Compressor enclosure and compressor unit

Abstract

To provide a compressor enclosure in which noise generated from a compressor can be reduced by a contact state among the compressor, a first cover, and a second cover.SOLUTION: A compressor enclosure 1 comprises: a first cover 21 internally housing and surrounding a compressor 2; a plurality of first connection parts 11 connecting the first cover 21 and the compressor 2 while a space is formed between the first cover 21 and the compressor 2; and a second cover 22 internally housing and surrounding the first cover 21, and whose density is higher than that of the first cover 21.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present disclosure relates to a compressor enclosure that houses a compressor therein and a compressor unit. [Background technology]

[0002] Electric compressors are used as compressors in the refrigeration cycles of air conditioning in electric and hybrid vehicles. Electric compressors have a compression section equipped with a scroll mechanism and the like that is driven by an electric motor. Electric compressors operate in response to air conditioning demands even when the vehicle is stopped, so further noise reduction is required.

[0003] There are two ways to reduce the noise of a compressor: reducing the sound pressure level of the noise source, and absorbing and insulating the generated noise. As the latter method of absorbing and insulating the noise, various structures have been proposed in which a soundproof cover is provided for the compressor. For example, the soundproof cover of Patent Document 1 includes a cover part that is a sound absorbing material that covers the compressor, and a sound insulating member that covers the cover part. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2022-147641 A Summary of the Invention [Problem to be solved by the invention]

[0005] However, although the cited document 1 describes that a sound-insulating material is arranged so as to cover the outer surface of the cover part which is a sound-absorbing material, it does not specifically describe the contact state between the cover part and the sound-insulating material, nor does it specifically describe the contact state between the compressor and the cover part.

[0006] As a result of extensive research, the inventors have found that the noise generated by the compressor can be effectively reduced by adjusting the contact state between the compressor and the first cover (sound-absorbing material) and the second cover (sound-proof material).

[0007] The present disclosure has been made in consideration of the above circumstances, and aims to provide a compressor enclosure and a compressor unit that can reduce noise generated by the compressor depending on the contact state between the compressor and the first cover and second cover. [Means for solving the problem]

[0008] A compressor enclosure according to one embodiment of the present disclosure includes a first cover that houses and surrounds a compressor, a plurality of first connection parts that connect the first cover to the compressor while forming a space between the first cover and the compressor, and a second cover that houses and surrounds the first cover and has a greater density than the first cover.

[0009] A compressor unit according to one aspect of the present disclosure includes the compressor enclosure described above, and a compressor housed in the compressor enclosure. Effect of the Invention

[0010] The noise generated by the compressor can be reduced depending on the contact state between the compressor and the first and second covers. [Brief description of the drawings]

[0011] [Figure 1] FIG. 1 is a perspective view showing a compressor enclosure according to a first embodiment of the present disclosure. [Diagram 2] FIG. 1 is a perspective view showing a compressor according to a first embodiment of the present disclosure. [Diagram 3] FIG. 2 is a vertical cross-sectional view showing an enclosure that houses a compressor according to the first embodiment of the present disclosure. [Figure 4] FIG. 4 is a schematic diagram showing a process of producing a first cover by removing a skin layer. [Diagram 5] FIG. 11 is a vertical cross-sectional view showing an enclosure that houses a compressor according to a second embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] [First embodiment] Hereinafter, a first embodiment of the present disclosure will be described with reference to the drawings. 1 shows an enclosure (enclosure for a compressor) 1 that covers the entire electric compressor. A main body 10 of the enclosure 1 has a shape corresponding to the external shape of the electric compressor, and is divided at a dividing plane P into two divided bodies 10A and 10B on the left and right.

[0013] The dividing plane P is provided so as to extend vertically when the mounting legs 3 of the compressor are positioned downward. The mounting legs 3 of the compressor are fixing parts for mounting the compressor to a fixing part on the vehicle side.

[0014] The main body 10 of the enclosure 1 has a double structure made up of a first cover 21 and a second cover 22, which will be described later with reference to FIG.

[0015] The left and right divided bodies 10A, 10B shown in FIG. 1 can be fixed to each other using various fixing methods, for example, engagement using bolts and nuts, claws, etc. can be used.

[0016] Fig. 2 shows the compressor 2 with the enclosure 1 shown in Fig. 1 removed. The compressor 2 shown in the figure does not have a shape that is strictly identical to the enclosure 1 shown in Fig. 1, for example, in terms of the number of mounting legs 3, but there is no significant difference in terms of the description of the compressor that is sound-insulated by the enclosure 1. In other words, the enclosure 1 according to this embodiment can be widely applied to compressors having the structure described below.

[0017] The compressor 2 constitutes a part of a refrigeration cycle used for vehicle air conditioning, and draws in the refrigerant guided from the evaporator, compresses it, and discharges the compressed refrigerant to the condenser. The compressor 2 has a substantially cylindrical shape with a longitudinal axis in the horizontal direction as shown in Fig. 2. The compressor 2 is an electric compressor, and includes a compression section 2A having a scroll mechanism, and a motor section (electric motor section) 2B having an electric motor that drives the scroll mechanism.

[0018] The compression section 2A is located on the front side of the compressor 2 (on the left side in FIG. 2), and includes a fixed scroll and an orbiting scroll therein. Since the orbiting scroll orbits while partially contacting the fixed scroll, the compression section 2A is the main source of vibration and noise for the compressor 2. A cylindrical discharge port (extension) 5 for discharging the compressed refrigerant is provided at the upper portion of the compression section 2A.

[0019] The motor section 2B is connected to the rear of the compression section 2A and is located on the rear side of the compressor 2 (on the right side in FIG. 2). The motor section 2B includes an electric motor having a stator and a rotor, and an inverter section that supplies power to the electric motor. The diameter of the motor section 2B is larger than the diameter of the compression section 2A. A cylindrical suction port 7 for drawing the refrigerant into the compressor 2 is provided at the top of the motor section 2B. Furthermore, a cylindrical wiring guide tube (extension) 9 for guiding harnesses such as power cables and signal lines to the outside of the compressor 2 is provided at the top of the motor section 2B and near the suction port (extension) 7.

[0020] Fig. 3 shows a vertical cross section of the compressor 2 in Fig. 2 with the enclosure 1 attached. Note that Fig. 3 is reversed from the compressor 2 shown in Fig. 2, with the compression unit 2A on the right and the motor unit 2B on the left. In other words, Fig. 3 is a vertical cross section seen from the rear side of Fig. 2.

[0021] As shown in FIG. 3, the main body 10 of the enclosure 1 includes a first cover 21 and a second cover 22, and has a double structure.

[0022] The first cover 21 accommodates and surrounds the entire compressor 2. The first cover 21 is rigid enough to bend under its own weight, and is made of a foamed resin material such as urethane foam (soft PUR foam). Therefore, the first cover 21 is softer and has a lower density (lower specific gravity and higher foam ratio) than rigid plastic materials such as PP (polypropylene) and PBT (polybutylene terephthalate).

[0023] Between the first cover 21 and the compressor 2, a gap of, for example, about 5 mm to 20 mm is provided, and the first cover 21 and the compressor 2 are in contact with each other at a plurality of points via the first connection portion 11. The first connection portion 11 has a protruding shape protruding from the inner surface of the first cover 21, and the tip of the first connection portion 11 is in contact with the outer surface of the compressor 2. The first connection portion 11 is preferably made of a material softer than the material of the first cover 21, and may be, for example, a rubber sponge such as an EPDM (ethylene propylene diene rubber) foam material such as Eptsealer (registered trademark), or an open-cell polyethylene. The first connection portion 11 is preferably fixed to the inner surface of the first cover 21 by adhesion or the like.

[0024] The first connection portion 11 is mainly provided in the motor portion 2B of the compressor 2. More specifically, the first connection portion 11 is provided in each of the front end portion A1, the rear end portion A2, and the intermediate portion A3 therebetween of the motor portion 2B. The first connection portion 11 in the intermediate portion A3 may be omitted as appropriate. The first connection portion 11 is provided at a plurality of locations in the circumferential direction of the compressor 2. For example, as shown by the arrow C in FIG. 2, the first connection portion 11 is provided on both the lower side and the upper side of the compressor 2. As in this embodiment, it is preferable to provide more first connection portions 11 on the motor portion 2B than on the compression portion 2A.

[0025] At a position corresponding to the discharge port 5, a hole is formed in the main body 10 so that the discharge port 5 can be inserted therethrough. In order to fill the gap between the edge of this hole and the side peripheral surface of the discharge port 5, a sealant 14 is provided as a first connecting portion 11 as shown in FIG. 3. The sealant 14 is arranged so as to wrap around the outer periphery of the cylindrical portion of the discharge port 5.

[0026] The second cover 22 accommodates and surrounds the entire first cover 21. The second cover 22 has a higher density (higher specific gravity and lower air bubble rate) than the first cover 21, and is rigid enough to maintain its shape under its own weight. For example, the material used for the first cover 21 is a hard resin material that is not foamed or is foamed only to a small extent. Alternatively, the second cover 22 can be made of a rigid plastic material such as PP (polypropylene) or PBT (polybutylene terephthalate).

[0027] A gap of, for example, about 5 mm to 20 mm is provided between second cover 22 and first cover 21, and second cover 22 is in contact with first cover 21 at multiple points via second connection parts 12. Second connection parts 12 are in the form of protrusions protruding from the inner surface of second cover 22, and a tip of second connection part 12 is in contact with the outer surface of first cover 21.

[0028] The second connection portion 12 may be a resin integrated with the second cover 22. In this case, the tip of the second connection portion 12 is connected to the outer surface of the first cover 21. When a foamed resin is used as the first cover 21, the outer surface of the first cover 21 is preferably a foamed surface 21c in which the skin layer 21a is removed and many recesses are exposed, as shown in FIG. 4(a). When a foamed resin is molded in a mold at a high temperature of 60°C or higher using polyurethane or the like as a raw material, as shown in FIG. 4(a), a core layer 21b that becomes a foamed layer and skin layers 21a that become solid layers are formed on the front and back sides of the core layer 21b. By removing the skin layers 21a by blasting or machining, a foamed surface 21c in which many recesses caused by foaming are exposed appears on the surface of the first cover 21, as shown in FIG. 4(b). Then, by resin molding the second cover 22 onto the first cover 21, the resin of the second connection portion 12 fills the numerous recesses in the foam surface 21c of the first cover 21, and the tip of the second connection portion 12 can be mechanically and / or chemically bonded to the outer surface of the first cover 21.

[0029] Instead of integrally molding the second connection part 12 with the second cover 22, a rubber sponge such as an EPDM (ethylene propylene diene rubber) foam material such as EPTSEALER (registered trademark), open-cell polyethylene, or the like may be used as the second connection part 12. In this case, the second connection part 12 is fixed to each of the inner surface of the second cover 22 and the outer surface of the first cover 21 by adhesion or the like.

[0030] The second connection portion 12 is provided at a position different from that of the first connection portion 11 when the first connection portion 11 is viewed from the second cover 22. In other words, the second connection portion 12 does not overlap with an area in which the first connection portion 11 exists. This prevents the first connection portion 11, the first cover 21, the second connection portion 12, and the second cover 22 from being continuously present in the thickness direction of the main body 10.

[0031] The effects of the present embodiment described above are as follows. Since a space can be formed between the compressor 2 and the inner surface of the first cover 21 by the plurality of first connection parts 11, the noise generated by the compressor 2 can be effectively suppressed. The second cover 22 is provided to house the first cover 21. As a result, sound generated by the compressor 2 is converted to thermal energy and attenuated as it propagates through the first cover 21. The sound is then reflected to the inside by the second cover 22, which has a higher density than the first cover 21. The reflected sound is further attenuated by the first cover 21. As a result, the low-density first cover 21 and the high-density second cover 22 can reduce the propagation of sound from the compressor 2 to the outside of the enclosure 1.

[0032] Since a space can be formed between the first cover 21 and the second cover 22 by the multiple second connection parts 12, it is possible to reduce the propagation of vibration from the first cover 21 to the second cover 22. In addition, due to the reflection and attenuation of sound waves at the boundary surface between the second connection parts 12 and the first cover 21, it is possible to reduce the radiation of sound from the second cover 22 to the outside. In addition, by forming a space between the first cover 21 and the second cover 22 by the second connection part 12, it is possible to prevent the first cover 21 from vibrating due to vibrations of a vehicle body equipped with the compressor 2, etc., and coming into contact with the second cover 22 and generating noise.

[0033] When the first connection part 11 is viewed from the second cover 22, the second connection part 12 is provided at a position different from the first connection part 11, so that it is possible to prevent sound (vibration) from the compressor 2 from being transmitted directly through a solid to the second cover 22 via the first connection part 11, the first cover 21 and the second connection part 12. Since the solid-borne sound propagating from the first connection portion 11 to the first cover 21 passes through the first cover 21 on the way to the second cover 22, the sound (vibration) can be absorbed and attenuated. In addition, since the second cover 22 is connected to the first cover 21 at the second connection portion 12, the first cover 21 can absorb and attenuate the vibration of the second cover 22.

[0034] By mechanically and / or chemically bonding the second connection portion 12 to the numerous depressions that appear on the surface of the foamed side of the first cover 21, the reliability of the bond is improved and it is possible to prevent the bond from peeling off and causing contact noise between the first cover 21 and the second connection portion 12.

[0035] By removing the skin layer 21a of the first cover 21, which is relatively dense and formed during the manufacture of the first cover 21, sound reflection on the surface can be reduced, thereby efficiently absorbing the sound from the compressor 2, the reflected sound from the second cover 22, and the solid-borne sound of the compressor 2 and the second cover 22.

[0036] [Second embodiment] Next, a second embodiment of the present disclosure will be described with reference to Fig. 5. In the first embodiment, a space is formed between the first cover 21 and the second cover 22 by providing the second connection portion 12, but in this embodiment, no space is formed between the first cover 21 and the second cover 22. Other configurations of the second embodiment are similar to those of the first embodiment, so the same reference numerals are used and the description thereof will be omitted.

[0037] 5, the second connecting portion 12 (see FIG. 3) of the first embodiment is not provided between the first cover 21 and the second cover 22, and the outer surface of the first cover 21 contacts the inner surface of the second cover 22. The first cover 21 and the second cover 22 may be joined together to form an integrated unit, or may simply be overlapped without being joined.

[0038] It is sufficient that there is essentially no space between the first cover 21 and the second cover 22; for example, a space that inevitably occurs when the first cover 21 and the second cover 22 are brought into contact with each other entirely is acceptable.

[0039] The effects of the present embodiment described above are as follows. The first cover 21 and the second cover 22 are in contact with each other so as not to form a space between the first cover 21 and the second cover 22. This allows the first cover 21 to efficiently absorb and damp vibrations of the second cover 22.

[0040] As in the first embodiment, the multiple first connection parts 11 can form a space between the compressor 2 and the inner surface of the first cover 21, thereby effectively suppressing noise generated by the compressor 2.

[0041] As in the first embodiment, the second cover 22 is provided to house the first cover 21. As a result, when sound generated by the compressor 2 propagates through the first cover 21, it is converted to thermal energy and attenuated. Then, the sound is reflected to the inside by the second cover 22, which has a higher density than the first cover 21. The reflected sound is further attenuated by the first cover 21. As a result, the low-density first cover 21 and the high-density second cover 22 can reduce the propagation of the sound of the compressor 2 to the outside of the enclosure 1.

[0042] As in the first embodiment, the skin layer 21a (see FIG. 4(a)) may be removed to create a large number of recesses on the foamed surface of the first cover 21. This mechanically and / or chemically bonds the second cover 22 to improve the reliability of the bonded portion and prevent the bonded portion from peeling off and generating contact noise between the first cover 21 and the second cover 22.

[0043] In the above embodiment, the first cover 21 and the second cover 22 are described on the assumption that they are made of a foamed resin material, but other porous resin materials may be used. For example, a porous resin material may be used that is made porous by blowing nitrogen or carbon dioxide into the resin material when kneading the resin material without using a foaming material. In this case, when molding the second cover 22, nitrogen or carbon dioxide is not blown into the resin when kneading the resin.

[0044] The compressor enclosure and the compressor unit described in each of the above-described embodiments can be understood, for example, as follows.

[0045] A compressor enclosure (1) according to a first aspect of the present disclosure includes a first cover (21) that houses and surrounds a compressor (2), a plurality of first connection parts (11) that connect the first cover and the compressor while forming a space between the first cover and the compressor, and a second cover (22) that houses and surrounds the first cover and has a higher density than the first cover.

[0046] Since a space can be formed between the compressor and the inner surface of the first cover by the plurality of first connection parts, noise generated by the compressor can be effectively suppressed. A second cover is provided to house the first cover. As a result, when sound generated by the compressor propagates through the first cover, it is converted to thermal energy and attenuated. The sound is then reflected to the inside by the second cover, which has a higher density than the first cover. The reflected sound is further attenuated by the first cover. As a result, the low-density first cover and the high-density second cover can reduce the propagation of compressor sound to the outside of the enclosure. The material of the first cover has a rigidity such that it can bend under its own weight, and may be, for example, a foamed resin material (such as soft PUR foam) made by foaming polyurethane, polyisocyanurate, or the like. The material for the second cover is rigid enough to maintain its shape without bending under its own weight, and may be, for example, a plastic material such as PP (polypropylene) or PBT (polybutylene terephthalate), or a hard resin material that does not foam or foams only to a small extent like the material used for the first cover. The first and second connection parts need only connect two opposing components when the enclosure is attached to the compressor, and may be fixed to the opposing components by integral molding, adhesive bonding, etc., or may be fixed by being pressed down with a compressive force in a removable manner without using adhesive, etc.

[0047] The compressor enclosure according to a second aspect of the present disclosure, in the first aspect, is provided with a plurality of second connection parts (12) that connect the first cover and the second cover while forming a space between the first cover and the second cover.

[0048] Since the multiple second connection parts can form a space between the first cover and the second cover, it is possible to reduce the propagation of vibration from the first cover to the second cover. Also, due to the reflection and attenuation of sound waves at the boundary surface between the second connection parts and the first cover, it is possible to reduce the radiation of sound to the outside from the second cover. In addition, by forming a space between the first cover and the second cover using the second connection part, it is possible to prevent the first cover from vibrating due to vibrations of a vehicle body equipped with a compressor, etc., and coming into contact with the second cover and generating noise.

[0049] A compressor enclosure according to a third aspect of the present disclosure is the first aspect, wherein the second connection portion is provided at a different position from the first connection portion when the first connection portion is viewed from the second cover.

[0050] Since the second connection part is located at a position different from the first connection part when viewed from the second cover, it is possible to prevent sound (vibration) from the compressor from being transmitted directly to the second cover through the first connection part, the first cover, and the second connection part. Since the solid-borne sound propagating from the first connection part to the first cover passes through the first cover on its way to the second cover, the sound (vibration) can be absorbed and attenuated. In addition, because the second cover is connected to the first cover at the second connection part, the first cover can absorb and attenuate the vibration of the second cover.

[0051] A compressor enclosure according to a fourth aspect of the present disclosure is the second or third aspect, wherein the first cover is made of foam, and the second connection portion is coupled to a foam surface (21c) of the first cover.

[0052] By mechanically and / or chemically bonding the second connection part to the numerous depressions that appear on the surface of the foamed side of the first cover, the reliability of the bond is improved and it is possible to prevent the bond from peeling off and causing contact noise between the first cover and the second connection part.

[0053] According to a fifth aspect of the present disclosure, in the compressor enclosure of the first aspect, the first cover and the second cover are in contact with each other so that no space is formed between the first cover and the second cover.

[0054] The first cover and the second cover are in contact with each other so that no space is formed between them, which allows the first cover to efficiently absorb and damp vibrations of the second cover. Note that "so as not to form a space" means that substantially no space is formed; for example, the space that inevitably occurs when the first cover and the second cover are brought into contact entirely is acceptable.

[0055] According to a sixth aspect of the present disclosure, in the compressor enclosure of the fifth aspect, the first cover is made of a foam, and the second cover is joined to a foam surface of the first cover.

[0056] By mechanically and / or chemically bonding the second cover to the numerous depressions that appear on the surface of the foamed side of the first cover, the reliability of the bond is improved and it is possible to prevent the bond from peeling off and causing contact noise between the first cover and the second cover.

[0057] According to a seventh aspect of the present disclosure, in the compressor enclosure of the fourth or sixth aspect, the foamed surface is formed by removing a surface of the first cover.

[0058] By removing the relatively dense surface of the first cover that was formed during the manufacture of the first cover, sound reflection on the surface can be reduced, making it possible to efficiently absorb sound from the compressor, reflected sound from the second cover, and solid-borne sound from the compressor and second cover. It is preferable to remove the skin layers on both the front and back surfaces of the first cover, because this makes it possible to suppress sound reflection on the front and back surfaces of the first cover.

[0059] A compressor unit according to a first aspect of the present disclosure includes the compressor enclosure of any of the above aspects, and a compressor housed in the compressor enclosure. [Explanation of symbols]

[0060] 1 Enclosure (Compressor Enclosure) 2. Compressor 2A Compression section 2B Motor section (electric motor section) 3 Mounting feet 5 Discharge port (extension part) 7 Suction port (extension) 9 Wiring guide tube (extension) 10 Main body 10A, 10B division body 11 First connection part 12 Second connection part 14 Sealing material 21 First Cover 21a Skin layer 21b Core layer 21c Foam Surface 22 2nd Cover P split plane

Claims

1. a first cover that houses and surrounds the compressor; a plurality of first connection portions that connect the first cover and the compressor in a state in which a space is formed between the first cover and the compressor; and a second cover that contains and surrounds the first cover and has a higher density than the first cover; 1. A compressor enclosure comprising:

2. 2. The compressor enclosure according to claim 1, further comprising a plurality of second connection portions that connect the first cover and the second cover with a space formed between the first cover and the second cover.

3. The compressor enclosure according to claim 2 , wherein the second connection portion is provided at a position different from that of the first connection portion when the first connection portion is viewed from the second cover.

4. The first cover is made of a foam.

3. The compressor enclosure of claim 2, wherein the second connection portion is bonded to a foam surface of the first cover.

5. 2. The compressor enclosure of claim 1, wherein the first cover and the second cover are in contact with each other such that no space is formed between the first cover and the second cover.

6. The first cover is made of a foam.

6. The compressor enclosure of claim 5, wherein said second cover is bonded to a foam surface of said first cover.

7. 7. The compressor enclosure according to claim 4, wherein the foamed surface is formed by removing a surface of the first cover.

8. A compressor enclosure according to claim 1; a compressor housed within the compressor enclosure; and A compressor unit comprising:

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