Manufacturing method of gas-liquid separator

Abstract

An upper end cover, a barrel and a cushion block are formed through a forming technology, the barrel is a hollow cylinder with the top open and the bottom closed, the circumferential outer wall of the lower portion of the barrel is perpendicular to the bottom face of the barrel and extends outwards to form a mounting part, and the mounting part protrudes out of the bottom face of the barrel; the mounting part and the barrel are integrally formed, and the outer surface, in the axial direction of the barrel, of the mounting part does not protrude out of the circumferential outer wall of the barrel; the upper end cover is welded to the open end of the top of the barrel, and the cushion block is welded and fixed to the axial outer surface of the barrel installation part. The cylinder structure designed by the invention can be formed by adopting a cold extrusion forming process, the utilization rate and the production efficiency of a forming material are favorably improved, the cylinder with the closed bottom and the mounting part is high in strength, the leakage risk caused by the welding quality problem is also reduced, and compared with the prior art, the working procedures are simplified, and the production efficiency is improved.

Description

Technical Field

[0001] The invention relates to a gas-liquid separator in an automobile air-conditioning system, and in particular to a method for manufacturing the gas-liquid separator. Background Art

[0002] The gas-liquid separator is one of the core parts in the automobile air-conditioning pipeline system. It plays the role of gas-liquid separation in the air-conditioning assembly, and also has the auxiliary role of filtering and connecting the air-conditioning pipeline. The shell of the traditional gas-liquid separator is mainly composed of an upper end cover and a cylinder. The cylinder is a cylinder with an open top and a closed bottom. The upper end cover is welded and fixed to the cylinder. The upper end cover is provided with a mounting portion for fixing the gas-liquid separator, that is, the traditional gas-liquid separator is fixed by the mounting portion on the upper end cover. With the integrated development of the automobile air-conditioning pipeline system, in order to facilitate the integrated installation of the gas-liquid separator in the air-conditioning assembly, the shell of the gas-liquid separator is gradually changed from the traditional structure to that shown in the announcement number CN219103403U, that is, the shell is composed of an upper end cover, a cylinder and a bottom cover. The cylinder is a hollow cylinder with open ends. The end cover and the bottom cover are respectively welded to the cylinder. A protruding mounting portion is provided on the circumferential outer wall of the bottom cover. The gas-liquid separator of this new structure is fixed on the air-conditioning assembly through the mounting portion on the bottom cover.

[0003] In the production process of the gas-liquid separator shell of the improved structure, the upper end cover, the cylinder and the bottom cover are independently formed, and then the upper end cover and the bottom cover are respectively welded to the cylinder by laser welding. In the existing manufacturing method, both the upper end cover and the bottom cover need to be welded to the cylinder, which requires high sealing performance of the gas-liquid separator shell. Once there is a defect in the welding quality, there is a risk of leakage of the product. Therefore, the welding process is extremely demanding. Summary of the invention

[0004] The invention discloses a method for manufacturing a gas-liquid separator, which can reduce the risk of product leakage, improve the strength of the product, simplify the process flow, and improve production efficiency.

[0005] In order to achieve the above object, the technical solution adopted by the present invention is: A method for manufacturing a gas-liquid separator, comprising the following contents: The upper end cover, the cylinder body and the spacer are respectively formed by a molding process; The cylinder is a hollow cylinder with an open top and a closed bottom. The circumferential outer wall of the lower part of the cylinder extends outward perpendicularly to the bottom surface of the cylinder to form a mounting portion. The mounting portion protrudes from the bottom surface of the cylinder. The mounting portion and the cylinder are integrally formed. The outer surface of the mounting portion along the axial direction of the cylinder does not protrude from the circumferential outer wall of the cylinder. The upper end cover is welded to the top open end of the cylinder, and the cushion block is welded and fixed to the axial outer surface of the cylinder mounting portion.

[0006] Furthermore, the cylinder is formed by a cold extrusion molding process.

[0007] Furthermore, the upper end cover is formed by a cold extrusion molding process.

[0008] Furthermore, the pad is formed by a cold extrusion process.

[0009] Furthermore, an inwardly concave groove is formed on the axial outer surface of the mounting portion, and the cushion block is embedded in the groove and fixed by welding.

[0010] Furthermore, after the cushion block is welded to the cylinder, the outer surface of the cushion block along the axial direction of the cylinder protrudes from the circumferential outer wall of the cylinder.

[0011] Furthermore, a through hole is formed on the cushion block, and a through hole is formed on the mounting portion of the formed cylinder along the radial direction of the cylinder. After the cushion block and the mounting portion are welded, the through hole of the cushion block is connected with the through hole of the mounting portion.

[0012] In terms of structural design, the present invention combines the structure of the split bottom cover and the cylinder in the prior art, and adopts an integrated molding process to form a cylinder with a bottom cover structure and a closed bottom, thereby reducing the welding process of the bottom cover and the cylinder in the prior art, simplifying the process flow, and being conducive to improving production efficiency and reducing the risk of leakage caused by poor welding quality; the one-piece molded cylinder with a closed bottom has improved product strength compared with the cylinder with open ends in the prior art; for the structural design of the mounting portion on the cylinder, taking into account the requirements of the cold extrusion molding process, the present invention splits the protruding mounting portion set on the bottom cover in the prior art into two parts, one part is a separately molded pad, and the other part is directly formed at the bottom of the cylinder by cold extrusion, and finally the pad is welded to the mounting portion of the cylinder. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 It is a schematic diagram of the shell assembly of the gas-liquid separator of the present invention; Figure 2 An exploded view of the shell of the gas-liquid separator of the present invention; Figure 3 It is a schematic diagram of the bottom structure of the cylinder of the gas-liquid separator of the present invention.

[0014] Reference numerals: 1. Upper end cover; 2. Cylinder body; 3. Spacer block. DETAILED DESCRIPTION

[0015] The technical solutions in the embodiments of the present invention will be described clearly and completely below in conjunction with the accompanying drawings in the embodiments of the present invention.

[0016] This embodiment discloses a method for manufacturing a gas-liquid separator, wherein the gas-liquid separator has a structure as follows: Figure 1 As shown, from Figure 1 It can be seen that the mounting part of the gas-liquid separator designed by the present invention is also located at the lower part of the cylinder, and the overall structural design is relatively close to the structure disclosed in CN219103403U in the prior art. In order to more clearly compare the difference between the gas-liquid separator structure designed by the present invention and the existing design, the problems existing in the product in the existing design CN219103403U are first introduced: the cylinder and the bottom cover of the patent are two independent components, the cylinder is a hollow cylinder with open ends, the mounting part is formed on the bottom cover, and the bottom cover is welded to the open end of the bottom of the cylinder by a laser welding process. In this existing structural design, since the mounting part on the bottom cover is protruding from the circumferential surface of the bottom cover, the bottom cover cannot be formed by a cold extrusion molding process, so a hot extrusion molding process is usually used. It is well known that compared with the hot extrusion molding process, the cold extrusion molding process has high molding accuracy, good surface quality of the molded product, high utilization rate of molding materials, and fast molding speed. Furthermore, the above-mentioned bottom cover and the cylinder are welded and assembled after the split design, which is prone to leakage risks due to welding quality problems.

[0017] The main purpose of the present invention is to avoid the risk of product leakage and improve production efficiency. Figures 1 to 3 As shown, the shell of the gas-liquid separator designed by the present invention is assembled by an upper end cover 1, a cylinder 2 and a cushion block 3. The main differences between the structure of the present invention and the existing design are concentrated on the cylinder 2 and the cushion block 3. The cylinder 2 of the present invention is open only at the top, and its bottom is closed. The inside of the cylinder 2 is hollow and has a cylindrical shape as a whole, and a mounting portion is provided on the lower circumferential outer wall of the cylinder 2 of the present invention. The present invention transfers the mounting portion originally designed on the bottom cover in the prior art to the cylinder 2, and forms a cylinder 2 with a closed bottom and a mounting portion through an integrated molding method, thereby saving the welding process of the bottom cover and the cylinder, simplifying the process flow, and helping to improve production efficiency. In addition, the cylinder 2 with a closed bottom and an integrated molding only needs to be welded with the upper end cover, so that the strength of the product is higher than that of the existing design, and reduces the risk of leakage of the product.

[0018] In accordance with the above, in the selection of the molding process, in order to improve the molding efficiency and material utilization rate, and to improve the molding accuracy, the present invention chooses to adopt the cold extrusion molding process to form the upper end cover 1, the barrel 2 and the cushion block 3 respectively. In order to enable the barrel 2 with the mounting portion to be formed by cold extrusion, the present invention splits the mounting portion originally protruding in the prior art into two parts, and divides the part protruding from the barrel 2 into the cushion block 3 in the present invention, while the remaining part (i.e. the mounting portion mentioned in the present invention) retained on the barrel 2 does not protrude from the circumferential outer wall of the barrel 2. In this way, after the structural splitting, the barrel 2 can be formed by cold extrusion. The mounting portion retained on the barrel 2 is located outside the bottom of the barrel 2 after cold extrusion integral molding, and protrudes from the bottom surface of the barrel 2, but the outer surface of the mounting portion along the axial direction of the barrel 2 does not protrude from the circumferential outer wall of the barrel 2. In this embodiment, in order to facilitate positioning when installing the gasket 3, an inwardly concave groove is formed on the axial outer surface of the mounting portion, and after the cylinder 2 is formed, a through hole is opened in the groove of the mounting portion along the radial direction of the cylinder 2. The gasket 3 is a rectangular block structure, and can also be formed by a cold extrusion molding process. A through hole is also opened on the gasket 3, and the gasket 3 is embedded in the groove, so that the through hole on the gasket 3 is connected with the through hole on the mounting portion of the cylinder 2, and the gasket 3 is fixed to the groove of the cylinder 2 by laser spot welding. After the gasket 3 is welded, the outer surface of the gasket 3 along the axial direction of the cylinder 2 protrudes from the circumferential outer wall of the cylinder 2.

[0019] The manufacturing method of the gas-liquid separator designed by the present invention to form its shell is summarized as follows: Step 1: First, the upper end cover 1, the cylinder 2 and the cushion block 3 are formed by cold extrusion molding process; Step 2: A through hole is opened on the mounting portion of the formed cylinder 2 along the radial direction of the cylinder 2; Step 3: Install the upper end cover 1 to the top open end of the cylinder 2 by laser welding; Step 4: embed the cushion block 3 into the mounting groove of the cylinder 2, and weld the cushion block 3 to the cylinder 2 by laser spot welding.

[0020] There is no order relationship between the above steps 3 and 4.

[0021] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A method for manufacturing a gas-liquid separator, characterized in that: It includes the following: The upper end cover, the cylinder body and the spacer are respectively formed by a molding process; The cylinder is a hollow cylinder with an open top and a closed bottom. The circumferential outer wall of the lower part of the cylinder extends outward perpendicularly to the bottom surface of the cylinder to form a mounting portion. The mounting portion protrudes from the bottom surface of the cylinder. The mounting portion and the cylinder are integrally formed. The outer surface of the mounting portion along the axial direction of the cylinder does not protrude from the circumferential outer wall of the cylinder. The upper end cover is welded to the top open end of the cylinder, and the cushion block is welded and fixed to the axial outer surface of the cylinder mounting portion.

2. The method for manufacturing a gas-liquid separator according to claim 1, characterized in that: The cylinder is formed by a cold extrusion process.

3. The method for manufacturing a gas-liquid separator according to claim 1, characterized in that: The upper end cover is formed by a cold extrusion process.

4. The method for manufacturing a gas-liquid separator according to claim 1, characterized in that: The cushion block is formed by a cold extrusion process.

5. The method for manufacturing a gas-liquid separator according to claim 1, characterized in that: An inwardly concave groove is formed on the axial outer surface of the mounting portion, and the cushion block is embedded in the groove and fixed by welding.

6. The method for manufacturing a gas-liquid separator according to claim 1, characterized in that: After the cushion block is welded to the cylinder, the outer surface of the cushion block along the axial direction of the cylinder protrudes from the circumferential outer wall of the cylinder.

7. The method for manufacturing a gas-liquid separator according to claim 1, characterized in that: The cushion block is provided with a through hole, and the formed cylinder body is provided with a through hole on its mounting portion along the radial direction of the cylinder body. After the cushion block and the mounting portion are welded, the through hole of the cushion block is connected with the through hole of the mounting portion.

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