JP2003176783A - Manufacturing method of valve plate - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a valve plate with which a valve seat is formed highly accurately. <P>SOLUTION: A port 32 is formed on the material 40W of the valve plate 40 by press work in a first process. The surface 40b of the formative predetermined spot Y of the valve seat 43 of the material 40W is polished in a second process. The valve seat 43 is formed on the material 40W by press work in a third process. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a valve plate which constitutes at least one of a suction valve mechanism and a discharge valve mechanism of a compressor.

[0002]

2. Description of the Related Art As a valve plate of this type, there is one disclosed in, for example, Japanese Patent Laid-Open No. 8-61240. That is, as shown in FIGS. 6 (a) and 6 (b), the valve plate 101 disclosed in the publication has a discharge valve 110 provided around the opening of the discharge port 102 opened and closed by the discharge valve 110. The valve seat 103 is formed in a convex shape. By thus forming the valve seat 103 in a convex shape, the contact area between the discharge valve 110 and the valve plate 101 can be reduced. Therefore, it is possible to suppress the sticking between the discharge valve 110 and the seat surface 103a of the valve seat 103 due to the interposition of the lubricating oil film, and prevent overcompression or the like.

Generally, the following method is adopted for manufacturing the valve plate 101. That is,
Port 102 and valve seat 1 for valve plate material
Press forming 03. A polishing process for removing large bulges of meat around the opening of the port 102 generated in the pressing process and for finishing the surface of the valve plate material.

[0004]

In the above-mentioned step of polishing the valve plate material, the seat surface 103a of the valve seat 103 formed in the pressing step, which is the preceding step, is also polished. Becomes Seat surface 1 of valve seat 103
When 03a is polished, sagging occurs on the inner and outer peripheral edges of the seat surface 103a. If the degree of this sagging can be predicted, the press surface step is performed with the sag amount taken into account, so that the seat surface 103a having a desired area can be obtained even after the polishing step.

However, for the polishing, for example, the valve seat 10 of a grindstone is used.
The contact state with respect to 3 is different each time, so that the seat surface 103a
It is impossible to predict the amount of sagging. Therefore, for example, if the amount of sag is small and the area of the seat surface 103a is too large, the problem of sticking of the valve 110 cannot be solved. On the contrary, if the amount of sag is large and the area of the seat surface 103a is too small, gas leakage occurs and the efficiency of the compressor deteriorates.

An object of the present invention is to provide a method of manufacturing a valve plate which can form a valve seat with high accuracy.

[0007]

In order to achieve the above object, in the invention of claim 1, the valve seat is formed by the third step which is the pressing step after the second step which is the polishing step. Therefore, the influence of the polishing process can be eliminated and the valve seat can be formed with high accuracy.

The invention of claim 2 is the third aspect of the invention according to claim 1.
In the process, the valve seat is formed by recessing the circumference of the planned seat of the valve seat by press working. That is, the depression around the planned formation makes the valve seat convex. With this configuration, it is easy to set the seat surface of the valve seat to be flush with the end surface of the valve plate. If the seat surface of the valve seat is flush with the end surface of the valve plate, the valve body is not inclined with respect to the valve seat in the closed state of the port, so that the sealing property between the two can be improved.

The invention of claim 3 is the same as that of claim 2
In a step prior to the step, an annular groove is formed outside the site where the valve seat is to be formed. That is, in the third step, the area inside the annular groove of the valve plate material is pressed. Therefore, during the third step (press working), the stress acting in the vicinity of the planned seat of the valve seat can be released by the bulging of the meat into the annular groove. Therefore, for example, distortion of the seat surface of the valve seat due to the action of this stress can be prevented.

The invention of claim 4 is the third aspect of the present invention.
The process consists of raising the planned seat of the valve seat in the valve plate material by pressing. By doing so, the shape of the press die used in the third step can be simplified.

The invention of claim 5 is the third aspect of the invention according to claim 4.
In a step prior to the step, a process is performed in which a region wider than the planned site for forming the valve seat is recessed.
Therefore, the start of the swelling of the planned seat of the valve seat in the third step starts from within the recess lower than the end surface of the valve plate, and it is easy to set the seat surface of the valve seat flush with the end surface of the valve plate. Become.

[0012]

BEST MODE FOR CARRYING OUT THE INVENTION The first and second embodiments in which the present invention is embodied in a method of manufacturing a valve plate used in a piston type compressor constituting a refrigeration cycle of a vehicle air conditioner will be described below. explain. In addition,
In the second embodiment, only the differences from the first embodiment will be described, the same or corresponding members will be assigned the same reference numerals, and description thereof will be omitted.

First Embodiment (Piston Type Compressor) As shown in FIG. 1, a front housing 12 is joined to the front end of a cylinder block 11. A rear housing 14 is joined to the rear end of the cylinder block 11 via a valve / port forming body 13 having a suction valve mechanism 18 and a discharge valve mechanism 19.
Each of these members 11 to 14 is fastened and fixed via a through bolt 17. The left side of the drawing is the front and the right side is the rear.

A crank chamber 15 is defined in a region surrounded by the cylinder block 11 and the front housing 12. A drive shaft 16 is rotatably arranged in the crank chamber 15. The drive shaft 16 is operatively connected to an engine (not shown) that is a traveling drive source of the vehicle, and is rotated by receiving power from the engine. Crank chamber 1
In FIG. 5, a swash plate 23 is connected to the drive shaft 16 so as to be synchronously rotatable.

A plurality of cylinder bores 11a (only one place is shown in the drawing) are formed in the cylinder block 11 so as to penetrate therethrough in the front-rear direction. The single-headed piston 25 is reciprocally housed in each cylinder bore 11a. The front and rear openings of the cylinder bore 11a are closed by the valve / port forming body 13 and the piston 25,
A compression chamber 26 whose volume changes according to the reciprocating movement of the piston 25 is defined in the cylinder bore 11a. Each piston 25 is moored to the outer peripheral portion of the swash plate 23 via a shoe 27. Therefore, the rotation of the swash plate 23 accompanying the rotation of the drive shaft 16 is converted into the reciprocating motion of the piston 25 via the shoe 27.

A suction chamber 2 is provided in the rear housing 14.
8 and the discharge chamber 29 are formed by division. Then, the refrigerant gas containing the lubricating oil in the suction chamber 28 moves from the top dead center position of each piston 25 to the bottom dead center side, and the compression gas is passed through the suction valve mechanism 18 of the valve / port forming body 13. Two
6 is inhaled. The refrigerant gas sucked into the compression chamber 26 is
The piston 25 is compressed to a predetermined pressure by moving from the bottom dead center position to the top dead center side, and is discharged into the discharge chamber 29 via the discharge valve mechanism 19 of the valve / port forming body 13.

(Valve / Port Forming Body) As shown in FIG. 2 (a), the valve / port forming body 13 is a suction valve forming plate 3
5, a valve plate 40 made of an iron-based metal, a discharge valve forming plate 36, and a retainer plate 37 are stacked in the same order from the front side to the rear side of the compressor. The suction valve forming plate 35 is provided with a suction valve 35a made of a reed valve as a valve body. The discharge valve forming plate 36 is provided with a discharge valve 36a which is a reed valve as a valve body. The retainer plate 37 is provided with a retainer 37a that abuts and regulates the maximum opening of the discharge valve 36a.

The valve plate 40 includes a suction valve 35.
An intake port 30 opened and closed by a is formed so as to communicate with the intake chamber 28 and the compression chamber 26.
A discharge port 32, which is opened and closed by a discharge valve 36a, is formed through the valve plate 40 so as to connect the discharge chamber 29 and the compression chamber 26 to each other.

The suction valve 35a of the suction valve forming plate 35 and the suction port 30 of the valve plate 40 constitute a suction valve mechanism 18. The discharge valve 36 a of the discharge valve forming plate 36, the retainer 37 a of the retainer plate 37, and the discharge port 32 of the valve plate 40 constitute the discharge valve mechanism 19.

As shown in FIGS. 2 (a) and 2 (b),
On the front end face 40a of the valve plate 40, a convex suction valve seat 41 is formed in an annular region around the opening of the suction port 30. Valve plate 40
On the rear end face 40b, a convex valve seat 43 for the discharge valve is formed in an annular region around the opening of the discharge port 32. The front and rear end faces 40a, 40 of the valve plate 40
In b, on the inner peripheral side and the outer peripheral side of each valve seat 41, 43,
Recesses 45 and 46 that make the valve seats 41 and 43 convex are formed. Although FIG. 2B is a view of the discharge valve mechanism 19 from the front, the front view of the intake valve mechanism 18 can be represented in substantially the same manner. Therefore, the member numbers corresponding to the intake valve mechanism 18 are shown in parentheses. It is shown.

The front and rear end faces 40 of the valve plate 40
In each of a and 40b, an annular groove 42 as an annular groove is formed deeper than the recess 45 in a region surrounding the valve seats 41 and 43 (outer peripheral side than the outer recess 45). In the front and rear end surfaces 40a, 40b of the valve plate 40, the inner and outer regions bounded by the annular groove 42 and the outer recess 45 are set to be flush. That is, each valve seat 4
The bearing surfaces 41a and 43a of the valve plates 1 and 43 have valve plates 40
Are set flush with the end faces 40a and 40b.

In this way, by making the intake valve valve seat 41 and the discharge valve valve seat 43 respectively convex, each valve seat 41,
43 seat surfaces 41a, 43a and the respective valves 35 seated thereon
The contact area with a and 36a can be reduced. Therefore, each valve 35a, 36a and the seat surface 41 of the valve seat 41, 43
Since a lubricating oil film is interposed between a and 43a,
It is possible to suppress sticking of both. Therefore, it is possible to prevent the volumetric efficiency of the compressor from being reduced due to the suction valve 35a sticking to the valve plate 40, and to prevent overcompression due to the discharge valve 36a sticking to the valve plate 40.

(Method for Manufacturing Valve Plate) The valve plate 40 is manufactured through the following first to third steps. Only the formation of the discharge port 32 and the valve seat 43 for the discharge valve will be described below, and the suction port 3 that is performed in the same process as the formation of the discharge port 32 and the valve seat 43 for the discharge valve.
Description of the formation of 0 and the intake valve valve seat 41 is omitted. In addition, the first of the intake port 30 and the intake valve valve seat 41
The third step is performed in parallel with the same step of forming the discharge port 32 and the discharge valve valve seat 43.

As shown in FIG. 3A, in the first step, the discharge port 32 and the annular groove 42 are formed in the valve plate material 40W by pressing.
In the drawing, a press die P1 used for this press working is shown by a chain double-dashed line. A region inside the annular groove 42 on the upper surface (the surface that will be the rear end surface of the valve plate 40 later) 40b of the valve plate material 40W, which has been made convex through the first step, is the valve seat for the discharge valve. The planned site Y of 43 (a region to be the seating surface 43a later) is included and is wider in the inner and outer directions than the planned site Y of formation.

As shown in FIG. 3 (b), in the second step, with respect to the upper surface 40b of the valve plate material 40W, that is, the surface 40b of the discharge valve valve seat 43 on the side Y where the valve seat 43 is to be formed,
A polishing process is performed. This polishing process removes large swells of meat generated around the opening of the discharge port 32 in the first step (pressing) and the suction port 30 (see FIG. 2).
The purpose is to remove burrs around the opening (see (a)) and finish the entire surface. In the drawing, the grindstone G used for the polishing process is shown by a two-dot chain line.

As shown in FIG. 3 (c), in the third step, the valve seat 43 for the discharge valve is formed on the valve plate material 40W by pressing. The formation of the valve seat 43 for the discharge valve is performed by forming a recess in the inner and outer peripheral regions except the planned site Y where the valve seat 43 for the discharge valve is formed, in the region inside the annular groove 42 formed in the convex shape in the first step. 45,46
Is formed. In the drawing, a press die P2 used for this press working is shown by a chain double-dashed line.

The present embodiment having the above-described structure has the following effects. (1) The suction valve valve seat 41 and the discharge valve valve seat 4 are processed by the third step, which is a pressing step, after the second step, which is a polishing step.
3 is being formed. Therefore, the valve seats 41 and 43 can be formed with high accuracy by eliminating the influence of the polishing process. Therefore, for example, the seat surfaces 41a, 4 of the valve seats 41, 43
It is easy to set the area (sealing area) of 3a narrower than that of the conventional one.
It is possible to more effectively suppress the sticking of a to the valve plate 40.

(2) In the third step, in the valve plate material 40W, the valve seats 41, 43 are formed by recessing the periphery of the planned site Y for forming the valve seats 41, 43 by press working. Therefore, the seat surface 41 of the valve seats 41 and 43
a, 43a to the end surfaces 40a, 40a of the valve plate 40
The setting to be flush with b is also easy. The seat surfaces 41a and 43a of the valve seats 41 and 43 are replaced with the end surfaces 40a of the valve plate 40,
If it is flush with 40b, the valves 35a and 36a are not inclined with respect to the valve seats 41 and 43 in the closed state of the ports 30 and 32, so that the sealing property between them can be improved.

(3) In the steps before the third step,
An annular groove 42 is provided outside the planned site Y where the valve seats 41 and 43 are formed.
Is formed. Therefore, as shown in FIG. 3C, during the third step (pressing), the stress acting in the vicinity of the planned site Y of the valve seats 41 and 43 is increased by the bulge B of the meat into the annular groove 42. Can be escaped by. Therefore, for example, the seat surfaces 41a, 43 of the valve seats 41, 43 due to the action of this stress
It is possible to prevent distortion and the like of a.

(4) The annular groove 42 is formed by pressing at the same time as the formation of the ports 30 and 32 in the first step. Therefore, the manufacturing process of the valve plate 40 can be simplified and the manufacturing cost can be reduced.

Second Embodiment (Valve Plate) As shown in FIG. 4C, the valve plate 40 of this embodiment has a recess 48 formed in an annular region around the opening of the discharge port 32. A part of the recess 48 is annularly raised, and the raised portion forms the discharge valve valve seat 43. Although not shown, the intake valve valve seat 41 has the same configuration as the discharge valve valve seat 43.

(Method for Manufacturing Valve Plate) The valve plate 40 is manufactured through the following first to third steps. Only the formation of the discharge port 32 and the valve seat 43 for the discharge valve will be described below. The description of the formation is omitted.
The first to third steps of the suction port 30 and the suction valve valve seat 41 are performed in parallel with the same steps of the discharge port 32 and the discharge valve valve seat 43.

As shown in FIG. 4A, in the first step, the discharge port 32 and the recess 48 are formed in the valve plate material 40W by pressing. In the drawing, a press die P3 used for this press working is shown by a chain double-dashed line. The recess 48 formed through the first step includes the planned formation site Y of the discharge valve valve seat 43 and is wider in the inner and outer peripheral directions than the planned formation site Y.

As shown in FIG. 4B, in the second step, similar to the first embodiment, the upper surface 40b of the valve plate material 40W, that is, the planned site Y of the discharge valve valve seat 43, is formed on the Y side. Polishing treatment is applied to the surface 40b.

As shown in FIG. 4C, in the third step, the valve seat 43 for the discharge valve is formed by pressing on the valve plate material 40W. The discharge valve valve seat 43 is formed by forming the recess 4 formed in the first step.
8 is performed by raising the planned formation site Y of the valve seat 43 for the discharge valve. In the drawing, a cylindrical press die P4 having a diameter slightly larger than that of the discharge port 32, which is used for this press working, is shown by a chain double-dashed line. By hitting the cylindrical end surface of the press die P4 around the opening of the discharge port 32, the discharge valve valve seat 43 is formed like a crater on the outer peripheral side of the press die P4 in the recess 48.

In this embodiment, the same effect as (1) of the first embodiment is obtained. In addition, the following effects are achieved. (1) In the third step, in the valve plate material 40W, the valve seats 41 and 43 are formed by raising the planned formation site Y of the valve seats 41 and 43 by press working. Therefore, the press die P4 may have a simple columnar shape, and it is possible to reduce the die cost and the manufacturing cost.

(2) In the steps before the third step,
This planned site Y including the planned site Y of the valve seats 41 and 43
The recess 48 is formed in a wider area. Therefore, the start of the rising of the planned site Y for forming the valve seats 41 and 43 in the third step starts from within the recess 48 that is lower than the end surfaces 40a and 40b of the valve plate 40, and the seating surfaces 41 of the valve seats 41 and 43.
a, 43a to the end faces 40a, 40b of the valve plate 40
It becomes easy to set the same level. The seat surfaces 41a and 43a of the valve seats 41 and 43 are replaced with the end surfaces 40a and 4a of the valve plate 40, respectively.
0b is flush with the valves 35a, 36a and the valve seats 41, 4
It is possible to improve the sealing property with the No. 3 sheet.

(3) The depression 48 is formed by pressing at the same time as the formation of the ports 30 and 32 in the first step. Therefore, the manufacturing process of the valve plate 40 can be simplified and the manufacturing cost can be reduced.

It should be noted that, for example, the following embodiments can be carried out without departing from the spirit of the present invention. -The first embodiment is modified so that the annular groove 42 is formed, for example, before the first step (see FIG. 3A), the first step (see FIG. 3A), and the second step. To be performed between the steps (see FIG. 3 (b)). That is, the annular groove 42 should be formed in a separate process from the formation of the ports 30 and 32. In this case, the formation of the annular groove 42 is not limited to press working, and may be grinding, for example.

By changing the second embodiment, the formation of the depression 48 can be performed, for example, before the first step (see FIG. 4A) or before the first step (see FIG. 4A). 2 steps (Fig. 4
(See (b)). That is, the formation of the depression 48 should be performed in a separate process from the formation of the ports 30 and 32.
In this case, the formation of the depression 48 is not limited to the press working, and may be a grinding working, for example.

In the second embodiment, the valve seat 4
The bearing surfaces 41a and 43a of the valves 1 and 43 are flush with the end surfaces 40a and 40b of the valve plate 40. But,
For example, as shown in FIG. 5, the seat surface 43a (41a) of the valve seat 43 (41) may be set higher than the end surface 40b (40a) of the valve plate 40, as shown in FIG. By doing so, it is not necessary to form the recess 48 in the valve plate 40, and the press die P3 can be simplified in the first step (see FIG. 4A), and the manufacturing cost can be reduced.

In each of the above embodiments, the method of manufacturing the valve plate 40 of the compressor using the single-headed piston 25 is embodied. However, the present invention is not limited to this, and may be embodied in a method of manufacturing the valve plate in a compressor using a double-headed piston. In a compressor using a double-headed piston, the cylinder bores are arranged not only on the rear side of the housing but also on the front side, so that a valve / port formation body (suction valve mechanism and discharge valve mechanism) on the front side is configured. The valve plate manufacturing method of the present invention can be applied to the valve plate.

In a compressor provided with a rotary valve that rotates in synchronism with the drive shaft 16 in a suction valve mechanism, it should be embodied in a method of manufacturing a valve plate 40 used for the compressor.
In this case, the valve / port forming body 13 is provided with only the discharge valve mechanism 19, and thus the valve plate 40 is provided with only the discharge port 32 and the discharge valve valve seat 43.

The present invention may be embodied in a method of manufacturing a valve plate used in a compressor other than a refrigeration cycle, such as an air compressor. The technical idea that can be understood from each of the above embodiments will be described.

(1) The method for manufacturing a valve plate according to any one of claims 1 to 5, wherein the valve element is a reed valve. (2) The annular groove is pressed at the same time as the port in the first step. The method for manufacturing a valve plate according to claim 3.

(3) The method for manufacturing a valve plate according to claim 5, wherein the recess is pressed at the same time as the port in the first step.

[0047]

According to the present invention having the above structure, the valve seat can be formed with high accuracy.

[Brief description of drawings]

FIG. 1 is a sectional view of a piston type compressor.

2A is an enlarged view of a main part of FIG. 1, and FIG. 2B is a front view of a discharge valve mechanism.

FIG. 3 is a diagram showing a manufacturing process of the valve plate,
(A) shows a 1st process, (b) shows a 2nd process, (c) shows a 3rd process, respectively.

FIG. 4 is a diagram showing a manufacturing process of the valve plate in the second embodiment, in which (a) is a first process and (b) is a second process.
Step (c) shows the third step, respectively.

FIG. 5 is a diagram showing another example.

6A and 6B are views showing a conventional technique, in which FIG. 6A is a sectional view of a discharge valve mechanism, and FIG. 6B is a front view of the discharge valve mechanism.

[Explanation of symbols]

18 ... Suction valve mechanism, 19 ... Discharge valve mechanism, 30 ... Suction port as port, 32 ... Discharge port as port,
35a ... Intake valve as valve element, 36a ... Discharge valve as valve element, 40 ... Valve plate, 40W ... Valve plate material, 41 ... Intake valve valve seat, 43 ... Discharge valve valve seat, Y ...
Planned site for the valve seat.

   ─────────────────────────────────────────────────── ─── Continued front page    (72) Inventor Tomoji Tarutani             2-1, Toyota-cho, Kariya City, Aichi Stock Association             Inside Toyota Toyota Industries (72) Inventor Yoshinobu Ishigaki             2-1, Toyota-cho, Kariya City, Aichi Stock Association             Inside Toyota Toyota Industries F-term (reference) 3H003 AA03 AB06 AC03 CC06                 3H058 AA15 BB29 CB14 CB16 EE13                 3H076 AA06 BB50 CC12 CC20 CC92                       CC93

Claims (5)

[Claims] 1. A port constituting at least one of a suction valve mechanism and a discharge valve mechanism of a compressor, the port being opened and closed by a valve body, and a convex valve formed in an annular region around the opening of the port. A valve plate having a seat; a first step of forming a port on the material of the valve plate by press working; and a second step of polishing the surface of the valve plate material on the side where the valve seat is to be formed. And a third step of forming a valve seat on the valve plate material by press working. 2. The method of manufacturing a valve plate according to claim 1, wherein the third step comprises forming a recess in the valve plate material around the planned seat of the valve seat by press working. 3. In a step before the third step,
The method for manufacturing a valve plate according to claim 2, wherein the annular groove is formed outside the planned site of the valve seat. 4. The method for manufacturing a valve plate according to claim 1, wherein the third step is to press up a planned site for forming the valve seat in the valve plate material by press working. 5. In a step before the third step,
The method for manufacturing a valve plate according to claim 4, wherein a process of recessing a region wider than the planned site for forming the valve seat is performed.