Hermetic compressor and manufacturing method of suction muffler

Abstract

This relates to a hermetic compressor and a manufacturing method of a suction muffler, and discloses a technique for making energy efficiency higher and reducing noise. According to that technique, in a suction muffler 140 having a sound attenuation space 143, by foam-molding a wall 147, such as an opposite surface and the like, where open ends 145 a , 146 a within the sound attenuation space among the walls constituting a casing 140 C of the suction muffler 140 are opened, it is possible to reduce the heating action of refrigerant gas released into the sound attenuation space 143 effectively in a space-saving manner, and make a sucking efficiency higher, and effectively absorb a refrigerant pulsation tone radiated in the open end 145 a within the sound attenuation space, and consequently reduce the noise.

1 . A hermetic compressor including: a motor element within a hermetic vessel; a compression element driven by said motor element; and a suction muffler made of synthetic resin which is linked to said compression element, wherein at least a part of a casing of said suction muffler is foam-molded.  
     
     
         2 . The hermetic compressor according to  claim 1 , wherein a bubble diameter obtained by said foam-molding is 50 μm or less.  
     
     
         3 . The hermetic compressor according to  claim 1 , wherein a material of said foam-molding is crystal synthetic resin.  
     
     
         4 . The hermetic compressor according to  claim 1 , wherein a skin layer in which a bubble does not exist substantially is formed on a surface of said foam-molding.  
     
     
         5 . The hermetic compressor according to  claim 4 , wherein a thickness of said skin layer is 30% or less of a plate thickness in the thinnest portion.  
     
     
         6 . The hermetic compressor according to  claim 1 , wherein a foaming magnification of said foam-molding is 1.2 times or more.  
     
     
         7 . The hermetic compressor according to  claim 1 , wherein among a plurality of walls constituting said casing, a plate thickness of the wall in which the maximum projection area is obtained is thicker than plate thicknesses of the other plate thicknesses.  
     
     
         8 . The hermetic compressor according to  claim 1 , wherein said casing is produced by combining at least two parts, and said two parts are separated and divided in a direction substantially vertical to the wall in which the maximum projection area of said casing is obtained.  
     
     
         9 . The hermetic compressor according to  claim 1 , wherein plate thicknesses of a corner of said casing and a portion having a high curvature are relatively larger than the other portions.  
     
     
         10 . The hermetic compressor according to  claim 1 , wherein said suction muffler includes a sound attenuation space formed inside said casing, a first linkage path to link said compression element and said sound attenuation space, and a second linkage path to link an inner portion of said hermetic vessel and said sound attenuation space, and 
 wherein a wall of said casing, which is close to at least one of said motor-element, said compression element, an open end within said sound attenuation space of said first linkage path, and an open end within said sound attenuation space of said second linkage path is designed so as to have at least one of a configuration that it is thicker than the other walls of said casing and a configuration that it is higher in foaming magnification.    
     
     
         11 . The hermetic compressor according to  claim 1 , wherein a lubricating oil is stored in said hermetic vessel, and at least one of walls of said casing of said suction muffler to which said lubricating oil is supplied is designed so as to have at least one of a configuration that it is thicker than the other walls of said casing and a configuration that it is higher in foaming magnification.  
     
     
         12 . The hermetic compressor according to  claim 1 , wherein the casing of said suction muffler has a suction muffler body and a suction muffler cover, and wherein a bonding portion between said suction muffler body and said suction muffler cover has a foaming magnification which is relatively lower as compared with portions except said bonding portion, or it is not foam-molded.  
     
     
         13 . The hermetic compressor according to  claim 1 , wherein the linkage path to link the inner portion of said hermetic vessel and the sound attenuation space of said suction muffler is formed integrally with the farthest element from the motor element, among a plurality of elements constituting the casing of said suction muffler.  
     
     
         14 . The hermetic compressor according to  claim 1 , wherein a part of the casing of said suction muffler is interposed between a cylinder head and a valve plate which constitute said compression element, and said interposed part of said casing has a relatively low foaming magnification or it is not foam-molded.  
     
     
         15 . The hermetic compressor according to  claim 1 , wherein a part of the casing of said suction muffler is interposed between a cylinder head and a valve plate which constitute said compression element, and the thickness of said interposed part of said casing is thicker than the other portions.  
     
     
         16 . The hermetic compressor according to  claim 1 , wherein said motor element is inverter-driven at a rotation number including a rotation number less than a commercial power supply frequency.  
     
     
         17 . The hermetic compressor according to  claim 16 , wherein said rotation number is 20 r/sec or less.  
     
     
         18 . The hermetic compressor according to  claim 1 , wherein a refrigerant gas compressed by said compression element is R600a.  
     
     
         19 . A manufacturing method of a suction muffler, which foam-molds at least a part of a casing of a suction muffler made of synthetic resin for a hermetic compressor, wherein in said molding course, a core-back is used to move a part of a die, enlarge a cavity and make a plate thickness thicker.  
     
     
         20 . A manufacturing method of a suction muffler, which foam-molds at least a part of a casing of a suction muffler made of synthetic resin for a hermetic compressor, wherein a section area of a gate serving as a resin supplying portion to cavities inside a die is equal to or greater than 70% of a square of a plate thickness of said casing.  
     
     
         21 . A manufacturing method of a suction muffler, which foam-molds at least a part of a casing of a suction muffler made of synthetic resin for a hermetic compressor, wherein two or more gates serving as resin supplying portions to cavities inside a die are installed for at least one unit.