Orbiting Scroll Member Hardness via Preliminary Casting

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Solution Overview

Problem

Conventional methods for manufacturing scroll members, such as cast iron for scroll compressors, result in portions with low heat capacity and hardness, leading to wear and deformation when the compression mechanism is driven, as the spiraling formation with low thickness is prone to cooling and stress concentration.

Innovation Solution

A method involving the formation of cast iron with specific dimensions and shapes, including increased thickness in stress-concentrated areas and a spiraling part design that maintains higher heat capacity and hardness, achieved through semi-molten die casting and precise cutting techniques to enhance the scroll member's durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the cast iron is formed into the same shape as the finished products of scroll members, then the manufacturing process is simple, but the hardness cannot be increased in the spiraling part with low thickness

Engineering Contradiction:
Improvemanufacturing process simplicityVSAvoidhardness of spiraling part
Core Design Contradiction:
Ease of manufactureVSStrength

Solution Approach 1:

The patent applies preliminary action by forming the cast iron with a thickness greater than the final required thickness before machining. This allows the spiraling part to be pre-formed with sufficient material to achieve the desired hardness through heat treatment, while still enabling the final product to have the correct thin profile after cutting. The preliminary formation of the casting with excessive thickness resolves the contradiction by providing raw material flexibility without complicating the overall manufacturing process.

Inventive Principle:
Principle #10Preliminary action

2Strength

If the thickness of the spiraling part is increased to increase strength, then the hardness and wear resistance improve, but the size of the compression mechanism is increased

Engineering Contradiction:
Improvehardness and wear resistanceVSAvoidsize of compression mechanism
Core Design Contradiction:
StrengthVSLength of moving object

Solution Approach 1:

The patent applies local quality by concentrating the increased thickness specifically in the spiraling part where it is most needed for wear resistance and hardness, while maintaining the overall compact size of the compression mechanism. The casting is designed with localized thickness variation - thicker in the spiraling compression area and thinner in other regions - allowing strength enhancement without proportionally increasing the entire mechanism size. This localized approach resolves the contradiction by providing targeted reinforcement rather than uniform thickening.

Inventive Principle:
Principle #3Local quality

3Productivity

If the cast iron is formed into the same shape as the finished products, then the manufacturing steps are reduced, but the portion with low heat capacity is easy to cool and suffers wear or deformation

Engineering Contradiction:
Improvemanufacturing efficiencyVSAvoidwear and deformation resistance
Core Design Contradiction:
ProductivityVSReliability

Solution Approach 1:

The patent applies preliminary action by creating a casting with excessive thickness before the final machining step. This preliminary formation allows the spiraling part to have sufficient heat capacity and hardness during the cooling phase, preventing wear and deformation. The final thin profile is achieved through cutting after the hardness has been established, maintaining manufacturing efficiency while ensuring reliability. The preliminary thick formation resolves the contradiction by decoupling the heat capacity requirement from the final dimensional requirement.

Inventive Principle:
Principle #10Preliminary action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The method effectively increases the hardness and resistance to wear and deformation of the scroll member, reducing the risk of failure and maintaining the size of the compression mechanism while improving machining ease and heat resistance.

Implementation Method 1

the cast iron is formed by semi-molten die casting in step (a)

Methodology Applied
Scientific EffectSemi-molten die casting: Melting

Data Source

PatentEP2143950B1Scroll member, method of producing the scroll member, compression mechanism, and scroll compressor
Publication Date: 2019.10.02 DAIKIN INDUSTRIES LTD
  • EP2143950B1 patent drawingFigure 1
  • EP2143950B1 patent drawingFigure 2
  • EP2143950B1 patent drawingFigure 3

AI summary

An object of this invention is to reduce wear and deformation in a scroll member. A method for manufacturing an orbiting scroll includes a step (a) and a step (b). In step (a), cast iron is formed and an iron casting (261) is obtained. In step (b), the iron casting (261) obtained in step (a) is cut and an orbiting scroll is obtained. The iron casting (261) obtained in step (a) has a fixing part (261a) and a spiraling part (261b). The spiraling part (261b) is fixed to the fixing part (261a), and extends in a spiraling formation around a center (9). A dimension of a specified portion of the spiraling part (261b) is greater than the dimension of the same portion after step (b) is performed. Specifically, in a portion (2612) of an end (2611) at the center (9) of the spiral, a thickness (d1) is greater than a thickness (h1) of the portion (2612) after step (b) is performed.