Method for manufacturing compressor enclosure

Abstract

The present invention provides a method for manufacturing a compressor enclosure, the method allowing the easy manufacturing of a first cover for covering a compressor, and a second cover for covering the first cover and having a shape corresponding to the first cover. This method is for manufacturing a compressor enclosure comprising: a first cover (21) that houses and encloses a compressor therein; and a second cover (22) that houses and encloses the first cover (21) therein, and has a greater density than the first cover (21). The method for manufacturing the compressor enclosure includes: a first step for molding the second cover (22) in a mold (30); and a second step for molding the first cover (21) in a state in which the molded second cover (22) is disposed in the mold (30).

Description

Method for manufacturing a compressor enclosure

[0001] The present disclosure relates to a method of manufacturing a compressor enclosure that houses a compressor therein.

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

[0003] Compressor noise can be reduced by reducing the sound pressure level of the noise source or by absorbing or insulating the generated noise. As a means for absorbing or insulating the noise, various structures have been proposed that provide a soundproof cover for the compressor. For example, Patent Document 1 discloses a structure that includes a compressor, sound-absorbing material, and a support bracket, with a cover that is a sound-absorbing material and a sound-insulating material stacked on top of each other. The cover is made of urethane foam resin, and the sound-insulating material is made of vinyl chloride resin or polyolefin-based resin.

[0004] Japanese Patent Application Laid-Open No. 2022-147641

[0005] However, in a double-layered soundproof cover made of resin material as in Patent Document 1, the inner surface of the outer cover must 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 method for manufacturing 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 that corresponds to the first cover.

[0007] A method for manufacturing a compressor enclosure according to one aspect of the present disclosure is a method for manufacturing a compressor enclosure that includes 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, and includes 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.

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

[0009] FIG. 1 is a perspective view showing an enclosure for a compressor according to a first embodiment of the present disclosure; FIG. 2 is a perspective view showing a compressor according to a first embodiment of the present disclosure; FIG. 3 is a longitudinal sectional view showing an enclosure accommodating a compressor according to a first embodiment of the present disclosure; FIG. 4 is a schematic view showing a method for manufacturing the enclosure of FIG. 3; FIG. 5 is a schematic view showing a step of manufacturing a first cover by removing a skin layer; FIG. 6 is a longitudinal sectional view showing an enclosure accommodating a compressor according to a second embodiment of the present disclosure; FIG. 7 is a schematic view showing a method for manufacturing the enclosure of FIG. 6;

[0010] [First embodiment] A first embodiment according to the present disclosure will be described below with reference to the drawings. Fig. 1 shows an enclosure (compressor enclosure) 1 that entirely covers a compressor 2. A main body 10 of the enclosure 1 has a shape corresponding to the outer shape of the compressor 2, and is divided into two left and right sections 10A, 10B at a dividing plane P.

[0011] The dividing plane P extends vertically when the mounting legs 3 of the compressor 2 are positioned downward. The mounting legs 3 of the compressor 2 are fixing parts for fixing the compressor 2 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, such as engagement using bolts and nuts, claws, etc.

[0014] Figure 2 shows the compressor 2 with the enclosure 1 shown in Figure 1 removed. The compressor 2 shown in this figure does not have an exact same shape as the enclosure 1 shown in Figure 1, for example, in terms of the number of mounting legs 3, but there is no significant difference in terms of the compressor 2 being 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 part of a refrigeration cycle used in vehicle air conditioning, and draws in refrigerant guided from an evaporator, compresses it, and discharges the compressed refrigerant to a condenser. As shown in Figure 2, the compressor 2 has a generally cylindrical shape with a horizontal longitudinal axis. 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 (left side in FIG. 2 ) of the compressor 2 and includes a fixed scroll and an orbiting scroll therein. Because 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 compressed refrigerant is provided at the top of the compression section 2A.

[0017] The motor unit 2B is connected to the rear of the compression unit 2A and is located on the rear side of the compressor 2 (on the right side in FIG. 2 ). The motor unit 2B includes an electric motor having a stator and a rotor, and an inverter unit that supplies power to the electric motor. The diameter of the motor unit 2B is larger than the diameter of the compression unit 2A. A cylindrical suction port 7 is provided at the top of the motor unit 2B for drawing refrigerant into the compressor 2. Furthermore, a cylindrical wiring guide tube (extension) 9 is provided at the top of the motor unit 2B near the suction port (extension) 7 for guiding harnesses such as power cables and signal lines to the outside of the compressor 2.

[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 has a double structure including a first cover 21 and a second cover 22 .

[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 porosity) than rigid plastic materials such as PP (polypropylene) and PBT (polybutylene terephthalate).

[0021] A gap of, for example, 5 mm to 20 mm is provided between the first cover 21 and the compressor 2, and the first cover 21 contacts the compressor 2 at multiple locations via the first connection portion 11. The first connection portion 11 has a protruding shape that protrudes from the inner surface of the first cover 21, and the tip of the first connection portion 11 contacts 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 open-cell polyethylene. The first connection portion 11 is preferably fixed to the inner surface of the first cover 21 by adhesive or the like.

[0022] The first connection portions 11 are mainly provided in the motor section 2B of the compressor 2. More specifically, they are provided at the front end A1, the rear end A2, and the intermediate section A3 between the front end A1 and the rear end A2 of the motor section 2B. The first connection portion 11 at the intermediate section A3 may be omitted as appropriate. The first connection portions 11 are provided at a plurality of locations in the circumferential direction of the compressor 2. For example, as shown by arrow C in FIG. 2 , they are provided at both the lower and upper sides of the compressor 2. As in this embodiment, it is preferable to provide more first connection portions 11 in the motor section 2B than in the compression section 2A.

[0023] A hole is formed in the main body 10 at a position corresponding to the discharge port 5 so that the discharge port 5 can be inserted therethrough. To fill the gap between the edge of this hole and the side surface of the discharge port 5, a sealant 14 is provided as a first connecting portion 11, as shown in Figure 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 void content) than the first cover 21, and is rigid enough to maintain its shape under its own weight. For example, the first cover 21 may be made of a hard resin material that does not foam or foams only to a small extent. Alternatively, the second cover 22 may 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, and for example, a space that inevitably occurs when the first cover 21 and the second cover 22 are brought into contact entirely is acceptable.

[0027] <Manufacturing Method> Next, a method for manufacturing the enclosure 1 having the above configuration will be described. As shown in Fig. 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 upper first split mold 34a forms the entire upper portion of the upper mold 31, and a horizontally extending plate-like first shim 33a is inserted into a recess formed on the underside. The insertion of the first shim 33a makes the underside of the first split mold 34a flush. The second split mold 34b, the third split mold 34c, and the fourth split mold 34d are arranged horizontally, from left to right, in contact with the underside of the first split mold 34a. A vertically extending plate-like second shim 33b is provided between the second split mold 34b and the third split mold 34c, and a vertically extending plate-like third shim 33c 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 mold 30 described above has a cavity set to the thickness of the second cover 22. A resin material containing no foaming agent is supplied to the cavity of the mold 30, and the second cover 22 is molded at a low temperature of about 20 to 30°C (first step). Polyurethane and polyisocyanurate can be used as the resin material. Alternatively, PP (polypropylene) and PBT (polybutylene terephthalate) can also be used as the resin material.

[0030] 4B, 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] 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 after the first step in FIG. 4(a) by removing the upper mold 31 and leaving the second cover 22 placed in the lower mold 32.

[0032] 4(c), the upper mold 31 is configured with only four split molds 34a, 34b, 34c, and 34d after the three shims 33a, 33b, and 33c have been removed. As a result, the cavity formed between the upper mold 31 and the lower mold 32 has a thickness equal to 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, and 33c, the split molds 34a, 34b, 34c, and 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). The resin material may be polyurethane, polyisocyanurate, or the like.

[0034] Thereafter, the first cover 21 and the second cover 22 are removed from the mold 30 and separated from each other using the release layer 36 .

[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 foam layer and skin layers 21a that serve as solid layers on the front and back sides of the core layer 21b. By removing these skin layers 21a by blasting, machining, or the like, a foamed surface 21c appears on the surface of the first cover 21, exposing numerous depressions caused by foaming, 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 with the second cover 22 placed in the mold 30. This makes it possible to easily mold the first cover 21 having an outer surface shaped to correspond to the inner surface of the second cover 22. Because the second cover 22 is provided to house the first cover 21, sound generated by the compressor 2 is converted to thermal energy and attenuated as it propagates through the first cover 21. The second cover 22, which has a higher density than the first cover 21, then reflects the sound to the interior. 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 sound of the compressor 2 from propagating outside 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 sound from the compressor 2 and solid-borne sound of the compressor 2 can be efficiently absorbed.

[0038] Since the second step is performed after forming the release layer 36, the first cover 21 and the second cover 22 are not bonded together. This reduces the propagation of vibrations from the first cover 21 to the second cover 22. Furthermore, the reflection and attenuation of sound waves at the boundary surface 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, it is possible to reduce material costs and simplify the manufacturing process.

[0040] Second Embodiment Next, a second embodiment of the present disclosure will be described. While 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, the enclosure 1 of this embodiment differs in that a 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 descriptions thereof will be omitted.

[0041] 6, a gap of, for example, about 5 mm to 20 mm is provided between the second cover 22 and the first cover 21, and the second cover 22 is in contact with the first cover 21 at multiple locations via the second connection portions 12. The second connection portions 12 have a protruding shape that protrudes from the inner surface of the second cover 22, and the tip of the second connection portion 12 is in contact with the outer surface of the first cover 21.

[0042] The second connection portion 12 is provided at a different position from 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 the 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, the first cover 21 is molded using a mold 40. The mold 40 includes an upper mold 41 and a lower mold 42. The inner surface of the lower mold 42 has a shape corresponding to the inner surface of the first cover 21 after molding.

[0044] The upper mold 41 is divided into three split molds 44a, 44b, and 44c. From left to right, 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 surfaces of the first split mold 44a, the second split mold 44b, and the third split mold 44c corresponds to the shape of the outer surface of the first cover 21.

[0045] The mold 40 described above 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 40, and the first cover 21 is molded at a high temperature of 60° C. or higher (first step). The resin material may be 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] 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 corresponding 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 positioned 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. These shims 43a, 43b, and 43c form a cavity having a shape corresponding to the first cover 21, the release layer 46, and the second cover 22.

[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. The resin material used is polyurethane, polyisocyanurate, or the like, similar to that of the first cover.

[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 to the first cover 21 while being embedded in a 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 while the first cover 21 is placed in the mold 40. This makes it possible to easily mold the second cover 22, which has an inner surface that corresponds 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, it is possible to reduce vibration propagation from the first cover 21 to the second cover 22.

[0053] By forming through holes in the release layer 46, the resin material flows through the through holes into the opposing first cover during the second process. As a result, the molded portions corresponding to the through holes become second connection portions 12, connecting the first cover 21 and the second cover 22. In particular, the resin material of the second cover 22 fills the numerous recesses in the surface of the first cover 21, further strengthening the mechanical bond. The multiple second connection portions 12 form spaces between the first cover 21 and the second cover 22, thereby reducing vibration propagation from the first cover 21 to the second cover 22.

[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, the first cover 21 is molded using a mold 50. The mold 40 includes an upper mold 51 and a lower mold 52. The inner surface of the lower mold 52 has a shape corresponding to the inner surface of the first cover 21 after molding.

[0057] The upper mold 51 is divided into three split molds 54a, 54b, and 54c. From left to right, 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 surfaces of the first split mold 54a, the second split mold 54b, and the third split mold 54c corresponds to the shape of the outer surface of the first cover 21.

[0058] The mold 50 described above 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 may be polyurethane, polyisocyanurate, or the like.

[0059] Then, as shown in FIG. 8B, the first cover 21 is removed after molding, 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 a release layer formed thereon, 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 cavities having shapes corresponding to the first cover 21 and the second cover 22.

[0061] Then, the second cover 22 is molded from a resin material containing no foaming agent at a low temperature of about 20 to 30°C (second step). The resin material used is polyurethane, polyisocyanurate, or the like, similar to that used for the first cover. This second step results in the enclosure 1 in which the first cover 21 and the second cover 22 are joined together.

[0062] The effects of the present embodiment described above are as follows. Since the second cover is molded on the first cover 21 after it has been molded without forming a release layer, the first cover 21 and the second cover 22 can be firmly bonded together. This prevents the bonded portion from peeling and suppresses the generation of contact noise between the first cover 21 and the second cover 22. Because the first cover 21 and the second cover 22 are bonded together, the first cover 21 can absorb and dampen 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 in which nitrogen or carbon dioxide is blown into the resin material during kneading, without using a foaming agent. In this case, when molding the second cover 22, nitrogen or carbon dioxide is not blown into the resin during kneading.

[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, and includes 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] The first cover is molded after the second cover is molded, with the second cover placed in the mold. This allows for easy molding of a first cover having an outer surface shaped to correspond to the inner surface of the second cover. Alternatively, the second cover is molded after the first cover is molded, with the first cover placed in the mold. This allows for easy molding of a second cover having an inner surface shaped to correspond to the outer surface of the first cover. Since the second cover is provided to accommodate the first cover, sound generated by the compressor is converted to thermal energy and attenuated as it propagates through the first cover. The second cover, which has a higher density than the first cover, then reflects the sound to the interior. The reflected sound is further attenuated by the first cover. This allows for reduced transmission of compressor sound outside the enclosure by the low-density first cover and the high-density second cover. The first cover may be made of a material rigid enough to bend under its own weight, such as a foamed resin material (e.g., soft PUR foam) made from 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 a plastic material such as PP (polypropylene) or PBT (polybutylene terephthalate), or a hard resin material that does not foam or foams 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 is the same as in the first aspect, and includes a step of removing a surface layer of the inner and / or 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 method for manufacturing a compressor enclosure according to the 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 vibration propagation from the first cover to the second cover. Furthermore, sound waves are reflected and attenuated at the boundary between the first cover and the second cover, reducing sound propagation 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 method for manufacturing a compressor enclosure according to the third aspect, wherein the thickness of the release layer corresponds to the 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 corresponding to the gap between the first cover and the second cover when the cover is attached to the compressor. This allows a desired gap to be formed 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 transmission from the first cover to the second cover.

[0074] According to a fifth aspect of the present disclosure, in the method for manufacturing a compressor enclosure of 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 or second cover during the second process. This allows the molded portion corresponding to the holes to become a connecting portion, connecting the first and second covers. In particular, when the resin material for the second cover flows into the surface of the first cover and is molded, the resin material fills the numerous depressions on the surface, resulting in a stronger mechanical bond. The multiple connecting portions create a space between the first and second covers, reducing vibration transmission from the first cover to the second cover.

[0076] In the method for manufacturing 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 can suppress the generation of contact noise between the first cover and the second cover due to the bonded portion peeling off. By bonding the first cover and the second cover together, the first cover can absorb and dampen vibrations from 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 step and the second step use the same resin material and change the molding temperature depending on the first cover and the second cover to be molded.

[0079] Because the same resin material is used, chemical bonding strength can also be added when the first cover and the second cover are joined. When the same resin material is used, a low-density first cover and a high-density second cover can be molded by changing the molding temperature. For example, when polyurethane or polyisocyanurate is used as the resin material and azodicarbonamide, carbonate, or bicarbonate is used 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 approximately 20 to 30°C.

[0080] DESCRIPTION OF SYMBOLS 1 Enclosure (enclosure for compressor) 2 Compressor 2A Compression section 2B Motor section (electric motor section) 3 Mounting leg section 5 Discharge port (extension section) 7 Intake port (extension section) 9 Wiring guide tube (extension section) 10 Main body section 10A, 10B Divided body 11 First connection section 12 Second connection section 14 Sealing material 21 First cover 21a Skin layer 21b Core layer 21c Foamed surface 22 Second cover 30, 40, 50 Mold 31, 41, 51 Upper mold 32, 42, 52 Lower mold 33a, 43a, 53a First shim 33b, 43b, 53b Second shim 33c, 43c, 53c Third shim 34a, 44a, 54a First divided mold 34b, 44b, 54b Second divided mold 34c, 44c, 54c Third divided mold 34d Fourth divided mold 36, 46 Release layer P Divided surface

Claims

1. A method for manufacturing an enclosure for a compressor comprising: 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 method comprising: 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.

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

3. A method for manufacturing a compressor enclosure as claimed in claim 1 or 2, further comprising forming a release layer on the second cover or the first cover after molding and placed in a mold, prior to the second step.

4. A method for manufacturing a compressor enclosure as set forth in claim 3, wherein the thickness of the release layer corresponds to the gap between the first cover and the second cover when the cover 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. A method for manufacturing a compressor enclosure as claimed in claim 1 or 2, wherein the first and second steps use the same resin material and the molding temperature is changed depending on the first cover and the second cover to be molded.

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