Description:FIELD
The present disclosure relates to field of compressors. In particular, the present disclosure relates to the soundproofing of hermetically sealed reciprocating compressors.
BACKGROUND
A compressor is a device that raises the pressure of a fluid by compressing it to a specific level. One common example is the compressor found in air conditioners, which compresses a vapor refrigerant. The vapor refrigerant passes through condenser and phase change takes place from vapor to liquid. This liquid refrigerant then evaporates in an evaporator, absorbing heat from the air in a room and thereby cooling it. Refrigeration compressors, specifically gas compressors, play a crucial role in refrigerators and air conditioners. Many efforts have been made to enhance the performance of compressors.
Typically, reciprocating compressors generate significant noise during operation due to the movement of various components. The conventional approach to reducing compressor noise involves increasing the thickness of the compressor's shell to confine the sound within. However, this conventional method also results in increased weight and bulkiness of the compressor. Moreover, the thicker shell adds to the overall cost of the compressor, making it economically less viable.
Accordingly, there exists a need to provide a valve plate assembly for a hermetically sealed reciprocating compressor which overcomes the abovementioned drawbacks.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
An object of the present disclosure is to provide a valve plate assembly for a hermetically sealed reciprocating compressor.
Another object of the present disclosure is to provide a valve plate assembly for a compressor which dampen the noise of the compressor.
Still another object of the present disclosure is to provide a valve plate assembly for a compressor which enhances the portability of compressors.
Yet another object of the present disclosure is to provide a valve plate assembly for a compressor which maintain the cost-effectiveness of compressors.
Still another object of the present disclosure to provide a valve plate assembly for a compressor which is easily constructed.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure envisages a valve plate assembly for a hermetically sealed reciprocating compressor. The valve plate assembly is configured to be operatively mounted within the compressor. between a cylinder head and a cylinder block to maintain a desired pressure range within a cylinder. The valve plate assembly comprises a valve plate defined by a first surface and a second surface, the first surface is configured with at least one discharge port and at least one valve seat; at least one discharge reed which is configured to be operatively mounted on the valve plate (10), and is further configured to be complementary to the valve seat to operatively open and close the at least one discharge port based on the pressure difference generated within the cylinder; and at least an arcuate resilient valve retainer, a free end of the retainer is configured to be spaced apart to enable an operative portion of the discharge reed to vibrate from the closed position to an open position of the at least one discharge port. In an operative configuration of the valve plate assembly, the movement of the discharge reed is configured to be dampened by the arcuate resilient valve retainer.
In an embodiment, the arcuate resilient valve retainer is coated by a polymeric resilient material selected from Polybutylene terephthalate (PBT), Polyetherimide (PEI), Liquid Crystal Polymer (LCP), Polyether ether ketone (PEEK), Polyphenylene Sulphide (PPS), polyamide, visco-elastic material or combination thereof.
In an embodiment, the thickness of the coating of the retainer is in the range of 50microns-500microns.
In an embodiment, the retainer is selected from a material consisting of Cold Rolled Close Annealed Steel (CRCA) or corrosion-resistant alloy (CRA), carbon steel, corrosion resistant steel (CRS), Phosphorised steel, Spring steel.
In an embodiment, the discharge reed and the retainer are configured to be fastened on the valve plate by means of a plurality of rivets or a plurality of fasteners.
In an embodiment, the thickness of the discharge reed is in the range of 0.2 mm to 0.4mm.
In an embodiment, the discharge reed is selected from a group of materials consisting of stainless steel, hardened steel, tempered bright fine polished flapper valve steel, flapper valve stainless steel, flapper valve carbon steel, or any combination thereof.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
A valve plate assembly for a hermetically sealed reciprocating compressor, of the present disclosure will now be described with the help of the accompanying drawing, in which:
Fig. 1 illustrates a perspective side view of a valve plate assembly in accordance with an embodiment of the present disclosure.
Fig. 2 illustrates a perspective isometric exploded view of a valve plate assembly in accordance with an embodiment of the present disclosure.
Fig. 3 illustrates a perspective top view of an arcuate resilient valve retainer in accordance with an embodiment of the present disclosure.
Fig. 4A illustrates a perspective side view of the valve plate assembly with the discharge reed resting in the valve seat in accordance with an embodiment of the present disclosure.
Fig. 4B illustrates a perspective side view of the valve plate assembly with the discharge reed abutting the inner periphery of retainer in accordance with an embodiment of the present disclosure.
Fig. 5 illustrate a perspective isometric view of a mounting arrangement of the valve plate assembly within the cylinder head of the compressor in accordance with an embodiment of the present disclosure.
Fig. 6 illustrates a statistical comparison of the conventional retainer (without coating) and the retainer with coating in accordance with an embodiment of the present disclosure.
LIST OF REFERENCE NUMERALS
100 valve plate assembly
10 valve plate
12 discharge port
14 valve seat
16 discharge reed
18 retainer
20 fastening means
22 hermetically sealed reciprocating compressor
24 motor or driving means
28 cylinder head
30 piston
32 gaskets
34 discharge muffler
36 suction muffler
DETAILED DESCRIPTION
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms “a”, “an” and “the” may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms “comprises”, “comprising”, “including” and “having” are open-ended transitional phrases and therefore specify the presence of stated features, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, elements, components, and/or groups thereof.
When an element is referred to as being “mounted on”, “engaged to”, “connected to” or “coupled to” another element, it may be directly on, engaged, connected or coupled to the other element. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed elements.
The terms first, second, third, etc., should not be construed to limit the scope of the present disclosure as the aforementioned terms may be only used to distinguish one element, component, region, layer or section from another component, region, layer or section. Terms such as first, second, third etc., when used herein do not imply a specific sequence or order unless clearly suggested by the present disclosure.
Terms such as “bottom”, “inner”, “outer”, “beneath”, “below”, “lower”, “above”, “upper” and the like, may be used in the present disclosure to describe relationships between different elements as depicted from the figures.
Typically, reciprocating compressors generate significant noise during operation due to the movement of various components. The conventional approach to reducing compressor noise involves increasing the thickness of the compressor's shell to confine the sound within. However, this conventional method results in increase in weight and bulkiness of the compressor. Moreover, the thicker shell adds to the overall cost of the compressor, making it economically less viable.
In order to address the aforementioned problems, the present disclosure envisages a valve plate assembly (100) (here in after referred as assembly 100) for a hermetically sealed reciprocating compressor. Fig. 1 illustrates a perspective side view of a valve plate assembly (100) in accordance with an embodiment of the present disclosure. The valve plate assembly (100) is configured to be operatively mounted within the compressor between a cylinder head and a cylinder block to maintain a desired pressure range within a cylinder. The valve plate assembly (100) comprises a valve plate (10), at least one discharge reed (16) and at least an arcuate resilient valve retainer (18). Fig. 2 illustrates a perspective isometric exploded view of a valve plate assembly (100) in accordance with an embodiment of the present disclosure.
The valve plate (10) is defined by a first surface and a second surface. The first surface of the valve plate (10) is provided with at least one discharge port (12) and at least one valve seat (14). The at least one discharge reed (16) is configured to be complementary to the shape of the valve seat (14). The discharge reed (16) is operatively mounted on the valve plate (10) such that it completely seat in the valve seat (14) to operatively open and close the at least one discharge port (12) based on the pressure difference generated within the cylinder. Therefore, the discharge reed (16) is intermittently coupled to the discharge port (12) of the valve plate (10) in an operative configuration of the valve plate assembly (100).
In an embodiment, depending on the number of valve seat (14), the number of discharge reed (16) and the retainer (18) can vary to operatively cover the discharge port (12) of the valve plate assembly (100).
In an embodiment, the discharge reed (16) is selected from a group of materials consisting of stainless steel, hardened steel, tempered bright fine polished flapper valve steel or any combination thereof.
In an embodiment, the thickness of the discharge reed (16) is in the range of 0.2 mm to 0.4mm.
Further, the retainer (18) is an arcuate resilient valve retainer (18). A free end of the retainer (18) is configured to be spaced apart to enable an operative portion of the discharge reed (16) to vibrate from the closed position to an open position of the at least one discharge port (12) to maintain the desired pressure within the cylinder. An operative end of the retainer (18) and the discharge reed (16) are mounted to the valve plate (10) by means of plurality of fastening means (20).
In an embodiment, the plurality of fastening means (20) is selected from a group consisting of rivets, fasteners or any combination thereof.
In an embodiment, the retainer (18) is selected from a material consisting of Cold Rolled Close Annealed Steel (CRCA), corrosion-resistant alloy (CRA), carbon steel, corrosion resistant steel (CRS), Phosphorised steel, Spring steel or any combination thereof.
Fig. 3 illustrates a perspective top view of an arcuate resilient valve retainer.
Further, the retainer (18) is coated by a layer of a polymeric resilient material. Thus, it provides proper cushioning as well as dampening effect during the operative condition of the discharge reed (16) and thus facilitates in noise absorption within the compressor.
In an embodiment, the polymeric resilient material is selected from a group consisting of Polybutylene terephthalate (PBT), Polyetherimide (PEI), Liquid Crystal Polymer (LCP), Polyether ether ketone (PEEK), Polyphenylene Sulphide (PPS), polyamide, visco-elastic material or combination thereof.
In an embodiment, the thickness of said coating of the retainer (18) is in the range of 50microns-500microns.
Advantageously, the encapsulation of retainer (18) by polymeric resilient material reduces the noise inside the compressor. The striking noise or high frequency noise generated between the discharge reed (16) and the retainer (18) is reduced by the presence of coating on the retainer (18).
Further, in an operative condition of the valve plate assembly (100), when the pressure inside the cylinder increases beyond the desired pressure range, an operative portion of the discharge reed (16) is allowed to move and vibrate to thereby it touches the inner peripheral surface of the arcuate resilient valve retainer (18) to open the discharge port (12). Therefore, during the course of touching the discharge reed (16) to the retainer (18), the coating provided over the retainer (18) provides sufficient dampening to the discharge reed (16) and thus reduces the noise of the compressor.
Fig. 4A illustrates a perspective side view of the valve plate assembly with the discharge reed resting in the valve seat and Fig. 4B illustrates a perspective side view of the valve plate assembly with the discharge reed abutting the inner periphery of retainer in accordance with an embodiment of the present disclosure.
Further, in the operative state of the valve plate assembly (100), when the pressure within the cylinder surpasses the desired pressure range, an operative portion of the discharge reed (16) is permitted to move and vibrate. As a result, it makes contact with the inner operative surface of the arcuate resilient valve retainer (18), leading to the opening of the discharge port (12). This interaction between the discharge reed (16) and the retainer (18) generates a sudden impact within the cylinder, and during this phase, the coating present on the retainer (18) effectively dampens the impact of the discharge reed (16). Consequently, the coating provided over the retainer effectively absorb the impact of the reed and thus results in a reduction or suppress in the overall noise generated by the compressor.
In an embodiment, the coating provided over the retaining plate also provided protecting coating from the corrosion.
Figure 5 illustrates a perspective view of mounting arrangement of the valve plate assembly (100) within a cylinder head (28) of the hermetically sealed reciprocating compressor (22) in accordance with an embodiment of the present disclosure. The compressor (22) includes a driving means or a motor (24) coupled to a piston (30) to drive the piston in an operative configuration of the assembly (100). The piston (30) protrudes within the cylinder head (28). The cylinder head (28) is configured to enclose and mount the valve plate assembly.
In an embodiment, the valve plate assembly (100) is configured to be mounted within the cylinder head (28) with a pair of gaskets (32) thereon.
In an embodiment, an operative portion of the cylinder head (28) is mounted with a discharge muffler (34) and a suction muffler (36).
Additionally, the coating also provided exceptional abrasion resistance, thermal and chemical resistance, including inertness to oils, Flexibility and machining suitability, Low friction coefficient, excellent resistance to chlorinated chemicals and hot water, Noise and vibration dampening and Compatibility with lubes and refrigerants.
Additionally, the coating of the retainer (18) also acts as Noise and Vibration dampener on stationary parts like Cylinder Head, Shock Loop; on moving part like spring to reduce intermetallic noise and friction and act as dampening layer between the matting parts to attenuate the frequencies on cylinder head, body castings.
EXAMPLE
In an exemplary embodiment, a conventional retainer (18) without any coating and a retainer (18) of present disclosure is examined from a frequency range between 100Hz-10KHz.. The tested data are tabulated below:
Frequency (Hz) Retainer without coating Coated Retainer
100 47 59
125 55 68
160 52 60
200 52 55
250 61 58
315 59 53
400 46 54
500 51 54
630 56 59
800 59 60
1000 61 62
1250 70 62
1600 63 59
2000 59 56
2500 62 58
3150 61 64
4000 63 60
5000 68 63
6300 58 57
8000 57 56
10000 55 57
LWA 75 72
The Fig 5 illustrates a statistical comparison of the conventional retainer (18) (without coating) and the retainer (18) with coating. It has been observed that the coated retainer (18) absorbs more impact and thus suppress more sound as compared to the retainer (18) without coating and has been evaluated through a simulation testing using real time operational parameters.
The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
TECHNICAL ADVANCEMENTS AND ECONOMIC SIGNIFICANCE
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of the valve plate assembly for a hermetically sealed reciprocating compressor, that:
• effectively dampen the noise of the compressor;
• enhances the portability of compressors since the thickness of the shell remain unaltered and thus weight of the compressor remains unchanged;
• maintain the cost-effectiveness of compressors; and
• facilitates ease of construction.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein.
The foregoing description of the specific embodiments so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation. , Claims:WE CLAIM:
1. A valve plate assembly (100) for a hermitically sealed reciprocating compressor, said valve plate assembly (100) comprising:
• a valve plate (10) defined by a first surface and a second surface, said first surface configured with at least one discharge port (12) and at least one valve seat (14);
• at least one discharge reed (16) configured to be operatively mounted on said valve plate (10), and further configured to be complementary to said valve seat (14) to operatively open and close said at least one discharge port (12) based on the pressure difference generated within the cylinder; and
• at least an arcuate resilient valve retainer (18), a free end of said retainer (18) configured to be spaced apart to enable an operative portion of said discharge reed (16) to vibrate from the closed position to an open position of said at least one discharge port (12),
wherein movement of discharge reed (16) configured to be dampened by said arcuate resilient valve retainer (18) in an operative configuration of said valve plate assembly (100).
2. The valve plate assembly (100) as claimed in claim 1, wherein said arcuate resilient valve retainer (18) is coated by a polymeric resilient material selected from Polybutylene terephthalate (PBT), Polyetherimide (PEI), Liquid Crystal Polymer (LCP), Polyether ether ketone (PEEK), Polyphenylene Sulphide (PPS), polyamide, visco-elastic material or combination thereof.
3. The valve plate assembly (100) as claimed in claim 2, wherein the thickness of said coating of said retainer (18) is in the range of 50microns-500microns.
4. The valve plate assembly (100) as claimed in claim 1, wherein said retainer (18) is selected from a material consisting of Cold Rolled Close Annealed Steel (CRCA) or corrosion-resistant alloy (CRA), carbon steel, corrosion resistant steel (CRS), Phosphorised steel, Spring steel or any combination thereof.
5. The valve plate assembly (100) as claimed in claim 1, wherein said discharge reed (16) and said retainer (18) are configured to be fastened on said valve plate (10) by means of a plurality of rivets or a plurality of fasteners.
6. The valve plate assembly (100) as claimed in claim 1, wherein the thickness of said discharge reed (16) is in the range of 0.2 mm to 0.4mm.
7. The valve plate assembly (100) as claimed in claim 1, wherein said discharge reed (16) is selected from a group of materials consisting of stainless steel, hardened steel, tempered bright fine polished flapper valve steel or any combination thereof.

Dated this 19th day of August, 2023

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA – 25
of R.K.DEWAN & CO.
Authorized Agent of Applicant

TO,
THE CONTROLLER OF PATENTS
THE PATENT OFFICE, AT MUMBAI