TERMINAL COVER STRUCTURE FOR COMPRESSOR, COMPRESSOR AND METHOD

FOR MANUFACTURING COMPRESSOR

FIELD OF INVENTION

The present invention relates to a terminal cover structure for a compressor, the compressor, and a method for manufacturing the compressor.

BACKGROUND OF THE INVENTION

It is known that a large terminal cover for connecting the power supply cable to the compressor is provided on the top lid of the compressor, as disclosed Japanese Unexamined Patent Application Publication No. 2005-327557A hereinafter called PTL1.

In recent years, the improvement of a water-proof and dust-proof performance between the terminal cover and the compressor has been required.

In PTL1, a large fixing plate may be required to fix the terminal cover that houses the power supply cable inside, on a top lid of the compressor, since the large fixing plate that can support the large terminal cover with an appropriate size is needed.

Moreover, the top lid of the compressor is fixed to a shell of the compressor by welding so that an annual welded portion is formed. As such, the large fixing plate interferes with welding.

In particular, in the case of a small compressor, the large fixing plate interferes with welding when welding the top lid to the shell of the compressor, which complicates the welding work.

Therefore, the development of the terminal cover structure for the compressor, that can ensure the water-proof and dust-proof performance between the terminal cover and the top lid of the compressor, as well as facilitate welding work between the shell and the top lid of the compressor, is required.

CITATION LIST Patent Literature

PTL 1: Japanese Unexamined Patent Application Publication No. 2005-327557A

SUMMARY OF THE INVENTION It is an objective of the present inventions to provide a terminal cover structure for a compressor that can ensure the water- proof and dust-proof performance between a terminal cover and a top lid of the compressor, as well as that can facilitate welding work between a shell and the top lid of the compressor.

In order to achieve the above objective, a first embodiment of the present invention provides a terminal cover structure for a compressor comprising: a terminal cover including a terminal cover opening at the bottom; a seal assembly that is provided below the terminal cover and includes a base plate and a seal member, the seal assembly covering a whole peripheral edge part of the terminal cover opening of the terminal cover; and a terminal plate that is provided below the seal assembly, and welded on a top lid of the compressor so that the seal assembly and the terminal cover are detachably attached; wherein the seal member includes a first seal that covers one side of the base plate to seal between the terminal cover and the base plate and a second seal that covers the other side of the base plate to seal between the base plate and the terminal plate.

Firstly, according to the embodiment of the present invention, the seal assembly is provided between the terminal plate and the terminal cover and includes the base plate and the seal member. Moreover, the seal member includes the first seal that covers one side of the base plate to seal between the terminal cover and the base plate and the second seal that covers the other side of the base plate to seal between the base plate and the terminal plate, so that the seal assembly covers the whole peripheral edge part of the terminal cover opening of the terminal cover.

As such, since the terminal cover opening of the terminal cover is sealed by the first seal on the base plate of the seal assembly, it is possible to improve an airtightness of the terminal cover and thereby to reduce the size of the base plate of the seal assembly as long as the seal assembly covers the whole peripheral edge part of the terminal cover opening.

Secondly, since the terminal plate is welded on the top lid of the compressor to support the terminal cover and the seal assembly as well as the airtightness of the terminal cover is kept, the terminal plate does not need to be as large as the base plate of the seal assembly.

As such, it is possible to make the terminal plate that supports the terminal cover as small as possible. As a result, during welding to form an annual welded portion between the top lid and a shell of the compressor, it is possible to suppress interference between the terminal plate and a welding torch. Therefore, the welding work can be facilitated. Furthermore, even in case of a small compressor, interference between the terminal plate and the welding torch can be suppressed during welding, and thereby the welding work can be facilitated. Thirdly, since the seal member include the first seal and the second seal, it is possible to improve the water- proof and dust-proof performances between the terminal cover and the seal assembly as well as between the seal assembly and terminal plate.

Therefore, according to the first embodiment of the terminal cover structure of the present invention, it is possible to ensure the water- proof and dust-proof performance between the terminal cover and the top lid of the sealed container of the compressor, as well as to facilitate welding work between the shell and the top lid of the sealed container of the compressor.

A second embodiment of the present invention provides a compressor comprising the terminal cover structure, the top lid and a shell. Moreover, the shell further including an annular shell welded portion securing the lid and the shell together.

According to the second embodiment of the present invention, it is possible to ensure the water- proof and dust-proof performance between the terminal cover and the top lid of the compressor, as well as to facilitate welding work between the shell and the top lid of the compressor.

A third embodiment of the present invention provides a method for manufacturing a compressor on which the terminal cover structure is installed on a top lid of the compressor, comprising: forming the seal assembly in which the base plate and the seal member are integrated; welding the terminal plate on the top lid so that an annular terminal plate welded portion is formed as an area where the terminal plate and the top lid are welded together; welding the top lid to a shell of the compressor so that an annular shell welded portion is formed as an area where the top lid and the shell are welded together; attaching the terminal cover on the seal assembly; and attaching the terminal cover and the seal assembly on the terminal plate.

According to the third embodiment of the present invention, it is possible to manufacture the compressor that can secure the water-proof and dust-proof performance between the terminal cover and the top lid of the compressor, as well as to facilitate welding work between the shell and the top lid of the compressor.

BRIEF DESCRIPTION OF DRAWINGS

The principle of the present invention and its advantages will become apparent in the following description taking in consideration with the accompanying drawings in which: FIG. 1 is a perspective view of a terminal cover structure 10 according to an embodiment of the present invention, which is installed on a top lid 3 of a sealed container 2 of a compressor 1; FIG.2 is a perspective view of the terminal cover structure 10 of FIG. 1 excluding a terminal cover 20 and a seal assembly 40; FIG.3 A is a top view of the terminal cover structure 10 of FIG. 1, which is installed on the top lid 3 of the sealed container 2 of the compressor 1;

FIG.3B is a top view of the terminal cover structure 10 of FIG. 1 excluding the terminal cover 20 and the seal assembly 40;

FIG.4A is a perspective view of the terminal cover 20;

FIG.4B is a top view of the terminal cover 20;

FIG.4C is a cross sectional view taken along line IVC-IVC of FIG.4B;

FIG.5A is a perspective view of the seal assembly 40 when viewed from diagonally above; FIG.5B is a perspective view of the seal assembly 40 when viewed from diagonally below; FIG.5C is a top view of the seal assembly 40;

FIG.5D is a cross sectional view of the seal assembly 40 taken along line VD-VD of FIG.5C; FIG.6A is a perspective view of a base plate 42 of the seal assembly 40 when viewed from diagonally above;

FIG.6B is a top view of the base plate 42 of FIG.6A;

FIG.6C is a cross sectional view of the base plate 42 taken along line VIC-VIC of FIG.6B;

FIG.7A is a perspective view of a seal member 50 of the seal assembly 40 when viewed from diagonally above;

FIG.7B is a top view of the seal member 50 of FIG.7A;

FIG.7C is a cross sectional view of the seal member 50 taken along line VIIC-VIIC of FIG.7B; FIG.8 is a schematic cross sectional view of the terminal cover structure 10 taken along line VIII-VIII of FIG.1; and

FIG.9 is a development view of the terminal cover structure 10.

DETAILED DESCTIPTION OF EMBODIMENTS OF THE INVENTION

Hereinafter, an embodiment of the present invention will be described in detail with reference to the drawings.

FIG. 1 is a perspective view of a terminal cover structure 10 according to an embodiment, which is installed on a top lid 3 of a seal container 2 of a compressor 1. The seal container 2 includes a cylindrical shell 4 and the top lid 3 that is welded and attached to the shell 4. A light gray colored annular shell welded portion “A” is formed as an area where the top lid 3 and the shell 4 are welded together.

As shown in FIG. 1 to FIG. 3B and FIG. 8, the terminal cover structure 10 includes a terminal plate 60 that is welded on the top lid 3 of the sealed container 2, a terminal cover 20 that is provided above the terminal plate 60 and that houses a power cable 5 and signal lines 6 inside, and a seal assembly 40 that is provided between the terminal plate 60 and terminal cover 20.

As shown in FIG. 1, FIG. 3 A, FIG. 4A to FIG. 4C, and FIG. 8, the terminal cover 20 is a box-shaped member with a chamber inside. The terminal cover 20 is made of aluminum, but not limited to this. In the terminal cover 20, a circular terminal cover hole 22 is formed to secure the power cable 5 and install a cable gland 9 for ensuring the water- proof and dust- proof performance between the power cable 5 and the terminal cover 20. Moreover, in the terminal cover 20, a rectangular terminal cover opening 24 is formed at the bottom.

The power cable 5 includes signal lines 6 inside, each of which is covered by an insulating coating layer. Through the terminal cover opening 24, the signal line 6 is connected to a connection terminal 7 provided on the sealed terminal 8 fixed to the top lid 3 of the sealed container 2, by crimping or welding.

The terminal cover 20 includes a pair of jaw members 26 that are formed to extend outward from the side of the lower end and extend in the longitudinal direction of the terminal cover 20. In each jaw member 26, three through-holes 28 for fixing the terminal cover 20 to the seal assembly 40 and the terminal plate 60 are formed.

As shown in FIG. 5A to FIG. 5D, the seal assembly 40 consists of a base plate 42, and a seal member 50 that covers both sides of the base plate 42. The base plate 42 includes a circular first hole 43 formed so that the power cable 5 can be inserted (See FIG.6A to FIG.6C.). The seal assembly 40 is provided between the terminal plate 60 and terminal cover 20. A detailed explanation of the seal assembly 40 will be described later.

As shown in FIG. 2, FIG. 3B, and FIG. 8, the terminal plate 60 is an approximately elliptical flat plate member when viewed from above and includes a circular second hole 62 formed in the approximately center of the terminal plate 60 so that the power cable 5 can be inserted. The terminal plate 60 is made of low carbon steel or carbon steel (not limited to them).

The terminal plate 60 is formed to be smaller than the base plate 42 when viewed from above. As such, it is possible to make the terminal plate 60 that supports the terminal cover 20 as small as possible.

As will be described later, when the top lid 3 to which the terminal plate 60 is welded and secured is welded to the shell 4, the top lid 3 is annularly welded to the shell 4. Therefore, since the terminal plate 60 that supports the terminal cover 20 is formed as small as possible, interference between the terminal plate 60 and a welding torch (not shown) during welding can be suppressed, and the welding work can be facilitated. Even if the terminal cover structure 10 is installed into a small compressor, interference between the terminal plate 60 and the welding torch can be suppressed during welding, and thereby the welding work can be facilitated.

The terminal plate 60 is a member that supports the terminal cover 20 and the seal assembly 40 of the terminal cover structure 10 from below. Moreover, the terminal plate 60 is welded on the top lid 3 of the sealed container 2.

As shown by an annular terminal plate welded portion A highlighted in dark gray in FIG. 3B, an entire circumference of the edge of the terminal plate 60 facing the second hole 62 is welded to the top lid 3 of the sealed container 2 and fixed to the top lid 3 of the sealed container 2. As such, it is possible to ensure the water- proof and dust-proof performances between the terminal plate 60 and the top lid 3 of the sealed container 2.

As shown in FIG. 2 and FIG. 3B, four cylindrical terminal plate nut members 64 are formed on the terminal plate 60 at positions corresponding to the positions of four through holes of the terminal cover 20 when the terminal cover structure 10 is attached to the top lid 3 of the sealed container 2. Female threads are formed on the inner peripheral wall of each terminal plate nut member 64.

Regarding the seal assembly 40, as shown in FIG. 5A to FIG. 5D, the seal assembly 40 consists of the base plate 42 that includes the circular first hole 43 and the seal member 50 that covers both sides of the base plate 42.

As shown in FIG. 6A to FIG. 6C, the base plate 42 is a flat member and made of low carbon steel or carbon steel (not limited to them) . In the base plate 42, four cylindrical first nut members 44 and two cylindrical second nut members 46 are formed at positions corresponding to the positions of six through holes of the terminal cover 20 when the terminal cover structure 10 is attached to the top lid 3 of the sealed container 2. Female threads are formed on the inner peripheral wall of each of the first nut member 44 and the second nut member 46.

A first bolt 12 having a male thread capable of being screwed with female threads of the first nut member 44 of the base plate 42 of the seal assembly 40 and the terminal plate nut member 64 of the terminal plate 60 is inserted into the through-hole 28, the first nut member 44 of the base plate 42 of the seal assembly 40 and the terminal plate nut member 64.

As such, since the terminal plate 60, the terminal cover 20, and the seal assembly 40 are fixed by 4-point tightening, the terminal cover 20 can be fixed with respect to the terminal plate 60.

A second bolt 14 having a male thread capable of being screwed with female thread of the second nut member 46 of the base plate 42 of the seal assembly 40 and the terminal plate nut member 64 of the terminal plate 60 is inserted into the through-hole 28, the first nut member 44 of the base plate 42 of the seal assembly 40.

As such, since the terminal plate 60 and the seal assembly 40 are fixed by 2- point tightening, the terminal cover 20 can be easily attached to the seal assembly 40.

As shown in FIG. 7A to FIG. 7C, the seal member 50 includes a first seal 52 that covers one side of the base plate 42, a second seal 54 that covers the other side of the base plate 42, and a connection part 58 that connects the first seal 52 and the second seal 54 and that is inserted and installed in the first hole 43. The seal member 50 includes a seal member hole 56 formed to penetrate the first seal 52, the second seal 54 and the connection part 58.

The first seal 52 is formed in the shape of a thin flat plate so that it can be easily deformed. The second seal 54 is formed so as to surround the seal member hole 56 on the opposite side of the connection part 58 from the first seal 52.

The connection part 58 is formed so as to surround the seal member hole 56 and be sealed by contacting the entire inner peripheral surface of the first hole 43. As shown in FIG. 7C, to make it easier for an outer peripheral portion of the connection part 58 to engage with the first hole 43 of the base plate 42, the outer peripheral portion of the connection part 58 is formed so as to be recessed toward the seal member hole 56 with respect to the outer peripheral portion of the second seal 54.

The seal member 50 is made of rubber, but not limited to this, is required to be a deformable member when the terminal cover structure 10 is formed.

Since the first seal 52 is a member that is easily deformed, a part of the first seal 52 can be inserted into the first hole 43 of the base plate 42 after deforming the first seal 52, and then the thin flat plate- shaped first seal 52 can be placed on the base plate 42 so as to be in close contact with the base plate 42. As such, it is possible to form the seal assembly 40 in which the base plate 42 and the seal member 50 are integrated.

The first seal 52 includes a pair of curved portions 52a formed so as to be recessed inward from the outer edge portion of the first seal 52. The second seal 54 includes four notches 54a formed so as to be recessed inward from the outer edge portion of the second seal 54.

When the terminal cover structure 10 attached to the top lid 3 of the sealed container 2 is viewed from above, the curved portions 52a of the first seal 52 and the notches 54a of the second seal 54 are formed so as to be at the positions where the through holes of the terminal cover 20 are located.

As such, as the curved portions 52a and the notches 54a are formed in the seal member 50, two second bolts 14 can be easily screwed into the terminal plate nut member 64 of the terminal plate 60 and the second nut member 46 of the base plate 42 of the seal assembly 40 in this order. As a result, the terminal plate 60 and the seal assembly 40 are fixed by 2-point tightening, as well as the terminal cover 20 can be easily attached to the seal assembly 40. Moreover, the terminal plate 60, the terminal cover 20, and the seal assembly 40 are fixed by 4- point tightening, as well as the terminal cover 20 can be fixed with respect to the terminal plate 60 so that it does not move.

Next, a method of attaching the terminal cover structure 10 on the top lid 3 of the sealed container 2 is described in detail with reference to FIG.8 and FIG.9.

Firstly, the seal assembly 40 in which the base plate 42 and the seal member 50 are integrated, is formed. Since the first seal 52 of the seal member 50 is a member that is easily deformed, a part of the first seal 52 can be inserted into the first hole 43 (See FIG.6A to FIG.6C.) of the base plate 42 after deforming the first seal 52, and then the thin flat plate-shaped first seal 52 can be placed on the base plate 42, and thereby the integrated seal assembly 40 is formed.

Secondly, the sealed terminal 8 with the connection terminals 7 is installed on the top lid 3. In FIG.9, the signal lines 6 connected to the connection terminals 7 are omitted.

Thirdly, the terminal plate 60 is welded on the top lid 3. As shown in FIG.3B, the entire circumference of the edge of the terminal plate 60 facing the second hole 62 is welded to the top lid 3 and fixed to the top lid 3. A dark gray colored annular terminal plate welded portion “B” is formed as the area where the terminal plate 60 and the top lid 3 are welded together. As such, it is possible to ensure the water-proof and dust-proof performances between the terminal plate 60 and the top lid 3 of the sealed container 2.

Fourthly, the top lid 3 is welded to the shell 4 so that the light gray colored annular shell welded portion “A” is formed as the area where the top lid 3 and the shell 4 are welded together.

Since the terminal plate 60 is formed to be smaller than the base plate 42 when viewed from above, it is possible to make the terminal plate 60 that supports the terminal cover 20 as small as possible. Therefore, since interference between the terminal plate 60 and the welding torch during welding can be suppressed, the welding work can be facilitated. Furthermore, even in case of a small compressor, interference between the terminal plate 60 and the welding torch can be suppressed during welding, and thereby the welding work can be facilitated.

Fifthly, the terminal cover 20 is attached on the seal assembly 40. Since the curved portions 52a and the notches 54a (See FIG. 7A and FIG.7B. ) are formed in the seal member 50 of the seal assembly 40, each of two second bolts 14 can be easily screwed into the terminal plate nut member 64 of the terminal plate 60 and the second nut member 46 of the base plate 42 of the seal assembly 40 in this order. As such, since the terminal plate 60 and the seal assembly 40 are fixed by 2- point tightening, the terminal cover 20 can be temporarily attached to the seal assembly 40 easily.

Sixthly, the terminal cover 20 and the seal assembly 40 are attached on the terminal plate 60. Since the curved portions 52a and the notches 54a are formed in the seal member 50 of the seal assembly 40, each of four first bolts 12 can be easily screwed into the through- hole 28 of the terminal cover 20, the first nut member 44 of the base plate 42 of the seal assembly 40 and the terminal plate nut member 64.

As such, since the terminal plate 60, the terminal cover 20, and the seal assembly 40 are fixed by 4-point tightening, the terminal cover 20 can be fixed with respect to the terminal plate 60 so that it does not move.

Finally, the cable gland 9 for ensuring the water- proof and dust-proof performance between the power cable 5 and the terminal cover 20, is installed to the terminal cover 20 ( See FIG.8 ).

As mentioned above, by ensuring the water-proof and dust-proof performance of the terminal cover structure 10 and the water- proof and dust- proof performance between the terminal cover 20 and the top lid 3 of the sealed container 2, there is no need to provide the large terminal plate 60 to support the terminal cover 20.

As such, since the large fixing plate is not required to fix the terminal cover 20 on the top lid 3 of the sealed container 2 of the compressor 1, it is possible to facilitate welding work between the shell 4 and the top lid 3 of the sealed container 2.

According to the embodiment, since the seal assembly 40 is provided between the terminal plate 60 and the terminal cover 20 and includes the base plate 42 and the seal member 50 that covers both sides of the base plate 42, it is possible to improve the water-proof and dustproof performances between the terminal cover 20 and the seal assembly 40 as well as between the seal assembly 40 and terminal plate 60. Moreover, as the terminal plate 60 is welded on the top lid 3 of the sealed container 2, it is possible to ensure the water- proof and dust-proof performance between the terminal cover 20 and the top lid 3 of the sealed container 2 of the compressor 1.

Therefore, according to the embodiment, it is possible to ensure the water-proof and dustproof performance between a terminal cover 20 and the top lid 3 of the sealed container 2 of the compressor 1 surely, as well as to facilitate welding work between the shell 4 and the top lid 3 of the sealed container 2 of the compressor 1 even with a small compressor.

Although specific embodiments of the invention have been disclosed and described as well as illustrated in the companying drawings, it is simply for the purpose of better understanding of the principle of the present invention and it is not as a limitation of the scope and spirit of the teaching of the present invention. Adaption and modification to various structures such as design or material of the invention, mounting mechanism of various parts and elements or embodiments are possible and apparent to a skilled person without departing from the scope of the present invention which is to be determined by the claims.

List of reference:

1: compressor

2: sealed container

3 : top lid

4: shell

5 : power cable

6: signal line

7 : connection terminal

8: sealed terminal

9: cable gland

10: terminal cover structure

12: first bolt

14: second bolt

20: terminal cover

22: terminal cover hole

24: terminal cover opening

26: jaw member

28: through-hole

40: seal assembly

42: base plate

43: first hole

44: first nut member

46: second nut member

50: seal member

52: first seal

52a: curved portion

54: second seal

54a: notch 56: seal member hole

58: connection part

60: terminal plate

62: second hole 64: terminal plate nut member

A: shell welded portion

B: terminal plate welded portion