Scroll manufacturing method and scroll compressor including scroll manufactured thereby

Abstract

The present invention relates to a scroll manufacturing method and a scroll compressor including a scroll formed thereby, wherein the scroll manufacturing method comprises the steps of forming a scroll wrap and forming a scroll plate, wherein the scroll plate is formed by a die casting method, and the step of forming the scroll plate comprises the steps of inserting a base portion of the scroll wrap into a mold and injecting molten metal into the mold into which the base portion of the scroll wrap is inserted to form the scroll plate and integrating it with the base portion of the scroll wrap, thereby reducing costs.

Description

Technology Field

[0001] The present invention relates to a method for manufacturing a scroll and a scroll compressor comprising a scroll formed thereby, and more specifically, to a method for manufacturing a scroll capable of reducing costs and a scroll compressor comprising a scroll formed thereby. Background Technology

[0002] Generally, automobiles are equipped with an air conditioning (A / C) system for heating and cooling the interior. As a component of the cooling system, this air conditioning system includes a compressor that compresses low-temperature, low-pressure gaseous refrigerant drawn in from the evaporator into high-temperature, high-pressure gaseous refrigerant and sends it to the condenser.

[0003] Compressors are classified into reciprocating types, which compress refrigerant through the reciprocating motion of a piston, and rotary types, which perform compression through rotational motion. Depending on the drive source transmission method, reciprocating types include crank types, which use a crank to transmit power to multiple pistons, and swashplate types, which use a rotating shaft equipped with swashplates. Rotary types include vane rotary types, which use a rotating rotary shaft and vanes, and scroll types, which use a slewing scroll or a fixed scroll.

[0004] Scroll compressors are widely used for refrigerant compression in air conditioning systems and other applications due to their advantages, such as the ability to achieve a relatively high compression ratio compared to other types of compressors, and stable torque resulting from the smooth succession of the refrigerant suction, compression, and discharge strokes.

[0005] FIG. 1 is a flowchart illustrating a conventional scroll manufacturing method, and FIG. 2 is a cross-sectional view illustrating a scroll compressor including a rotating scroll and a stationary scroll formed by the scroll manufacturing method of FIG. 1.

[0006] Referring to FIG. 2, a conventional scroll compressor includes a fixed scroll (20) fixed to a casing (10), a pivot scroll (30) that engages with the fixed scroll (20) and forms a compression chamber, a drive shaft (50) that is rotated by a drive source (40), such as an electric motor, and an eccentric bush (60) that rotates together with the drive shaft (50) and causes the pivot scroll (30) to pivot.

[0007] Here, the fixed scroll (20) includes a disc-shaped fixed scroll plate (21) and a fixed scroll wrap (22) protruding from the fixed scroll plate (21) toward the pivoting scroll (30).

[0008] And, the rotary scroll (30) includes a disc-shaped rotary scroll plate (31) facing the fixed scroll plate (21) and a rotary scroll wrap (32) that protrudes from the rotary scroll plate (31) toward the fixed scroll (20) and engages with the fixed scroll wrap (22).

[0009] And, the fixed scroll (20) and the rotating scroll (30) are manufactured by the scroll manufacturing method illustrated in FIG. 1. That is, the fixed scroll (20) and the rotating scroll (30) are each manufactured by a scroll manufacturing method comprising a forging step (A) of processing a base material by a forging method to have a predetermined strength, and a cutting step (B) of cutting the forged product manufactured through the forging step (A) to have a predetermined shape and dimensions.

[0010] However, in this conventional scroll manufacturing method and the scroll compressor including the scroll formed thereby, there was a problem of increased cost.

[0011] Specifically, taking the above-mentioned slewing scroll (30) as an example, the slewing scroll plate (31) and the slewing scroll wrap (32) are formed together in the above-mentioned forging step (A). That is, not only the slewing scroll wrap (32), which requires relatively high strength, but also the slewing scroll plate (31), which requires relatively low strength, are formed by the forging method. Accordingly, a very large force is required to perform the forging, and the cost increases.

[0012] In addition, since it is difficult to form a shape and dimensions determined in advance due to the characteristics of the forging process, the cutting step (B) must be performed after the forging step (A), which increases the cost.

[0013] And, the above-mentioned pivot scroll (30) further comprises a cylindrical pivot scroll post (33) protruding from the center of the pivot scroll plate (31) toward the opposite side of the pivot scroll wrap (31), a pivot scroll recess (34) formed cylindrically in the center of the front end surface of the pivot scroll post (33), and a pivot anti-rotation element pocket (35) formed in the outer periphery of the pivot scroll plate (31). Since a bearing (70) interposed between the pivot scroll (30) and the eccentric bush (60) is inserted into the pivot scroll recess (34), the pivot scroll recess (34) must be formed with a predetermined shape and dimensions. The pivot anti-rotation element pocket (35) includes a pivot anti-rotation element (80) that prevents the pivot scroll (30) from rotating, and a wear prevention element to prevent the pivot anti-rotation element pocket (35) from being worn by the pivot anti-rotation element (80). Since the ring (90) is inserted, the anti-rotation element (80) must also be formed with a predetermined shape and dimensions. However, since the pivot scroll recess (34) and the anti-rotation element pocket (35) are also formed through the forging step (A) and the cutting step (B), the cost is further increased. Prior art literature

[0014] Republic of Korea Published Patent Application No. 10-2024-0148894 The problem to be solved

[0015] Accordingly, the present invention aims to provide a method for manufacturing a scroll capable of reducing costs and a scroll compressor comprising a scroll formed thereby. means of solving the problem

[0016] The present invention provides a method for manufacturing a scroll, comprising the steps of: forming a scroll wrap; and forming a scroll plate; wherein the scroll plate is formed by a die casting method, and the step of forming the scroll plate comprises the steps of inserting a base portion of the scroll wrap into a mold and injecting molten metal into the mold into which the base portion of the scroll wrap is inserted to form the scroll plate and integrating it with the base portion of the scroll wrap.

[0017] The above scroll manufacturing method may further include a step of plasma treating the base portion of the scroll wrap before inserting it into the mold.

[0018] The above scroll manufacturing method may further include a step of preheating the base portion of the scroll wrap before plasma treating it.

[0019] The base portion of the scroll wrap includes a surface portion connected to the leading portion of the scroll wrap and a deep portion located on the opposite side of the leading portion of the scroll wrap relative to the surface portion, and the thickness of the deep portion may be formed to be greater than the thickness of the surface portion.

[0020] The scroll plate may include an anti-detachment portion that covers a stepped surface formed by a thickness difference between the surface layer and the deep layer.

[0021] The thickness of the surface layer can be formed to be equal to the thickness of the leading edge of the scroll wrap.

[0022] The scroll plate may include at least one groove formed in intaglio from the outer surface and into which a predetermined part is inserted.

[0023] When the above scroll plate is formed by a die casting method, the at least one groove can be formed with a predetermined shape and dimensions.

[0024] The above scroll wrap can be formed of a metal such as the metal forming the scroll plate.

[0025] The above scroll wrap can be formed by a forging method.

[0026] The step of forming the scroll wrap may include the step of forging the scroll wrap base material and the step of processing the scroll wrap forging into a predetermined shape and dimensions.

[0027] The scroll wrap may be formed of a material having at least one of strength, wear resistance, and heat resistance superior to the metal forming the scroll plate.

[0028] The scroll wrap may be formed of a material having a coefficient of thermal expansion such that the difference from the coefficient of thermal expansion of the metal forming the scroll plate falls within a predetermined range.

[0029] The present invention provides a scroll compressor comprising: a fixed scroll; and a pivoting scroll that forms a compression chamber with the fixed scroll and moves pivotally, wherein the fixed scroll comprises a fixed scroll plate and a fixed scroll wrap protruding from the fixed scroll plate toward the pivoting scroll side, and the pivoting scroll comprises a pivoting scroll plate opposite to the fixed scroll plate and a pivoting scroll wrap protruding from the pivoting scroll plate toward the fixed scroll side and engaging with the fixed scroll wrap, and at least one of the fixed scroll and the pivoting scroll is manufactured by the scroll manufacturing method. Effects of the invention

[0030] A scroll manufacturing method according to the present invention and a scroll compressor including a scroll formed thereby, wherein the scroll manufacturing method comprises the steps of forming a scroll wrap and forming a scroll plate, and the scroll plate is formed by a die casting method, and the step of forming the scroll plate comprises the steps of inserting a base portion of the scroll wrap into a mold and injecting molten metal into the mold into which the base portion of the scroll wrap is inserted to form the scroll plate and integrating it with the base portion of the scroll wrap, thereby reducing costs. Brief explanation of the drawing

[0031] FIG. 1 is a flowchart illustrating a conventional scroll manufacturing method, FIG. 2 is a cross-sectional view illustrating a scroll compressor including a rotating scroll and a stationary scroll formed by the scroll manufacturing method of FIG. 1. FIG. 3 is a flowchart illustrating a method for manufacturing a scroll according to an embodiment of the present invention, FIG. 4 is a cross-sectional view illustrating one embodiment of a pivoting scroll formed by the scroll manufacturing method of FIG. 3. FIG. 5 is a rear view illustrating the rotating scroll of FIG. 4, FIG. 6 is a cross-sectional view illustrating another embodiment of a swivel scroll formed by the scroll manufacturing method of FIG. 3. Specific details for implementing the invention

[0032] Hereinafter, a method for manufacturing a scroll according to the present invention and a scroll formed thereby will be described in detail.

[0033] A scroll compressor according to one embodiment of the present invention may include a fixed scroll fixed to a casing, a pivot scroll that meshes with the fixed scroll and forms a compression chamber, a drive shaft rotated by a drive source such as an electric motor, and an eccentric bush that rotates together with the drive shaft and causes the pivot scroll to pivot.

[0034] Here, the fixed scroll may include a disc-shaped fixed scroll plate and a fixed scroll wrap protruding toward the pivoting scroll side from a fixed scroll plate compression surface, which is a circular surface of the fixed scroll plate.

[0035] And, the above-mentioned rotating scroll can be manufactured by the scroll manufacturing method shown in FIG. 3 and formed as shown in FIG. 4 and FIG. 5.

[0036] FIG. 3 is a flowchart illustrating a method for manufacturing a scroll according to one embodiment of the present invention, FIG. 4 is a cross-sectional view illustrating one embodiment of a rotating scroll formed by the method for manufacturing a scroll of FIG. 3, and FIG. 5 is a rear view illustrating the rotating scroll of FIG. 4.

[0037] Referring to FIG. 4, the pivot scroll (300) according to the present embodiment may include a disc-shaped pivot scroll plate (310) facing the fixed scroll plate and a pivot scroll wrap (320) that protrudes toward the fixed scroll side from a pivot scroll plate compression surface (312), which is a circular surface of the pivot scroll plate (310), and engages with the fixed scroll wrap.

[0038] Here, the rotary scroll (300) may have the rotary scroll wrap (320) formed separately and then the rotary scroll plate (310) additionally formed.

[0039] Specifically, referring to FIG. 3, a method for manufacturing a scroll according to an embodiment of the present invention comprises the steps of forming a scroll wrap (S1) and forming a scroll plate (S4). The step of forming the scroll wrap (S1) comprises the step of forging a scroll wrap base material made of metal (S11) and the step of cutting the scroll wrap forging to a predetermined shape and dimensions (S12). The step of forming the scroll plate (S4) comprises the step of inserting the base portion of the scroll wrap into a die-casting mold (S41) and the step of injecting molten metal into the die-casting mold into which the base portion of the scroll wrap is inserted to form the scroll plate and integrate it with the base portion of the scroll wrap (S42). The rotating scroll (300) is formed such that the rotating scroll wrap (320) is separately formed first according to the step of forming the scroll wrap (S1), and then the rotating scroll plate (310) is formed according to the step of forming the scroll plate (S4), wherein the rotating scroll plate (310) is of the rotating scroll wrap (320). It can be formed integrally with the base (322) afterwards.

[0040] According to this, only the swivel scroll wrap (320), which requires relatively high strength, is formed by a forging method, and the swivel scroll plate (310), which requires relatively low strength, is formed by a die casting method, so that less force is required to perform the forging, and thus the cost can be reduced.

[0041] In addition, since the above-mentioned pivot scroll plate (310) is formed by a die casting method, it can be formed with a predetermined shape and dimensions without separate cutting, so only the above-mentioned pivot scroll wrap (320) needs to be additionally cut, which can further reduce the cost.

[0042] Here, the pivot scroll (300) may further include a cylindrical pivot scroll post (330) protruding from the center of the pivot scroll plate back surface (314), which is the back surface of the pivot scroll plate compression surface (312), a pivot scroll recess (340) formed cylindrically in the center of the front end surface of the pivot scroll post (330), and an anti-rotation element pocket (350) formed in the outer periphery of the pivot scroll plate back surface (314). Furthermore, since a bearing interposed between the pivot scroll (300) and the eccentric bushing is inserted into the pivot scroll recess (340), the pivot scroll recess (340) must be formed with a predetermined shape and dimensions. In addition, since the anti-rotation element pocket (350) has an anti-rotation element that prevents rotation of the rotating scroll (300) and a wear-prevention ring that prevents the anti-rotation element pocket (350) from being worn by the anti-rotation element, the anti-rotation element must also be formed with a predetermined shape and dimensions. However, in the case of the present embodiment, if the shapes of the rotating scroll post (330), the rotating scroll recess (340), and the anti-rotation element pocket (350) are reflected in the die-casting mold, the rotating scroll post (330), the rotating scroll recess (340), and the anti-rotation element pocket (350) can be formed with a predetermined shape and dimensions together with the rotating scroll plate (310) without any additional cutting process, thereby further reducing the cost.

[0043] And, as the rotary scroll plate (310), the rotary scroll post (330), the rotary scroll recess (340), and the anti-rotation element pocket (350) are formed after the rotary scroll wrap (320) is formed, the rotary scroll plate (310), the rotary scroll post (330), the rotary scroll recess (340), and the anti-rotation element pocket (350) can be prevented from being deformed when the rotary scroll wrap (320) is machined.

[0044] Meanwhile, as the rotating scroll plate (310) is subsequently formed integrally with the rotating scroll wrap (320) after the rotating scroll wrap (320) is formed, there may be concerns regarding reduced strength, cracking, leakage, etc., at the connection point between the rotating scroll wrap (320) and the rotating scroll plate (310).

[0045] Considering this, in the present embodiment, the scroll manufacturing method further includes a step (S3) of plasma treating the base portion of the scroll wrap before inserting it into the die casting mold. Since the base portion (322) of the rotating scroll wrap (320) is plasma treated before being inserted into the die casting mold, foreign substances (e.g., oxide film) on the surface of the base portion (322) of the rotating scroll wrap (320) are removed, the bonding strength between the base portion (322) of the rotating scroll wrap (320) and the rotating scroll plate (310) can be increased. Here, it may be cost-effective to plasma treat only the base portion (322) of the rotating scroll wrap (320) rather than plasma treating the entire rotating scroll wrap (320).

[0046] Furthermore, the above-described scroll manufacturing method further includes a step (S2) of preheating the base portion of the scroll wrap before plasma treatment. As the surface energy increases because the base portion (322) of the rotating scroll wrap (320) is preheated before plasma treatment, foreign substances on the surface of the base portion (322) of the rotating scroll wrap (320) can be removed more smoothly, and consequently, the bonding strength between the base portion (322) of the rotating scroll wrap (320) and the rotating scroll plate (310) can be further increased. Here, if preheating is performed after plasma treatment, the effect of removing foreign substances does not improve compared to the case where only plasma treatment is performed without preheating, and only the cost increases; therefore, it may be preferable to perform preheating before plasma treatment as in this embodiment.

[0047] In addition, so that the rotational scroll wrap (320) is prevented from separating from the rotational scroll plate (310) due to a difference in thermal expansion, it may be preferable for the rotational scroll wrap (320) to be formed of a metal such as the metal forming the rotational scroll plate (310).

[0048] Here, if necessary, the swivel scroll wrap (320) may be formed of another metal or non-metal (e.g., a resin such as PEEK) having at least one of strength, wear resistance, and heat resistance superior to the metal forming the swivel scroll plate (310). In this case, it may be preferable for the swivel scroll wrap (320) to be formed of a material having a coefficient of thermal expansion such that the difference from the coefficient of thermal expansion of the metal forming the swivel scroll plate (310) falls within a predetermined range, in terms of suppressing separation between the swivel scroll wrap (320) and the swivel scroll plate (310) due to the difference in thermal expansion.

[0049] Meanwhile, in the present embodiment, the pivot scroll (300) is formed by the scroll manufacturing method, but is not limited thereto. That is, at least one of the pivot scroll (300) and the fixed scroll may be formed by the scroll manufacturing method.

[0050] Meanwhile, as illustrated in FIG. 6, in order to further suppress the separation of the rotating scroll wrap (320) from the rotating scroll plate (310), the base portion (322) of the rotating scroll wrap (320) includes a surface portion (322a) connected to the front portion (324) of the rotating scroll wrap (320) and a deep portion (322b) located on the opposite side of the front portion (324) of the rotating scroll wrap (320) relative to the surface portion (322a), and the radial thickness of the deep portion (322b) is formed to be greater than the radial thickness of the surface portion (322a), and the rotating scroll plate (310) may preferably include a detachment prevention portion (316) covering a stepped surface (322c) formed by the difference in radial thickness between the surface portion (322a) and the deep portion (322b). To this end, it may be preferable that when the base portion (322) of the above-mentioned pivot scroll wrap (320) is inserted into the die-casting mold, not only the deep portion (322b) but also the surface portion (322a) is inserted into the die-casting mold, and thereafter the pivot scroll plate (310) is formed.

[0051] In addition, to prevent cracks from occurring between the surface layer (322a) and the leading edge (324) of the rotating scroll wrap (320), it may be preferable for the radial thickness of the surface layer (322a) to be equal to the radial thickness of the leading edge (324) of the rotating scroll wrap (320). Explanation of the symbols

[0052] 300: Swirl Scroll 310: Swivel scroll plate 316: Anti-detachment part 320: Swirl Scroll Wrap 322: Base 322a: Surface layer 322b: Deep 322c: Step surface 324: Tip 340: Swivel Scroll Recess 350: Anti-rotation element pocket S1: Step of forming a scroll wrap S2: Preheating step S3: Plasma treatment step S4: Step of forming a scroll plate S11: Forging step S12: Cutting step S41: Step of inserting the base of the scroll wrap into the mold S42: Step of injecting metal into the mold

Claims

Claim 1 A method for manufacturing a scroll, comprising: a step of forming a scroll wrap; and a step of forming a scroll plate; wherein the scroll plate is formed by a die casting method, and the step of forming the scroll plate includes a step of inserting a base portion of the scroll wrap into a mold and a step of injecting molten metal into the mold into which the base portion of the scroll wrap is inserted to form the scroll plate and integrating it with the base portion of the scroll wrap. Claim 2 A method for manufacturing a scroll according to claim 1, further comprising the step of plasma treating the base portion of the scroll wrap before inserting it into the mold. Claim 3 A method for manufacturing a scroll, further comprising the step of preheating the base portion of the scroll wrap before plasma treatment in paragraph 2. Claim 4 A method for manufacturing a scroll according to claim 1, wherein the base portion of the scroll wrap includes a surface portion connected to the leading portion of the scroll wrap and a deep portion located on the opposite side of the leading portion of the scroll wrap based on the surface portion, and the thickness of the deep portion is formed to be greater than the thickness of the surface portion. Claim 5 A method for manufacturing a scroll according to claim 4, wherein the scroll plate includes an anti-detachment portion covering a stepped surface formed by a thickness difference between the surface layer and the deep layer. Claim 6 A method for manufacturing a scroll according to claim 4, wherein the thickness of the surface layer is formed to be equal to the thickness of the leading edge of the scroll wrap. Claim 7 A method for manufacturing a scroll according to claim 1, wherein the scroll plate is formed in a recessed shape from the outer surface and includes at least one groove into which a predetermined part is inserted. Claim 8 A method for manufacturing a scroll according to claim 7, wherein when the scroll plate is formed by a die casting method, the at least one groove is formed with a predetermined shape and dimensions. Claim 9 A method for manufacturing a scroll in which, in claim 1, the scroll wrap is formed of a metal such as the metal forming the scroll plate. Claim 10 In claim 9, the scroll lap is formed by a scroll manufacturing method using a forging process. Claim 11 A method for manufacturing a scroll according to claim 10, wherein the step of forming the scroll lap comprises the step of forging a scroll lap base material and the step of processing a scroll lap forging into a predetermined shape and dimensions. Claim 12 A method for manufacturing a scroll according to claim 1, wherein the scroll wrap is formed of a material having at least one of strength, wear resistance, and heat resistance superior to the metal forming the scroll plate. Claim 13 A method for manufacturing a scroll according to claim 12, wherein the scroll wrap is formed of a material having a coefficient of thermal expansion such that the difference from the coefficient of thermal expansion of the metal forming the scroll plate falls within a predetermined range. Claim 14 A scroll compressor comprising: a fixed scroll; and a pivoting scroll that forms a compression chamber with the fixed scroll and pivots; wherein the fixed scroll comprises a fixed scroll plate and a fixed scroll wrap protruding from the fixed scroll plate toward the pivoting scroll side, and the pivoting scroll comprises a pivoting scroll plate opposite to the fixed scroll plate and a pivoting scroll wrap protruding from the pivoting scroll plate toward the fixed scroll side and engaging with the fixed scroll wrap, and at least one of the fixed scroll and the pivoting scroll is manufactured by a scroll manufacturing method according to any one of claims 1 to 13.

Images