Patent Description:
Conventionally, as an electromagnetic valve integrated expansion valve used in refrigerant circulation systems, the one described in Patent Document <NUM> below is known. This electromagnetic valve integrated expansion valve includes a valve seat disposed between a valve chamber and an outlet refrigerant flow path, a valve element that approaches or separates from the valve seat, a valve element actuation mechanism for displacing the valve element (a power element), a bypass path that connects the valve chamber and the outlet refrigerant flow path, and an electromagnetic valve for opening and closing the bypass path.

According to such an electromagnetic valve integrated expansion valve, by opening the bypass path when the electromagnetic valve is opened, the balance of the force applied to the valve element is lost, and it is possible to separate the valve element from the valve seat. On the other hand, by closing the bypass path when the electromagnetic valve is closed, the balance of the force applied to the valve element is restored, and it is possible to drive the valve element using a diaphragm actuation mechanism.

<CIT> discloses a solenoid valve integrated expansion valve suitable for use in, for example, a vehicle air conditioner having a refrigeration cycle on the front and rear sides of a vehicle interior. <CIT> discloses an electromagnetic valve integrated expansion valve according to the preamble of claim <NUM>.

Similar integrated expansion valve constructions are disclosed in <CIT>, <CIT>, <CIT>, <CIT> and <CIT>.

An electromagnetic valve is provided with a cord for receiving power from a control device of a refrigerant circulation system or the like, and a connector (referred to as a valve-side connector) is connected to this cord. When attaching an electromagnetic valve integrated expansion valve to the refrigerant circulation system, by fitting such a connector to a mating connector, electrical conduction is realized between the control device and the electromagnetic valve.

Here, refrigerant circulation systems equipped with electromagnetic valve integrated expansion valves have various forms, and the position and orientation of the mating connector are various. Accordingly, conventionally, the valve-side connector is not fixed to the electromagnetic valve integrated expansion valve, but is oriented in any direction in accordance with the mating connector.

For this reason, since the valve-side connector hangs from the cord due to its own weight, the operator who attaches the electromagnetic valve integrated expansion valve to the refrigerant circulation system needs to grip the valve-side connector with one hand to adjust the orientation and fit it to the mating connector gripped with the other hand, which causes a problem of poor workability.

Accordingly, an object of the present invention is to provide an electromagnetic valve integrated expansion valve having excellent workability.

An electromagnetic valve integrated expansion valve according to the present invention is defined in claim <NUM>. It includes: a valve main body having a valve chamber; a valve element that restricts passage of a fluid by being seated on a valve seat and allowing passage of the fluid by separating from the valve seat; a coil spring that biases the valve element toward the valve seat; an operation rod that contacts the valve element at one end; a power element that is attached to the valve main body and drives the operation rod; and an electromagnetic valve that opens or closes a principal valve opening that is provided between the valve chamber and an outflow side passage, wherein: the electromagnetic valve includes a case that is fixed to the valve main body, an electromagnetic valve element that separates from or approaches the principal valve opening, a coil that drives the electromagnetic valve element, and a connector connected to a cord that supplies power to the coil, and the connector is supported by a bracket that extends from the case.

According to the present invention, it is possible to provide an electromagnetic valve integrated expansion valve having excellent workability.

Hereinafter, embodiments according to the present invention will be described with reference to the drawings.

In the present specification, the direction from the valve element toward the operation rod is defined as an "upward direction," and the direction from the operation rod toward the valve element is defined as a "downward direction. " Accordingly, in the present specification, the direction from the valve element toward the operation rod is referred to as an "upward direction," regardless of the posture of the expansion valve.

In <FIG>, the electromagnetic valve integrated expansion valve <NUM> has a valve main body <NUM> having a substantially prismatic shape. An inlet refrigerant passage <NUM> for supplying high-pressure refrigerant from the compressor side of the refrigeration cycle is formed inside the lower portion of the valve main body <NUM>, and the inlet refrigerant passage <NUM> communicates with a valve chamber <NUM> formed inside the valve main body <NUM>. A ball-shaped valve element <NUM> is arranged in the valve chamber <NUM> and is supported by a coil spring <NUM> via a support member <NUM>.

The upper end of the valve element <NUM> is in contact with the lower end of the operation rod <NUM>. The operation rod <NUM> extends within the valve main body <NUM> through an orifice portion <NUM> connected to the valve seat <NUM>, a sliding portion <NUM> for guiding the operation rod <NUM>, and a return passage <NUM>. A seal member <NUM> that comes into contact with the operation rod <NUM> and the valve main body <NUM> is provided between the sliding portion <NUM> and the return passage <NUM>.

A nut member <NUM> is screwed into an opening portion 10d at the lower end of the valve chamber <NUM>, and the opening portion 10d is sealed via an O-ring <NUM>. By screwing in the nut member <NUM>, the coil spring <NUM> is compressed, and the valve element <NUM> can be biased upward via the support member <NUM> with a predetermined elastic force. When the valve is opened, a refrigerant (fluid) in the valve chamber <NUM> passes between the valve element <NUM> and the valve seat <NUM> and flows out to the outlet refrigerant flow path 13a (illustrated by the dotted line in <FIG>) formed on the side opposing the inlet refrigerant passage <NUM>. The refrigerant from the outlet refrigerant flow path 13a is sent to an evaporator (not illustrated in the figure).

The refrigerant returned from the evaporator passes through the return passage <NUM> provided in the upper portion of the valve main body <NUM> and is returned to the compressor (not illustrated in the figure). The refrigerant temperature in the return passage <NUM> is transmitted to the pressure actuation chamber PA of the power element <NUM> attached to the upper portion of the valve main body <NUM>.

The power element <NUM> provided at the upper end of the valve main body <NUM> has a plug <NUM>, an upper lid member <NUM>, a diaphragm <NUM>, a stopper member <NUM>, and a receiving member <NUM>.

An opening portion 52a is formed at the top of the substantially conical upper lid member <NUM>, and can be sealed by the plug <NUM>.

The diaphragm <NUM> is made of a thin plate material in which a plurality of concentric uneven shapes are formed, and has an outer diameter that is substantially the same as the outer diameter of the upper lid member <NUM> and the receiving member <NUM>.

The substantially cylindrical receiving member <NUM> having a conical upper portion has a male screw 55a on the outer circumference of the lower end thereof.

The stopper member <NUM> has a disk portion 54a and a cylindrical portion 54b coaxially joined to the lower surface of the disk portion 54a. A fitting hole 54c is formed in the center of the lower end of the cylindrical portion 54b.

The assembly procedure of the power element <NUM> will be described. In a state in which the outer circumferential portions of the upper lid member <NUM>, the diaphragm <NUM>, and the receiving member <NUM> are overlapped with each other, these outer circumferential portions are peripherally welded and integrated together using TIG welding, laser welding, plasma welding, or the like, for example.

Subsequently, a working gas is sealed in a space (referred to as the pressure actuation chamber PA) surrounded by the upper lid member <NUM> and the diaphragm <NUM> from the opening portion 52a formed in the upper lid member <NUM>, and then the opening portion 52a is sealed with the plug <NUM>, and the plug <NUM> is fixed to the upper lid member <NUM> by projection welding or the like.

At this time, since the diaphragm <NUM> receives pressure in a form in which it protrudes toward the receiving member <NUM> due to the working gas sealed in the pressure actuation chamber PA, it is supported in contact with the upper surface of the stopper member <NUM> that is arranged in the lower space LS surrounded by the diaphragm <NUM> and the receiving member <NUM>. It should be noted that, since the disk portion 54a of the stopper member <NUM> is held by the inner surface of the receiving member <NUM>, the stopper member <NUM> does not come out of the power element <NUM>.

When the power element <NUM> assembled as described above is attached to the valve main body <NUM>, the male screw 55a on the outer circumference of the lower end of the receiving member <NUM> is screwed into the female screw 10b formed on the inner circumference of the recess portion 10a of the valve main body <NUM>. When the male screw 55a is screwed into the female screw 10b, the lower end of the receiving member <NUM> comes into contact with the upper end surface of the valve main body <NUM>. As a result, the power element <NUM> can be fixed to the valve main body <NUM>. In such a state, the lower space LS of the power element <NUM> communicates with the return flow path <NUM>, that is, the same internal pressure is obtained.

At this time, a packing PK is interposed between the power element <NUM> and the valve main body <NUM> to prevent the refrigerant from leaking from the recess portion 10a when the power element <NUM> is attached to the valve main body <NUM>.

In the electromagnetic valve integrated expansion valve <NUM>, since the internal pressure of the pressure actuation chamber PA changes in accordance with the pressure and temperature of the refrigerant flowing out of the evaporator and passing through the return flow path <NUM>, the diaphragm <NUM> changes shape and the operation rod <NUM> is driven as a result. The biasing force of the operation rod <NUM>, the refrigerant pressure in the valve chamber <NUM>, and the biasing force of the coil spring <NUM> are applied to the valve element <NUM>, and the gap between the valve element <NUM> and the valve seat <NUM> is adjusted by the balance of these forces.

Specifically, when the heat load of the evaporator is large, the gap between the valve element <NUM> and the valve seat <NUM> becomes large, and a large amount of refrigerant is supplied to the evaporator. Conversely, when the heat load is small, the gap becomes small, and the flow rate of the refrigerant supplied to the evaporator is reduced.

An electromagnetic valve <NUM> is attached to the side surface of the valve main body <NUM>. The electromagnetic valve <NUM> has a case <NUM> that is screwed to the valve main body <NUM>. A hollow suction element <NUM> is attached so as to extend into the case <NUM> from the bottomed opening portion 10c formed in the valve main body <NUM>.

The opening portion 10c communicates with the valve chamber <NUM> in the valve main body <NUM> via a communication passage (not illustrated in the figure). Accordingly, the pressure in the opening portion 10c is substantially equal to the internal pressure in the valve chamber <NUM>.

A cylindrical cover <NUM> connected to the suction element <NUM> is arranged in the center of the case <NUM>, a cylindrical plunger <NUM> is slidably arranged inside the cover <NUM>, and a valve shaft <NUM> is slidably inserted in the plunger <NUM>. The spring <NUM> provided between the plunger <NUM> and the valve shaft <NUM> biases the valve shaft <NUM> in a direction such that the valve shaft <NUM> protrudes from the plunger <NUM>. In addition, the spring <NUM> arranged between the suction element <NUM> and the plunger <NUM> is biased in a direction such that the plunger <NUM> separates from the suction element <NUM>.

A pilot valve element <NUM> is arranged on the inner side of the suction element <NUM> screwed into and attached to the opening portion 10c. The pilot valve element <NUM> has an annular valve element <NUM> made of PTFE and a brass pilot valve main body <NUM> that includes the valve element <NUM>. The pilot valve main body <NUM> has a bleed port 154a that penetrates in parallel with the valve element <NUM>. The electromagnetic valve element is composed of the valve shaft <NUM> and the pilot valve element <NUM>.

The pilot valve element <NUM> is held so as to be relatively displaceable along the axis with respect to the suction element <NUM>, is biased toward the valve shaft <NUM> by the coil spring <NUM>, and is in contact with the step portion on the inner circumference of the suction element <NUM>. A pilot valve port <NUM> formed at the center of the valve element <NUM> faces the tapered tip <NUM> of the valve shaft <NUM> protruding from the plunger <NUM>.

In the opening portion 10c, a conduit <NUM> is provided opposing the pilot valve element <NUM>. The inner side of the conduit <NUM> constitutes a principal valve opening <NUM> connected to the introduction ports 10c and 10f that are connected to the outlet refrigerant flow path (the outflow side passage) <NUM>.

As illustrated in <FIG>, the case <NUM> is bent into a U shape by press-molding one plate material, and the coil <NUM> is arranged inside the case <NUM>. The coil <NUM> is connected to one end of the two cords <NUM>. The other end of the cords <NUM> are connected to the connector <NUM>.

The connector <NUM> includes a resin tubular main body <NUM>, a resin clip portion <NUM> for attaching to the bracket <NUM>, and a metal terminal (not illustrated in the figure) connected to the cords <NUM> in the tubular main body <NUM>. The clip portion <NUM> has a shape formed by joining a plurality of conical portions in series, and is continuously provided on the tubular main body portion <NUM>.

<FIG> is a plan view of an intermediate product obtained in the manufacturing process of the bracket <NUM>. By punch processing one metal plate material, the substantially L-shaped intermediate product IM illustrated in <FIG> is formed. At the time of punch processing, a first hole <NUM> near one end of the intermediate product IM, and a second hole <NUM> and a third hole <NUM> near the other end may be formed at the same time. The first hole <NUM> and the second hole <NUM> are both circular, but the third hole <NUM> has two protruding portions 183a whose inner circumferences oppose each other.

The intermediate product IM is bent at a right angle around a first folding line FL1 near the first hole <NUM>. In addition, the intermediate product IM is bent approximately <NUM> degrees around a second folding line FL2 in the middle (see <FIG>). Further, the intermediate product IM is bent at a right angle at a third folding line FL3 near the third hole <NUM>. In this way, the bracket <NUM> is formed. It should be noted that by bending the bracket twice or more, the orientation of the connector <NUM> can be set in any three-dimensional direction.

The connector <NUM> is attached to the bracket <NUM> by inserting the clip portion <NUM> into the third hole <NUM> of the bracket <NUM>. When the clip portion <NUM> is inserted into the third hole <NUM>, any number of the conical portions of the clip portion <NUM> elastically change shape such that they can pass through the protruding portion 183a of the third hole <NUM>. However, when a force is applied in the direction of pulling out the clip portion <NUM> from the third hole <NUM>, the protruding portion 183a engages with any number of the conical portions to prevent the clip portion <NUM> from being pulled out. It should be noted that the second hole <NUM> can be used to fix another component.

The bracket <NUM> can be attached to the valve main body <NUM> by screwing the screw SC inserted into the first hole <NUM> of the bracket <NUM> into the screw hole of the valve main body <NUM>. By providing the screw hole for screwing the screw SC on the same surface as the screw hole for screwing the case <NUM> to the valve main body <NUM>, machining is facilitated.

At this time, the connector <NUM> attached to the bracket <NUM> via the third hole <NUM> is arranged so as to face diagonally downward with respect to the valve main body <NUM> (see <FIG>). By fitting together a mating connector (not illustrated in the figure) and the connector <NUM>, it is possible to connect to an external control device via the cord <NUM> so that power can be supplied.

The electromagnetic valve <NUM> can open or close the communication between the valve chamber <NUM> and the outlet refrigerant flow path 13a. When the electromagnetic valve <NUM> is energized, the coil <NUM> becomes excited, such that the plunger <NUM> approaches the suction element <NUM> against the biasing force of the spring <NUM>. In addition, the valve shaft <NUM> held by the plunger <NUM> is also displaced toward the pilot valve element <NUM>, and the pilot valve port <NUM> is closed by the tip <NUM> thereof.

As a result, the refrigerant in the opening portion 10c flows into the space between the valve shaft <NUM> and the pilot valve element <NUM> via the bleed port 154a, and the pressure in this space increases, such that the pilot valve element <NUM> is displaced toward the conduit <NUM> and closes the principal valve opening <NUM>. By closing the principal valve opening <NUM>, the communication between the valve chamber <NUM> and the outlet refrigerant flow path 13a is closed.

At this time, as described above, the valve element <NUM> is seated on or separated from the valve seat <NUM> as the operation rod <NUM> is displaced in response to the operation of the diaphragm <NUM>.

On the other hand, when the excitation of the coil <NUM> is deenergized by interrupting the energization of the electromagnetic valve <NUM>, the plunger <NUM> is separated from the suction element <NUM> by the biasing force of the spring <NUM>. Then, since the valve shaft <NUM> held by the plunger <NUM> is also displaced in a direction away from the pilot valve element <NUM>, the pilot valve port <NUM> that was closed by the tip <NUM> is opened.

As a result, more refrigerant than flows into the space between the valve shaft <NUM> and the pilot valve element <NUM> from the bleed port 154a flows out from the pilot valve port <NUM>, such that the pressure in this space decreases, the pilot valve element <NUM> is separated from the conduit <NUM>, and the principal valve opening <NUM> is opened. By opening the principal valve opening <NUM>, the refrigerant in the valve chamber <NUM> flows toward the outlet refrigerant flow path 13a.

In this way, refrigerant having a controlled flow rate can be circulated even when the valve element <NUM> is seated on the valve seat <NUM>.

According to the present embodiment, since the connector <NUM> is attached by using a bracket <NUM> that is three-dimensionally bent, the orientation of the connector <NUM> can be set to an optimal direction regardless of the posture of the valve main body <NUM>. Accordingly, when attaching the electromagnetic valve integrated expansion valve <NUM> to the refrigerant circulation system, the connector <NUM> can be easily connected to the mating connector even if the operator does not hold the connector <NUM>, and the ease of assembly is improved.

Further, by separating the case <NUM> and the bracket <NUM>, a plate material having a thickness suitable for the clip portion <NUM> to be inserted into the third hole <NUM> can be selected to form the bracket <NUM>. Accordingly, even in the case that the specifications of the clip portion <NUM> are changed, the original case <NUM> can be used in common. It should be noted that a screw hole may be formed in the case <NUM> and one end of the bracket <NUM> may be screwed therein.

<FIG> is a perspective view of an electromagnetic valve integrated expansion valve 1A according to the second embodiment representing the present invention, <FIG> is a top view of the electromagnetic valve integrated expansion valve 1A, <FIG> is a front view of the electromagnetic valve integrated expansion valve 1A, and <FIG> is a side view of the electromagnetic valve integrated expansion valve 1A. Configurations similar to those of the above-described embodiments are denoted by the same reference numerals, and redundant descriptions thereof are omitted.

In the present embodiment, a portion of the electromagnetic valve case also serves as a connector bracket. More specifically, the case 110A of the electromagnetic valve 100A is formed by processing one metal plate material with press molding. The case 110A has a first plate portion <NUM> screwed to the valve main body <NUM>, a second plate portion <NUM> parallel to the first plate portion <NUM>, and a third plate portion <NUM> that connects the ends of the first plate <NUM> and the second plate <NUM>.

A portion of the free end side of the second plate portion <NUM> is extended to form an extension portion <NUM>. As illustrated in <FIG>, the extension portion <NUM> constituting the bracket has a shape that is substantially L-shaped, and has a root portion 114a integrally formed with the second plate portion <NUM> and a widening portion 114b that is wider than the root portion 114a. At the center of the widening portion 114b, an attachment hole 114c having the same shape as the third hole <NUM> of the first embodiment is formed.

One side edge that is straight and continuous over the second plate portion <NUM>, the root portion 114a, and the widening portion 114b is bent to form a common rib 114d. In addition, the other side edge of the root portion 114a is also bent to form a rib 114e, and the other side edge of the widening portion 114b is also bent to form a rib 114f. By forming the ribs 114d, 114e, 114f, the rigidity of the case 110A is increased, which is advantageous with respect to vibrations and the like.

The connector <NUM> is attached to the case 110A by inserting the clip portion <NUM> into the attachment hole 114c in the same manner as in the above-described embodiment.

According to the present embodiment, since the case 110A is also used as a mounting bracket for the connector <NUM>, the number of parts is reduced. In addition, since the case 110A can be formed by press molding, the cost can be kept low even if the case <NUM> is also used as a mounting bracket.

Here, it is difficult to freely change the shape and dimensions of the first plate portion <NUM>, the second plate portion <NUM>, and the third plate portion <NUM> in order to hold a coil of a predetermined size. However, at the location of the folding line FL4 indicated by the dotted line in <FIG>, for example, the root portion 114a can be bent with respect to the second plate portion <NUM>, and as a result the connector <NUM> can be tilted to an arbitrary position around the folding line FL4. In addition to this, since the orientation of the connector <NUM> with respect to the attachment hole 114c (<FIG>) can be freely changed, ease of assembly is ensured in the embodiment as well.

Claim 1:
An electromagnetic valve integrated expansion valve (1A) comprising:
a valve main body (<NUM>) having a valve chamber (<NUM>);
a valve element (<NUM>) that restricts passage of a fluid by being seated on a valve seat (<NUM>) and allowing passage of the fluid by separating from the valve seat (<NUM>);
a coil spring (<NUM>) that biases the valve element (<NUM>) toward the valve seat (<NUM>);
an operation rod (<NUM>) that contacts the valve element (<NUM>) at one end;
a power element (<NUM>) that is attached to the valve main body (<NUM>) and drives the operation rod (<NUM>); and
an electromagnetic valve (100A) that opens or closes a principal valve opening (<NUM>) that is provided between the valve chamber (<NUM>) and an outflow side passage (<NUM>),
wherein:
the electromagnetic valve (100A) includes a case (110A) that is fixed to the valve main body (<NUM>), an electromagnetic valve element that separates from or approaches the principal valve opening (<NUM>), a coil (<NUM>) that drives the electromagnetic valve element, and a connector (<NUM>) connected to a cord (<NUM>) that supplies power to the coil (<NUM>), and
characterized in that the connector (<NUM>) is supported by a bracket (<NUM>) that extends from the case (110A),
the case (110A) is formed by bending one plate material, and the bracket (<NUM>) is a part of the plate material.