JP2020193581A - Scroll-type compressor and its manufacturing method - Google Patents

Abstract

To provide a scroll-type compressor capable of surely suppressing leakage of a refrigerant even in mass production, and hardly causing power loss.SOLUTION: In a first process of a manufacturing method, a coating material including a binder resin, a solid lubricant, and a hardener capable of polymerizing the binder resin by ultraviolet ray, frontal polymerizing the same, and further thermally polymerizing the same, is prepared. In a second process, a coating layer is formed by applying the coating material, and in a third process, a non-fluid layer is created from the coating layer by applying ultraviolet ray to the coating layer. In a fourth process, a scroll-type compressor is assembled, and in a fifth process, the binder resin in the non-fluid layer is frontal-polymerized and thermally polymerized by operating the scroll-type compressor, so that the hardened layer is created from the non-fluid layer.SELECTED DRAWING: Figure 2

Description

The present invention relates to a scroll compressor and a method for manufacturing the same.

Scroll compressors include fixed scrolls and movable scrolls. The fixed scroll has a fixed substrate and a fixed swirl wall. The movable scroll has a movable substrate and a movable spiral wall. The fixed substrate, the fixed spiral wall, the movable substrate and the movable spiral wall form a compression chamber whose volume is changed.

Patent Document 1 discloses a conventional method for manufacturing this scroll type compressor. This manufacturing method includes the first to fourth steps. In the first step, a coating material is prepared. The coating material contains polyamide-imide (PAI) and particulate molybdenum disulfide (MoS ₂ ). This coating material is cured by drying and heating. In the second step, a coating material is applied to the fixed substrate and the fixed spiral wall of the fixed scroll and the movable substrate and the movable spiral wall of the movable scroll to form a coating layer. In the third step, the scroll type compressor is assembled by the fixed scroll and the movable scroll before the coating layer is cured. In the fourth step, after the third step, the coating layer is cured by drying and heating by operating a scroll type compressor to form a cured layer. During this time, it is considered that the hardened layer can minimize the gap between the fixed scroll and the movable scroll by the relative movement.

Therefore, it is considered that the scroll type compressor thus obtained can suppress the leakage of the refrigerant from the compression chamber. Further, in the cured layer, since particulate molybdenum disulfide is dispersed in PAI, it is considered that the fixed scroll and the movable scroll slide satisfactorily. In this way, this scroll type compressor is considered to exhibit excellent refrigerating capacity.

Japanese Unexamined Patent Publication No. 2003-35284

However, when mass-producing scroll type compressors, the gap between the fixed scroll and the movable scroll tends to vary individually. Therefore, if the scroll type compressor is assembled before the coating layer is cured and the coating layer is cured only by operating the scroll type compressor as in the above manufacturing method, the coating layer is improperly biased. It may be cured to form a cured layer while having a portion. In this case, the cured layer that should minimize the gap between the fixed scroll and the movable scroll may conversely create a gap and promote the leakage of the refrigerant. In addition, the improperly biased portion of the cured layer hinders the relative movement of the movable scroll with respect to the fixed scroll, which tends to cause power loss.

The present invention has been made in view of the above-mentioned conventional circumstances, and has solved the problem of providing a scroll type compressor that can more reliably suppress refrigerant leakage and is less likely to cause power loss even in mass production. It is an issue that should be done.

The method for manufacturing a scroll type compressor of the present invention includes a fixed scroll having a fixed substrate and a fixed spiral wall, and a movable scroll having a movable substrate and a movable spiral wall, and includes the fixed substrate, the fixed spiral wall, and the movable. The substrate and the movable spiral wall are a method for manufacturing a scroll type compressor that forms a compression chamber whose volume is changed.
The first step of preparing a coating material containing a binder resin, a solid lubricant, and a curing agent capable of polymerizing and frontal-polymerizing the binder resin by ultraviolet rays and being thermally polymerizable.
A second step of applying the coating material to at least one of the fixed substrate and the fixed spiral wall of the fixed scroll and the movable substrate and the movable spiral wall of the movable scroll to form a coating layer.
A third step of polymerizing the binder resin in the coating layer by irradiating the coating layer with ultraviolet rays to make the coating layer a non-fluid layer in a moldable state while having non-fluidity.
After the third step, the fourth step of assembling the scroll type compressor by the fixed scroll and the movable scroll, and
After the fourth step, by operating the scroll type compressor, the binder resin in the non-fluidized bed is frontal-polymerized and thermally polymerized to form the non-fluidized bed into a cured layer. It is characterized by being.

In the manufacturing method of the present invention, a coating material is prepared in the first step, and this coating material is applied to a predetermined position of a fixed scroll or a movable scroll in the second step to form a coating layer, and this coating layer is applied in the third step. Irradiate with ultraviolet rays. At this time, the binder resin in the coating layer is polymerized by ultraviolet rays by the curing agent. Therefore, the coating layer becomes a non-fluidized layer in a moldable state while having non-fluidity. After that, the scroll type compressor is assembled in the fourth step, and the scroll type compressor is operated in the fifth step. At this time, even if the irradiation of ultraviolet rays is completed in the scroll type compressor, the binder resin in the non-fluidized bed undergoes frontal polymerization by the curing agent. Further, the binder resin in the non-fluidized bed is heated by the frictional heat in the scroll type compressor and thermally polymerized by the curing agent. In this way, the non-fluidized bed becomes a cured layer. During this period, since the non-fluidized layer is in a formable state while having non-fluidity, it is easy to be suitable for individual fixed scroll and movable scroll when the fixed scroll and the movable scroll are relatively moved. Therefore, the cured layer can more reliably minimize the gap between the fixed scroll and the movable scroll. Further, after the fifth step, the cured layer suitable for each fixed scroll and the movable scroll does not hinder the relative movement of the movable scroll with respect to the fixed scroll, and power loss is unlikely to occur.

Therefore, the scroll type compressor obtained by the manufacturing method of the present invention can more reliably suppress the leakage of the refrigerant and is less likely to cause power loss even in mass production.

In the second step, it is preferable to form a coating layer on the fixed substrate and the fixed spiral wall of the fixed scroll. That is, in the second step, it is preferable not to form a coating layer on the movable substrate and the movable spiral wall of the movable scroll. In this case, even if the scroll type compressor is operated, the fixed scroll does not move, so that centrifugal force does not act on the non-fluidized bed, and the non-fluidized bed is easily formed into a cured layer suitable for the movable scroll. Further, when a coating layer is formed on both the fixed scroll and the movable scroll, it is difficult to adjust the gap between the non-fluidized layer of the fixed scroll and the non-fluidized layer of the movable scroll due to the same hardness. In this case, the gap is fixed. The non-fluidized bed of the scroll is more likely to be formed by a harder movable scroll. Further, the consumption of the coating material can be reduced.

In the second step, it is also preferable to form a coating layer on the movable substrate and the movable spiral wall of the movable scroll. That is, in the second step, it is preferable not to form a coating layer on the fixed substrate and the fixed spiral wall of the fixed scroll. When a coating layer is formed on both the fixed scroll and the movable scroll, it is difficult to adjust the gap between the non-fluidized layer of the fixed scroll and the non-fluidized layer of the movable scroll due to the same hardness. In this case, the movable scroll The non-fluidized bed is more likely to be molded by a harder fixed scroll. Further, the consumption of the coating material can be reduced.

The scroll type compressor of the present invention includes a fixed scroll having a fixed substrate and a fixed spiral wall, and a movable scroll having a movable substrate and a movable spiral wall, and includes the fixed substrate, the fixed spiral wall, the movable substrate, and the movable scroll. A scroll compressor that forms a compression chamber whose volume is changed by a movable spiral wall.
A cured layer is formed on at least one of the fixed substrate and the fixed spiral wall of the fixed scroll and the movable substrate and the movable spiral wall of the movable scroll.
The cured layer contains a binder resin and a solid lubricant, and is characterized by being polymerized by ultraviolet rays, frontal polymerization, and thermal polymerization.

In the scroll type compressor of the present invention, the cured layer is in a state suitable for individual fixed scrolls and movable scrolls. Therefore, in this scroll type compressor, the possibility of promoting the leakage of the refrigerant and causing power loss is reduced.

Even in mass production, the scroll type compressor of the present invention can more reliably suppress the leakage of the refrigerant and is less likely to cause power loss.

FIG. 1 is a cross-sectional view of the scroll type electric compressor of the first embodiment. FIG. 2 is a cross-sectional view of a fixed scroll and a movable scroll in the scroll type electric compressor of the first embodiment. FIG. 3 is a cross-sectional view of a fixed scroll and a movable scroll in the scroll type electric compressor of the second embodiment.

<First step>
In the first step, a coating material containing a binder resin, a solid lubricant, and a curing agent capable of polymerizing and frontal polymerizing the binder resin by ultraviolet rays and being thermally polymerizable is prepared.

(Binder resin)
Binder resin has the retention of solid lubricant that makes it difficult to remove the solid lubricant, durability against shearing force that repeatedly acts under the layered coating (hardness as a base), wear resistance that is hard to break, heat resistance, etc. Demonstrate. As the binder resin, an epoxy resin, a polyimide resin, a phenol resin or the like can be adopted. As the polyimide-based resin, polyamide-imide (PAI), polyimide, or the like can be adopted.

(Solid lubricant)
The solid lubricant is held in the binder resin and exhibits low shear force and low friction coefficient on the outermost surface. As the solid lubricant, fluororesin such as PTFE, molybdenum disulfide, graphite, ultra-high molecular weight polyethylene, melamine cyanurate (MCA), calcium fluoride, and soft metals such as copper and tin can be adopted.

(Hardener)
As the curing agent, one that can polymerize and frontal polymerize the binder resin by ultraviolet rays and can be thermally polymerized is adopted. Here, the frontal polymerization by ultraviolet rays refers to a radical reaction in which a polymerization zone is formed in the composition by irradiation with ultraviolet rays, and the polymerization zone proceeds to the entire composition even after the irradiation with ultraviolet rays is stopped. For example, when an epoxy resin or PAI is used as the binder resin, a photoacid generator and a thermoacid generator can be used.

The coating material may contain additives in addition to the binder resin, solid lubricant and curing agent. As the additive, those that improve the hardness of the hardened layer, such as hard particles such as titanium dioxide, calcium tertiary phosphate, alumina, silica, silicon carbide, and silicon nitride, can be adopted.

<Second step>
In the second step, a coating material is applied to at least one of the fixed substrate and the fixed spiral wall of the fixed scroll and the movable substrate and the movable spiral wall of the movable scroll to form a coating layer. A coating layer may be formed on the fixed substrate and the fixed spiral wall of the fixed scroll and the movable substrate and the movable spiral wall of the movable scroll, or the coating layer may be formed only on the fixed substrate and the fixed spiral wall of the fixed scroll. The coating layer may be formed only on the movable substrate and the movable spiral wall of the scroll. This is because the compression chamber is formed by the fixed substrate, the fixed spiral wall, the movable substrate, and the movable spiral wall.

<Third step>
In the third step, the binder resin in the coating layer is polymerized by irradiating the coating layer with ultraviolet rays to make the coating layer a non-fluidized layer. The non-fluidized bed is in a moldable state because the coating material has non-fluidity in which the coating material does not flow and the curing is not completed. The irradiation amount and irradiation time of ultraviolet rays are appropriately selected within the range of desired non-fluidity and moldability of the non-fluidized bed.

<4th process>
In the fourth step, after the third step, a scroll type compressor is assembled by a fixed scroll and a movable scroll.

<Fifth step>
In the fifth step, after the fourth step, the binder resin in the non-fluidized bed is frontal-polymerized and thermally polymerized by operating a scroll type compressor to make the non-fluidized bed a cured layer. The time from the third step to the end of the fifth step is appropriately selected as long as the non-fluidized bed after the fourth step exhibits desired non-fluidity and moldability and the fifth step can be completed. It is preferable that the scroll type compressor is operated without filling the refrigerant. It suffices if the area around the compression chamber is heated to 150 to 200 ° C by the operation of the scroll type compressor.

(Example 1)
As shown in FIG. 1, this scroll type compressor is an electric compressor for a vehicle air conditioner. This electric compressor includes a scroll-type compression mechanism 10, a motor mechanism 12, and a housing 16. The housing 16 has a front housing 1 and a motor housing 3.

The front housing 1 and the motor housing 3 are butted against each other and fastened to each other by a plurality of bolts 9. The motor housing 3 has a bottomed cylindrical shape having an opening on the front housing 1 side. A shaft support member 11 is provided in the motor housing 3, and a plate 14 and a fixed scroll 13 are provided in front of the shaft support member 11. The front housing 1 and the motor housing 3 are housed in a state where the fixed scroll 13, the plate 14, and the shaft support member 11 are in contact with each other. A gasket 2 is sandwiched between the fixed scroll 13 and the front housing 1.

A cylindrical shaft support portion 3b is projected forward toward the center of the inner surface of the bottom wall 3a of the motor housing 3. On the other hand, the shaft support member 11 includes a cylindrical main body portion 11a and a flange portion 11b protruding outward from the opening edge of the front end of the main body portion 11a. A shaft hole 11c is formed through the center of the main body portion 11a. The flange portion 11b is fixed to the inner peripheral surface of the motor housing 3. A rotation prevention mechanism 17 is provided between the collar portion 11b and the movable scroll 15, which will be described later, to regulate the rotation of the movable scroll 15 and allow only the revolution.

A rotating shaft 19 extending in the front-rear direction is inserted through the shaft hole 11c. Each end of the rotating shaft 19 is rotatably supported by the shaft support member 11 and the shaft support portion 3b via radial bearings 21 and 23. A sealing material 25 is provided behind the radial bearing 21. A columnar eccentric pin 19a is formed so as to project from the front end of the rotating shaft 19, and a bush 27 having a balance weight is fitted and supported on the eccentric pin 19a. A movable scroll 15 is provided between the bush 27 and the fixed scroll 13 via a radial bearing 29.

As shown in FIG. 2, the fixed scroll 13 has a disk-shaped fixed substrate 13a extending in the radial direction, a shell 13b extending rearwardly on the outer peripheral side of the fixed substrate 13a, and inside the shell 13b. It is composed of a fixed spiral wall 13c extending in a spiral shape from the fixed substrate 13a toward the rear. A hardened layer 43 is formed on the surfaces of the fixed substrate 13a, the shell 13b, and the fixed spiral wall 13c.

The movable scroll 15 includes a disk-shaped movable substrate 15a extending in the radial direction and a movable spiral wall 15b extending forward from the movable substrate 15a in a spiral shape. The movable swirl wall 15b is meshed with the fixed swirl wall 13c. As shown in FIG. 1, the compression chamber 31 is partitioned by the fixed substrate 13a, the fixed spiral wall 13c, the movable substrate 15a, and the movable spiral wall 15b.

In the motor housing 3, a motor chamber 3c is formed behind the shaft support member 11. The motor chamber 3c also serves as a suction chamber. A stator 33 is fixed in the motor chamber 3c. Inside the stator 33, a rotor 35 fixed to the rotating shaft 19 is provided. A motor mechanism 12 for driving the compression mechanism 10 by a rotor 35, a stator 33, and a rotating shaft 19 is configured. A three-phase alternating current is supplied to the motor mechanism 12 by an inverter (not shown). When the rotor 35 and the rotating shaft 19 rotate integrally by energizing the stator 33, the driving force thereof is transmitted to the movable scroll 15 via the eccentric pin 19a and the bush 27, and the movable scroll 15 revolves.

The motor housing 3 is provided with a suction port 3e that communicates the outside with the motor chamber 3c. The suction port 3e is connected to an evaporator (not shown) by a pipe. The evaporator is connected to the expansion valve and the condenser by piping. The low-pressure and low-temperature refrigerant in the evaporator is introduced into the motor chamber 3c from the suction port 3e, and is supplied to the compression chamber 31 via a suction passage (not shown) formed in the shaft support member 11.

A discharge chamber 37 is formed between the fixed substrate 13a of the fixed scroll 13 and the front housing 1. A discharge port 13d is formed through the center of the fixed substrate 13a, and the discharge port 13d communicates the compression chamber 31 and the discharge chamber 37. Further, the fixed substrate 13a is provided with a discharge valve 39 and a retainer 41 in the discharge chamber 37.

The front housing 1 is provided with a discharge port 1a that communicates the outside with the discharge chamber 37. The discharge port 1a is connected to a condenser (not shown) by a pipe. The refrigerant introduced into the discharge chamber 37 is discharged to the condenser through the discharge port 1a. A compression mechanism 10 that compresses the refrigerant is configured by a motor chamber 3c, a rotating shaft 19, a bush 27, a radial bearing 29, a movable scroll 15, a fixed scroll 13, a discharge chamber 37, a discharge valve 39, a retainer 41, and the like. An oil separator may also be included in the discharge chamber 37.

The electric compressor configured as described above is manufactured as follows.
<First step>
A coating material whose composition is shown in Table 1 is prepared.

<Second step>
A coating layer is formed by spraying on the surfaces of the fixed substrate 13a, the shell 13b, and the fixed spiral wall 13c of the fixed scroll 13.

<Third step>
The fixed scroll 13 is placed in an ultraviolet irradiation device, and the coating layer is irradiated with ultraviolet rays at a predetermined irradiation amount and for a predetermined time. At this time, the binder resin in the coating layer is polymerized by ultraviolet rays by the curing agent. Therefore, the coating layer becomes a non-fluidized layer in a moldable state while having non-fluidity.

<4th process>
The electric compressor is assembled by the housing 16, the fixed scroll 13, the movable scroll 15, and the like.

<Fifth step>
Operate the electric compressor without filling the refrigerant. At this time, even if the irradiation of ultraviolet rays is completed in the electric compressor, the binder resin in the non-fluidized bed is frontal-polymerized by the curing agent. Further, the binder resin in the non-fluidized bed is heated to 150 to 200 ° C. by the frictional heat in the electric compressor, and is thermally polymerized by the curing agent. In this way, the non-fluidized bed becomes the cured layer 43. During this period, since the non-fluidized layer is in a moldable state while having non-fluidity, it is easy to be suitable for the individual fixed scroll 13 and the movable scroll 15 when the fixed scroll 13 and the movable scroll 15 are relatively moved. Therefore, the cured layer 43 can more reliably minimize the gap between the fixed scroll 13 and the movable scroll 15. Further, after the fifth step, the individual fixed scroll 13 and the cured layer 43 suitable for the movable scroll 15 do not hinder the relative movement of the movable scroll 15 with respect to the fixed scroll 13, and power loss is unlikely to occur.

Therefore, the electric compressor thus obtained can more reliably suppress the leakage of the refrigerant even in mass production, and is less likely to cause power loss.

Further, in this manufacturing method, since the coating layer is formed only on the fixed scroll 13 and the coating layer is not formed on the movable scroll 15, the non-fluidized layer is easily formed into the cured layer 43 suitable for the movable scroll 15. Further, the non-fluidized layer of the fixed scroll 13 is easily formed by the movable scroll 15 having a higher hardness. Further, the consumption of the coating material can be reduced.

(Example 2)
In this manufacturing method, as shown in FIG. 3, in the second step, a coating layer is formed only on the movable substrate 15a and the movable spiral wall 15b of the movable scroll 15, and the coating layer is a non-fluidized layer and thus a cured layer 45. .. Other configurations and steps are the same as in Example 1.

In this manufacturing method, the non-fluidized layer of the movable scroll 15 is easily formed by the fixed scroll 13 having a higher hardness. Other effects are the same as in Example 1.

In the above, the present invention has been described in accordance with Examples 1 and 2, but the present invention is not limited to the above Examples 1 and 2, and can be appropriately modified and applied without departing from the spirit thereof. Needless to say.

For example, the scroll type compressor of the present invention may be belt-driven instead of electric. Further, in the fourth step, only the compression mechanism 10 of the electric compressor may be assembled.

The present invention can be used for manufacturing methods of air conditioners and the like.

13a ... Fixed substrate 13c ... Fixed swirl wall 13 ... Fixed scroll 15a ... Movable substrate 15b ... Movable swirl wall 15 ... Movable scroll 31 ... Compression chambers 43, 45 ... Hardened layer

Claims (4)

A fixed scroll having a fixed substrate and a fixed spiral wall, and a movable scroll having a movable substrate and a movable spiral wall are provided, and the volumes of the fixed substrate, the fixed spiral wall, the movable substrate, and the movable spiral wall are changed. A method for manufacturing a scroll type compressor that forms a compression chamber.
The first step of preparing a coating material containing a binder resin, a solid lubricant, and a curing agent capable of polymerizing and frontal-polymerizing the binder resin by ultraviolet rays and being thermally polymerizable.
A second step of applying the coating material to at least one of the fixed substrate and the fixed spiral wall of the fixed scroll and the movable substrate and the movable spiral wall of the movable scroll to form a coating layer.
A third step of polymerizing the binder resin in the coating layer by irradiating the coating layer with ultraviolet rays to make the coating layer a non-fluid layer in a moldable state while having non-fluidity.
After the third step, the fourth step of assembling the scroll type compressor by the fixed scroll and the movable scroll, and
After the fourth step, the scroll type compressor is operated to frontally polymerize the binder resin in the non-fluidized bed and thermally polymerize the non-fluidized layer to form a cured layer. A method for manufacturing a scroll type compressor, which is characterized in that it is used. The method for manufacturing a scroll type compressor according to claim 1, wherein in the second step, the coating layer is formed on the fixed substrate of the fixed scroll and the fixed spiral wall. The method for manufacturing a scroll type compressor according to claim 1, wherein in the second step, the coating layer is formed on the movable substrate of the movable scroll and the movable spiral wall. A fixed scroll having a fixed substrate and a fixed spiral wall, and a movable scroll having a movable substrate and a movable spiral wall are provided, and the volume is changed by the fixed substrate, the fixed spiral wall, the movable substrate, and the movable spiral wall. A scroll-type compressor that forms a compression chamber.
A cured layer is formed on at least one of the fixed substrate and the fixed spiral wall of the fixed scroll and the movable substrate and the movable spiral wall of the movable scroll.
The scroll type compressor, wherein the cured layer contains a binder resin and a solid lubricant, and is polymerized by ultraviolet rays, frontal polymerization, and thermal polymerization.

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