Patent Abstract:
The present invention discloses a method for fabricating a semi-hermetic scroll compressor and its structure, especially to the method for fabricating the structure of the semi-hermetic scroll compressor being by way of assembling a plurality of sub-casings with fixing design therein and fewer compressor elements. The method comprise: (1) having a plurality of sub-casings with fixing design, the fixing design being initially configured inside at least one internal surface of the sub-casings; (2) cooperating with the fixing design to compose of at least one fixing device, at least one driving device, at least one compressing device and a partition device in the plural sub-casings; (3) fastening the plural sub-casings together; (4) finishing the method.

Full Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     The present invention generally relates to a method for fabricating a semi-hermetic scroll compressor and its structure, especially to the method for fabricating the structure of the semi-hermetic scroll compressor being by way of assembling a plurality of sub-casings with fixing design therein and fewer compressor elements and providing a function of quality control as well.  
         [0003]     2. Description of the Prior Art  
         [0004]     Please refer to  FIG. 1 , which is a sectional view of a hermetic scroll compressor in prior arts. A casing  10 ′ of the compressor adopts steel to be structured by way of welding. Components inside the casing are piled up, therefore, it is known that the components being installed in the casing  10 ′ shall be in sequence from a bottom of the compressor to a top of the compressor, and then to weld the casing  10 ′ for enclosing.  
         [0005]     As it can be seen in the  FIG. 1 , the components are mainly accumulated in the casing  10 ′ in sequence as a lower bearing  13 ′, a motor stator  16 ′, a motor rotor  17 ′, a drive shaft  18 ′ with an eccentric crank pin  23 ′, an upper counterweight  19 ′, a bearing base  21 ′, a main bearing  14 ′, a lower counterweight  20 ′, an upper bearing  15 ′, a brace  24 ′, an orbiting scroll member  25 ′, a fixed scroll member  26 ′, a partition plate  31 ′, a floating seal  30 ′ and a discharging port  34 ′. A motor base  11 ′, a lubricant tank  12 ′, a boss  22 ′, plural compressing chambers  27 ′,  28 ′ and  29 ′, a high-pressure passage  32 ′, a high-pressure chamber  33 ′ and plural lubricant channels  35 ′ are naturally formed while aforesaid accumulated components being assembled.  
         [0006]     The following will describe in detail for the relationships of the components. Firstly, to offer a lower part of the casing  10 ′, and the motor base  11 ′ and the lubricant tank  12 ′ are initially shaped in the lower part of the casing  10 ′. Then the motor stator  16 ′ and the motor rotor  17 ′ are installed in as a motor part in the compressor. The drive shaft  18 ′ is assembled with the lower bearing  13 ′, the main bearing  14 ′, the upper counterweight  19 ′ and the lower counterweight  20 ′ in the lower part of the casing  10 ′. Of course, the bearing base  21 ′ is put together as well in the step. The brace  24 ′ is fit in for accepting the orbiting scroll member  25 ′ and the fixed scroll member  26 ′ continuously, and therefore the two scroll members being mounted on. Meanwhile, the boss  22 ′ of the orbiting scroll member  25 ′ surround with the eccentric crank pin  23 ′ of the drive shaft  18 ′. Obviously, the orbiting scroll member  25 ′ is driven by the drive shaft  18 ′ via the eccentric crank pin  23 ′, and the structures of the orbiting scroll member  25 ′ and the fixed scroll member  26 ′ are corresponded together to have the plurality of compressing chambers  27 ′,  28 ′ and  29 ′, which achieve high pressure while the orbiting scroll member  25 ′ being in motion to decrease volumes of the compressing chambers. The partition plate  31 ′ is then covered on a top of the lower part of the casing  10 ′ with the floating seal  30 ′. The floating seal  30 ′ functions to prevent leaking, therefore the high-pressure passage  32 ′ is configured and to let compressed high-pressure vapor refrigerant pass through. Finally, to weld an upper part of the casing  10 ′ is to form the high-pressure chamber  33 ′ for containing the high-pressure vapor refrigerant. Meantime the discharging port  34 ′ is mounted also while fixing the upper part of the casing  10 ′. Furthermore, some lubricant channels are configured on relevant components for lubricant going back to the lubricant tank  12 ′ and avoiding to bring lubricant back into the high-pressure chamber  33 ′ via inlet refrigerant. Hence, an important issue is extended, which is that the components are accumulated while in assembly, and how to accurately connect two adjacent components for configuring a lubricant channel or channels is a must for technical consideration.  
         [0007]     Up to now, there are some problems being raised as following since relative relationships among the motor part, including the drive shaft  18 ′, the motor stator  16 ′ and the motor rotor  17 ′, the bearing part, including the lower bearing  13 ′, the main bearing  14 ′ and the upper bearing  15 ′, and others being made, especially an eccentric distance for the eccentric crank pin  23 ′ generated by the scroll structure: 
    1. The components are piled up, and therefore each component with its own precisions of dimensions, locations, etc. must be very accurate. Therefore the time for manufacturing will be longer comparatively.     2. The prior art has only one positioning portion for a stand height, that is, the motor base  11 ′, other components are thus accumulated thereon. Obviously, almost all of the components must be positioned so as to that causing harder and longer assembly.     3. Welding causes high temperature to further affect the dimensional precisions of distances between components, each component and the casing  10 ′. Hence, the quality control is difficult to approach or the clearance between each component should be enlarged to cover the dimensions of each component due to high temperature.     4. All of the components are already in machining before installing, and consequently some places for two or more components accumulated together may be more precise by requests, hence the precision being asked is raised to cause longer assembly time. 
 
 As aforesaid, to develop another type of compressor to solve those problems becomes an important issue in the field. 
   
 
       SUMMARY OF THE INVENTION  
       [0013]     The main objective of the present invention is to offer a method for fabricating a semi-hermetic scroll compressor and its structure to adopt a plurality of suitable portions on several sub-casings of the semi-hermetic scroll compressor for sectional positioning standards. Therefore, firstly the precisions may not be lost while in installment. Logically, the number of components in the semi-hermetic scroll compressor is not as many as prior arts&#39;, and secondly the assembly time is proportional down.  
         [0014]     The other objective of the present invention is to offer a method for fabricating a semi-hermetic scroll compressor and its structure to accept different fastening way for combining the plural sub-casings rather than welding. It is that no more high temperature effect being generated.  
         [0015]     Other and further features, advantages and benefits of the invention will become apparent in the following description taken in conjunction with the following drawings. It is to be understood that the foregoing general description and following detailed description are exemplary and explanatory but are not to be restrictive of the invention. The accompanying drawings are incorporated in and constitute a part of this application and, together with the description, serve to explain the principles of the invention in general terms. Like numerals refer to like parts throughout the disclosure. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0016]     The objects, spirits and advantages of the preferred embodiments of the present invention will be readily understood by the accompanying drawings and detailed descriptions, wherein:  
         [0017]      FIG. 1  is a sectional view of a hermetic scroll compressor in prior arts.  
         [0018]      FIG. 2  is a sectional view of a first preferred embodiment of the present invention.  
         [0019]      FIG. 3  is a sectional view of a second preferred embodiment of the present invention.  
         [0020]      FIG. 4  is a flow chart of a method of the first preferred embodiment of the present invention.  
         [0021]      FIG. 5  is a flow chart of a method of the second preferred embodiment of the present invention.  
         [0022]      FIG. 6  is a top view of a shoulder with continuous of the present invention.  
         [0023]      FIG. 7  is a top view of a shoulder with discontinuous of the present invention.  
         [0024]      FIG. 8  is a sectional view of plural lubricant channels of the first preferred embodiment. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0025]     Referring to  FIG. 2 , which is a sectional view of a first preferred embodiment of the present invention. Normally, the embodiment is divided by two parts, an upper casing  10  and a lower casing  40 , and most of components are installed and configured in the lower casing  40 . There are two designs for originally shaped in the lower casing  40  for installing height standards and bringing lubricant back to where it is from, one is a fixing bearing portion  11  and a fixing bearing base portion  36  of fixing design and another is plural lubricant channels  35  of lubricant design. That is, to help the precisions for positioning being not lost while the components in installment and inlet gas refrigerant being not mixed with lubricant then brought into compressing chambers.  
         [0026]     The structure of the semi-hermetic scroll compressor comprises: a plurality of sub-casings with fixing design and lubricant design, the fixing design and the lubricant design are initially configured on at least one internal surface of the plurality of sub-casings, the sub-casings include the upper casing  10  and the lower casing  40 , the upper casing  10  has a high-pressure chamber  33  of a high-pressure device and a partition plate  31  of a partition device being equipped in the upper casing  10  for separation; the lower casing  40  has the fixing bearing base portion  36  and the fixing bearing portion  11  of the fixing design both being initially configured on an internal surface of the lower casing  40  as standard heights for positioning, the plurality of lubricant channels  35  of the lubricant design being initially configured on the internal surface of the lower casing  40 , an upper bearing  15 , a main bearing  14 , a lower bearing  13 , a brace  24  and a bearing base  21  of a fixing device being equipped in the lower casing  40  and cooperating with the fixing design for positioning, a drive shaft  18 , a motor stator  16  and a motor rotor  17  of a driving device being equipped in the lower casing  40  and positioned by the fixing design and the fixing device, a fixed scroll member  26  and an orbiting scroll member  25  of a compressing device being equipped in the lower casing  40  and positioned by the fixing design and the fixing device, further that, the compressing device being driven by the driving device, and a lubricant tank  12  of a lubricant device, wherein the driving device drives the compressing device to achieve high-pressure vapor refrigerant into the high-pressure chamber  33  separated by the partition plate  31 , the lubricant tank  12  in a bottom of the lower casing  40  pumps some lubricant to lubricate while the driving device being in motion; wherein the structure further include an upper counterweight  19 , a lower counterweight  20  and a discharging port  34 .  
         [0027]     The drive shaft  18  is driven by the motor rotor  17 , thus an eccentric crank pin  23  on a top of the drive shaft  18  being wrapped around by a boss  22  of the orbiting scroll member  25  generates a centrifugal force to make the orbiting scroll member  25  and the fixed scroll member  26  produce rotary motion. A plurality of compressing chambers  27 ,  28  and  29  increase the refrigerant pressure by reducing the volume of the chambers to compress the gas refrigerant into the high-pressure chamber  33  via a high-pressure passage  32 , because a switching valve  30  will guide the high-pressure refrigerant toward the high-pressure chamber  33  while operating and change the direction of refrigerant to the chamber in lower casing while in compressor shut-off. Surely, the pumped gas refrigerant will be delivered with high speed through the discharging port  34 .  
         [0028]     The high-pressure chamber  33  is with the immersed type  101  which makes high pressure side without connecting with outer surface of compressor, that is, the upper casing  10  totally covers the partition plate  31  for avoiding any the condition of leakage and exploding danger to operator.  
         [0029]     Referring to  FIG. 3 , which is a sectional view of a second preferred embodiment of the present invention. The structure of the semi-hermetic scroll compressor comprises: a plurality of sub-casings with fixing design and lubricant design, the fixing design and the lubricant design are initially configured on at least one internal surface of the plurality of sub-casings, the sub-casings include an upper casing  60 , a middle casing  89  and a lower casing  90 , the upper casing  60  has a high-pressure chamber  83  with immersed type of a high-pressure device and a partition plate  81  of a partition device being equipped in the upper casing  60  for separation; the middle casing  89  has a radial fixing scroll member portion  87 , an axial fixing scroll member portion  86 , a fixing motor portion  88  of the fixing design being initially configured on an internal surface of the middle casing  89  as standard heights for positioning, the plurality of lubricant channels  85  of the lubricant design being initially configured on an internal surface of the middle casing  89 , an upper bearing  65 , a main bearing  64  of a fixing device being equipped in the middle casing  89  and cooperating with the fixing design for positioning, a drive shaft  68 , a motor stator  66  and a motor rotor  67  of a driving device being equipped in the middle casing  89  and positioned by the fixing design and the fixing device, a fixed scroll member  76  and an orbiting scroll member  75  of a compressing device being equipped in the middle casing  89  and positioned by the fixing design and the fixing device, further that, the compressing device being driven by the driving device; the lower casing  90  has a lower bearing  63  of the fixing device, the plurality of lubricant channel  85  of the lubricant design being initially configured on an internal surface of the lower casing  90 , a fixing bearing portion  61  of the fixing design and a lubricant tank  62  of a lubricant device, wherein the driving device drives the compressing device to generate high-pressure vapor refrigerant into the high-pressure chamber  83  separated by the partition plate  81 , the lubricant tank  62  in a bottom of the lower casing  90  provides some lubricant to lubricate while the driving device being in motion; wherein the structure further include a upper counterweight  69 , a lower counterweight  70  and a discharging port  84 .  
         [0030]     The drive shaft  68  is driven by the motor rotor  67 , thus a eccentric crank pin  73  on a top of the drive shaft  68  being wrapped around by a boss  72  of the orbiting scroll member  75  generates a centrifugal force to make the orbiting scroll member  75  and the fixed scroll member  76  produce rotary motion. A plurality of compressing chambers  77 ,  78  and  79  increase the refrigerant pressure by reducing the volume of the chambers to compress the gas refrigerant into the high-pressure chamber  83  via a high-pressure passage  82 , because a switching valve (not shown in the Figure) will guide the high-pressure refrigerant toward the high-pressure chamber  83  while operating and change the direction of refrigerant to the chamber in lower casing while in compressor shut-off. Surely, the pumped gas refrigerant will be delivered with high speed through the discharging port  84 .  
         [0031]     The high-pressure chamber  83  is with the immersed type  601  which makes high pressure side without connecting with outer surface of compressor, that is, the upper casing  60  totally covers the partition plate  81  for avoiding any condition of leakage and exploding danger to operator.  
         [0032]     Referring to  FIG. 4 , which is a flow chart of a method of the first preferred embodiment of the present invention. For constructing the first preferred embodiment, the method comprises: 
    1. having an upper casing  10  and a lower casing  40  with fixing design and lubricant design, wherein the upper casing  10  further includes a high-pressure device (a high-pressure chamber  33  with immersed type and discharging port  34 ) and the partition device (a partition plate  31 ), the lower casing  40  further includes the fixing design (a fixing bearing base portion  36  and a fixing bearing portion  11 ) as standard height for positioning, the lubricant design (plural lubricant channels  35 ) for bringing lubricant back to a lubricant device, the fixing device (an upper bearing  15 , a main bearing  14 , a lower bearing  13 , a brace  24  and a bearing base  21 ), the driving device (a drive shaft  18 , a motor stator  16  and a motor rotor  17 ), the compressing device (a fixed scroll member  26  and an orbiting scroll member  25 ), the lubricant device (a lubricant tank  12 ) and a counterweight device (an upper counterweight  19  and a lower counterweight  20 ), the fixing design and the lubricant design being initially configured inside at least one internal surface of the lower casing  10 ;     2. cooperating with the fixing design to compose of the fixing device, the driving device, the compressing device and the partition device in the upper casing  10  and the lower casing  40 ;     3. adopting bolts and nuts to tighten the upper casing  10  and the lower casing  40 , and the two casings can be disassembled for service needs;     4. finishing the method.    
 
         [0037]     Referring to  FIG. 5 , which is a flow chart of a method of the second preferred embodiment of the present invention. For constructing the second preferred embodiment, the method comprises: 
    1. having an upper casing  60 , a middle casing  89  and a lower casing  90  with fixing design and lubricant design, wherein the upper casing  60  further includes a high-pressure device (a high-pressure chamber  83  with hiding type) and a partition device (a partition plate  81 ), the middle casing  89  further includes the fixing design (a radial fixing scroll member portion  87 , an axial fixing scroll member portion  86  and a fixing motor portion  88 ) as standard height for positioning, the lubricant design (plural lubricant channels  85 ) for bringing lubricant back to a lubricant device, the fixing device (an upper bearing  65  and a main bearing  64 ), the driving device (a motor stator  66 , a motor rotor  67  and a drive shaft  68 ), the compressing device (a fixed scroll member  76  and an orbiting scroll member  75 ) and a counterweight device (an upper counterweight  69 ), the lower casing  90  further includes the fixing device (a lower bearing  63 ), the fixing design (a fixing bearing portion  61 ), the lubricant device (a lubricant tank  62 ) and the counterweight device (a lower counterweight  70 ), the fixing design and the lubricant design being initially configured inside at least one internal surface of the sub-casings;     2. cooperating with the fixing design to compose of the fixing device, the driving device, the compressing device and the partition device in the upper casing  60 , the middle casing  89  and the lower casing  90 ;     3. adopting bolts and nuts to tighten the upper casing  60 , a middle casing  89  and a lower casing  90 , and the three casings can be disassembled for service needs;     4. finishing the method.    
 
         [0042]     The aforesaid two embodiments adopt the casting to figure the casings, and positioning and standard planes for assembling are ready after machining, therefore the following advantages are made: 
    1. To control better inner clearance with the same machining precision as prior arts: due to the ways of welding and accumulating components to assembly, the inner clearances for prior arts may be design to enlarge; on the other hand, the present invention should not have the two factors so as to that having better precision.     2. Easily assembling the components to make conditions of shorter manufacturing time, fewer components and less accumulated tolerance: a relationship between the positioning and the assembling can be made while casting and forming the casings, hence the required components is less.     3. Lowering down the factors for affecting precisions: to accept multiple sections of the casing and to fasten the multiple sub-casings with screws.     4. Lowering down the machining cost: some components or portions of the sub-casings being not precise, such as lubricant channels, may adopt the way of casting to form.     5. Highly decreasing noise and vibration while running: due to the cast casing being with the plurality of fixing portions while the casing configured initially, thus the components to be positioned are totally less than prior arts&#39; to result the noise reduced, and the cast casing is with the feature of anti-vibration.    
 
         [0048]     Referring to  FIG. 6  and  FIG. 7 , which are top views of a shoulder with continuous and discontinuous. Shoulder is defined as a standard assembling and positioning plane, so it can be as a continuous type, a shoulder  4  in  FIG. 4 ; or a discontinuous type, a shoulder  5  in  FIG. 5 . The two types of shoulders are designed to have components thereon for being as standard planes. It is then greatly decreasing required precisions, cost, the complexity of assembling and accumulated tolerance.  
         [0049]     Referring to  FIG. 8 , which is a sectional view of plural lubricant channels of the first preferred embodiment. Lubricant is pump up to the location among the boss  22 , the eccentric crank pin  23 , the orbiting scroll member  25 , the fixed scroll member  26  and some other related components from the lubricant tank  12  along with the drive shaft  18  for lubrication, after that, lubricant channel  35  being initially formed while the casing being shaped provides a passage for bringing lubricant back to the lubricant tank  12 . As a result, lubricant channel stays away from the chance for mixing lubricant and gas refrigerant  
         [0050]     Although this invention has been disclosed and illustrated with reference to particular embodiments, the principles involved are susceptible for use in numerous other embodiments that will be apparent to persons skilled in the art. This invention is, therefore, to be limited only as indicated by the scope of the appended claims.

Technology Classification (CPC): 5