U.S. patent application number 09/951149 was filed with the patent office on 2002-03-14 for variable displacement compressors.
Invention is credited to Hiramatsu, Osamu, Iida, Hidenori, Inoue, Yoshinori, Kawaguchi, Masahiro, Narukawa, Kiyoshi, Ota, Masaki, Sawa, Takenori, Tanaka, Hirohiko, Tarutani, Tomoji, Usui, Naoki.
Application Number | 20020031433 09/951149 |
Document ID | / |
Family ID | 26599949 |
Filed Date | 2002-03-14 |
United States Patent
Application |
20020031433 |
Kind Code |
A1 |
Sawa, Takenori ; et
al. |
March 14, 2002 |
Variable displacement compressors
Abstract
Variable displacement compressor may include a swash plate
inclinably coupled to a drive shaft. A piston may be disposed
within a cylinder bore and an end portion of the piston may be
connected to a peripheral edge of the swash plate by a shoe. The
piston preferably reciprocates within the cylinder bore in order to
compress a refrigerant in response to rotation of the inclined
swash plate. The inclination angle of the swash plate can be
changed to change the compressor output discharge capacity. A rotor
is preferably coupled to the drive shaft so that the rotor rotates
together with the rotating drive shaft. A hinge mechanism connects
the swash plate with the rotor by means of a guide on a rotary disk
of the rotor. The hinge mechanism transmits torque from the drive
shaft to the swash plate regardless of the inclination angle of the
swash plate. The rotor preferably includes a set of functional
parts defined by a rotary disk, a guide disposed on the rotary disk
and a weight disposed on the rotary disk to adjust the weight
balance of the rotating rotor. At least one of the functional parts
is formed by pressing and punching a metal plate. In addition or in
the alternative, two or more of the functional parts may be
integrally and seamlessly manufactured by pressing and punching a
metal plate.
Inventors: |
Sawa, Takenori; (Kariya-shi,
JP) ; Kawaguchi, Masahiro; (Kariya-shi, JP) ;
Ota, Masaki; (Kariya-shi, JP) ; Hiramatsu, Osamu;
(Kariya-shi, JP) ; Tanaka, Hirohiko; (Kariya-shi,
JP) ; Usui, Naoki; (Kariya-shi, JP) ; Inoue,
Yoshinori; (Kariya-shi, JP) ; Narukawa, Kiyoshi;
(Kariya-shi, JP) ; Tarutani, Tomoji; (Kariya-shi,
JP) ; Iida, Hidenori; (Kariya-shi, JP) |
Correspondence
Address: |
MORGAN & FINNEGAN, L.L.P.
345 Park Avenue
New York
NY
10154
US
|
Family ID: |
26599949 |
Appl. No.: |
09/951149 |
Filed: |
September 13, 2001 |
Current U.S.
Class: |
417/222.2 |
Current CPC
Class: |
F04B 27/1072
20130101 |
Class at
Publication: |
417/222.2 |
International
Class: |
F04B 001/26 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 14, 2000 |
JP |
2000-279066 |
May 28, 2001 |
JP |
2001-159355 |
Claims
1. A variable displacement compressor comprising: a drive shaft, a
swash plate inclinably coupled to the drive shaft, a piston
disposed within a cylinder bore, an end portion of the piston
connected to a peripheral edge of the swash plate by a shoe, the
piston reciprocating within the cylinder bore to compress the
refrigerant in response to rotation of the inclined swash plate,
wherein the inclination angle of the swash plate can be changed to
change the compressor output discharge capacity, a rotor coupled to
the drive shaft, wherein the rotor rotates together with the
rotating drive shaft, the rotor includes functional parts defined
by a rotary disk, a guide disposed on the rotary disk and a weight
disposed on the rotary disk to regulate the weight balance of the
rotating rotor, at least one of the functional parts is formed by
pressing a plate and a hinge mechanism connecting the swash plate
with the rotor by means of the guide on the rotary disk of the
rotor, the hinge mechanism transmitting torque from the driving
shaft to the swash plate regardless of the inclination angle of the
swash plate.
2. A variable displacement compressor according to claim 1, wherein
each functional part is separately manufactured by pressing and
punching a plate.
3. A variable displacement compressor comprising: a drive shaft, a
swash plate inclinably coupled to the drive shaft, a piston
disposed within a cylinder bore, an end portion of the piston
connected to a peripheral edge of the swash plate by a shoe, the
piston reciprocating within the cylinder bore to compress the
refrigerant in response to rotation of the inclined swash plate,
wherein the inclination angle of the swash plate can be changed to
change the compressor output discharge capacity, a rotor coupled to
the drive shaft, wherein the rotor rotates together with the
rotating drive shaft, the rotor includes functional parts defined
by a rotary disk, a guide disposed on the rotary disk and a weight
disposed on the rotary disk to adjust the weight balance of the
rotating rotor and wherein at least two of the functional parts are
integrally and seamlessly manufactured by pressing and punching a
plate, a hinge mechanism connecting the swash plate with the rotor
by means of the guide on the rotary disk of the rotor, the hinge
mechanism transmitting torque from the driving shaft to the swash
plate regardless of the inclination angle of the swash plate.
4. A variable displacement compressor according to claim 3, wherein
the rotary disk and the weight are integrally and seamlessly
manufactured by pressing and punching a plate.
5. A variable displacement compressor according to claim 3, wherein
the weight and the guide are integrally and seamlessly manufactured
by pressing and punching a plate.
6. A variable displacement compressor comprising: a drive shaft, a
swash plate inclinably coupled to the drive shaft, a piston
disposed within a cylinder bore, an end portion of the piston
connected to a peripheral edge of the swash plate by a shoe, the
piston reciprocating within the cylinder bore to compress the
refrigerant in response to rotation of the inclined swash plate,
wherein the inclination angle of the swash plate can be changed to
change the compressor output discharge capacity, a rotor that
includes a rotary disk rotatably coupled to the drive shaft and a
hinge mechanism that includes a guide member and a guide protrusion
that receives the guide member, the hinge mechanism connecting the
swash plate with the rotor to transmit torque from the driving
shaft to the swash plate by means of the guide member engaged with
the guide protrusion regardless of the inclination angle of the
swash plate, wherein at least one of the guide member and the guide
protrusion is manufactured independent from the rotary disk and is
then integrally joined to the rotary disk.
7. A variable displacement compressor according to claim 6, wherein
the rotary disk is manufactured by pressing and punching a
plate.
8. A variable displacement compressor according to claim 6, wherein
the guide is manufactured by pressing and punching a plate.
9. A variable displacement compressor according to claim 6 further
comprising a thrust bearing that includes a roller to rotatably
support the rotor, wherein the thrust bearing is provided between
the inner surface of the compressor housing and the rotor and the
roller directly contacts the front surface of the rotor.
10. A method of manufacturing a variable displacement compressor
according to claim 1 comprising: pressing and punching a metal
plate in order to form at least one functional part, wherein the
functional parts are then joined in order to form the rotor.
11. A method of manufacturing a variable displacement compressor
according to claim 2 comprising: separately pressing and punching a
plurality of metal plates in order to form the functional part,
wherein the functional parts are then joined in order to form the
rotor.
12. A method of manufacturing a variable displacement compressor
according to claim 3, wherein at least two functional parts are
integrally and seamlessly manufactured using at least two types of
manufacturing processes defined by pressing and punching a
plate.
13. A method according to claim 12, wherein the rotary disk and the
weight are integrally and seamlessly manufactured.
14. A method according to claim 12, wherein the weight and the
guide are integrally and seamlessly manufactured.
15. A method for manufacturing a compressor comprising: forming a
rotary disk by pressing a metal plate W to a thickness
corresponding the final thickness of the rotary disk, punching the
metal plate to form an intermediate disk part and then deeply
drawing the intermediate disk part to form the rotary disk, and
assembling the rotary disk with a guide member and a weight on a
drive shaft of the compressor.
16. A method for manufacturing a compressor comprising: forming a
guide member by pressing a metal plate W to a thickness
corresponding the final thickness of the guide member, punching the
metal plate to form an intermediate guide part and then bending the
intermediate guide part to form the guide member, and assembling
the guide member with a rotary disk and a weight on a drive shaft
of the compressor.
17. A method for manufacturing a compressor comprising: forming a
balancing weight by pressing a metal plate W to a thickness
corresponding the final thickness of the rotary disk, punching the
metal plate to form the balancing weight, and assembling the
balancing weight with a rotary disk and a guide member on a drive
shaft of the compressor.
18. A method as in claim 17, wherein the balancing weight is
integrally and seamlessly manufactured with the rotary disk by
pressing and punching the metal plate to form an intermediate disk
part and then bending and drawing the intermediate disk part to
form the balancing weight and the rotary disk.
19. A method as in claim 18, further comprising forming link parts
by bending the intermediate disk part.
20. A method as in claim 17, wherein the balancing weight is
integrally and seamlessly manufactured with the guide member by
pressing and punching the metal plate to form an intermediate disk
part and then bending and drawing the intermediate disk part to
form the balancing weight and the guide member.
21. A method according to claim 15, wherein the metal plate is
cold-rolled steel plate or carbon steel, such as S35C or S45C.
22. A method according to claim 16, wherein the metal plate is
cold-rolled steel plate or carbon steel, such as S35C or S45C.
23. A method according to claim 17, wherein the metal plate is
cold-rolled steel plate or carbon steel, such as S35C or S45C.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The present invention relates to variable displacement
compressors that utilize a rotating swash plate to the output
discharge capacity of a compressed refrigerant. More particular,
the present invention relates to compressors that may rotate the
swash plate using a relatively simple and lightweight structure and
to methods for making such compressors. Such compressors may be
utilized in air conditioning systems and more preferably in
automobile air conditioning systems.
[0003] 2. Description of the Related Art
[0004] One type of variable displacement compressor is described in
Japanese Laid-open Patent Publication No. 11-264371. This known
variable displacement compressor is reproduced herein in FIG. 15
and includes a swash plate 104 coupled to a driving shaft 102 that
is disposed within a driving chamber 101b. A compressor front
housing 101 encloses the swash plate 104 and pistons 105 are
slidably supported within respective cylinder bores 101a provided
within a cylinder block 106. A shoe 110 engages the end portion of
each piston 105 with the swash plate 104. A hinge mechanism 107
inclinably and slidably coupled the swash plate 104 to a rotor
103.
[0005] The rotor 103 is also coupled to the driving shaft 102. When
the pressure within the driving chamber 101b increases or decreases
in order to change the inclination angle of the swash plate 104,
the length of the piston stroke is changed in response to the
change of the inclination angle of the swash plate 104. As the
result, the compressor output discharge capacity changes. The hinge
mechanism 107 includes a guide 109 and a guide protrusion 108. The
guide 109 is provided on the rotor 103 and has a guide hole 109a.
The guide protrusion 108 is provided on the swash plate 104 and has
a guide pin 108a. The guide pin 108a is slidably engaged with the
guide hole 109a. Further, a thrust bearing 112 is disposed between
the rotor 103 and the front housing 101.
[0006] The rotor 103 also includes a rotary disk 103a. A weight 111
is disposed on the rotary disk 103 to adjust the weight balance of
the rotor 103. Also, the guide 109 is disposed on the rotary disk
103. The weight 111 and the guide 109 are molded by simultaneously
casting these parts together with the rotary disk 103. The rotor
103 and hinge mechanism 107 rotate together with the drive shaft
102. Thus, the rotor 103 and hinge mechanism 107 are required to be
relatively light in view of the centrifugal force exerted to the
rotor 103 and hinge mechanism 107 due to the rotation together with
the drive shaft 102. On the other hand, because it is relatively
difficult to mold a complicated and thin shape using casting
techniques, it has been difficult to reduce the weight of the rotor
103 and the hinge mechanism 107 using the known art.
SUMMARY OF THE INVENTION
[0007] It is, therefore, an object of the present invention to
provide variable displacement compressors that may utilize lighter
weight parts for the torque transmitting structure disposed between
the drive shaft and the swash plate. Methods of making such lighter
weight parts are also described.
[0008] According to the present teachings, the functional parts of
the rotor, such as the rotary disk, the guide and the weight may
preferably be manufactured by pressing and punching a piece of
plate metal. Each functional part may be separately manufactured in
this manner or two or more parts may be preferably manufactured in
an integral or seamless manner using these techniques.
[0009] Because the functional part(s) may be manufactured by
pressing a plate, the thickness of the rotor can be reduced, as
compared to known manufacturing techniques, without reducing the
strength or integrity of the rotor. Thus, the weight of the torque
transmitting structure between the drive shaft and the swash plate
can be reduced. Preferably, the functional part(s) actually have
greater strength and integrity than rotors manufactured using known
techniques.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 shows a variable displacement compressor according to
the first representative embodiment.
[0011] FIG. 2 shows the torque transmitting structure of the first
representative embodiment.
[0012] FIG. 3 schematically shows the hinge mechanism.
[0013] FIG. 4 shows a perspective view of the rotor.
[0014] FIG. 5(A) to FIG. 5(C) show a representative process for
manufacturing the rotary disk by pressing a plate.
[0015] FIG. 6(A) to FIG. 6(C) show a representative process for
manufacturing the guide by pressing a plate.
[0016] FIG. 7(A) and FIG. 7(B) show a representative process for
manufacturing the weight by pressing a plate.
[0017] FIG. 8 shows the torque transmitting structure according to
the second representative embodiment.
[0018] FIG. 9 shows the torque transmitting structure according to
the third representative embodiment.
[0019] FIG. 10 shows a perspective view of the rotor manufactured
using a press.
[0020] FIG. 11(A) to FIG. 11(C) show a representative process for
manufacturing the rotary disk together with the weight.
[0021] FIG. 12(A) to FIG. 12(C) show a representative process for
manufacturing the guide.
[0022] FIG. 13 shows a perspective view of the rotor manufactured
by pressing a plate according to the third embodiment.
[0023] FIG. 14(A) to FIG. 14(C) show a representative process for
manufacturing the guide by pressing a plate.
[0024] FIG. 15 shows the torque transmitting structure according to
a known variable displacement compressor.
DETAILED DESCRIPTION OF THE INVENTION
[0025] Representative variable displacement compressors according
to the present teachings may include a drive shaft, a swash plate,
a piston, a rotor and a hinge mechanism. The swash plate may be
inclinably coupled to the drive shaft. The piston may be disposed
within a cylinder bore and the end portion of the piston may be
connected to a peripheral edge of the swash plate by utilizing a
shoe. The piston can reciprocate within the cylinder bore to
compress the refrigerant in response to rotation of the inclined
swash plate. The inclination angle of the swash plate can be
changed. When the inclination angle is changed, the compressor
output discharge capacity can be changed. The rotor may be coupled
to the drive shaft and the rotor may rotate together with the
rotating drive shaft.
[0026] The rotor may include functional parts, such as a rotary
disk, a guide disposed on the rotary disk and a weight disposed on
the rotary disk. The weight may be utilized to adjust the weight
balance of the rotating rotor. According to the present teachings,
at least one of the functional parts can be formed by pressing and
punching a plate of metal. The hinge mechanism may connect the
swash plate with the rotor by means of the guide on the rotary disk
of the rotor.
[0027] The hinge mechanism transmits torque from the driving shaft
to the swash plate, regardless of the inclination angle of the
swash plate. Because at least one of the functional parts is
manufactured by pressing and punching a plate, the thickness of the
rotor can be reduced and the weight of the torque transmitting
structure between the drive shaft and the swash plate can be
reduced.
[0028] Although each functional part may be separately manufacture
by pressing and punching a plate, any two of the functional parts
may be integrally or seamlessly manufactured by pressing and
punching a plate. For example, the rotary disk and the weight, or
the weight and the guide may be integrally manufactured by pressing
and punching a plate.
[0029] According to the another aspect of the present teachings, a
hinge mechanism may connect the swash plate with the rotor in order
to transmit torque from the driving shaft to the swash plate. For
example, a guide member may be engaged with a guide protrusion.
Moreover, either the guide member or the guide protrusion may
preferably be manufactured independent from the rotary disk and may
then be integrally joined to the rotary disk. Preferably, the
rotary disk and/or the guide may be manufactured by pressing and
punching a plate in order to reduce the weight of the torque
transmitting structure.
[0030] Each of the additional features and method steps disclosed
above and below may be utilized separately or in conjunction with
other features and method steps to provide improved variable
displacement compressors and air conditioning systems and methods
for making and using such variable displacement compressors and air
conditioning systems. Representative examples of the present
invention, which examples utilize many of these additional features
and method steps in conjunction, will now be described in detail
with reference to the drawings. This detailed description is merely
intended to teach a person of skill in the art further details for
practicing preferred aspects of the present teachings and is not
intended to limit the scope of the invention. Only the claims
define the scope of the claimed invention. Therefore, combinations
of features and steps disclosed in the following detail description
may not be necessary to practice the invention in the broadest
sense, and are instead taught merely to particularly describe some
representative examples of the invention, which detailed
description will now be given with reference to the accompanying
drawings.
[0031] Although the following detailed representative embodiments
are preferably utilized in an air conditioning system for an
automotive, other uses of the present teachings are naturally
contemplated.
[0032] The first representative embodiment will now be described in
further detail with reference to FIGS. 1 to 7. As shown in FIG. 1,
the representative compressor 1a includes a compressor housing
defined by a front housing 1, a cylinder block 2 and a rear housing
3. The front housing 1 is coupled to the front end of the cylinder
block 2. The rear housing 3 is coupled to the rear end of the
cylinder block 2. A valve plate 4 is provided between the cylinder
block 2 and the rear housing 3.
[0033] A crank chamber 5 is defined by a space within the front
housing 1. A drive shaft 6 is rotatably supported within the crank
chamber 5. Although it is not particularly shown in the drawings,
the drive shaft 6 is preferably connected to an automotive engine
by an electromagnetic clutch. That is, the engine causes the drive
shaft 6 to rotate when clutch mechanism couples the driving force
of the engine to the drive shaft 6.
[0034] Within the crank chamber 5, a rotating swash plate 8 is
inclinably and slidably coupled to the drive shaft 6 via a rotor 7.
The rotor 7 is coupled to the drive shaft 6 and can rotate together
with the drive shaft 6. The drive shaft 6 extends through a
penetration hole 8a formed in the center of the swash plate 8. A
hinge mechanism 20 is provided between the rotor 7 and the swash
plate 8 in order to transmit torque from the drive shaft 6 to the
swash plate 8, which swash plate 8 may rotate at various
inclination angles.
[0035] In order to allow the swash plate 8 to incline, the
penetration hole 8a preferably has a support point 8b. The hinge
mechanism 20 preferably includes a guide member 23 disposed on the
rotor 7 and a guide pin 9 disposed on the swash plate 8. The guide
member 23 corresponds to a "rotor-side member". The guide member 23
and the guide pin 9 are mutually engaged to connect the swash plate
8 with the rotor 7.
[0036] The cylinder block 2 preferably includes six cylinder bores
2a that are disposed in six pistons 11. However, FIG. 1 only shows
one piston for purposes of illustration. Each piston 11 is
reciprocally and slidably supported each cylinder bore 2a. The
piston 11 is coupled to the swash plate 8 via a shoe 12. The
rotational movement of the swash plate 8 is converted into
reciprocating movement of the pistons 11 via the shoe 12.
[0037] A suction chamber 3a and a discharge chamber 3b are
respectively defined by spaces within the rear housing 3. A suction
port 4a, a suction valve 4b, a discharge port 4c, and a discharge
valve 4d are preferably disposed on the valve plate 4. When the
piston 11 reciprocates, refrigerant in the suction chamber 3a is
drawn into the cylinder bore 2a from the suction port 4a via the
suction valve 4b. Then, the refrigerant is compressed and the
compressed refrigerant is discharged from the discharge port 4c to
the discharge chamber 3b via the discharge valve 4d.
[0038] The crank chamber 5 preferably communicates with the
discharge chamber 3b via a capacity control passage 16. The
capacity control passage 16 is opened and closed by a capacity
control valve 17. The pressure state within the crank chamber 5 is
controlled by opening and closing the capacity control passage 16.
In addition, a bleeding passage 15 preferably connects the crank
chamber 5 and the suction chamber 3a.
[0039] As shown in FIG. 4, the rotor 7 preferably includes
functional parts, such as a rotary disk 22 coupled to the drive
shaft 6, the guide member 23 and a weight 24. As described above,
the guide member 23 and the guide pin 9 together define the hinge
mechanism 20. The weight 24 offsets any weight imbalance of the
rotor 7 caused by the guide member 23 when the rotor rotates
together with the drive shaft 6. In this representative embodiment,
each functional part is formed independently of the others. As
shown in FIG. 2, the rotary disk 22 has a disk-like shape and an
insertion hole 22a is defined substantially in the center of the
rotary disk 22. Further, the rotary disk 22 is mounted to the drive
shaft 6 by inserting the drive shaft 6 into the insertion hole 22a.
The insertion hole 22a is formed in a tube-like shape that extends
toward the rear of the rotary disk 22 along the drive shaft 6. A
thrust bearing 25 is disposed between the front face of the rotary
disk 22 and the front housing 1, which thrust bearing 25
circumferentially surrounds the drive shaft 6. In addition, the
thrust bearing 25 preferably includes a roller 25a that directly
contacts the rotary disk 22. Thus, the compressive reaction force
generated by the reciprocation of the pistons 11 is received by the
front housing 1 through the shoe 12, the swash plate 8, the hinge
mechanism 20, and the thrust bearing 25.
[0040] As shown in FIG. 2, the guide member 23 is fixed to the rear
face of the rotary disk 22 in order to correspond to the upper dead
point D of the swash plate 8. The upper dead point of the swash
plate 8 defines the top clearance of the pistons 11. FIG. 3 shows a
plan view of the hinge mechanism 20, in which each end of the guide
member 23 substantially has a curved shape that defines a support
23a for receiving the guide pin 9. Further, the guide member 23 has
a plane that defines a connecting portion 23b that affixes the
guide member 23 to the rotary disk 22. The central axis S of the
support 23a extends parallel to the plane that includes the
rotational axis L of the drive shaft 6 and the position
corresponding to the upper dead point D of the swash plate 8. The
guide member 23 is fixed to the rotary disk 22 by spot welding at a
plurality points.
[0041] As shown in FIG. 2, the weight 24 is fixed to the bottom
part on the rear face of the rotary disc 22. Because the guide
member 23 is fixed to the rotor 7, the center of gravity of the
rotor 7 is shifted from the rotational axis L of the drive shaft 6.
In order to rectify this weight imbalance, the weight 24 is
provided on the lower rear edge of the rotor 7 at a position that
is opposite to the guide member 23. Thus, the center of gravity of
the rotor 7 is adjusted to correspond to the axis of rotation
defined by the axis L of the drive shaft 6. In this embodiment, the
weight 24 is preferably fixed to the rotary disk 22 by spot
welding, although other attaching methods may naturally be
utilized.
[0042] As shown in FIG. 4, the rotary disk 22, the guide member 23,
and the weight 24 are manufactured independently of one another and
then, joined together to form the rotor 7. Therefore, each part can
be made of a different material that may be appropriate for the
particular application, and each part can be manufactured
differently in order to provide optimal properties for each of the
functional parts. Representative manufacturing methods for each
functional part of the rotor 7 are respectively shown in FIGS. 5 to
7. For example, FIG. 5(A) to FIG. 5(C) show a representative
manufacturing process for the rotary disk 22. In order to make the
rotary disk 22, a plate W is first prepared by pressing a
cold-rolled steel plate or carbon steel, such as S35C or S45C, into
an appropriate thickness (see FIG. 5(A)). Then, the plate W is
punched with an appropriate cutting device, e.g. a die, in order to
form a disk Al having a circular insertion hole defined in the
center of the disk Al (see FIG. 5(B)). Thereafter, the rotary disk
22 is manufactured by deeply drawing the disk Al (see FIG.
5(C)).
[0043] FIGS. 6(A) to FIG. 6(C) show a representative manufacturing
process for the guide member 23. First, a plate W is prepared by
pressing a cold-rolled steel plate or carbon steel, such as S35C or
S45C, to an appropriate thickness (see FIG. 6(A)). Then, the plate
W is punched to form a rectangular plate B1 (see FIG. 6(B)).
Thereafter, the guide member 23 is manufactured by utilizing a
bending machine (see FIG. 6(C)). FIGS. 7(A) and (B) show a
representative manufacturing process for the weight 24. As with the
previous representative techniques, a plate W is pressed to an
appropriate thickness (see FIG. 7(A)) and then the plate W is
punched provide the weight 24 having a semicircular shape (see FIG.
7(B)).
[0044] After the above-described manufacturing process, any
distortions are removed from the supports 23a and the supports 23a
are surface-treated with induction hardening in order to improve
the strength and wear-resistance of the supports 23a. Similarly, a
thrust bearing receiver 22c of the rotary disk 22 is
surface-treated with induction hardening. Because each functional
part of the rotor 7 is individually manufactured, such
surface-treating process can be easily performed. After the
manufacturing process is completed, the guide member 23 and the
weight 24 are welded to the rotary disk 22 (see FIG. 4) in order to
provide the rotor 7.
[0045] The guide pin 9 corresponds to a "guide protrusion" as
utilized herein. As shown in FIG. 2, a pair of guide pins 9
protrudes from the front face of the swash plate 8 toward the guide
member 23. The guide pins 9 straddle the position corresponding to
the upper dead point D of the swash plate 8. A spherical portion 9a
is formed on the top of each guide pin 9. The spherical portion 9a
is inserted into and engaged with the guide member 23. The radius
of curvature of the spherical portion 9a is slightly less than the
radius of curvature of the support 23a. Thus, the swash plate 8 can
slide while inclining toward the drive shaft 6 in the direction of
the axis L of the drive shaft 6, due to the slide-guide
relationship between the spherical portions 9a of the guide pins 9
and the supports 23a of the guide member 23, as well as due to the
slide-support action by the drive shaft 6 by way of the insertion
hole 8a.
[0046] In the first representative embodiment, the rotary disk 22,
the rotor-side member 23, and the weight 24 are independently
manufactured and each functional part is manufactured with a press
and a punch. Therefore, each part may be hardened and lightened.
Further, the thickness of the rotor can be reduced as compared to
known rotors.
[0047] Because the rotary disk 22 is manufactured with a press,
material having high wear resistance can be utilized for the rotary
disk 22. Therefore, the roller 25a of the thrust bearing 25 can
directly contact the rotary disk 22 during operation of the
compressor. In other words, because it is not necessary to provide
a race with the thrust bearing 25, a reduction in the number of
parts can be achieved.
[0048] The second representative embodiment is shown in FIG. 8, in
which the rotary disk 22 and the weight 22d are integrally formed
as one part. That is, rotary disk 22 and the weight 22d are
manufactured at the same time using a press machine and there are
no seams between the rotary disk 22 and the weight 22d. As the
result, the weight 22d is formed in a unitary manner on the lower
rear face of the rotary disk 22.
[0049] In addition, a different type of the hinge mechanism is
utilized in the second representative embodiment. In this case, the
guide member 23 has a plate-like shape and includes an elongated
hole 26. The swash plate 8 includes a pin 27 that is engaged in the
elongated hole 26. As the result, the hinge mechanism is defined by
a link-and-pin mechanism. All other features of the second
representative embodiment are substantially identical to the
corresponding features of the first representative embodiment.
According to the second representative embodiment, because the
functional parts of the rotor 7 are integrally (seamlessly)
manufactured at the same time using a press, the number of parts of
the torque transmitting structure can be reduced.
[0050] The third representative embodiment is shown in FIGS. 9 to
13. As shown in FIGS. 9 and 10, the rotary disk 22 and the weight
22d are manufactured at the same time using a press in the second
representative embodiment. The weight 22d is provided on the outer
circumference of the lower rear face of the rotary disk 22. As
described above, the weight 22d can correct the weight imbalance of
the rotor 7 when the hinge mechanism 20 rotates together with the
drive shaft 6.
[0051] In the third embodiment, a link-type hinge mechanism 20 is
utilized. As shown in FIG. 10, an insertion hole 23c is defined
within the guide member 23 and link parts 23d are disposed on the
right and left sides of the guide member 23. Each link part 23d
includes an elongated hole 26. The inner diameter of the insertion
hole 23c is defined to correspond to the outer circumferential
diameter of a cylindrical boss part 22f of the rotary disk 22. By
inserting the boss part 22f to the insertion hole 23, the guide
member 23 is coupled to the rotary disk 22. As shown in FIG. 9, a
guide pin 27 is provided on the swash plate 8 and is engaged with
the elongated hole 26. All other features of the third
representative embodiment are substantially identical to the
features of the first representative embodiment as described
above.
[0052] A representative manufacturing process for the rotary disk
22 with the weight 22d is shown in FIG. 11(A) to FIG. 11(C). First,
a plate W is prepared by pressing a cold-rolled steel plate or
carbon steel, such as S35C or S45C, into an appropriate thickness
(see FIG. 11(A)). Then, the plate W is punched to form a disk A2
having a circular insertion hole in the center of the disk A2 (see
FIG. 11(B)). Thereafter, the rotary disk 22 with the weight 22d is
manufactured by bending and drawing the disk A2 (see FIG. 11(C)). A
representative manufacturing process for the guide member 23 is
shown in FIG. 12(A) to FIG. 12(C). First, a plate W is prepared by
pressing a cold-rolled steel plate or carbon steel, such as S35C or
S45C, to an appropriate thickness (see FIG. 12(A)). Then, the plate
W is punched to form a disk B2 having a insertion hole formed in
the center of the disk B2 (see FIG. 11(B)). Thereafter, link parts
23d are formed by bending the disk B2 (see FIG. 12(C)). After the
rotary disk 22 and the guide member 23 are independently
manufactured, the guide member 23 is fixed to the rotary disk 22 by
joining the cylindrical boss part 22f of the rotary disk 22 to the
insertion hole 23c of the guide member 23. After the joining, the
guide member 23 is welded to the rotary disk 22.
[0053] A thrust bearing receiving portion 22c (see FIG. 9) and the
inner circumferential surface of the elongated hole 26 are
preferably treated by induction hardening in order to increase the
strength and the wear resistance of these parts. All other features
of the third representative embodiment are substantially identical
to the features of the first representative embodiment as described
above. According to the third representative embodiment, a
relatively lightweight rotor 7 can be easily manufactured.
[0054] The fourth representative embodiment is shown in FIGS. 13
and 14. According to the fourth embodiment, the guide member 23 and
the weight 22d are integrally and seamlessly manufactured using a
press. All other features of the fourth representative embodiment
are substantially identical to the features of the first
representative embodiment as described above.
[0055] A representative manufacturing process for the guide member
23 with the weight 22d is shown in FIG. 14(A) to FIG. 14(C). First,
a plate W is prepared by pressing a cold-rolled steel plate or
carbon steel, such as S35C or S45C, to an appropriate thickness
(see FIG. 11(A)). Then, the plate W is punched to form a disk B3
(see FIG. 14(B)). Thereafter, the guide member 23 with the weight
22d is manufactured by bending and drawing the disk B3 (see FIG.
14(C)). The joining of the guide member 23 (with the weight 22d)
and the rotary disk 22 is completed by welding.
[0056] Various modifications can be made to the representative
embodiments. For example, the support 23a of the guide member 23
may be formed to have a cylindrical shape. Further, the functional
parts of the rotor 7 can be fixed with each other by utilizing a
screw or rivet, instead of welding.
[0057] Moreover, the guide member may be provided with the swash
plate 8. In the alternative, the guide protrusion (guide pin) may
be provided with the rotor 7.
[0058] Further, the functional parts of the rotor 7 may be
integrally and seamlessly manufactured using a press. That is, the
rotary disk, including the guide member and the weight, may be
unitarily manufactured by pressing a plate. Thus, the number of the
steps to manufacture the rotor can be reduced.
* * * * *