JP2006348954A - Manufacturing method of muffler for compressor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a muffler for a compressor by providing a flat panel resonator between muffler members separated into two parts and forming a muffler body by once welding process. <P>SOLUTION: The resonator 3 with a plurality of protrusions 33 is fit to the opening step part 15 of a front part chamber 1 of the muffler members separated into the two parts and a tip end of the protrusion 33 is positioned at an opening end face of the front part chamber 1. A protruding part 23 is provided along an inner circumference of an opening end part of a rear part chamber 2 of the muffler members separated into the two parts and an opening end face of the rear part chamber 2 is butted at the opening end face of the front part chamber 1. By heat-welding along an outer circumference part of the butted end face, the front part chamber 1, the rear part chamber 2 and the resonator 3 can be simultaneously welded and integrated. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a muffler for a compressor, and more particularly to a method for manufacturing a muffler for a compressor in which a plate-like resonator is interposed between two divided muffler members and these are welded together. .

Conventionally, as a muffler of a hermetic type electric compressor among compressor mufflers, for example, the inner space of the muffler is divided into two upper and lower chambers by an intermediate partition plate, and an insertion tube that opens to a lower chamber is provided. There is disclosed a muffler having a structure in which a through-hole is provided in the upper chamber and a communication pipe leading from the upper chamber into the cylinder head is provided (for example, see Patent Document 1).
JP-A 61-19988

  Many mufflers for sealed electric compressors having a structure different from that of the above muffler have also existed in the past. For example, as shown in FIG. And the rear chamber A2, the front chamber A1 is provided with an introduction pipe C and a lead-out pipe D, and a mounting plate E also serving as a cover is connected to the muffler main body A and fixed to the upper part of the compression section F. Known muffler is known

  In this muffler, the low pressure gas supplied from the gas supply port G is introduced into the front chamber A1 by the introduction pipe C, and the rear chamber A2 is formed from the lower region of the through hole by a passage provided in the front chamber A1 through a partition wall. The low pressure gas is silenced by the throttling effect of the through holes.

  The silenced low-pressure gas returns from the upper region of the through hole into the front chamber A1, flows into the outlet pipe D from an opening provided in a part of the partition wall, and the cylinder head H of the compression section F from the outlet pipe D. And is sucked into a cylinder (not shown). The high-pressure gas compressed by the piston that reciprocates in the cylinder is discharged to the cylinder head H, and is discharged to the outside from the gas discharge port J through the pipe I connected to the discharge portion.

  The conventional muffler as described above includes a front chamber A1 integrally formed of synthetic resin together with the introduction pipe C, outlet pipe D, and a partition wall (not shown), and a rear chamber integrally formed of synthetic resin together with the mounting plate E. The muffler body A is configured by heat-welding A2 and a resonator B, which is also formed of a synthetic resin.

  In the heat welding of these constituent members, first, a flat plate resonator B is welded and fixed to the opening step surface of the front chamber A1 as shown in FIG. 6 (a), and then the front chamber A1 as shown in FIG. 6 (b). And the opening end surfaces of the rear chamber A2 are welded and fixed together. Therefore, in order to manufacture the muffler main body A, two steps of welding are required, which not only lowers the welding workability but also requires a welding apparatus and a welding mold for each step, which causes a rise in manufacturing costs. It has become.

  On the other hand, a method of bonding with an adhesive rather than heat welding is also conceivable, but it takes a long time for the bonding process, workability is not good, unevenness in the bonding finish is likely to occur, and bonding failure may occur. It is not preferable. In addition, the odor of the adhesive or the solvent may be filled, or the workplace environment may be deteriorated, such as rough skin and allergic symptoms.

  The present invention is made in order to solve such a conventional muffler manufacturing problem, and provides a method for manufacturing a muffler for a compressor, in which a muffler body can be manufactured by welding the three constituent members in one step. For the purpose.

  In order to achieve the above object, the present invention provides a muffler for a compressor that forms a muffler body by interposing a plate-like resonator between two divided muffler members and welding them. A compressor characterized in that a plurality of protrusions are provided on one surface of the resonator, the tips of the protrusions are positioned on the mating surfaces of the two muffler members, and these are simultaneously welded and integrated to form a muffler body. This is a method for manufacturing a muffler for a vehicle.

  As described above, according to the invention of claim 1 according to the present invention, a flat resonator is interposed between two divided muffler members, and these are welded to form a muffler main body. In the muffler manufacturing method, a plurality of protrusions are provided on one surface of the resonator, the ends of the plurality of protrusions are positioned on the mating surfaces of the two muffler members, and these are simultaneously welded and integrated to form a muffler body. Welding, which has conventionally been two steps, can be completed in one step, and a welding mold and a welding apparatus are required for one step. Thereby, while improving the welding workability | operativity of a muffler main body, reduction of manufacturing cost can be aimed at.

  Next, an embodiment of a compressor muffler manufacturing method according to the present invention will be described with reference to the accompanying drawings. FIG. 1 is a perspective view of a muffler constituent member before welding as viewed obliquely from below. FIG. 2A is a schematic cross-sectional view of a main part showing a state before the muffler constituent member is welded and a perspective view of a resonator, and FIG. 2B is a schematic cross-sectional view of the main part showing a state after welding. FIG. 3 is a perspective view showing the welded muffler body.

  In FIG. 1, reference numeral 1 denotes a front chamber of two divided muffler members, a substantially box-shaped base body 11 having one end opened, and an introduction pipe 12 provided continuously below the base body 11 in the vertical direction; A substantially L-shaped lead-out tube 13 provided in a horizontal direction on the side of the base 11 and a mounting plate 14 provided in a protruding manner in the horizontal direction on the top of the base 11 are provided. Further, a step portion 15 is provided along the inner periphery at the opening end of the front chamber 1, and partition walls 16 and 17 are provided inside the front chamber 1. The front chamber 1 is integrally formed of a synthetic resin such as PBT (polybutylene terephthalate).

  Reference numeral 2 denotes a rear chamber of the two-divided muffler member, which has a substantially box-like base body 21 having one end opened corresponding to the opening of the front chamber 1, and the mounting plate 14 on the top of the base body 21. And a cover 22 having a substantially L-shaped cross section extending in the direction. Further, a substantially band-like convex portion 23 is provided intermittently along the inner periphery at the opening end of the rear chamber 2. The rear chamber 2 is also integrally formed with a synthetic resin, for example, PBT (polybutylene terephthalate), like the front chamber 1.

  In addition, a stepped portion 24 protruding inward is provided at one lower corner portion of the rear chamber 2 along the length direction. Therefore, the opening end portion of the rear chamber 2 is not rectangular, but one lower corner portion. It has a form that is folded inside. Similarly to this, the front chamber 1 is also provided with a step portion 18 at one lower corner along the length direction, so that the opening end is not rectangular but one lower corner is folded inward. is there.

  Reference numeral 3 denotes a flat plate resonator, in which a square hole-shaped through hole 31 is provided in the vicinity of one lower corner portion, and a notch 32 corresponding to the step portion 18 of the front chamber 1 is provided in the other lower corner portion. Furthermore, a plurality of (four in the illustrated example) square bar or round bar-like projections 33 are provided on the outer peripheral portion of one surface in an up-down and left-right manner. Similarly to the front chamber 1 and the rear chamber 2, the resonator 3 is also integrally formed of a synthetic resin such as PBT (polybutylene terephthalate). The resonator 3 is fitted from the opening end of the front chamber 1 and is received by the step portion 15.

  In order to manufacture the muffler main body by heating and welding the front chamber 1, the rear chamber 2, and the resonator 3 configured as described above, first, as shown in FIG. 2A, from the opening end of the front chamber 1. The resonator 3 is inserted and received by the step portion 15. At this time, it is important to set the length (height) of the projection 33 in advance so that the tip of each projection 33 of the resonator 3 is located in the same plane as the opening end surface of the front chamber 1.

  Since the resonator 3 is provided with the notch 32 at the lower corner portion as described above and cannot be fitted unless the notch 32 is inserted into the opening end so as to be aligned with the stepped portion 18 of the front chamber 1, the resonator 3 The insertion direction of 3 is restricted to single. Thereby, the resonator 3 is not inserted in a wrong direction, and an operator's insertion mistake can be prevented.

  Thereafter, when the opening end of the rear chamber 2 is butted against the opening end of the front chamber 1 as shown in FIG. 2 (b), the tips of the projections 33 of the resonator 3 are located within the butting end surface, and The tips of the protrusions 33 come into contact with or face the convex portions 23 located at the opening end portions of the rear chamber 2.

  Also in the abutting between the opening end of the front chamber 1 and the opening end of the rear chamber 2, the abutting direction is restricted to a single by the non-rectangular opening end facing each other. Thereby, the rear chamber 2 is not abutted in a wrong direction, and an operator's abutting mistake can be prevented in advance.

  The abutting state is held by a welding mold (not shown), and a welding process is performed by heating along the outer periphery of the abutting end surface by a welding apparatus. By this welding process, the front chamber 1, the rear chamber 2, and the resonator 3 sandwiched therebetween are simultaneously welded and integrated. That is, the muffler main body 4 shown in FIG. 3 can be manufactured by one welding process. The butted portion between the cover 22 and the mounting plate 14 is also welded and fixed at the same time.

  The muffler main body 4 manufactured in this way is used by being assembled by screwing the mounting plate 14 onto the upper part of the constituent members in the hermetic electric compressor 5, for example, as shown in FIG. In FIG. 4, 51 is an airtight container, which is formed by joining and welding two upper and lower divided metal case members. In this airtight container 51, the electric part 52 is at the lower part and the reciprocating compression part 53 is at the upper part. It is placed and accommodated.

  The electric part 52 is composed of a rotor 52a around which a crankshaft 54 is attached, and a stator 52b. The compression portion 53 is provided with a cylindrical cylinder 53a, a piston 53b that reciprocates in the cylinder 53a, a front end attached to the piston 53b via a pin, and a rear end that is eccentric to the crankshaft 54. The scotch yoke connecting rod 53c is engaged and connected to the crank pin 54a.

  The compression part 53 and the electric part 52 are fixed to a holding member 55 and supported on the inner wall of the hermetic container 51 at a plurality of places (usually three places) in an elastically suspended state via springs 56. A bearing portion 55 a that supports the crankshaft 54 is integrally formed with the holding member 55. In this case, the cylinder 53 a is formed separately from the holding member 55, but may be formed integrally with the holding member 55.

  The crankshaft 54 is provided with a spiral groove 54b through which lubricating oil passes on the outer peripheral surface. An oil passage hole 54c communicating with the groove 54b is formed along the axial direction, and a centrifugal pump member 56 is formed at the lower end. Is inserted. Further, although not shown, there are an oil passage hole that passes from the upper end of the spiral groove 54b to the crank pin 54a, and a spiral groove that leads from the oil passage hole to the upper end through the outer peripheral surface of the crank pin 54a. Is formed.

  In the hermetic electric compressor 5 configured as described above, when the rotor 52a rotates by energizing the motor unit 52, the crankshaft 54 rotates axially and the crankpin 54a rotates eccentrically. The gas is converted into a reciprocating motion via the Scotch yoke type connecting rod 53c, and the piston 53b reciprocates to compress the gas sucked into the cylinder 53a.

  Although not shown in FIG. 4, the gas is supplied to the hermetic electric compressor 5 by feeding it into the introduction pipe 12 of the muffler main body 4 from the gas supply port as in the prior art (see FIG. 3). In the case of the present embodiment, the gas supplied to the introduction pipe 12 of the muffler body 4 flows into the front chamber 1 and from the first space 1 a partitioned by the partition wall 16 to the lower region of the through hole 31 of the resonator 3. And flows into the rear chamber 2. At this time, since the gas is throttled by the through hole 31 and flows into the large space of the rear chamber 2, the pulsation is prevented and the sound is muted.

  The gas flowing into the rear chamber 2 returns to the front chamber 1 through the upper region of the through hole 31 and enters the second space portion 1b surrounded by the partition walls 16 and 17 and the wall surface of the resonator 3, It flows into the third space portion 1c located on the other side of the partition wall 17 through the gap S provided between the partition wall 17 and the resonator 3 from the second space portion 1b.

  And the gas in the 3rd space part 1c is sent into the cylinder head 53d shown in FIG. The gas sent into the cylinder head 53d is sucked into the cylinder 53a through a valve portion 53e having a suction valve and a discharge valve.

  The gas compressed by the reciprocating motion of the piston 53b is discharged from the cylinder 53a to the discharge portion of the cylinder head 53d via the valve portion 53e, and is supplied to the gas discharge port through a pipe connected to the discharge portion as in the conventional case. It is guided and discharged to the outside from this gas discharge port (see FIG. 5). Although not shown in FIG. 5> 5, a discharge pipe and a supply pipe are connected to the gas discharge port and the gas supply port, respectively.

  During the operation of the hermetic electric compressor 5, the centrifugal pump member 56 pumps up the lubricating oil in the lubricating oil storage container 57 fixed to the bottom of the hermetic container 51. The pumped lubricating oil is fed to the crank pin 54a through the oil passage 54c and the spiral groove 54b, lubricates the engaging portion of the bearing portion 55a and the connecting rod 53c, and further from the crank pin 54a. The sliding portion of the piston 53b is lubricated by the released lubricating oil.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows an embodiment of a compressor muffler manufacturing method according to the present invention, and is a perspective view of a muffler constituent member before welding as viewed obliquely from below. (A) is the schematic sectional drawing of the principal part which shows the state before welding of the muffler structural member which concerns on this invention, and the perspective view of a resonator, (b) is the schematic sectional drawing of the principal part which shows the state after welding. is there. It is a perspective view of the muffler main body after welding. It is a schematic sectional drawing which shows the example of the hermetic type electric compressor which assembled | attached the muffler main body which concerns on this invention. It is a partially broken perspective view which shows the example of the hermetic type electric compressor which assembled | attached the conventional muffler main body. It is the schematic sectional drawing of the principal part which shows the state after the 1st welding process of the conventional muffler structural member, and the perspective view of a resonator, (b) is the schematic sectional drawing of the principal part which shows the state after a 2nd welding process. is there.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Front chamber 12 ... Introducing pipe 13 ... Outlet pipe 14 ... Mounting plate 15 ... Step part 2 ... Rear chamber 22 ... Cover 23 ... Convex part 3 ... Resonator 31 ... Through hole 32 ... Notch 33 ... Protrusion 4 ... Muffler body 5 ... Sealed electric compressor

Claims (1)

  In a method for manufacturing a muffler for a compressor in which a muffler main body is formed by interposing a flat plate resonator between two divided muffler members and welding them, a plurality of protrusions are provided on one surface of the resonator, A method of manufacturing a muffler for a compressor, wherein the plurality of protrusion tips are positioned on a mating surface of both the muffler members, and these are simultaneously welded and integrated to form a muffler body.