CN101310956A - Manufacturing method of suction muffler - Google Patents

Abstract

The invention relates to a method for manufacturing a suction muffler and discloses a technique for making energy efficiency higher and reducing noise. In the method, foam of the suction muffler molds a component of a casing which is made of synthetic resin and used for the suction muffle of a sealing compressor, wherein in the molding process, a die core is used to reciprocally moving the at least one component of a die, a die cavity is expanded and a plate is thickened. As a result, the foaming is improved by expanding the die, lessening pressure and inflating gas, consequently, in addition to the effects hereinbefore, significant heat insulating property can be obtained due to acquirement of higher foaming amplifying rate, thus increasing the rate of suction.

Description

Suck the manufacture method of silencer

The application is that the application number of submitting to Patent Office of the People's Republic of China in applicant Panasonic Electric Equipment Industrial Co.,Ltd and on October 8th, 2004 is 200480029715.4, and denomination of invention is divided an application for the application for a patent for invention of " hermetic compressor and suck the manufacture method of silencer ".

Technical field

The present invention relates to a kind of hermetic compressor that is used in refrigerator, air-conditioning, refrigerating equipment or the like; In particular, relate to the improvement that it sucks silencer and manufacture method thereof.

Background technology

In recent years, its noise that causes except work of hermetic compressor that strong hope is used in refrigerating equipment or the like will hang down this fact, and it is high that its energy efficiency is wanted.

As conventional hermetic compressor, the raising that a kind of its energy efficiency of hermetic compressor is arranged is by improving the noise elimination effect that sucks silencer and effectively utilizing this noise elimination effect, thereby increase the refrigerant circulation quantity (for example, with reference to following patent documentation 1) that enters discharge chambe.

In addition, a kind of raising of its energy efficiency of hermetic compressor being arranged is to remain on low temperature and highdensity state and be drawn into (for example patent documentation 2 below the reference) in the discharge chambe by the refrigerant gas that will return from freeze cycle.

Patent documentation 1: unexamined patent disclosure, publication number 2003-42064

Patent documentation 2: unexamined patent disclosure, publication number 11-303739

The structure of conventional hermetic compressor above-mentioned is described below with reference to accompanying drawing.

Figure 17 illustrates the sectional view of conventional hermetic compressor, and Figure 18 illustrates the sectional view of the suction silencer among Figure 19, and Figure 19 demonstrates the behavior of refrigerant gas for velocity vector illustrates it by using flow vector in the suction silencer shown in Figure 18.

In Figure 17, hermetically sealed can 1 has held motor component 5, and it is made up of rotor 4 and the stator 3 that holds coiler part 2, and by motor component 5 compressor driven elements 6.Lubricating oil 8 is stored in the hermetically sealed can 1.

The schematic configuration of compressing member 6 is described below.Crank axle 10 has: main shaft portion 11 rotors 4 are pressed into there and cooperate and fixing, and eccentric part 12 its form relative rotating shaft part 11 off-centre.In main shaft portion 11, be provided with oil pump 13 to be opened in the lubricating oil 8.

The cylinder block 20 that is formed on motor component 5 tops has: the discharge chambe 22 of approximate circle tubular, and the axle eyelid retractor 23 that supports the main shaft portion 11 with axle.Piston 30 is inserted in the discharge chambe 22 of cylinder block 20 so that can reciprocatingly slide therein and be connected on the eccentric part 12 by coupling arrangement 31.

The valve plate 35 that is used for the open end of seal compression chamber 22 has inlet hole 38 and is coupled to discharge chambe 22 with the opening/closing action according to inlet valve 34.Cylinder head 36 is fixed to the opposition side of discharge chambe 22 by valve plate 35.

Suction line 37 is fixed on the hermetically sealed can 1 and is connected to the low-pressure side (not shown) of freeze cycle, and the refrigerant gas (not shown) is incorporated in the hermetically sealed can 1.Suck silencer 40 and fix because it is clipped between valve plate 35 and the cylinder head 36, and it by synthetic resin for example polybutylene terephthalate (PBT) etc. make, mainly add glass fibre therein.

In Figure 18, sucking silencer 40 has muffler space 43 and also have: second linkage path 46 open end 46b there is coupled to hermetically sealed can 1 and open end 46a opens and extends to muffler space 43 simultaneously, and first linkage path 45 there open end 45b be coupled to the inlet hole 38 of valve plate 35 and open end 45a opens and extends to muffler space 43 simultaneously.

Figure 19 illustrates velocity vector 60, and it illustrates the behavior of the refrigerant gas in sucking silencer 40 that obtains by computer simulation.The length of each vector is represented the size of flow velocity, and the orientation of vector is represented the flow direction of refrigerant gas.

In addition, each arrow represent by the ascending air the refrigerant gas that sucks from the open end 46a of second linkage path 46 produce on eddy current 61 and the following eddy current 62 that produces by the down current the refrigerant gas that sucks at open end 46a from second linkage path 46.

The operation of the conventional hermetic compressor of structure as mentioned above is described below.

When the rotor 4 rotating crank axles 10 of motor component 5, because rotatablely moving of eccentric part 12 is passed to piston 30 by coupling arrangement 31, piston 30 moves back and forth in discharge chambe 22.Because this operation, refrigerant gas is incorporated into the hermetically sealed can 1 by suction line 37 from the cooling system (not shown).The refrigerant gas that is incorporated in the hermetically sealed can 1 is discharged into muffler space 43 from the open end 46b suction of suction silencer 40 and from open end 46a.

D/d refrigerant gas, with as shown in figure 19 near and wall collision in the face of the housing of the suction silencer 40 of open end 46a after, eddy current 61 and following eddy current 62 generations in, and pass through muffler space 43 and circulate.After this, mainly the refrigerant gas that is made of last eddy current 61 is drawn into first linkage path 45 and is introduced in the inlet hole of opening on valve plate 35 38 from open end 45a.

Then, when inlet valve 34 was opened, refrigerant gas was inhaled into discharge chambe 22, and by the reciprocating motion of piston 30 compression, and be discharged in the cooling system.

Here, the direction of its propagation of pressure fluctuation of the refrigerant that produces when refrigerant is inhaled into discharge chambe 22 and the flowing opposite of refrigerant above-mentioned propagate into muffler space 43 from open end 45a.Therefore, because first linkage path 45 extends in the stronger muffler space of noise elimination effect 43, and open end 45a for example is positioned on the node of the sound of 3 to 4kHz scopes, and the noise of this frequency band is especially horrible, can obtain high noise elimination effect in specific frequency band.

In addition, can further weaken the noise pulsation that in muffler space 43, weakens by the size of adjustment muffler space 43 and the length and the internal diameter of second linkage path 46.Like this, can obtain the effect of better eliminating the noise.

Equally, Figure 20 illustrates the sectional view of the suction silencer of another kind of conventional hermetic compressor.Another conventional example is described below with reference to the accompanying drawings.In passing, the entire infrastructure except sucking silencer is similar to example above-mentioned.Therefore omit detailed explanation.

In Figure 20, suck silencer 50 and have the resonance space 58 that is set to around sucking space 57.In second linkage path 56, an end is connected to hermetically sealed can 1 and the other end is connected to and sucks space 57.In first linkage path 55, open end 55a opens to sucking space 57, and the other end is connected to discharge chambe 22 by inlet valve 34, and has a connection holes 59 to connect first linkage path 55 and resonance space 58.

The following describes the operation of another conventional hermetic compressor of structure above-mentioned.

The refrigerant gas of the low temperature that returns from the refrigeration system (not shown) be drawn into the suction space 57 that sucks silencer 50 from second linkage path 56 after, is drawn into the discharge chambe 22 from first linkage path 55.At this moment, surrounded by resonance space 58, suck space 57 by the wall part heat insulation of the refrigerant gas in resonance space 58 with the housing that constitutes resonance space 58 owing to suck space 57.

Therefore, the refrigerant gas in sucking space 57 is not directly heated by the hyperthermia induced refrigerant gas in hermetically sealed can 1, and highdensity refrigerant gas can be inhaled in the discharge chambe 22.Like this, can make suction efficiency higher.In addition, suck space 57 because resonance space 58 is connected to by connection holes 59, it plays the effect of resonant chamber, and can reduce noise.

Yet, in conventional structure, as shown in figure 19, reciprocating motion by piston 30 is drawn into the refrigerant gas that sucks silencer 40 and be discharged into muffler space 43 from second linkage path 46 from the cooling system (not shown) by hermetically sealed can 1, not to flow directly in first linkage path 45, it with near and in the face of the housing collision of the suction silencer 40 of open end 46a, produce then and go up eddy current 61 and following eddy current 62 and cycle through muffler space 43.

Because this reason is carried out heat exchange between cryogenic coolant gas that returns and the hyperthermia induced refrigerant gas in hermetically sealed can 1 from cooling system.Thereby it is greatly heated.

In addition, after the refrigerant gas heating that circulating of last eddy current 61 and 62 generations of following eddy current risen by the temperature owing to stay muffler space 43 inside, it is sucked and is flow into the discharge chambe 22 from open end 45a.Like this, can reduce with regard to the mass flow that has a problem promptly can be inhaled into the refrigerant in the discharge chambe 22 and suction efficiency decline.

Equally, open end 45a is near the wall of also facing the housing that sucks silencer 40.Therefore, the pulsation that is under pressure of the wall of the housing of the right suction silencer 40 of vicinal face is vibrated for the image of peaked open end 45a.The pulsation sound of refrigerant sends from the housing that sucks silencer 40.Therefore, just the problem that increases noise is arranged.

On the other hand, in another conventional hermetic compressor configuration, the suction space 57 that constitute to suck silencer 50 be arranged as by resonance space 58 around.Like this, can protect the refrigerant gas in sucking space 57 directly not heated, and can make suction efficiency higher by the hyperthermia induced refrigerant gas in hermetically sealed can 1.Yet, whole suction space 57 be configured to by resonance space 58 around.Like this, become big with regard to the whole dimension that has a problem promptly to suck silencer 50, the quantity of part becomes many or molded and becomes more complicated.

Summary of the invention

The present invention solves general issues above-mentioned, and its purpose is for providing suction efficiency height noise vibration little hermetic compressor, and the manufacture method that should suck silencer.

In order to solve general issues above-mentioned, in hermetic compressor of the present invention, parts that suck the housing of silencer at least are foam-molded.Like this, because the thermal insulation effect of the bubble that in the synthetic resin of foaming, produces, just have under same volume and greatly improve thermal insulation properties, and compare with Foamex not and to reduce because the effect of the loss that hot joining is caused, and have the effect that increases the transmission sound loss, because acoustic energy absorbs by the gas in steeping with around the friction between the synthetic resin material of bubble.

Hermetic compressor of the present invention can make the suction efficiency of refrigerant gas higher and reduce noise vibration.

The compressing member that one aspect of the present invention has motor component in hermetically sealed can, driven by this motor component and be connected to suction silencer on this compressing member by what synthetic resin was made, and parts that suck the housing of silencer at least are foam-molded, wherein do not exist the top layer of bubble to be formed on the surface of described foam-molded substantially.。Like this, because the thermal insulation effect of the bubble that produces in Foamex is compared with the solid material resin that do not foam, thermal insulation properties is greatly improved.In addition, the hot joining that can reduce to be drawn into the cryogenic coolant gas that sucks silencer largely is subjected to, and makes suction efficiency higher thus.In addition, the transmission loss that the absorption of the acoustic energy that causes by the gas in bubble with around the friction between the material that steeps has increased sound, it makes noise vibration reduce.

In the present invention on the other hand, the bulb diameter that foam-molded obtains is 50 μ m or littler.Like this, by the diameter of the bubble that reduces to produce in Foamex, the quantity that has increased bubble is so that thermal insulation effect is better.Therefore, except effect above-mentioned, can make suction efficiency higher.

In another aspect of this invention, this foam-molded material is a crystal synthetic resin.Like this, as the characteristic of crystal synthetic resin, its chemoresistance is stronger, and this resin material is lower to the solubility of refrigerant and lubricating oil.Like this, except effect above-mentioned, it can further improve the reliability of compressor and carry out stable operation.

In the present invention, owing to do not exist the top layer of bubble to be formed on the surface of foam-molded substantially, like this, refrigerant and lubricating oil are difficult to penetrate in the suction silencer.Therefore, except effect above-mentioned, the reliability that can further the improve compressor operation of line stabilization of going forward side by side.

In another aspect of this invention, the thickness on this top layer be the plate thickness of the thinnest part 30% or littler.Like this, except effect above-mentioned,, can make the foaming magnifying power higher, improve heat insulation characteristics and make suction efficiency higher by making the top layer attenuation that does not have foam and have low heat insulation characteristics.

In another aspect of this invention, the foaming magnifying power of foam-molded is 1.2 times or higher.Like this, owing to obtained fabulous thermal insulation properties, can make suction efficiency higher and obtain fabulous assimilation effect to acoustic energy.Therefore, except effect above-mentioned, can further reduce noise vibration.

In another aspect of this invention, in a plurality of walls that constitute housing, the plate thickness that obtains the wall at maximum outstanding area place will be thicker than the plate thickness of other walls.Like this,, except effect above-mentioned, can make the foaming magnifying power on the surface that occupies the most surfaces area higher, improve heat insulation characteristics thus and make suction efficiency higher owing to allow the space of foaming to become big.

In another aspect of this invention, the manufacturing of housing is by at least two parts of combination, these two parts be separated and with the vertical substantially direction of the wall at the outstanding area place of the maximum that obtains housing on separate.Like this,,, can make the foaming magnifying power on the surface that occupies the most surfaces area higher, improve heat insulation characteristics thus and make suction efficiency higher because composition surface is placed on the side except effect above-mentioned.In addition, when using mold core rollback (core-back), by enlarging the mould perpendicular to the surface of outstanding area larger part, the foaming magnifying power that can make wide surface is higher and improve heat insulation characteristics and therefore make suction efficiency higher.

In another aspect of this invention, because the bight of housing is more relatively large than other parts with the plate thickness with high curvature part, the resin flows resistance when molded reduces.Like this, except effect above-mentioned, because can be molded at low temperatures, promoted growth, and, reduced the loss that rises by the hot joining spasm because the foaming magnifying power is higher so make heat insulation characteristics higher by the bubble of foamed gas.

In another aspect of this invention, suck silencer and comprise the muffler space that is formed in the housing, first linkage path that connects compressing member and muffler space, and second linkage path that connects hermetically sealed can and muffler space, the wall of its middle shell, its close motor component, compressing member, first linkage path open end in muffler space at least, and second the open end of linkage path in muffler space one of them, be designed to have at least it than the structure of other wall thickness of housing and it a kind of in the higher structure on the foam magnifying power.Like this at the thermal source in hermetically sealed can and the heat exchange that is drawn between the cryogenic coolant that sucks in the silencer can in smaller volume, be suppressed effectively.Therefore, except effect above-mentioned, can under smaller volume, make suction efficiency higher effectively.

In another aspect of this invention, lubricating oil is stored in the hermetically sealed can, and one of the wall of housing that is provided the suction silencer of lubricating oil at least is designed to have at least it than the structure of other wall thickness of housing and it a kind of in the higher structure on the foam magnifying power.Heat exchange on the wall of the suction silencer of high temperature lubricating oil flow place is effectively suppressed like this.Therefore, except effect above-mentioned, can under smaller size smaller, make suction efficiency higher effectively.

In another aspect of this invention, the housing that sucks silencer has the muffler body of suction and sucks muffler cover, at the foam magnifying power that sucks the bonding part between muffler body and the suction muffler cover, compare relatively lowly with the part except that the bonding part, perhaps it is non-foam molded.Because the shock absorption by bubble is suppressed, and except effect above-mentioned, can make bond strength higher.

In another aspect of this invention, connect the interior section of hermetically sealed can and suck silencer muffler space linkage path with from motor component, the element farthest between a plurality of elements that constitute the housing that sucks silencer forms as one.Like this, except effect above-mentioned, the quantity that can reduce parts is to reduce cost.In addition, be placed on a side, make the thermal insulation properties of suction silencer as a whole higher, and reduced the loss that is caused by hot joining away from motor component by the surface that will have low thermal insulation properties.

In another aspect of this invention, parts that suck the housing of silencer are arranged between cylinder head and the valve plate, and it constitutes compressing member, and the parts in the middle of the lid of housing is arranged on have relatively low foam magnifying power, and perhaps it is non-foam molded.Like this, kept the intensity of bonding part, feasible fixing silencer stably.Like this, except effect above-mentioned, can prevent unusual tone or the like.

In another aspect of this invention, parts of the housing of described suction silencer are arranged between cylinder head and the valve plate, and it constitutes described compressing member, and the thickness of the described parts of described housing will be thicker than other parts.Like this, kept the intensity of bonding part, feasible fixing silencer stably.Therefore, except effect above-mentioned, can prevent unusual tone or the like.

In another aspect of this invention, on comprising that revolution is less than source power supply frequency or littler revolution, motor component is driven by inverter, and it absorbs and the relevant noise of the quick TRANSFER BY PULSATING FLOW of refrigerant when the very big quick revolution operation of refrigerant circulation quantity.Like this, except effect above-mentioned, can further reduce noise.

In another aspect of this invention, therefore revolution is 20r/sec or lower, and it has suppressed be drawn into the heat exchange between the thermal source of cryogenic coolant gas in the suction silencer and for example hyperthermia induced refrigerant gas in hermetically sealed can etc. when the slow speed operation descends refrigerant flow speed.Like this, except effect above-mentioned, can further reduce suction efficiency.

In another aspect of this invention, be R600a, increased refrigerant circulation quantity, and absorbed the high frequency noise in the heard zone relevant with the quick TRANSFER BY PULSATING FLOW of refrigerant owing to be compressed the refrigerant gas of compression element.Like this, except effect above-mentioned, can further reduce noise.

One aspect of the present invention relates to a kind of manufacture method that sucks silencer, parts of the housing of the suction silencer that is used for hermetic compressor that its foam-molded is made by synthetic resin, wherein in molding process, a part of using mold core rollback to move moulds makes die cavity become big and makes thickness of slab thicker.So, by enlarging mould, reduce pressure and gas is expanded, promote foaming thus.Like this, except effect above-mentioned,, can obtain fabulous thermal insulation properties, can allow suction efficiency become higher thus owing to obtained higher foam magnifying power.

Another embodiment of the present invention is the manufacture method that sucks silencer, at least one parts of the housing of the suction silencer that is used for hermetic compressor that its foam-molded is made by synthetic resin, wherein as the area of section to the cast gate of the resin support section of the die cavity in the mould be equal to or greater than the housing thickness of slab square 70%.Like this, because the resistance decline when resin is mobile from cast gate, except effect above-mentioned, can be under low pressure molded, it promotes the growth of bubble by foamed gas.Therefore, higher and make the foam magnifying power higher by making the foam magnifying power, can reduce the loss that is caused by hot joining.

Another embodiment of the present invention is the manufacture method that sucks silencer, parts of the housing of the suction silencer that is used for hermetic compressor that its foam-molded is made by synthetic resin wherein are that at least one unit is installed as two or more cast gates to the resin support section of the die cavity in the mould.Like this, a plurality of cast gates being installed makes resin easily to put in the mould.Therefore, except effect above-mentioned, can be under low pressure molded, and promote the growth of bubble by foamed gas.Therefore, higher and make the foam magnifying power higher by making the foam magnifying power, can reduce the loss that is caused by hot joining.

Description of drawings

Fig. 1 illustrates the sectional view of the hermetic compressor of first embodiment of the invention;

Fig. 2 illustrates the sectional view of the suction silencer among the same embodiment;

Fig. 3 illustrates the amplification sectional view of the A part of Fig. 2 mesospore;

Fig. 4 illustrates the sectional view of major part in the bight of the hermetic compressor among the same embodiment;

Fig. 5 A illustrates the structural representation of the foam-molded machine among the same embodiment;

Fig. 5 B illustrates the structural representation of the foam-molded machine among the same embodiment;

Fig. 5 C illustrates the structural representation of the foam-molded machine among the same embodiment;

Fig. 6 illustrates the main body of the suction silencer among the same embodiment and the front view of running channel;

Fig. 7 illustrates the sectional view of the suction silencer of the second embodiment of the present invention;

Fig. 8 illustrates the enlarged drawing of the foaming part of the suction silencer among the same embodiment;

Fig. 9 illustrate among the same embodiment the rearview of suction muffler body;

Figure 10 illustrate among the same embodiment the decomposition diagram of suction silencer;

Figure 11 is illustrated in the lid among the same embodiment and sucks the enlarged drawing of the bonding part between the silencer;

Figure 12 A illustrates the structural representation of the supercritical foam molding machine among the same embodiment;

Figure 12 B illustrates the structural representation of the supercritical foam molding machine among the same embodiment;

Figure 12 C illustrates the structural representation of the supercritical foam molding machine among the same embodiment;

Figure 13 illustrates the sectional view of the hermetic compressor of third embodiment of the invention;

Figure 14 illustrates the exploded view of the suction silencer among the same embodiment;

Figure 15 A illustrates the structural representation of the supercritical foam molding machine among the same embodiment;

Figure 15 B illustrates the structural representation of the supercritical foam molding machine among the same embodiment;

Figure 15 C illustrates the structural representation of the supercritical foam molding machine among the same embodiment;

Figure 16 illustrates the exploded view of the suction silencer of fourth embodiment of the invention;

Figure 17 illustrates the sectional view of conventional hermetic compressor;

Figure 18 is illustrated in the sectional view of the suction silencer in the conventional hermetic compressor;

Figure 19 illustrates the velocity vector diagram in the suction silencer of conventional hermetic compressor; And

Figure 20 is illustrated in the sectional view that sucks silencer in the conventional hermetic compressor.

The specific embodiment

Below with reference to describing one embodiment of the invention as figure.Incidentally, this embodiment does not limit the present invention.

(first embodiment)

Fig. 1 illustrates the sectional view of the hermetic compressor of first embodiment of the invention, and Fig. 2 illustrates the sectional view of the suction silencer of the hermetic compressor among the same embodiment.Fig. 3 illustrates the amplification sectional view of the A part of Fig. 2 mesospore.Fig. 4 illustrates the sectional view of major part in the bight of the hermetic compressor among the same embodiment.Fig. 5 A illustrates the structural representation of the foam-molded machine among the same embodiment to 5C.Fig. 6 illustrates the main body of the suction silencer among the same embodiment and the front view of running channel.

In Fig. 1, hermetically sealed can 101 holds: by rotor 104 with hold the motor component 105 that the stator 103 of coiler part 102 is formed; And the compressing member 106 that drives by motor component 105.Lubricating oil 108 is stored in the hermetically sealed can 101.Incidentally, use R600a nature refrigerant as the refrigerant gas (not shown).

In addition, motor component 105 is driven by inverter method, comprises 20r/sec or littler revolution.

The schematic configuration of compressing member 106 will be described below.

Crank 110 has: main shaft portion 111 rotors 104 are pressed into there and cooperate and fixing, and eccentric part 112 its form relative main shaft portion 111 off-centre.In main shaft portion 111, be provided with oil pump 113 to be opened in the lubricating oil 108.

The cylinder block 120 that is formed on motor component 105 tops has: the discharge chambe 122 of approximate circle tubular, and the axle eyelid retractor 123 that supports the main shaft portion 111 with axle.Piston 130 is inserted in the discharge chambe 122 of cylinder block 120 so that can reciprocatingly slide therein and be connected on the eccentric part 112 by coupling arrangement 131.

The valve plate 135 that is used for the open end of seal compression chamber 122 has inlet hole 138 and is coupled to discharge chambe 122 with the opening/closing action according to inlet valve 134.Cylinder head 136 is fixed to the opposition side of discharge chambe 122 by valve plate 135.Suction line 137 is fixed on the hermetically sealed can 101 and is connected to the low-pressure side (not shown) of freeze cycle, and the refrigerant gas (not shown) is incorporated in the hermetically sealed can 101.

Suck silencer 140 and fix because it is clipped between valve plate 135 and the cylinder head 136, and it by synthetic resin for example polybutylene terephthalate (PBT) etc. make, mainly add glass fibre therein.

In addition, sucking silencer 140 has: the housing 140C that is made of a plurality of walls; First linkage path 145 and second linkage path 146, muffler space 143 is formed on housing 140C inside.Near and wall 147 in the face of the housing 140C of the suction silencer 140 of open end 145a, 146a in the muffler space in, in order on 1.2 times or higher foaming magnifying power, to produce the bubble of a large amount of about 100 μ m, one non-foaming top layer 151 is formed on such position, thickness of slab is 3 to 5 millimeters and is thicker than other parts on this position, and does not steep near surface.

In addition, the thickness E on top layer, F are about 10% to 20% of thickness of slab G.Therefore, the thickness of slab B of the bight 140a of the housing 140C of suction silencer 140 will be thicker than thickness of slab C, the D of flat part.

Incidentally, molding temperature and molding pressure when thickness by regulating wall and foam-molded, the bubble of being made by foamed resin molded (back will be described) 150 produces to be of a size of and steeps density about 10 ⁷Cell/cm ³And the about 100 μ m of bulb diameter.Because the thermal insulation effect of bubble 150 is compared with the solid material that do not foam, and has obtained the raising of about thermal insulation properties of 5 to 10%.

On the other hand, to shown in the 5C, injection (mo(u)lding) machine 170 is provided with raw material inserter 171, melt syringe 172, die unit 177, controller (not shown) device and is used to control the driving of die unit 177 and chilling temperature etc. and regulates bubble density and bulb diameter as Fig. 5 A.

Describe below by using the molding process of 170 pairs of foamed resins of injection (mo(u)lding) machine.

At first, as Fig. 5 A to shown in the 5C, the raw material bead of polybutylene terephthalate (PBT) and for example being put in the raw material inserter 171 by the CBA bead of the azo-compound of representatives such as azodicarbonamide.Raw material bead that drops in melt syringe 172 and blowing agent bead melt on about 250 ℃ or higher temperature, are mixed by the screw rod 175 that is built in the melt syringe 172, by screw rod 175 extruding and be expelled in the die unit 177.

Then, as shown in Figure 6, the molten resin that is fed to die unit 177 from inlet 181 is by as the running channel 182 of flow channel and be fed to and have a plurality of die cavities 183 that are formed on the shape that is molded product in the mould.To parts, be provided with two as the cast gate 185,186 of resin to die cavity 183.They are selected as making that the cross section of cast gate 185,186 will be thinner than running channel 182, and thickness is 30% to 40% of wall thickness, and width is about three times of thickness.

For the molten resin that flow into the die cavity 183 from cast gate 185,186, when its friction during by cast gate 185,186 causes temperature to rise and pressure descends.Relevant with this chemical reaction etc., the fusing blowing agent of mixing gasifies in die cavity 183, and it becomes the foamed gas in melt raw material, and produces bubble.

On the other hand, because die unit 177 has structure by gas and liquid cools, be cooled on the constant temperature and also be molded thereby be expelled to raw material in the die cavity 183 that limits by die unit 177 and foamed gas.At this moment, controller is regulated raw material and the injection volume of blowing agent and the chilling temperature of injection temperature and die unit 177 etc., and controls the temperature and pressure when molded.Like this, can adjust the bubble density and the bulb diameter of foamed resin arbitrarily.

Specifically, be volume by the amount that will be expelled to the molten resin in the die cavity 183 that limits by die unit 177, and fill remaining space, can obtain high foam magnifying power by foaming and intumescing less than die cavity 183.

In addition, molten resin viscosity is bigger.Thereby when molten resin was flowed through the die cavity 183 that is limited by die unit 177, this center that is flowing in the thickness of slab that is molded parts was the fastest.When it during near die unit 177 surperficial, it is slower that speed becomes.The almost immobilising zone of resin appears at the surface of very close die unit 177.

For this reason, because molten resin tightly is attached on the low temperature die unit 177 under basic static state, it is cooled off fast.Like this on the surface of die unit 177, resin before forming bubble with regard to hardening.Therefore, formed the top layer that does not have bubble substantially.

Like this, when thickness of slab became thinner, the ratio with layer of the bubble that is created between top layer and the top layer diminished, and causes such situation promptly as a whole, steeped less and heat insulation characteristics is lower.

Yet, as what illustrated, by set near and in the face of the thickness of slab to 3 of the wall of the suction silencer 140 of open end 145a, 146a in muffler space to 5 millimeters its be thicker than the thickness of slab of other walls, the thickness E on top layer, F can be limited to about 10% to 20% of thickness of slab G, by setting the foam magnifying power is to the weight ratio of solid-state component about 1.2 times, can partly improve heat insulation characteristics.

In addition, just as what can understand easily from the mechanism of the formation on top layer, when thickness of slab was thinner, it is very narrow that the gap that in fact molten resin can flow becomes, and to the resistance that the flows increase of molten resin.

On the other hand, the pressure that causes by foamed gas a little less than.Like this, if the part with big resistance is arranged, resin can be fully not mobile.Therefore, the die cavity 183 that is limited by die unit 177 can not be filled for resin.On the contrary, for fear of lack of fill, be with a large amount of resin of high-pressure injection, this causes the decline of foam magnifying power.

As shown in Figure 4,, can make the foam magnifying power higher, and can make heat insulation characteristics higher by increasing the thickness that resistance becomes the bight 140a of big mould especially easily antithesis.In addition, because from two cast gates 185,186 supply resins, even in the situation of and the mould that flow resistance is bigger thin at thickness of slab, even under low pressure, also fill up resin easily in entire die, this makes that the foam magnifying power is higher and makes heat insulation characteristics better.

In addition, by adjusting the position of cast gate, the thickness of slab of parts and mold temperature also can be adjusted the foam magnifying power to each part.

Explained later has the operation of the hermetic compressor of structure above-mentioned in this embodiment.

The refrigerant gas that is incorporated into by the reciprocating motion of piston in the hermetically sealed can 101 is sucked from sucking silencer 140, and is discharged into the muffler space 143 from the open end 146a in muffler space.D/d refrigerant gas, with near and in the face of wall 147 collisions of the housing 140C of the suction silencer 140 of the open end 146a in the muffler space, then by muffler space 143 circulations.After this, mainly the refrigerant gas by the top circulation is drawn into first linkage path 145 by the open end 145a in muffler space, and is compressed and is discharged in the cooling system in discharge chambe 122.

Here, in order only the wall 147 of the housing that sucks silencer 140 wherein to be flow into the main flow of the refrigerant gas of the open end 145a in the muffler space from the open end 146a in the muffler space in this place generation, keep 1.2 times or higher foam magnifying power, thickness of slab is set at 3 to 5 millimeters, obtains the higher thermal insulation effect of part thus.Therefore, and compare, can on smaller volume, obtain effective thermal insulation effect as the situation of foam-molded suction silencer 140 as a whole.

The result is, can allow effectively be used for refrigerant gas is remained on the with better function of low temperature and highdensity state, increases the mass flow of refrigerant gas thus.Particularly, when 20r/sec or lower low operation revolution, at that time the flow velocity of refrigerant gas descend and refrigerant gas to rest on the time that sucks in the silencer 140 longer, to because the reduction effect of the loss that hot joining is caused is very huge.

Because the temperature in the refrigerant gas above-mentioned raises and is suppressed, the temperature between open end 146a in muffler space and the open end 145a in muffler space raises can be suppressed to 2K or lower.Like this, the specification that sucks silencer with routine is compared, and freezing performance has improved 1.5%, and efficient (hereinafter referred to as COP) has improved more than 1.0%.

On the other hand, the refrigerant gas in sucking silencer 140 becomes and corresponding interrupted the flowing of the reciprocating motion of piston 130.At this moment, pressure fluctuation with the direction of refrigerant gas flowing opposite on propagate, towards the open end 145a in muffler space, towards near and produce back waves in the face of the wall 147 of the open end 145a in the muffler space.

For this back wave, the vibration loss that causes by the vibration of the wall components self that constitutes the housing that sucks silencer 140, and be absorbed by gas in bubble and the vibrational energy that causes around the friction between the material that steeps, this can increase acoustic transmission loss.Particularly, can determine, to influential in the acoustic transmission loss that can hear the radio-frequency component in the scope.

Particularly, because present embodiment uses the R600a for natural refrigerant, compare with the situation of R134a, refrigerant circulation quantity increases.Thereby it is very fast to be drawn into the pulsation stream that sucks the refrigerant gas in the silencer 140, and this brings out high frequency noise easily.This trend seriously appears on the revolution or higher revolution of source power supply frequency.For this phenomenon and since the back wave radiation towards, near and in the face of the wall 147 of the open end 145a in the muffler space, is foam-molded, to can hear noise in the scope to alleviate effect very strong.

In addition, owing to suck the polybutylene terephthalate (PBT) that silencer 140 uses as crystal synthetic resin, its chemoresistance is strong.This resin is not dissolved in refrigerant and the lubricating oil 108 substantially, and this has improved reliability and has made can the stable operation compressor.

In addition, do not exist the top layer 151 of bubble to be formed on the near surface that foam-molded sucks the wall 147 at silencer 140 places.Thereby refrigerant and lubricating oil 108 are never permeated into the inner space that sucks silencer 140, and this has improved reliability and has made can the stable operation compressor.

In addition, by the foam magnifying power being set at about 1.2 times, with the solid material that uses Foamex not and make and suck silencer and form identical shaped situation and compare, can reduce the use amount of resin material, cost of raw and processed materials is rationalized.

Like this, can reduce the loss that is caused by hot joining and make suction efficiency higher, and can also reduce noise, and can improve reliability and realize stable operation.

(second embodiment)

Fig. 7 illustrates the sectional view of the suction silencer of the hermetic compressor in the second embodiment of the invention, and Fig. 8 illustrates the enlarged drawing of the foaming part of the suction silencer among the same embodiment.Fig. 9 illustrate among the same embodiment the rearview of suction muffler body, Figure 10 illustrates the decomposition diagram of the suction silencer of the hermetic compressor among the same embodiment, and Figure 11 is illustrated in the lid among the same embodiment and sucks the enlarged drawing of the bonding part between the muffler body.Figure 12 A illustrates the structural representation of the supercritical foam molding machine among the same embodiment to 12C.Incidentally, except sucking silencer, the structure of the hermetic compressor of present embodiment is basically the same as those in the first embodiment.Thereby omit its explanation.

As shown in Figure 7, suck silencer 240 and have housing 240C, first linkage path 245 and second linkage path 246 that is made of a plurality of walls, muffler space 243 is formed on housing 240C inside.Here, housing 240C molded that sucks silencer 240 is by using supercritical foam molded (back can specify), and bulb diameter is that the microvesicle of 1 to 50 μ m rests on the whole wall except thickness thin location part.Here, it is generated as about 10 the bubble that produces with the supercritical foam molding process 250 ⁹To 10 ¹⁵Cell/cm ³High density.Thereby, to compare with the solid material that do not foam, thermal insulation properties improves about 20% or more.Here, bubble 250 is formed on the inside of the wall of housing 240C.Though not shown, the surface of the wall of housing 240C is covered on the top layer that does not have bubble 250.

In addition, as shown in Figure 9, the suction muffler body 241 that constitutes the major part of housing 240C has: lubricating oil service duct 252 its for the rib shape and be formed on the outer surface that sucks muffler body 241 to transmit lubricating oil 108; And lubricating oil supply orifice 253 sucks the silencer 240 so that lubricating oil is drawn into from lubricating oil service duct 252.

On the other hand, after first linkage path 245 was inserted and be assembled in the suction muffler body 241, solder-bump 245b mated with the hole 242b that sucks muffler cover 242 on the position.Afterwards, suck muffler body 241 and suck muffler cover 242, suck silencer 240 and finish by joints such as use ultrasonic welding methods.

Here, sucking silencer 240 is configured to by engaging around sucking main body side bonding part 254 that muffler body 241 forms and the lid side engagement part 255 that forms around suction muffler cover 242.The wall thickness of main body side bonding part 254 and lid side engagement part 255 all is designed to be equal to or less than the basic wall thickness of the housing 240C that sucks silencer 240.

Incidentally, being used for the supercritical foam molding machine 270 of molded suction silencer 240 in the present embodiment is provided with raw material inserter 271, supercritical gas generator 274, melt syringe 272, die unit 277, controller (not shown) it is used to control the driving and the chilling temperature of die unit 277, as Figure 12 A to shown in the 12C.Owing to used inactive gas, for example carbon dioxide, nitrogen or the like and do not have to use blowing agents such as azo-compound as the carrying capacity of environment material, flon can be beneficial to the molded of environment (environmentally friendly).

Describe below by using the molding process of 270 pairs of foamed resins of supercritical foam moulding press.

At first, the raw material bead of polybutylene terephthalate (PBT) is put in the raw material inserter 271.The raw material bead that drops in melt syringe 272 melts on about 250 ℃ or higher temperature.On the other hand, in supercritical gas transmitter 274, become the carbon dioxide of above-critical state or the physical blowing agent of nitrogen and be injected in the melt syringe 272, and as being mixed by screw rod 275 with the high-pressure solution of resin raw material.Afterwards, with the raw material that is fused by screw rod 275, the blowing agent that is in above-critical state is injected in the die unit 277.

Then, the rapid Volume Changes and the variations in temperature that cause when being expelled to die unit 277 make the blowing agent gasification at above-critical state, produce bubble thus.At this moment, controller is adjusted the amount and the injection temperature of the injection of raw material and blowing agent, and the pressure and temperature of die unit 277 etc., and controls the temperature and pressure when molded.Can regulate the bubble density and the bulb diameter of foamed resin so arbitrarily.

In addition, molten resin viscosity is bigger.Thereby when molten resin was flowed through by die unit 277, this center that is flowing in thickness of slab was the fastest.When it during near die unit 277 surperficial, it is slower that speed becomes.The almost immobilising zone of resin appears at the surface of very close die unit 277.Thereby because molten resin tightly is attached on the low temperature die unit 277 under the basic static state, it is cooled off fast.Like this on the surface of die unit, resin before forming bubble with regard to hardening.Therefore, formed the top layer that does not have bubble substantially.

The operation of constructed as above mentioned hermetic compressor is described below.

In the present embodiment, carbon dioxide that is in above-critical state and the nitrogen be dissolved in the resin material of molten state gasify in response to the variation of temperature and pressure, and this makes that producing diameter is the atomic vesicle of 1 to 50 μ m.

The result is to produce microvesicle on all walls, and the basic design size that sucks silencer 240 is not had any change.Like this, can improve all walls near high temperature heat source, for example be provided with motor component 105 and form the suction muffler body 241 of lubricating oil service duct 252 rear wall, be connected to compressing member 106 the open end neighbouring, be inhaled into the cryogenic coolants that suck in the silencer 240 be released to muffler space 243 places near and in the face of the wall of the open end 246a in the muffler space or the like, thermal insulation properties.

The result is, can quite big degree reduces to be drawn into the hot joining that sucks the cryogenic coolant gas in the silencer 240 and to be subjected to, and makes the density of refrigerant gas remain low thus and increases the mass flow of the refrigerant gas that sucks.

As above-mentioned structure, the reduction of the loss that is caused by the hot joining from refrigerant gas can improve suction efficiency.Compare with conventional example, freezing performance has improved 2.5%, and COP has improved 2.0% or more.

On the other hand, owing to the raising effect that a large amount of bubbles that covered whole suction silencer 240 by generation are caused, alleviated to a considerable extent to the noise vibration that causes that flows near the reflection of the wall emission of facing housing by TRANSFER BY PULSATING FLOW and the open end 245a in muffler space to acoustic transmission loss.Particularly, the transmission sound reduction that can hear the radio-frequency component in the scope is produced effect.

In addition, use the supercritical foam molding technique to make in the present embodiment and on all walls that suck silencer 240, produce small independent bubbles.Thereby, can not reduce the mechanical strength of material substantially, and be 1.2 times or more by setting the foam magnifying power, can make the use amount of raw material reduce 20%, and expense of raw materials is rationalized.

In addition, in main body side bonding part 254 that sucks muffler body 241 and lid side engagement part 255, by making wall thickness be thinner than basic wall thickness, the generation that can suppress to steep, the vibration that is suppressed in the bonding part reduces effect, and realizes that such idea promptly keeps bond strength by the vibration of ultrasonic bonding.

Incidentally, in the present embodiment, the basic wall thickness of wall ratio in main body side bonding part 254 and lid side engagement part 255 will approach.Yet by wall thickness being equaled or being thicker than basic wall thickness and bubble is rested in all walls that suck silencer 240, natural energy further reduces from the light of refrigerant gas to be accepted.

In addition, in this embodiment, omitted explanation with the equitant item of first embodiment.Yet, even also can obtain similarly in this embodiment, the reliability that obtains by the chemoresistance of crystal synthetic resin and to osmotic protection effect to refrigerant and lubricating oil by the top layer, and to the raising on the effect of the operational stability of compressor.

In addition, compare with first embodiment, reduction noise result in the heard scope relevant with the quick TRANSFER BY PULSATING FLOW of refrigerant gas under high revolution, and with refrigerant gas 20r/sec or more relevant being reduced in of flowing of the low speed the during slow-speed of revolution suck the effect that the hot joining in the silencer 240 is subjected to, it is stronger to become.

(the 3rd embodiment)

Figure 13 illustrates the sectional view of the hermetic compressor of third embodiment of the invention, and Figure 14 illustrates the exploded view of the suction silencer among the same embodiment.Figure 15 A illustrates the structural representation of the supercritical foam molding machine among the same embodiment to 15C.Incidentally, except sucking silencer, the structure of the hermetic compressor of present embodiment is identical with second embodiment's.Thereby omit its explanation.

Sucking silencer 340 is made of motor component sidepiece 341, contrary motor component sidepiece 342 and center 343 these three parts.The major part of these elements constitutes housing 340C.The suction silencer 340 that motor component sidepiece 341, contrary motor component sidepiece 342 and center 343 these three parts constitute has first linkage path 345 and second linkage path 346, and muffler space 347 is formed among the housing 340C.In addition, first linkage path 345 is formed on the composition surface between center and the contrary motor component sidepiece 342, and second linkage path 346 forms as one with Partial Inverse motor component sidepiece 342.

In addition, suck silencer 340 and be arranged between cylinder head 136 and the valve plate 135, the thickness of this bonding part will be thicker than other parts.

In addition, suck the said structure element (comprising housing 340C) of silencer 340 by using supercritical foam molded next molded.Particularly, molded in the 341 enterprising enforcements of motor component sidepiece with the supercritical foam of mold core rollback.

The molding process that foamed resin is used mold core rollback in supercritical foam molding machine 370 is described below.

At first, the raw material bead of polybutylene terephthalate (PBT) is put in the raw material inserter 371.The raw material bead that drops in melt syringe 372 melts on about 250 ℃ or higher temperature.On the other hand, in supercritical gas transmitter 374, become the carbon dioxide of above-critical state or the physical blowing agent of nitrogen and be injected in the melt syringe 372, and as being mixed by screw rod 375 with the high-pressure solution of resin raw material.Afterwards, with the raw material that is fused by screw rod 375, the blowing agent that is in above-critical state is injected in the die unit 377.Heretofore, this process all is similar among second embodiment.

Then, because the rapid Volume Changes and the variations in temperature that cause in the die cavity that is expelled to die unit 377 by cast gate the time are in the blowing agent gasification of above-critical state, produce bubble thus.Yet, select to make the thickness of gate portions be wall thickness 60% and width is three times of this thickness.Area of section approximate wall thickness square.Compare with first embodiment, area is wideer, for example twice.

Like this, the area of section of gate portions will be wider than second embodiment, and the resin flow behavior is fabulous.Therefore, when the air pressure that keeps physical blowing agent in steeping less situation was higher, the resin of fusing was filled into die cavity.

Afterwards, a parts 377a of die unit is drawn out of on the direction of arrow, carries out mold core rollback to enlarge the space of die cavity.Like this, the pressure in the die cavity reduces, and bubble expands.Therefore, the foam magnifying power has increased 30% to 40%, and it has surpassed the supercritical foaming that does not use mold core rollback.The result is, can further improve the heat insulation characteristics of the housing 340C that sucks silencer 340, improves performance thus.

Incidentally, suck that silencer 340 is separated and with obtain maximum outstanding area be in the vertical substantially direction of wall on separate.To move with the direction that enlarges die cavity be the projected direction that obtains to suck the outstanding area place of maximum of silencer 340 to the parts of die unit when in addition, molded.The result is, the thickness that enlarges surface with maximum area increased by the thermal insulation properties of mold core rollback improve effect and foam magnifying power, and improved suction efficiency.Here, maximum outstanding area refers to when finish the outstanding area of the maximum that is obtained when giving prominence to from different directions on target component.

In addition, mold core rollback helps to improve thermal insulation properties, is applied to the complex parts that are integrated with pipe or the like than difficulty.Yet according to present embodiment, be configured to based on relative simple surface near motor component sidepiece 341, and can effectively use mold core rollback, obtain the raising of efficient thus as the compressing member 106 of thermal source and motor component 105.On the other hand, second linkage path 346 is integrally molded at opposition side and contrary motor component sidepiece 342.Therefore, reduce the quantity of part and reduced expense.

In the situation of using the supercritical foaming technology, to compare with conventional foaming technique, the reduction on the intensity that is caused by foaming is less.Yet along with the foam magnifying power is higher, intensity further descends.Incidentally; fix owing to suck silencer 340, in the part that is arranged between valve plate 135 and the cylinder head 136, thicker relatively by making thickness of slab; can strength retention, protect the generation of the unusual tone that the leakage by vibration that sucks silencer and gas causes thus.

(the 4th embodiment)

Figure 16 illustrates the exploded view of suction silencer of the hermetic compressor of fourth embodiment of the invention.Incidentally, except sucking silencer, the structure of hermetic compressor in this embodiment is identical with structure among the 3rd embodiment, and the molded method of supercritical foam is also similar.Therefore, omission is to its explanation.

In Figure 16, the housing 440C that sucks silencer 440 constitutes by sucking muffler body 441 and sucking muffler cover 442 these two parts, and assembles with methods such as welding.In addition, be arranged between cylinder head 136 and the valve plate 135, suck silencer 440 and be fixed owing to suck muffler cover 442.

Because do not carry out foam-molded, suck muffler cover 442 and have enough intensity.Like this, can protect the generation of the unusual tone that the leakage by vibration that sucks silencer 440 and gas causes.

On the other hand, similar with the 3rd embodiment, sucking muffler body 441 is to make with supercritical foam is molded.In addition, mold core rollback is executed on the projected direction of the maximum outstanding area of acquisition shown in the arrow among Figure 16.Therefore, occupy the housing 440C most surfaces area that sucks silencer 440 and, be made as the thickness of slab I that is thicker than other walls, make that the foam magnifying power is higher near the thickness of slab H of the wall of motor component 105 grades of high temperature.Like this, improve the thermal insulation properties of whole suction silencer 440, improved suction efficiency thus.

Industrial applicability

As mentioned above, the manufacture method according to hermetic compressor of the present invention and suction silencer can make suction Efficient is higher and also alleviate noise vibration. Thereby they can be applied to the use field, for example air-conditioning, Refrigerating equipment etc.

Claims (1)

1. manufacture method that sucks silencer, parts of the housing of the suction silencer that is used for hermetic compressor that its foam-molded is made by synthetic resin, wherein in described molding process, at least one parts that uses mold core rollback to move moulds enlarge die cavity and make thickness of slab thicker.

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