Manufacturing method for compressor enclosure

Abstract

To provide a manufacturing method for a compressor enclosure that can easily manufacture a first cover covering a compressor, and a second cover covering the first cover, and having a shape corresponding to the first cover.SOLUTION: Provided is a manufacturing method for a compressor enclosure comprising a first cover 21 internally housing and surrounding a compressor, 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. The manufacturing method for the compressor enclosure comprises a first step of molding the second cover 22 in a mold 30, and a second step of molding the first cover 21 while the molded second cover 22 is arranged in the mold 30.SELECTED DRAWING: Figure 4

Description

[Technical field]

[0001] The present disclosure relates to a method of manufacturing a compressor enclosure that houses a compressor therein. [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 means of absorbing and insulating the noise, various structures have been proposed in which a soundproof cover is provided for the compressor. For example, Patent Document 1 discloses a structure including a compressor, sound absorbing material, and a support bracket, in which a cover part, which is a sound absorbing material, and a sound insulating material are layered on top of each other. The cover part is made of urethane foam resin, and the sound insulating material is made of polyvinyl chloride resin or polyolefin resin. [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, in a double-layered soundproof cover using a resin material as in the cited document 1, the inner surface of the outer cover needs to have a shape that corresponds to the outer surface of the inner cover, and a simple manufacturing method that can accommodate this is required.

[0006] The present disclosure has been made in consideration of the above circumstances, and aims to provide a manufacturing method for a compressor enclosure that can easily manufacture a first cover that covers the compressor, and a second cover that covers the first cover and has a shape corresponding to the first cover. [Means for solving the problem]

[0007] A manufacturing method for a compressor enclosure according to one embodiment of the present disclosure is a manufacturing method for a compressor enclosure including a first cover that houses and surrounds a compressor, and a second cover that houses and surrounds the first cover and has a higher density than the first cover, the manufacturing method including a first step of molding the second cover or the first cover in a mold, and a second step of molding the first cover or the second cover with the molded second cover or the first cover placed in the mold. Effect of the Invention

[0008] The first cover that covers the compressor and the second cover that covers the first cover and has a shape corresponding to that of the first cover can be easily manufactured. [Brief description of the drawings]

[0009] [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] 4A to 4C are schematic diagrams illustrating a method for manufacturing the enclosure of FIG. 3. [Diagram 5] FIG. 4 is a schematic diagram showing a process of producing a first cover by removing a skin layer. [Figure 6] FIG. 11 is a vertical cross-sectional view showing an enclosure that houses a compressor according to a second embodiment of the present disclosure. [Figure 7]7A to 7C are schematic diagrams illustrating a method for manufacturing the enclosure of FIG. 6. [Figure 8] 13A to 13C are schematic diagrams illustrating a method for manufacturing an enclosure according to a third embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] [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.

[0011] 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.

[0012] 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.

[0013] 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.

[0014] 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.

[0015] 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.

[0016] 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.

[0017] 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.

[0018] 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.

[0019] 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.

[0020] 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).

[0021] 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.

[0022] 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.

[0023] 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.

[0024] 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).

[0025] The outer surface of the first cover 21 and the inner surface of the second cover 22 are in contact with each other.

[0026] 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.

[0027] <Manufacturing method> Next, a method for manufacturing the enclosure 1 having the above configuration will be described. 4(a), first, the second cover 22 is molded using a mold 30. The mold 30 includes an upper mold 31 and a lower mold 32. The inner surface of the lower mold 32 has a shape corresponding to the outer surface of the second cover 22 after molding.

[0028] The upper mold 31 is divided into four split molds 34a, 34b, 34c, and 34d by three shims 33a, 33b, and 33c. The first split mold 34a located at the top forms the entire upper part of the upper mold 31, and a plate-like first shim 33a extending horizontally is inserted into a recess formed on the bottom surface. The bottom surface of the first split mold 34a is flush with the first shim 33a by inserting the first shim 33a. The second split mold 34b, the third split mold 34c, and the fourth split mold 34d are arranged horizontally from the left in contact with the bottom surface of the first split mold 34a. A plate-like second shim 33b extending vertically is provided between the second split mold 34b and the third split mold 34c, and a plate-like third shim 33c extending vertically is provided between the third split mold 34c and the fourth split mold 34d. The shape formed by the lower surface of the second split mold 34b, the lower surface of the second shim 33b, the lower surface of the third split mold 34c, the lower surface of the third shim 33c, and the lower surface of the fourth split mold 34d corresponds to the shape of the inner surface of the second cover 22.

[0029] The above-mentioned mold 30 has a cavity set so as to have the plate thickness of the second cover 22. A resin material not containing a foaming agent is supplied to the cavity of the mold 30 to mold the second cover 22 at a low temperature of about 20 to 30°C (first step). Polyurethane and polyisocyanurate can be used as the resin material. PP (polypropylene) and PBT (polybutylene terephthalate) can also be used as the resin material.

[0030] 4(b), a release agent is applied to the inner surface of the molded second cover 22 to form a release layer 36. Note that a release sheet may be used instead of the release agent.

[0031] Then, as shown in Fig. 4(c), the second cover 22 and the release layer 36 are placed on the lower mold 32. The step of forming the release layer 36 on the second cover 22 in Fig. 4(b) may be performed in a state where the upper mold 31 is removed after the first step in Fig. 4(a) and the second cover 22 is placed in the lower mold 32.

[0032] As shown in Fig. 4(c), the upper mold 31 is configured with only four split molds 34a, 34b, 34c, 34d after removing the three shims 33a, 33b, 33c. As a result, the cavity formed between the upper mold 31 and the lower mold 32 is the total thickness of the first cover 21 and the second cover 22. In other words, by appropriately adjusting the thickness and length of the three shims 33a, 33b, 33c, the split molds 34a, 34b, 34c, 34d can be used in common when molding the second cover 22 and when molding the second cover 22 and the first cover 21.

[0033] Then, the resin material mixed with the foaming agent is molded into the first cover 21 at a high temperature of 60° C. or higher (second step). As the resin material, polyurethane, polyisocyanurate, or the like is used.

[0034] Thereafter, the first cover 21 and the second cover 22 are removed from the mold 30, and the first cover 21 and the second cover 22 are separated from each other using the release layer .

[0035] As shown in Fig. 4(d), the inner and outer surfaces of the separated first cover 21 are removed by blasting, machining, or the like. As shown in Fig. 5(a), the molded first cover 21 has a core layer 21b that serves as a foamed layer, and skin layers 21a that serve as solid layers on the front and back sides of the core layer 21b. By removing the skin layers 21a by blasting, machining, or the like, a foamed surface 21c appears on the surface of the first cover 21, where numerous dents caused by foaming are exposed, as shown in Fig. 5(b).

[0036] The effects of the present embodiment described above are as follows. After molding the second cover 22, the first cover 21 is molded in a state in which the second cover 22 is placed in the mold 30. This makes it possible to easily mold the first cover 21 having an outer surface with a shape corresponding to the inner surface of the second cover 22. Since the second cover 22 is provided to house the first cover 21, the sound generated by the compressor 2 is converted to thermal energy and attenuated as it propagates through the first cover 21. 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.

[0037] By removing the skin layer 21a of the first cover 21 after molding, sound reflection at the skin layer 21a can be reduced, and the sound from the compressor 2 and the solid-borne sound of the compressor 2 can be efficiently absorbed.

[0038] Since the release layer 36 is formed before the second step, the first cover 21 and the second cover 22 are not bonded together. This reduces the propagation of vibration from the first cover 21 to the second cover 22. In addition, the reflection and attenuation of sound waves at the boundary between the first cover 21 and the second cover 22 reduces the propagation of sound to the outside air.

[0039] If the first cover 21 and the second cover 22 are made of the same resin material, such as polyurethane or polyisocyanurate, the material cost can be reduced and the manufacturing process can be simplified.

[0040] [Second embodiment] Next, a second embodiment of the present disclosure will be described. The enclosure 1 of the first embodiment is configured such that no space is formed between the first cover 21 and the second cover 22, but the enclosure 1 of this embodiment is different in that a space is formed between the first cover 21 and the second cover 22. This embodiment is different in that the other configurations of the second embodiment are the same as those of the first embodiment, so the same reference numerals are used and the description thereof is omitted.

[0041] 6, 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 portion 12. Second connection portion 12 has a protruding shape protruding from the inner surface of second cover 22, and a tip of second connection portion 12 is in contact with the outer surface of first cover 21.

[0042] 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.

[0043] <Manufacturing method> Next, a method for manufacturing the enclosure 1 having the above configuration will be described. As shown in Fig. 7(a), first cover 21 is molded using a mold 40. Mold 40 includes an upper mold 41 and a lower mold 42. The inner surface of lower mold 42 has a shape corresponding to the inner surface of first cover 21 after molding.

[0044] The upper mold 41 is divided into three split molds 44a, 44b, and 44c. From the left, the first split mold 44a, the second split mold 44b, and the third split mold 44c are arranged in contact with each other in the horizontal direction. The shape formed by the lower surface of the first split mold 44a, the lower surface of the second split mold 44b, and the lower surface of the third split mold 44c corresponds to the shape of the outer surface of the first cover 21.

[0045] The above-mentioned mold 40 has a cavity set to have the plate thickness of the first cover 21. A resin material containing a foaming agent is supplied to the cavity of the mold 40, and the first cover 21 is molded at a high temperature of 60°C or higher (first step). The resin material used is polyurethane, polyisocyanurate, or the like.

[0046] After molding, the first cover 21 is removed, and the skin layers 21a (see FIG. 5) on the inner and outer surfaces are removed in the same manner as in the first embodiment.

[0047] Then, as shown in Fig. 7(b), a release layer 46 is formed on the outer surface of the first cover 21. The thickness of the release layer 46 is set to a dimension equivalent to the gap between the first cover 21 and the second cover 22 when configured as the enclosure 1 as shown in Fig. 6. A through hole (hole) is formed in a predetermined position of the release layer 46 at a position corresponding to the second connection portion 12 (see Fig. 6).

[0048] 7(c), the first cover 21 on which the release layer 46 is formed is placed on the lower mold 32, and then the upper mold 41 on which the shims 43a, 43b, and 43c are placed is placed. The first shim 43a is inserted so as to be located around the cavity formed by the upper mold 41 and the lower mold 42. The second shim 43b is inserted between the first split mold 44a and the second split mold 44b, and the third shim 43c is placed between the second split mold 44b and the third split mold 44c. A cavity having a shape corresponding to the first cover 21, the release layer 46, and the second cover 22 is formed by these shims 43a, 43b, and 43c.

[0049] Then, the second cover 22 is molded (second step) from a resin material containing no foaming agent at a low temperature of about 20 to 30° C. As the resin material, polyurethane, polyisocyanurate, etc., similar to the first cover, is used.

[0050] 7(d), the first cover 21 and the second cover 22 are removed from the mold 40, and the release layer 46 is removed to form a space between the first cover 21 and the second cover 22. At this time, the second connection portion 12 is formed by the through holes formed in the release layer 46. The tip of the second connection portion 12 is joined in a state where it is embedded in a large number of recesses that appear on the outer surface of the first cover 21.

[0051] The effects of the present embodiment described above are as follows. After molding the first cover 21, the second cover 22 is molded in a state in which the first cover 21 is placed in the mold 40. This makes it possible to easily mold the second cover 22 having an inner surface having a shape corresponding to the outer surface of the first cover 21.

[0052] The thickness of the release layer 46 is set to a thickness corresponding to the gap between the first cover 21 and the second cover 22 when the cover is attached to the compressor 2. This makes it possible to form a desired gap between the first cover 21 and the second cover 22. By forming a space between the first cover 21 and the second cover 22, the propagation of vibration from the first cover 21 to the second cover 22 can be reduced.

[0053] Through holes are formed in the release layer 46 so that the resin material flows through the through holes into the opposing first cover in the second process. As a result, the molded portion corresponding to the through holes becomes the second connection portion 12, which connects the first cover 21 and the second cover 22. In particular, the resin material of the second cover 22 fills many recesses in the surface of the first cover 21, making the mechanical bond stronger. Since a space can be formed between the first cover 21 and the second cover 22 by the plurality of second connection portions 12, the propagation of vibration from the first cover 21 to the second cover 22 can be reduced.

[0054] Since the first cover 21 and the second cover 22 are made of the same resin material, such as polyurethane or polyisocyanurate, a chemical bonding force can be added at the joint between the second connection portion 12 and the first cover 21.

[0055] [Third embodiment] Next, a third embodiment of the present disclosure will be described. This embodiment is used when manufacturing the enclosure 1 (see FIG. 3) shown in the first embodiment.

[0056] <Manufacturing method> Next, a method for manufacturing the enclosure 1 having the above configuration will be described. As shown in Fig. 8(a), first cover 21 is molded using a mold 50. Mold 40 includes an upper mold 51 and a lower mold 52. The inner surface of lower mold 52 has a shape corresponding to the inner surface of first cover 21 after molding.

[0057] The upper mold 51 is divided into three split molds 54a, 54b, and 54c. From the left, the first split mold 54a, the second split mold 54b, and the third split mold 54c are arranged in contact with each other in the horizontal direction. The shape formed by the lower surface of the first split mold 54a, the lower surface of the second split mold 54b, and the lower surface of the third split mold 54c corresponds to the shape of the outer surface of the first cover 21.

[0058] The above-mentioned mold 50 has a cavity set to have the thickness of the first cover 21. A resin material containing a foaming agent is supplied to the cavity of the mold 50, and the first cover 21 is molded at a high temperature of 60°C or higher (first step). The resin material used is polyurethane, polyisocyanurate, or the like.

[0059] Then, as shown in FIG. 8(b), the molded first cover 21 is removed, and the skin layers 21a (see FIG. 5) on the inner and outer surfaces are removed in the same manner as in the first embodiment.

[0060] 8(c), the first cover 21 is placed on the lower mold 52 without forming a release layer, and then the upper mold 51 with the shims 53a, 53b, and 53c placed thereon is placed. The first shim 53a is inserted so as to be positioned around the cavity formed by the upper mold 51 and the lower mold 52. The second shim 53b is inserted between the first split mold 54a and the second split mold 54b, and the third shim 53c is placed between the second split mold 54b and the third split mold 54c. These shims 53a, 53b, and 53c form a cavity having a shape corresponding to the first cover 21 and the second cover 22.

[0061] Then, the second cover 22 is molded at a low temperature of about 20 to 30° C. using a resin material that does not contain a foaming agent (second step). The resin material used is polyurethane, polyisocyanurate, or the like, similar to that used for the first cover. By this second step, the enclosure 1 in which the first cover 21 and the second cover 22 are joined together is obtained.

[0062] The effects of the present embodiment described above are as follows. Since the second cover is molded on the first cover 21 after molding without forming a release layer, the first cover 21 and the second cover 22 can be firmly bonded together. This makes it possible to suppress the generation of contact noise between the first cover 21 and the second cover 22 caused by the bonded portion peeling off. By bonding the first cover 21 and the second cover 22 together, the first cover 21 can absorb and dampen the vibrations of the second cover 22.

[0063] Since the first cover 21 and the second cover 22 are made of the same resin material, such as polyurethane or polyisocyanurate, a chemical bonding force can be added at the joint between the second connection portion 12 and the first cover 21.

[0064] In the above-described embodiments, 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 it is mixed, 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 it is mixed.

[0065] The method of manufacturing the compressor enclosure according to each of the above-described embodiments can be understood, for example, as follows.

[0066] A manufacturing method for a compressor enclosure (1) according to a first aspect of the present disclosure is a manufacturing method for a compressor enclosure including a first cover (21) that houses and surrounds a compressor (2) therein, and a second cover (22) that houses and surrounds the first cover and has a higher density than the first cover, the manufacturing method including a first step of molding the second cover or the first cover in a mold (30, 40, 50), and a second step of molding the first cover or the second cover with the molded second cover or the first cover placed in the mold.

[0067] After the second cover is molded, the first cover is molded with the second cover placed in the mold, which makes it possible to easily mold the first cover having an outer surface with a shape corresponding to the inner surface of the second cover. Alternatively, the second cover is molded after the first cover is molded while the first cover is placed in a mold, which makes it possible to easily mold the second cover having an inner surface that corresponds to the outer surface of the first cover. Since the second cover is provided to house the first cover, the sound generated by the compressor is converted to thermal energy and attenuated as it propagates through the first cover. 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. This makes it possible to reduce the propagation of the compressor sound to the outside of the enclosure by the first cover, which has a low density, and the second cover, which has a high density. 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.

[0068] A method for manufacturing a compressor enclosure according to a second aspect of the present disclosure includes, in the first aspect, a step of removing a surface layer of an inner surface and / or an outer surface of the first cover after molding the first cover.

[0069] After molding, the first cover has a porous core layer located toward the center in the thickness direction, and solid skin layers formed on the inner and outer surfaces. By removing the skin layers, sound reflection at the skin layers can be reduced, and sound from the compressor and solid-borne sound of the compressor can be efficiently absorbed.

[0070] In the manufacturing method for a compressor enclosure according to a third aspect of the present disclosure, in the first or second aspect, a release layer (36, 46) is formed on the molded second cover or the molded first cover placed in a mold before the second step.

[0071] Since the second step is performed after forming the release layer, the first cover and the second cover are not bonded together. This reduces the vibration transmission from the first cover to the second cover. Also, the reflection and attenuation of sound waves at the boundary between the first cover and the second cover reduces the transmission of sound to the outside air. The release layer may be formed by applying a liquid release agent, or may be a release sheet.

[0072] A fourth aspect of the present disclosure relates to a manufacturing method for a compressor enclosure according to the third aspect, wherein a thickness of the release layer corresponds to a gap between the first cover and the second cover when attached to the compressor.

[0073] The thickness of the release layer is set to a thickness equivalent to the gap between the first cover and the second cover when the cover is attached to the compressor, thereby making it possible to form a desired gap between the first cover and the second cover. By forming a space between the first cover and the second cover, it is possible to reduce vibration propagation from the first cover to the second cover.

[0074] In the method for producing a compressor enclosure according to a fifth aspect of the present disclosure, in the third or fourth aspect, a plurality of holes are formed in the release layer.

[0075] By forming holes in the release layer, the resin material flows through the holes into the opposing first cover or second cover during the second process. This makes the molded portion corresponding to the hole a connecting portion, connecting the first cover and the second cover. In particular, when the resin material of the second cover flows into the surface of the first cover and is molded, the resin material fills many recesses on the surface, making the mechanical bond stronger. Since a space can be formed between the first cover and the second cover by the multiple connection parts, it is possible to reduce the propagation of vibration from the first cover to the second cover.

[0076] In the method for producing a compressor enclosure according to a sixth aspect of the present disclosure, in the first or second aspect, the second step is performed without forming a release layer.

[0077] Since the second cover or the first cover is molded on the first cover or the second cover after molding without forming a release layer, the first cover and the second cover can be firmly bonded together. This makes it possible to suppress the generation of contact noise between the first cover and the second cover caused by the bonded portion peeling off. By bonding the first cover and the second cover together, the first cover can absorb and dampen the vibration of the second cover.

[0078] In the method for manufacturing a compressor enclosure according to the seventh aspect of the present disclosure, in any one of the first to sixth aspects, the first and second steps use the same resin material and change the molding temperature depending on the first cover and the second cover to be molded.

[0079] Since the same resin material is used, a chemical bonding force can also be applied when the first cover and the second cover are joined together. When using the same resin material, a low-density first cover and a high-density second cover can be molded by changing the molding temperature. For example, when using polyurethane or polyisocyanurate as the resin material and azodicarbonamide, carbonate, or bicarbonate as the foaming material, the first cover is molded at a molding temperature of 60°C or higher, and the second cover is molded at a molding temperature of about 20 to 30°C. [Explanation of symbols]

[0080] 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 30,40,50 Mold 31,41,51 Upper mold 32,42,52 Lower mold 33a, 43a, 53a 1st sim 33b, 43b, 53b 2nd Sim 33c, 43c, 53c 3rd Sim 34a, 44a, 54a 1st split type 34b,44b,54b 2nd split type 34c,44c,54c 3rd division type 34d 4th division type 36,46 Release layer P split plane

Claims

1. a first cover that houses and surrounds the compressor; a second cover that contains and surrounds the first cover and has a higher density than the first cover; A method of manufacturing a compressor enclosure comprising: A first step of molding the second cover or the first cover in a mold; a second step of molding the first cover or the second cover while disposing the molded second cover or the molded first cover in a mold; A method for manufacturing a compressor enclosure having the following structure:

2. The method for manufacturing a compressor enclosure according to claim 1 , further comprising the step of removing a surface layer of an inner surface and / or an outer surface of the first cover after molding the first cover.

3. 3. The method for manufacturing a compressor enclosure according to claim 1, further comprising forming a release layer on the molded second cover or the molded first cover placed in a mold before the second step.

4. The method for manufacturing a compressor enclosure according to claim 3 , wherein a thickness of the release layer corresponds to a gap between the first cover and the second cover when the enclosure is attached to the compressor.

5. The method for manufacturing a compressor enclosure according to claim 3 , wherein the release layer has a plurality of holes formed therein.

6. The method for manufacturing a compressor enclosure according to claim 1 or 2, wherein the second step is carried out without forming a release layer.

7. The first step and the second step use the same resin material, The method for manufacturing a compressor enclosure according to claim 1 or 2, wherein a molding temperature is changed depending on the first cover and the second cover to be molded.

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