  may be controlled internally with the valve part  47  and the bellow device  40 , and the valve member  43  may be controlled externally with the plunger  51  and/or the coil  50  of the solenoid device  5 . 
     Accordingly, the control valve for compressor in accordance with the present invention includes an improved and simplified structure or configuration for allowing the compressor of the refrigeration system to be effectively actuated or operated by the internally and externally controlled control valve, and having both internally controlled mechanism and externally controlled mechanism in one control body unit. 
     Although this invention has been described with a certain degree of particularity, it is to be understood that the present disclosure has been made by way of example only and that numerous changes in the detailed construction and the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention as hereinafter claimed.