Vane compressor with elastic member protruding into the cylinder

Abstract

A vane-type compressor is provided. The vane-type compressor may include a cylindrical cylinder having opposite open ends along an axial direction, an inner circumferential surface of the cylinder being eccentric from an outer circumferential surface of the cylinder, a main bearing and a sub bearing, respectively, positioned at the open ends of the cylinder, a rotor coupled to a shaft supported by the main bearing and the sub bearing and installed eccentric from the inner circumferential surface of the cylinder, and a plurality of vanes coupled to the rotor to rotate along with the rotor, the plurality of vanes dividing the inner circumferential surface of the cylinder into a plurality of spaces including a suction chamber and a compression chamber when the rotor rotates. An elastic member may be installed at a point at which a minimum gap is maintained between the inner circumferential surface of the cylinder and the rotor so that a portion of the elastic member protrudes inward of the inner circumferential surface of the cylinder. An end of a discharge dimple formed in the inner circumferential surface of the cylinder extends up to the point.

Claims

1. A vane compressor, comprising: a cylinder having open ends along an axial direction, an inner circumferential surface of the cylinder being eccentric from an outer circumferential surface of the cylinder; a main bearing positioned at a first end of the cylinder and a sub bearing positioned at a second end of the cylinder; a rotor coupled to a shaft supported by the main bearing and the sub bearing and installed eccentric from the inner circumferential surface of the cylinder; and a plurality of vanes coupled to the rotor to rotate along with the rotor, the plurality of vanes dividing the inner circumferential surface of the cylinder into a plurality of chambers including a suction chamber and a compression chamber when the rotor rotates, wherein an elastic member is installed at a point at which a minimum gap is maintained between the inner circumferential surface of the cylinder and the rotor so that a portion of the elastic member protrudes inward of the inner circumferential surface of the cylinder, and wherein an end of a discharge dimple formed in the inner circumferential surface of the cylinder extends up to the point.

2. The vane compressor of claim 1, wherein the elastic member is a circular or leaf spring.

3. The vane compressor of claim 2, wherein a coating layer for lubrication is formed on a surface of the circular or leaf spring.

4. The vane compressor of claim 2, wherein the cylinder includes a spring recess that is circular into which the circular or leaf spring is inserted, and wherein at least a portion of the spring recess is open to an inside of the inner circumferential surface of the cylinder.

5. The vane compressor of claim 4, wherein a back pressure is formed at a back end of the circular or leaf spring inserted to the spring insertion recess.

6. The vane compressor of claim 1, wherein the shaft, the main bearing, and the sub bearing are positioned concentrically.

7. The vane compressor of claim 6, wherein the main bearing and the sub bearing each have a rail groove that is circular in a surface facing the plurality of vanes, and wherein each vane of the plurality of vanes includes a protrusion inserted into each of the respective rail grooves.

8. The vane compressor of claim 7, wherein the rail grooves are eccentric in the main bearing and the sub bearing.

9. The vane compressor of claim 8, wherein the rail grooves and the inner circumferential surface of the cylinder are each shaped as a circle.

10. The vane compressor of claim 9, wherein each of the plurality of vanes includes a tip which is concentric and smaller than a diameter of the inner circumferential surface of the cylinder at a predetermined angle between 40° and 160° in a rotational direction from a point at which suction is completed.

11. The vane compressor of claim 10, wherein each of the plurality of vanes is coupled to the rotor at an inclination angle ranging from 5° to 20° from a radial direction passing through a central axis of the rotor.

12. The vane compressor of claim 11, wherein a suction dimple is formed in the inner circumferential surface of the cylinder.

13. The vane compressor of claim 12, wherein the suction dimple includes a suction port.

14. The vane compressor of claim 8, wherein at least one of the rail grooves or the inner circumferential surface of the cylinder is not circular in shape.

15. The vane compressor of claim 14, wherein a suction dimple is formed in the inner circumferential surface of the cylinder.

16. The vane compressor of claim 15, wherein the suction dimple includes a suction port.

17. A vane compressor, comprising: a cylinder having open ends along an axial direction, an inner circumferential surface of the cylinder being eccentric from an outer circumferential surface of the cylinder; a main bearing positioned at a first end of the cylinder and a sub bearing positioned at a second end of the cylinder; a rotor coupled to a shaft supported by the main bearing and the sub bearing and installed eccentric from the inner circumferential surface of the cylinder; and a plurality of vanes coupled to the rotor to rotate along with the rotor, the plurality of vanes dividing the inner circumferential surface of the cylinder into a plurality of chambers including a suction chamber and a compression chamber when the rotor rotates; a recess formed in the cylinder; and a spring installed in the recess at a point at which a minimum gap is maintained between the inner circumferential surface of the cylinder and the rotor, wherein at least a portion of the recess is open to an inside of the inner circumferential surface of the cylinder such that a portion of the spring protrudes inward of the inner circumferential surface of the cylinder.

18. The vane compressor of claim 17, wherein the spring is a circular or leaf spring.

19. The vane compressor of claim 18, wherein a coating layer for lubrication is formed on a surface of the circular or leaf spring.

20. The vane compressor of claim 17, wherein an end of a discharge dimple formed in the inner circumferential surface of the cylinder extends up to the point.

21. The vane compressor of claim 17, wherein a back pressure is formed at a back end of the spring inserted into the recess.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Embodiments will be described in detail with reference to the following drawings in which like reference numerals refer to like elements, and wherein:

(2) FIG. 1 is a cross-sectional view illustrating a related art vane-type compressor;

(3) FIG. 2 is an exploded perspective view illustrating a compression element of the vane-type compressor of FIG. 1;

(4) FIG. 3 is a perspective view illustrating a second vane and a vane aligner of the vane-type compressor of FIG. 1;

(5) FIG. 4 is a plan view (rotational angle 90°) illustrating a compression element of the vane-type compressor of FIG. 1;

(6) FIG. 5 is a plan view illustrating a compression element showing a compression operation of the vane-type compressor as shown in FIG. 1;

(7) FIG. 6 is an exploded perspective view illustrating a compression element according to an embodiment;

(8) FIG. 7 is a plan view illustrating an assembled state of a rotor part, vane, and cylinder among compression elements as shown in FIG. 6;

(9) FIG. 8 is an enlarged view illustrating a main part of FIG. 7;

(10) FIG. 9 is a view illustrating a comparison between a discharge dimple angle according to the related art and a discharge dimple angle according to an embodiment.

DETAILED DESCRIPTION

(11) Hereinafter, embodiments are described hereinafter with reference to the accompanying drawings. The same or similar reference numerals may be used to denote the same or similar elements throughout the drawings and the specification, and repetitive description has been omitted.

(12) It will be understood that when an element or layer is referred to as being “on,” “connected to,” “coupled to,” or “adjacent to” another element or layer, it can be directly on, connected, coupled, or adjacent to the other element or layer, or intervening elements or layers may be present.

(13) When determined to make the subject matter unclear, description of known art or functions may be skipped.

(14) The accompanying drawings are provided merely for a better understanding of embodiments and the technical spirit or the scope are not limited by the drawings.

(15) As used herein, the term “disclosure” may be replaced with other terms, such as “disclosure,” “document,” “specification,” or “description.”

(16) Hereinafter, embodiments are described with reference to FIGS. 6 to 10.

(17) FIG. 6 is an exploded perspective view illustrating a compression element according to an embodiment. FIG. 7 is a plan view illustrating an assembled state of a rotor part, vane, and cylinder among compression elements as shown in FIG. 6. FIG. 8 is an enlarged view illustrating a main part of FIG. 7. FIG. 9 is a view illustrating a comparison between a discharge dimple angle according to the related art and a discharge dimple angle according to an embodiment. Although a vane-type compressor is described below as an example, the technology is also applicable to common sealed rotary compressors.

(18) According to an embodiment, the vane-type compressor may be applied to refrigerators, freezers, or air conditioners. For example, an air conditioner may include a vane-type compressor 100 to compress coolant according to an embodiment, a condenser, a decompressor, and an evaporator.

(19) Moreover, the vane-type compressor according to an embodiment is applicable to refrigerators, freezers, or air conditioners and may include a compression element, an electromotive element or unit (drive motor) that drives the compression element, and a sealed container that receives the compression element and the electromotive element.

(20) As the above-described sealed container and electromotive element according to the related art may be adopted as the sealed container and the electromotive element, the compression element alone is described hereinafter. According to an embodiment, the compression element of the vane-type compressor may include a cylinder 201, a main bearing 202, a sub bearing 203, a rotor shaft 204, a vane 209, and an elastic member 205, discussed hereinafter.

(21) The cylinder 201 may be substantially cylindrical in shape and both ends thereof, in the axial direction, may be open. Cylinder inner circumferential surface 201a may be eccentric with respect to an outer circumferential surface of the cylinder 201. A suction dimple 201b may be formed in the cylinder inner circumferential surface 201a by cutting in circle (at cross sectional view) to be externally larger than the cylinder inner circumferential surface 201a. An open suction port 201c may be formed in the cylinder inner circumferential surface 201a or the suction dimple 201b.

(22) At a point of the cylinder inner circumferential surface 201a, where a minimum gap is maintained between the cylinder inner circumferential surface 201a and rotor part or portion 204a, a spring insertion part or portion 201d which may be circular in shape and at least a portion of which may be open inward of the cylinder inner circumferential surface 201a may be formed, and in the cylinder inner circumferential surface 201a, a discharge dimple 201e formed by cutting in circle (at cross sectional view) to be externally larger than the cylinder inner circumferential surface 201a may be formed so that one end thereof extends up to the point. The cylinder inner circumferential surface 201a may be shaped as a circle or may be formed in other shapes.

(23) The main bearing 202 may have a substantially “T”-shaped cross-section, and a portion thereof, which abuts the cylinder 201, may have a substantially circulate plate shape. One opening (an upper one in FIG. 6) of the cylinder 201 may be closed.

(24) A circular rail groove 202a which may be eccentric from the main bearing 202 may be formed in the surface, on the side of the cylinder 201, of the main bearing 202. The rail groove 202a may be shaped as a circle or may be formed in other shapes. A middle portion of the main bearing 202 may be cylindrical in shape, and a rotational shaft part or portion 204b may be inserted therethrough.

(25) The sub bearing 203 may have a substantially “T”-shaped cross-section, and a portion thereof, which abuts the cylinder 201, may have a substantially circulate plate shape. The other opening (a lower one in FIG. 6) of the cylinder 201 may be closed.

(26) A circular rail groove 203a which may be eccentric from the sub bearing 203 may be formed in the surface, on the side of the cylinder 201, of the sub bearing 203. The rail groove 203a may be shaped as a circle or may be formed in other shapes. At least one of the rail groove 202a of the main bearing 202 or the rail groove 203a of the sub bearing 203 may be formed in a shape other than a circle. A middle portion of the sub bearing 203 may be cylindrical in shape, and a rotational shaft part or portion 204c may be inserted therethrough.

(27) The rotor shaft 204 may have a structure in which the rotor part 204a, which rotates on a central axis eccentric with respect to a central axis of the cylinder 201, and upper and lower rotational shaft parts 204b and 204c of the rotor part 204a are integrally formed with each other. The rotation shaft parts 204b and 204c may be engaged with a bearing part or portion of the main bearing 202 and a bearing part or portion of the sub bearing 203, respectively.

(28) The rotor part 204a may include a vane installation part or portion 204g which penetrates in an axial direction. The vane installation part 204g may have an inclination angle θ1 ranging from 5° to 20° from a radial direction which passes through a central axis of the rotor shaft 204. The rotor shaft 204, main bearing 202, and sub bearing 203 may be concentric to one another.

(29) The vane 209 may be shaped substantially as a rectangular plate and have protrusions 209a and 209b at both ends (top and bottom of FIG. 6) in the axial direction. The protrusions 209a and 209b may be fitted to the rail grooves 202a and 203a.

(30) A plurality of vanes 209 may include tips 209c which are concentric and smaller than a diameter of the cylinder inner circumferential surface 201a of the cylinder 201 at a specific or predetermined angle between 40° and 160° in a rotational direction from a point at which suction is completed.

(31) Each vane 209 may be coupled to the vane installation part 204g formed in the rotor part 204a and thus rotated along with the rotor part 204a. When the rotor part 204a is rotated, the vanes 209 partition the cylinder inner circumferential surface 201a of the cylinder 201 into a plurality of spaces including a suction chamber and a compression chamber.

(32) Although FIG. 6 illustrates an example in which vanes are provided, the number of the vanes is not limited thereto as long as two or more vanes are provided.

(33) The elastic member 205 may be formed as a circular or leaf spring and may be installed in spring insertion part or portion 201d formed at a point at which a minimum gap is maintained between the cylinder inner circumferential surface 201a and the rotor part 204a. A portion of the elastic member 205 may protrude inward of the inner circumferential surface 201a of the cylinder 201.

(34) A coating layer 205a for lubrication may be formed on a surface of the circular or leaf spring. A back pressure may form at a back end of the circular or leaf spring inserted to the spring insertion part 201d.

(35) When the spring insertion part 201d is overall formed in a circular shape, and the circular or leaf spring is installed in the spring insertion part 201, as shown in FIG. 8, a back pressure may be formed at the back end of the spring without using a separate structure. Thus, the circular or leaf spring may elastically contact the tip 209c of the vane 209, as shown in FIG. 8.

(36) FIG. 6 shows a state before the vane 209 is integrated with the rotor part 204a and the bearings 202 and 203. In practice, the vane 209 is coupled to the vane installation part 204g, and the protrusions 209a and 209b of the vane 209 are fitted into the rail grooves 202a and 203a.

(37) As the vane 209 is integrated with the rotor part 204a and the bearings 202 and 203, the number of components may be reduced as compared with the related art. Further, it is possible to effectively assemble the rotor part, vanes, and bearings (main bearing and sub bearing) and to reduce accumulated tolerances among components, thereby mitigating vibrational noise and reducing assembly and labor costs. It is also possible to make the vane-type compressor smaller and with more capacity by increasing an outer diameter or number of vanes.

(38) The vane 209 and the rotor part 204a which have been integrated together, are rotated around the central axis of the cylinder inner circumferential surface 201a, and a distance between the central axis of the cylinder inner circumferential surface 201a and the vane tip 209a remains smaller than (or substantially identical to) a radius of the cylinder inner circumferential surface 201a.

(39) Operations are described hereinafter. When the rotational shaft part 204b of the rotor shaft 204 receives a rotational force from a drive, for example, the electromotive element, or in the case of engine driving, an engine, the rotor part 204a rotates in the cylinder 201. As the rotor part 204a rotates, the vane 209 which is in the vane installation part 204g of the rotor part 204a is rotated along with the rotor part 204a.

(40) A direction of the vane 209 is restricted to a direction of normal to the cylinder 201 by the protrusions 209a and 209b rotatably coupled to the rail grooves 202a and 203a formed, concentrically to the cylinder inner circumferential surface 201a, in the end surfaces, on the side of the cylinder, of the main bearing 202 and the sub bearing 203. Thus, the vane 209 is rotated around the central axis of the cylinder inner circumferential surface 201a, and the distance between the central axis of the cylinder inner circumferential surface 201a and the vane tip 209a remains smaller than (or substantially identical to) the radius of the cylinder inner circumferential surface 201a. Thus, the vane 209 is rotated as the protrusions 209a and 209b slide along the rail grooves 202a and 203a, with the vane tip 209a not in contact with the cylinder inner circumferential surface 201a of the cylinder 201.

(41) As an arc of the vane tip 209a of the vane 209 and the cylinder inner circumferential surface 201a of the cylinder 201 have substantially a same radius, and their normal lines are substantially identical to each other, they rotate, with a fine gap formed therebetween. Thus, as the rotor part 204a of the rotor shaft 204 rotates, a volume of the suction chamber, intermediate chamber, and compression chamber in the cylinder 201 is varied so that coolant is suctioned and compressed.

(42) In the compressor according to an embodiment, as the discharge dimple 201e is formed up to the elastic member 205 and the rotor part 204a, overcompression may be reduced during suction and compression, thereby achieving about 0.5% more mechanical efficiency. As the elastic member 205 comes in line contact with the rotor part 204a, discharge-suction leakage may be reduced during suction and compression, thus increasing volume and indication efficiency by about 3%.

(43) Some of the above-described embodiments are interpreted as excluding or distinguishing from other embodiments. The components or functions in some embodiments described above may be used together or combined with components or functions in other embodiments.

(44) For example, component A described in connection with a particular embodiment and the drawings may be combined or merged with component B described in connection with another embodiment and the drawings. In other words, a combination of components, although not explicitly described, may be rendered possible unless stated as impossible.

(45) According to embodiments disclosed herein a vane-type compressor with improved efficiency and reduced noise by reducing overcompression and suction-discharge leakage is provided. According to embodiments disclosed herein, there is further provided a vane-type compressor with a reduced number of components, and by which assembly and labor costs may be decreased. According to embodiments disclosed herein, there is also provided a vane-type compressor which may be made more compact and with high capacity by increasing the outer diameter or the number of vanes.

(46) According to embodiments disclosed herein, a vane-type compressor includes a cylindrical cylinder having two opposite open ends along an axial direction, an inner circumferential surface of the cylinder eccentric from an outer circumferential surface of the cylinder, a main bearing positioned at one open end of the two opposite open ends of the cylinder and a sub bearing positioned at the other open end of the two opposite open ends of the cylinder, a rotor part or portion coupled to a rotor shaft supported by the main bearing and the sub bearing and installed eccentric from the inner circumferential surface of the cylinder, and a plurality of vanes coupled to the rotor part to rotate along with the rotor part, the plurality of vanes dividing the inner circumferential surface of the cylinder into a plurality of spaces including a suction chamber and a compression chamber when the rotor part rotates. An elastic member may be installed at a point where a minimum gap is maintained between the inner circumferential surface of the cylinder and the rotor part so that a portion of the elastic member may protrude inward of the inner circumferential surface of the cylinder. An end of a discharge dimple formed in the inner circumferential surface of the cylinder may extend up to the point. By the configuration of the compressor, as the discharge dimple may extend up to the point where the minimum gap is maintained between the inner circumferential surface of the cylinder and the rotor part, overcompression and discharge-suction leakage may be reduced.

(47) The elastic member may be formed as a circular or leaf spring. A coating layer for lubrication may be formed on a surface of the circular or leaf spring. Thus, frictional force may be reduced when a tip of the vane contacts the circular or leaf spring.

(48) The cylinder may include a circular spring insertion part or portion to which the circular or leaf spring may be inserted. At least a portion of the spring insertion part may be open to an inside of the inner circumferential surface of the cylinder. Thus, a portion of the circular or leaf spring may project inward of the inner circumferential surface of the cylinder through the open part.

(49) A back pressure may be formed at a back end of the circular or leaf spring inserted to the spring insertion part. Thus, a protrusion of the circular or leaf spring may elastically contact the tip of the vane.

(50) The rotor shaft, the main bearing, and the sub bearing may be positioned concentrically. The main bearing and the sub bearing each may have a circular rail groove in a surface facing the vane. The vane may include a protrusion inserted into the rail groove. Thus, it is possible to effectively assemble the rotor part, vanes, and bearings (main bearing and sub bearing) and to reduce accumulated tolerances to thereby mitigate vibrational noise.

(51) The rail groove may be eccentric from the main bearing and the sub bearing. Thus, an internal space of the cylinder may be divided into a plurality of spaces including a compression chamber and a suction chamber by the plurality of vanes.

(52) The rail groove and the inner circumferential surface of the cylinder may be formed in a circle in which case each of the plurality of vanes may include a tip which is concentric and is smaller than a diameter of the inner circumferential surface of the cylinder at a predetermined angle between 40° and 160° in a rotational direction from a point where suction is completed.

(53) Each of the plurality of vanes may be coupled to the rotor part at an inclination angle ranging from 5° to 20° from a radial direction passing through a central axis of the rotor part. A suction dimple may be formed in the inner circumferential surface of the cylinder. The suction dimple may have a suction port. As the suction dimple is formed in the inner circumferential surface of the cylinder, more gas (coolant) may be suctioned into the suction chamber.

(54) In contrast, at least one of the rail groove or the inner circumferential surface of the cylinder may not be formed in circle. Even in such a case, a suction dimple may be formed in the inner circumferential surface of the cylinder, and the suction dimple may have a suction port. As the suction dimple is formed in the inner circumferential surface of the cylinder, more gas (coolant) may be suctioned into the suction chamber.

(55) According to embodiments disclosed herein, the vane-type compressor may have improved efficiency and reduced noise by reducing overcompression and suction-discharge leakage. Further, according to embodiments disclosed herein, the vane-type compressor may have a reduced number of components and may thus decrease assembly and labor costs.

(56) It is also possible to make the vane-type compressor smaller and with more capacity by increasing the outer diameter or the number of vanes. Thus, the above description should be interpreted not as limiting in all aspects but as exemplary. The scope of the disclosure should be determined by reasonable interpretations of the appended claims and all equivalents of the disclosure belong to the scope of the disclosure.

(57) It will be understood that when an element or layer is referred to as being “on” another element or layer, the element or layer can be directly on another element or layer or intervening elements or layers. In contrast, when an element is referred to as being “directly on” another element or layer, there are no intervening elements or layers present. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

(58) It will be understood that, although the terms first, second, third, etc., may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer or section from another region, layer or section. Thus, a first element, component, region, layer or section could be termed a second element, component, region, layer or section without departing from the teachings of the present invention.

(59) Spatially relative terms, such as “lower”, “upper” and the like, may be used herein for ease of description to describe the relationship of one element or feature to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation, in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “lower” relative to other elements or features would then be oriented “upper” relative to the other elements or features. Thus, the exemplary term “lower” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

(60) The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

(61) Embodiments of the disclosure are described herein with reference to cross-section illustrations that are schematic illustrations of idealized embodiments (and intermediate structures) of the disclosure. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, embodiments of the disclosure should not be construed as limited to the particular shapes of regions illustrated herein but are to include deviations in shapes that result, for example, from manufacturing.

(62) Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

(63) Any reference in this specification to “one embodiment,” “an embodiment,” “example embodiment,” etc., means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. The appearances of such phrases in various places in the specification are not necessarily all referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with any embodiment, it is submitted that it is within the purview of one skilled in the art to effect such feature, structure, or characteristic in connection with other ones of the embodiments.

(64) Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.