Title of Invention

A COMPRESSOR SLIDER FOR A SCROLL COMPRESSOR

Abstract An object of the present invention is to provide a compressor slider that has high tensile strength, is capable of demonstrating sufficient durability during operation, can be easily "broken in" in the shortest possible period, and is free of seizing during abnormal operation. The compressor slider (17, 23, 24, 26, 39, 60, 96, 310b, 524, 526, 644, 646, 724, 726, 734, 736, 817, 821, 823, 824, 825, 826, 827, 921, 924) has a carbon content of 2.0 wt% to 2.7 wt%, a silicon content of 1.0 wt% to 3.0 wt%, a balance of iron that includes unavoidable impurities, graphite that is smaller than the flake graphite of flake graphite cast iron, and a hardness that is greater than HRB 90 but less than HRB 100 in at least a portion of the slider.
Full Text SPECIFICATION
COMPRESSOR SLIDER, SLIDER PREFORM, SCROLL PART,
AND COMPRESSOR
TECHNICAL FIELD
The present invention relates to a compressor, a compressor slider (scroll part,
cylinder block, piston, roller, and the like), and a slider preform (scroll part preform, cylinder
block preform, piston preform, roller preform, and the like).
BACKGROUND ART
A method for manufacturing a compressor slider has been proposed (e.g., see Patent
Document 1) in which "a compressor slider preform is manufactured by semi-molten die
casting." Adopting this manufacturing method allows high tensile strength and high
hardness to be obtained in comparison with adopting sand casting.
Japanese Laid-open Patent Application No. 2005-36693.
Japanese Laid-open Utility model Application No. 4-134686.
DISCLOSURE OF THE INVENTION
PROBLEMS THAT THE INVENTION IS TO SOLVE
In a scroll compressor, for example, the distal end of a tooth tip of a scroll is
ordinarily set so that an initial gap is provided with consideration given to deformation during
operation. This is because when a portion of the tooth tip of the scroll makes contact during
operation, large gaps are formed in other portion of the tooth tip, the thrust bearing surface
becomes unstable, function cannot be achieved, the movable scroll becomes interposed
between the fixed scroll and other components, damage is incurred, performance is reduced,
or other problems occur. However, contact of the tooth tip may occur during operation due
to machining tolerance of the parts, the condition of assembly based on geometric tolerance
and/or combined tolerance, and an increase in temperature inside the scroll. The problem is
gradually solved (this phenomenon is referred to as "breaking-in") by operating the
compressor in this state and creating wear in the distal ends of the teeth of the scroll that are
in contact with the fixed scroll or the movable scroll. In other words, rather ensuring
maximum hardness in the movable scroll and the fixed scroll that is as hard as possible, a
hardness is required that demonstrates sufficient durability and that allows "breaking-in" to
occur as soon as possible. When the hardness of the movable scroll and the fixed scroll is
extremely high, seizing resistance is degraded, seizing occurs between the teeth ends and the
teeth bases (particularly in the center portion) in the scroll compressor wrap during
pump-down operation (which readily occurs when a closed valve has inadvertently been left

unopened during installation, or in a refrigerant recovery operation during moving and
reinstallation) or gas shortage operation (which occurs when refrigerant is insufficiently
charged, has leaked from the piping, or has otherwise become insufficient), and the
compressor is likely to break down and must be replaced. On the other hand, when the
hardness of the movable scroll and the fixed scroll is extremely low, abrasion resistance is
reduced, abnormal abrasion (on the order of several tens of micrometers) occurs during
short-term abnormal operation (pump-down operation, gas shortage operation, and the like),
the gap at the distal ends of scroll portion during normal operation becomes excessive, and
performance is reduced. In extreme cases, operation is likely to become impossible because
the discharge gas becomes too hot due to a reduction in performance caused by gas leakage.
Ordinarily, the scroll portion of the movable scroll and the fixed scroll requires end milling,
and problems of tool service life and cutting resistance therefore readily occur when the
hardness is markedly high. In other words, when the movable scroll and the fixed scroll
require machining, a level of hardness is required that allows sufficient machinability to be
achieved and yet provides sufficient durability after completion. On the other hand, when
the hardness of the movable scroll and the fixed scroll is extremely low, a built-up edge is
readily formed and grinding is impeded because the ductility of the movable scroll and the
fixed scroll is excessively high. Therefore, from this point as well, the movable scroll, the
fixed scroll, and the like must be of sufficient hardness.
The same applies to producing such a suitable hardness in the piston and cylinder
block of a swing compressor, and in a roller and cylinder block of a rotary compressor. In
particular, producing such a suitable hardness in a piston and cylinder block is as important as
producing such a suitable hardness in a scroll part of a scroll compressor because the cylinder
block and the piston always make contact in the same position in a swing compressor.
An object of the present invention is to provide a slider that has high tensile strength,
can demonstrate sufficient durability during operation, is readily "broken in" as soon as
possible, and does not seize during abnormal operation, and to provide a compressor that
incorporates such a slider. Another object of the present invention is to provide a
compressor slider preform that exhibits good machinability.
MEANS OF SOLVING THE PROBLEMS
The compressor slider according to a first aspect is a slider having a carbon content of 2.0
wt% to 2.7 wt%, a silicon content of 1.0 wt% to 3.0 wt%, a balance of iron that includes
unavoidable impurities, graphite that is smaller than the flake graphite of flake graphite cast
iron, and a hardness that is greater than HRB 90 but less than HRB 100 in at least a portion of

the slider. The hardness is more preferably greater than HRB 90 but less than HRB 95.
The hardness can be adjusted by a heating treatment that follows molding. As used herein,
the term "slider" refers to a compressor slider, and examples include the following
components of a scroll compressor: a movable scroll, a fixed scroll, a bearing, a rotating shaft
(crankshaft), a rotation-preventing member, and a slide bush (slide block), as well as the
following components of a swing compressor and a rotary compressor: a cylinder block, a
front head, a rear head, a middle plate and rotating shaft (crankshaft), a piston, and a roller.
When the "slider" is a cylinder block of a swing compressor or a rotary compressor, the
hardness of at least the wall portion in which the cylinder hole is formed can be greater than
HRB 90 but less than HRB 100. When the hardness of the slider is HRB 90 or less, the
slider has poor abrasion resistance, abnormal abrasion (on the order of several tens of
micrometers) occurs during short periods of abnormal operation (pump-down operation,
insufficient gas operation, or the like), a gap at the distal end of the scroll portion during
normal operation becomes excessively large, and performance is reduced. In extreme cases,
performance is reduced due to gas leakage, the discharge gas becomes too hot, and operation
is likely to be no longer possible. When the slider is a scroll part, it is possible that the
effect of higher tensile strength of the scroll portion as a result of the improved tensile
strength will no longer be sufficiently utilized. On the other hand, when the hardness of the
slider is HRB 100 or greater, the seizing resistance of the slider is poor, seizing may occur in
the scroll portion during abnormal operation (pump-down operation, insufficient gas
operation, or the like) when the slider is a scroll part, and the compressor may malfunction
and require replacement. The range in which the hardness is greater than HRB 90 but less
than HRB 100 substantially corresponds to the range in which a ferrite surface area ratio of
the base composition is from 50% to 5%. The graphite surface area ratio of the base
composition substantially corresponds to a range from 6% to 2%. The range in which the
hardness is greater than HRB 90 but less than HRB 95 substantially corresponds to the range
in which the ferrite surface area ratio of the base composition is less than 50% and greater
than 25%. The graphite surface area ratio of the base composition substantially corresponds
to a range that is less than 6% and greater than 3%. Such a compressor slider is
manufactured by the semi-molten or semi-solid die casting and metal-mold casting of the
above-described iron material, then rapidly cooling the molded material to convert the entire
material to white iron, and then adjusting the hardness by heat treatment. When such a
compressor slider is molded by semi-molten die casting or semi-solid die casting, the molded
material can be given a near-net shape (a shape that approximates the final shape of the

product). On the other hand, the molded material must be brought to its final shape by
precision machining when such a compressor slider is molded by metal-mold casting.
The tensile strength of a molded article can be freely adjusted by heat treatment in a molded
article obtained by subjecting iron having the components described above to semi-molten or
semi-solid die casting and metal-mold casting, and thereafter rapidly cooling the molded
material to convert the entire material to white iron. It has been made apparent that the
tensile strength of a molded article manufactured via the heat treatment is in a proportional
relationship with the hardness of the molded article. The range in which the hardness is
greater than HRB 90 but less than HRB 100 substantially corresponds to a range in which the
tensile strength is from 600 MPa to 900 MPa. In other words, control of the tensile strength
of the molded article can be substituted with the hardness, which is easy to measure. There
are also merits when the slider is a scroll part in that the degree of freedom of design is
considerably improved, and the scroll part has a reduced diameter and is provided with
greater capacity. Therefore, the compressor slider demonstrates higher tensile strength than
a slider composed of flake graphite cast iron. Based on experimental results obtained by the
present inventor, it is apparent that when the hardness is in a range that is greater than HRB
90 but less than HRB 100, the slider can demonstrate sufficient durability during compressor
operation, "breaking-in" can occur as soon as possible, and seizing during abnormal operation
does not occur. Since the slider exhibits suitable hardness, there are merits in that the slider
is not easily damaged and is easy to handle. In summary of the above, the compressor slider
has high tensile strength, demonstrates sufficient durability during operation, can be "broken
in" as early as possible, and does not undergo seizing during abnormal operation. The
compressor slider is manufactured by a process in which iron having components such as
those described above is subjected to semi-molten or semi-solid die casting and metal-mold
casting, is then rapidly cooled to convert: the entire material to white iron, and is thereafter
heat treated. Therefore, merits and other advantages can be obtained in that thrust loss can
be reduced due to a small diameter, and higher capacity can be obtained by reducing the
thickness of the components, and damage is less likely to occur with regard to inclusion of
foreign matter and a sudden increase in internal pressure because of the higher toughness in
comparison with FC material. Even if damage were to occur, small scrapings are not
produced and pipes do not need to be cleaned. Such a compressor can be regarded to be
suitable in cases in which an upgrade is required.
The compressor slider according to a second aspect is the compressor slider according to the
first aspect, being manufactured by semi-molten die casting or semi-solid die casting, then

rapid cooling, and then a heat treatment.
This compressor slider is manufactured by semi-molten die casting or semi-solid die casting,
then rapid cooling, and then a heat treatment. Accordingly, the slider preform can be made
into a near-net shape. Therefore, the compressor slider can reduce machining costs and can
be manufactured at lower cost.
The compressor slider according to a third aspect is the compressor slider according to the
first aspect, being manufactured by metal-mold casting, then rapid cooling, and then a heat
treatment.
This compressor slider is manufactured by metal-mold casting, then rapid cooling, and then a
heat treatment. Accordingly, the pressure required in the molding step can be kept low.
Therefore, a press apparatus or a heating apparatus in die casting is not required, and
equipment costs can be reduced. As a result, the compressor slider reduces molding costs
and can be manufactured at lower cost.
The compressor slider according to a fourth aspect is the compressor slider according to any
of the first to third aspects, wherein the ratio of tensile strength to Young's modulus is 0.0046
or less. Young's modulus is preferably 175 to 190 GPa.
A compressor slider produced by die casting in which a semi-molten (semi-solid) iron
material is pressed into a mold to manufacture a casting is subjected to heat treatment by
being held at a prescribed temperature for a prescribed time, and by having the cooling speed
adjusted, whereby the tensile strength can be improved in comparison with a conventional
material such as FC250.
However, the inventors of the present invention discovered that when the tensile strength is
increased to a level not conventionally done, other problems occur when the ratio (H/T),
which is the ratio of the height (H) to thickness (T) of the scroll portion of the scroll, is
determined based solely on the viewpoint of the strength that would prevent fatigue damage,
as in a conventional manner. In other words, when the ratio (H/T) is made excessively high
because of the strength, drawbacks were noted in that the machining tolerance of end milling
or the like and the cutting speed cannot be increased even when there is no problem in terms
of strength, because the amount of deformation (amount of flexing) of the scroll portion
becomes excessive during cutting, machining time may be extended, the amount of
deformation (amount of flexing) of the scroll portion increases during compressor operation,
performance is reduced, and noise from contact with the counterpart scroll increases.
In view of the above, in the present invention, the ratio of the tensile strength in relation to
Young's modulus of the scroll after heat processing is determined so that costs are not

incurred to achieve excessive strength in heat treatment. The determination is based on
research to determine the level of tensile strength that is sufficient from the viewpoint of
fatigue strength. In this determination, the ratio (H/T) of the scroll portion is determined
with consideration given to the required upper limit of the deformation amount of the scroll
portion from the viewpoint of the machining time, performance reduction, and noise.
Specifically, the increase in strength by heat treatment is limited so that the ratio of the tensile
strength in relation to Young's modulus is set to be 0.0046 or less. Since the ratio of the
tensile strength in relation to Young's modulus is determined in this manner, a situation is
avoided in the scroll part according to the present invention in which the scroll portion is
subjected to an excessive increase in strength via heat treatment that involves costs and time,
and the heat treatment can be suitably performed.
It is illogical to conversely extend the heat treatment to keep strength low, and since failure
may occur in that abrasion resistance is reduced when the ferrite ratio of the metal structure is
increased, the ratio of the tensile strength in relation to Young's modulus is preferably kept at
0.0033 or higher.
When such a scroll is incorporated into a scroll compressor that is incorporated into a
refrigerant circuit of a refrigeration apparatus in which R410A is used as a refrigerant, the
value obtained by dividing the length (hereinafter referred to as scroll portion height (H)) in
the direction orthogonal to the flat plate portion of the scroll portion by the thickness
(hereinafter referred to as scroll portion thickness (T)) of the scroll portion is preferably kept
at 19 or less. Also, when such a scroll is incorporated into a scroll compressor that is
incorporated into a refrigerant circuit of a refrigeration apparatus in which carbon dioxide is
used as a refrigerant, the value obtained by dividing the scroll portion height (H) by the scroll
portion thickness (T) is preferably kept at 8 or less. The toughness of the scroll portion
(Young's modulus) becomes insufficient when the scroll portion height (H) is increased with
respect to the scroll portion thickness (T) and the scroll portion is made thinner relative to the
height of the scroll portion. Since molding is carried out by semi-molten or semi-solid die
casting and strength is increased in comparison with the case in which a material such as a
conventional FC250 is used, it is preferred that the ratio (H/T) be 10 or higher to assure a
thinner scroll portion for the case in which such a scroll is incorporated into a scroll
compressor that is incorporated into a refrigerant circuit of a refrigeration apparatus in which
R410A is used as a refrigerant. It is preferred that the ratio (H/T) be 2 or higher to assure a
thinner scroll portion for the case in which such a scroll part is incorporated into a scroll
compressor that is incorporated into a refrigerant circuit of a refrigeration apparatus in which

carbon dioxide is used as a refrigerant.
The compressor slider according to a fifth aspect is the compressor slider according to any of
the first to fourth aspects, wherein a portion thereof, e.g., a stress concentration area or a
sliding portion, is treated in partial heat treatment. As used herein, the term "partial heat
treatment" refers to the use of a high-frequency heating method, a laser heating method, or
another method. The eccentric shaft portion and the main shaft portion are preferably
treated in partial heat treatment when the slider is a crankshaft of a compressor incorporated
into a refrigerant circuit of a refrigerant apparatus in which carbon dioxide, R410A, or
another high-pressure refrigerant is used as the refrigerant. When a notched portion is
provided between the main shaft portion and the eccentric shaft portion in the crankshaft, the
peripheral area of the notched portion is preferably treated in partial heat treatment. A
balance weight is preferably integrally formed with the crankshaft. An inner-drive pin shaft
portion is preferably treated in partial heat treatment when the slider is an inner drive-type
movable scroll of a scroll compressor incorporated into the refrigerant circuit of a refrigerant
apparatus in which carbon dioxide, R410A, or another high-pressure refrigerant is used as the
refrigerant. The key portion, which is a slider portion, is preferably treated in partial heat
treatment when the slider is a rotation-preventing member (e.g., an Oldham ring (Oldham
coupling) or the like) of a scroll compressor incorporated into the refrigerant circuit of a
refrigerant apparatus in which carbon dioxide, R410A, or another high-pressure refrigerant is
used as the refrigerant. A wall portion in which a bushing accommodation hole is formed is
preferably treated in partial heat treatment when the slider is a cylinder block of a swing
compressor incorporated into the refrigerant circuit of a refrigerant apparatus in which carbon
dioxide, R410A, or another high-pressure refrigerant is used as the refrigerant. The
peripheral area of the base of the blade portion and the peripheral area of the notched portion
formed in the base of the blade portion are preferably treated in partial heat treatment when
the slider is a piston of a swing compressor incorporated into the refrigerant circuit of a
refrigerant apparatus in which carbon dioxide, R410A, or another high-pressure refrigerant is
used as the refrigerant. A wall portion in which a vane accommodation hole is formed is
preferably treated in partial heat treatment when the slider is a cylinder block of a rotary
compressor incorporated into the refrigerant circuit of a refrigerant apparatus in which carbon
dioxide, R410A, or another high-pressure refrigerant is used as the refrigerant.
This compressor slider has a portion, e.g., a stress concentration area, a sliding portion, or the
like, that is treated in partial heat treatment. Accordingly, sufficient fatigue strength and
abrasion resistance can be imparted to the stress concentration area, sliding portion, or the

like of the compressor slider. Such a slider is particularly effective in relation to a
high-pressure refrigerant, e.g., carbon dioxide or the like. Since the strength of the partially
heat-treated portions is increased, the partially heat-treated portions can be made thinner and
more lightweight.
The compressor slider according to a sixth aspect is the compressor slider according to the
fifth aspect, wherein the hardness of a location that is treated in partial heat treatment is
greater than HRC 50 but less than HRC 65.
With this compressor slider, the hardness of a location that is treated in partial heat treatment
is greater than HRC 50 but less than HRC 65. Accordingly, abrasion in such a portion can
be sufficiently reduced by setting the hardness of this portion to be greater than HRC 50 but
less than HRC 65 when, e.g., a bearing portion or other portion having particular hardness
requirements is present in the compressor slider.
The compressor slider according to a seventh aspect is the compressor slider according to the
fifth or sixth aspect, wherein a location that is treated in partial heat treatment is a stress
concentration area. As used herein, the term "stress concentration area" refers to a
peripheral area of the base of a scroll portion of the scroll, a notched area formed in the
vicinity of the center of the first plate surface side of the flat plate portion of the scroll, a
peripheral area of the base of the bearing portion of the scroll, or another area.
The stress concentration area of this compressor slider is treated in partial heat treatment.
Accordingly, in this compressor slider, good breaking-in characteristics are imparted to the
sliders that require slidability, and sufficient fatigue strength is imparted to the stress
concentration area. Such a slider is particularly effective in relation to high-pressure
refrigerant, e.g., carbon dioxide and the like.
The compressor slider according to an eighth aspect is the compressor slider according to any
of the first to seventh aspects, being manufactured using a mold having a convexity. The
convexity allows a prescribed portion in the vicinity of a center of the slider to be thinly
formed. The slider is provided with a thin prescribed portion in the vicinity of the center.
As used herein, the term "prescribed portion" is, e.g., an opening formation portion or the like.
When the compressor slider is a scroll part, the "prescribed portion" is, e.g., a portion in the
vicinity of the center of the end plate, a portion in which a discharge hole is to be formed in
the vicinity of the center, or another portion. In this case, the height of the convexity is
preferably set so that the thickness of the prescribed portion in the vicinity of the center of the
scroll is 4 mm or less. When the slider is a movable scroll, a movable scroll having a
bearing portion that fits onto the outside of a drive shaft reduces the generation of blowholes

to a greater extent than does a movable scroll of an inner drive in which the bearing portion
of a solid rounded rod fits inside the drive shaft. When the slider is a movable scroll of an
inner drive in which the bearing portion of a solid rounded rod fits inside the drive shaft, it is
preferred that at least a portion of the interior of the bearing portion is cored by using the
convexity.
In semi-molten molding, a semi-molten metal material is molded in a mold. Accordingly,
there is a problem in that blowholes will readily occur in the thick portions of a molded slider.
When a hole is furthermore formed in the preform in a state in which blowholes are present
inside the molded slider preform, the blowholes inside the preform tend to be exposed to the
exterior through the holed portion. When blowholes are exposed on an external surface of the
slider, the portion of the exposed blowhole readily becomes a source for fatigue failure of a
slider and is likely to have an undesirable affect on fatigue strength.
In response to such a problem, in the present invention, a thin prescribed portion is formed in
the vicinity of the center of the slider by subjecting a metal material to semi-molten molding
using a mold having a convexity. For this reason, the occurrence of blowholes is reduced in
this compressor slider.
The compressor slider according to a ninth aspect is the compressor slider according to any of
the first to seventh aspects, wherein a slider preform provided with a thin prescribed portion
in the vicinity of a center is molded using a mold having a convexity that allows a prescribed
portion in the vicinity of the center to be thinly formed, and a through-hole is formed in the
thin prescribed portion in the preform. As used herein, the term "prescribed portion" is, e.g.,
an opening formation portion or the like. When the compressor slider is a scroll part, the
"prescribed portion" is, e.g., a portion in the vicinity of the center of the end plate, a portion
in which a discharge hole is to be formed in the vicinity of the center, or another portion. In
this case, the height of the convexity is preferably set so that the thickness of the prescribed
portion in the vicinity of the center of the scroll is 4 mm or less. When the slider is a
movable scroll, a movable scroll having a bearing portion that fits onto the outside of a drive
shaft reduces the generation of blowholes to a greater extent than does a movable scroll part
of an inner drive in which the bearing portion of a solid rounded rod fits inside the drive shaft.
When the slider is a movable scroll of an inner drive in which the bearing portion, of a solid
rounded rod fits inside the drive shaft, it is preferred that at least a portion of the interior of
the bearing portion be cored using the convexity.
This compressor slider is manufactured by molding a preform having a thin prescribed
portion in the vicinity of the center with the aid of a mold having a convexity, and by forming

a through-hole in the thin prescribed portion in the preform.. For this reason, the occurrence
of blowholes is reduced in the compressor slider. Blowholes inside a slider are unlikely to
become exposed to the exterior when a through-hole is formed in the opening formation
portion, and degradation in fatigue strength can be reduced.
The compressor scroll according to a tenth aspect has a carbon content of 2.0 wt% to 2.7 wt%,
a silicon content of 1.0 wt% to 3.0 wt%, a balance of iron that includes unavoidable
impurities, graphite that is smaller than the flake graphite of flake graphite cast iron, the
compressor scroll comprising a plate portion and a scroll portion. The scroll portion extends
from a first plate surface of the plate portion in a direction perpendicular to the first plate
surface while a scroll shape is maintained. The plate portion and the scroll portion have a
hardness that is greater than HRB 90 but less than HRB 100. It is particularly preferred that
the hardness of the scroll portion at a distal end thereof be included in the hardness ranged
noted above. It is preferred that the hardness be greater than HRB 90 but less than HRB 95.
A range in which the hardness is greater than HRB 90 but less than HRB 100 substantially
corresponds to a range in which the ferrite surface area ratio of the base composition is from
50% to 5%. The graphite surface area ratio of the base composition substantially
corresponds to a range from 6% to 2%. The range in which the hardness is greater than
HRB 90 but less than HRB 95 substantially corresponds to a range in which the ferrite
surface area ratio of the base composition is less than 50% and greater than 25%. The
graphite surface area ratio of the base composition substantially corresponds to a range that is
less than 6% and greater than 3%. The hardness can be adjusted by a heating treatment that
follows molding. It is preferred that the scroll portion have a height, as measured from the
first plate surface, that is twice the width or less of the groove (trough portion) of the scroll
portion. This is because machining can be relatively easily performed even if the
pre-machining tolerance is high.
The compressor scroll is manufactured by performing the semi-molten or semi-solid die
casting and metal-mold casting of an iron material having the above-described components,
then rapidly cooling the molded material to convert the entire material to white iron, and then
performing a heat treatment. Accordingly, the tensile strength of the scroll portion can be
sufficiently improved. Therefore, the freedom to design the scroll portion is considerably
improved and the scroll portion can be made smaller and given greater capacity. Based on
experimental results obtained by the present inventor, it is apparent that when the hardness is
in a range that is greater than HRB 90 but less than HRB 100, the scroll can demonstrate
sufficient durability during compressor operation, "breaking-in" can occur as soon as possible,

and seizing during abnormal operation does not occur. For this reason, the compressor
scroll has high tensile strength, demonstrates sufficient durability during operation, can be
"broken in" as early as possible, and does not undergo seizing during abnormal operation.
The compressor scroll according to an eleventh aspect is the compressor scroll according to
the tenth aspect, wherein a draft angle of the scroll portion in relation to a mold varies in
accordance with a winding angle.
Since a wrap draft angle is not provided or is constant in a conventional scroll, there is a
problem in that the wrap shape is not determined in accordance with strength and quality, and
material is wasted during the manufacture of the scroll. Also, when the shape of the scroll is
considered, the mold is readily affected by stress when the scroll is separated from the mold
because the radius of curvature of the wrap is reduced in progression toward the center
portion of the scroll wrap. Accordingly, it is difficult to extend the service life of the mold.
In view of this problem, the draft angle in relation to the mold varies in accordance with the
winding angle of the scroll portion in the scroll according to the present invention.
Accordingly, with this scroll, the shape of the scroll portion is determined in accordance with
strength and quality, and wasted material can be eliminated.
The compressor scroll according to a twelfth aspect is the compressor scroll part according to
the eleventh aspect, wherein the scroll portion presents a scroll shape in which a draft angle
in relation to the mold in the portion where winding starts near a center is larger than the draft
angle of an outside portion where winding ends. The scroll portion is preferably set so that
the draft angle continuously and gradually changes from where winding starts to where
winding ends. The stress applied to the mold in the vicinity of the center of the scroll during
mold release is reduced, the service life of the mold can be extended, and wasted material can
be more effectively eliminated. The scroll portion is also preferably set so that a draft angle
changes in a stepwise fashion from where winding starts to where winding ends. The stress
applied to the mold in the vicinity of the center of the scroll during mold release is reduced,
the service life of the mold can be extended, the draft angle in each of the angle ranges of the
scroll portion can be set in a simple manner, and wasted material can be more effectively
eliminated. The scroll portion is preferably set so that the draft angle in a prescribed angle
range between where winding starts and where winding ends is greater than the draft angle in
other angle ranges. This is because the stress applied to the mold in the vicinity of the
center of the scroll during mold release is reduced, the service life of the mold can be
extended, adverse effect in relation to near-net shaping in the scroll portion overall can be
further reduced, and wasted material can be more effectively eliminated. It is preferred that

at least the scroll portion be coated with resin in this scroll. This is because a coated resin is
more easily machined than when a molded member is machined directly, machining precision
can be improved, leakage of compressed medium can be reduced by filling the gaps, and
noise can be reduced due to the elasticity of the resin when scroll portions make contact with
each other.
With this scroll, the draft angle in the portion where winding starts near the center of the
scroll portion is greater than the draft angle of the portion where winding ends at the outer
side. Accordingly, the stress applied to the mold in the vicinity of the center of the scroll
can be reduced during mold release in which the scroll is released from the mold. As a
result, the service life of the mold can be extended.
The compressor scroll part according to a thirteenth aspect is the compressor scroll part
according to the eleventh aspect, wherein the scroll portion presents a scroll shape in which a
draft angle in relation to the mold in the portion where winding ends at the outer side is larger
than a draft angle of the portion where winding starts near the center. The scroll portion is
preferably set so that the draft angle continuously and gradually changes from where winding
starts to where winding ends. The stress applied to the mold in the vicinity of the center of
the spiral during mold release is reduced, the service life of the mold can be extended, and
wasted material can be more effectively eliminated. The scroll portion is also preferably set
so that a draft angle changes in a stepwise fashion from where winding starts to where
winding ends. The stress applied to the mold in the vicinity of the center of the scroll during
mold release is reduced, the service life of the mold can be extended, the draft angle in each
of the angle ranges of the scroll portion can be set in a simple manner, and wasted material
can be more effectively eliminated. The scroll portion is preferably set so that the draft
angle in a prescribed angle range between where winding starts and where winding ends is
greater than the draft angle in other angle ranges. This is because the stress applied to the
mold in the vicinity of the center of the scroll during mold release is reduced, the service life
of the mold can be extended, any adverse effect in relation to near-net shaping in the scroll
portion overall can be further reduced, and wasted material can be more effectively
eliminated. It is preferred that at least the scroll portion be coated with resin in this scroll
part. This is because leakage of a compressed medium can be reduced, and noise can also
be reduced.
With this scroll, the draft angle in the portion where winding ends at the outer side of the
scroll portion is greater than the draft angle of the portion where winding begins near the
center. Accordingly, the external peripheral portion of the scroll portion is thin. Therefore,

this configuration is effective for cases in which it is difficult to achieve machining precision,
and the precision in the external peripheral portion of the scroll portion can be assured even
when the thickness of the scroll portion is reduced.
The compressor scroll part according to a fourteenth aspect is the compressor scroll part
according to the tenth aspect, wherein the scroll portion has a first surface that slopes at a first
angle with respect to a line that is orthogonal to the flat surface portion, the first surface being
positioned on the internal peripheral side of the portion in the vicinity of the start of winding
near the center. A surface other than the first surface of the scroll portion has a slope angle
in relation to the line orthogonal to the flat plate portion that is less than the first angle. The
first surface of the scroll portion preferably is a surface that is not in contact with a
counterpart scroll that meshes in the relative movement of the fixed scroll and the movable
scroll. This is because the use of a large slope is ordinarily disadvantageous from the point
of managing surface precision, but since the surface (first surface) is not a surface that makes
contact with a counterpart scroll and affects the airtightness of the compression chamber,
there are no demerits. A surface (the surface that makes contact with a meshing counterpart
scroll and affects the level of airtightness of the compression chamber) other than the first
surface of the scroll portion preferably has a slope angle in relation to the line orthogonal to
the flat plate portion that is essentially 0°. This is because the surface precision of the scroll
can be kept high, and malfunctions are reduced in which gas refrigerant leaks from the
meshing portion of the two scrolls to an adjacent chamber during operation of the scroll
compressor.
In the portion adjacent to where winding starts in the scroll portion, in which the received
pressure near the center is increased, a first surface on the internal peripheral side is sloped at
a first angle to reliably assure increased strength and less deformation. On the other hand,
the portion set at a distance from the center of the scroll portion has a slope angle that is less
than the first angle, and a considerable reduction in capacity is avoided. The external
peripheral surface of the scroll portion adjacent to where the winding starts is a surface that
makes contact with the counterpart scroll and performs compression work. When a large
slope is used, it is difficult to control the surface precision of the sloped surface, i.e., the
precision of the profile shape at each height from the flat plate portion of the scroll portion
and the precision of the rounded shape along the boundary between the scroll portion and the
flat plate portion; and since refrigerant gas leakage is likely to increase in the contact portions
of the two scrolls, the slope angle is set to be less than the first angle.
In this manner, with a scroll compressor in which the scroll of the present invention is

adopted, the slope angle is reduced with priority given to increasing the capacity rather than
strength and the amount of deformation because pressure is relatively low in portions other
than the portion of the scroll portion adjacent to where the winding starts. In the first
surface on the internal peripheral side of the portion of the scroll portion adjacent to where
the winding starts, the slope angle is increased with priority given to increasing strength and
reducing the amount of deformation because pressure is relatively high. In the external
peripheral surface of the portion of the scroll portion that is adjacent to where winding starts,
the slope angle is reduced with consideration given to surface precision control and the
airtightness of the compression chamber. Accordingly, it can be assured that the thickness
of the scroll portion overall is reduced and capacity is increased. On the other hand, in the
portion of the high-pressure scroll portion that is adjacent to where winding starts, a slope
having a first angle is used, whereby strength can be assured and the amount of deformation
can be reduced to an acceptable level.
Another advantage is that, in portions other than the portion of the scroll portion that is
adjacent to where winding starts, the slope angle is reduced and surface precision control and
the airtightness of the compression chamber can be assured.
In a compressor for compressing carbon dioxide or another high-pressure refrigerant, the
strength must be increased in the center portion of the scroll, where stress is concentrated in
the scroll. With the scroll according to the present invention, the first surface positioned on
the internal peripheral side of the portion adjacent to where winding starts near the center is
sloped by a first angle (9) with respect to the line orthogonal to the flat plate portion. For
this reason, strength in the center portion of the spiral is increased in this scroll part.
Therefore, in a scroll compressor in which such a scroll part has been incorporated, the slider
can withstand an increase in pressure due to high pressure differences when carbon dioxide or
another high-pressure refrigerant is compressed. This effect allows the height of the teeth of
the scroll to be increased. In other words, the capacity of the compression chamber can be
increased while the diameter of the scroll portion is reduced. When the diameter of the
scroll compressor is reduced by reducing the diameter of the scroll, the diameter of the trunk
portion of the casing is reduced. When the diameter of the trunk portion of the casing is
reduced, the casing can exhibit the same compression strength at the thinner thickness, in
comparison with a conventional casing. Accordingly, the raw material costs and the like of
the casing can be reduced. When the diameter of the scroll is reduced, the scroll portion is
reduced in size and the sliding surface area of the thrust portion, which is subject to rigorous
conditions, can be increased. When such a scroll is molded by semi-molten die casting or

the like, the scroll has a surface roughness that is reduced to less than that obtained using
conventional casting. For this reason, with a scroll compressor in which such a scroll part
has been incorporated, cracks are not likely to occur in the surface of the scroll even when
carbon dioxide or another high-pressure refrigerant is compressed. Even when the scroll is
an unfinished article, such damage is less likely to occur. The volume circulation rate of
carbon dioxide is low. Accordingly, with a compressor for compressing carbon dioxide or
another high-pressure refrigerant, the diameter of the discharge port may be less than that of a
conventional article. Therefore, the space between the discharge port and the scroll wall
surface can be increased in size. Accordingly, the slope angle 9 of the first surface can be
increased, and the strength of the center portion of the scroll can be further enhanced. As a
result, a greater effect can be obtained in a scroll compressor in which such a scroll part is
incorporated.
The compressor scroll part according to a fifteenth aspect is the compressor scroll part
according to the fourteenth aspect, wherein the portion of the scroll portion near where
winding starts has a thickness at the boundary with the flat portion that is greater than in other
portions of the scroll portion.
The compressor slider preform according to a sixteenth aspect has a carbon content of 2.0
wt% to 2.7 wt%, a silicon content of 1.0 wt% to 3.0 wt%, a balance of iron that includes
unavoidable impurities, graphite that is smaller than the flake graphite of flake graphite cast
iron, and a hardness that is greater than HRB 90 but less than HRB 100 in at least a portion of
the slider preform. The hardness is more preferably greater than HRB 90 but less than HRB
95. As used herein, the term "slider preform" refers to a yet unmachined precursor or the
like to obtain a completing slider. When the hardness of the slider preform is HRB 90 or
less, a built-up edge is readily formed when the slider preform is machined, and grinding
processability is likely to be degraded. On the other hand, when the hardness of the slider
preform is HRB 100 or greater, machining costs tend to increase because tool abrasion,
chipping, and the like readily occur in the machining of the slider preform, and machining
costs also tend to increase due to higher cutting resistance and limitations in the cutting depth
and machining speed. The range in which the hardness is greater than HRB 90 but less than
HRB 100 substantially corresponds to the range in which a ferrite surface area ratio of the
base composition is from 50% to 5%. The graphite surface area ratio of the base
composition substantially corresponds to a range from 6% to 2%. The range in which the
hardness is greater than HRB 90 but less than HRB 95 substantially corresponds to the range
in which the ferrite surface area ratio of the base composition is less than 50% and greater

than 25%. The graphite surface area ratio of the base composition substantially corresponds
to a range that is less than 6% and greater than 3%.
The tensile strength can be freely adjusted by heat-treating a molded article obtained by
subjecting iron having the components described above to semi-molten or semi-solid die
casting and metal-mold casting, and thereafter rapidly cooling the molded material to convert
the entire material to white iron. It has been made apparent that the tensile strength of a
molded article manufactured via the heat treatment is in a proportional relationship with the
hardness of the molded article. The range in which the hardness is greater than HRB 90 but
less than HRB 100 substantially corresponds to a range in which the tensile strength is from
600 MPa to 900 MPa. In other words, control of the tensile strength of the molded article
can be substituted with the hardness, which is easy to measure. Another merit is that when
the slider preform is a scroll part preform, the freedom of designing the scroll portion is
considerably expanded to allow a smaller diameter or greater capacity to be achieved.
Therefore, the compressor slider preform demonstrates higher tensile strength than a slider
preform composed of flake graphite cast iron. Based on experimental results obtained by
the present inventor, it is apparent that when the hardness of the slider preform is in a range
that is greater than HRB 90 but less than HRB 100, good machinability is exhibited for the
case in which the slider is manufactured by a process in which iron having components such
as those described above is subjected to semi-molten or semi-solid die casting and
metal-mold casting, is then rapidly cooled to convert the entire material to white iron, and is
thereafter heat treated. Still another merit is that good machinability reduces the likelihood
of tool abrasion and tool chipping, extends tool service life, makes it less likely that a built-up
edge will form, facilitates grinding, and reduces machining costs because machining time can
be reduced. Yet another merit is that since the slider preform exhibits suitable hardness, the
slider preform is less likely to be damaged and handling is facilitated. It should also be
noted that even though the slider preform has good characteristics in terms of tool abrasion
and machining time, because the slider preform has lower hardness in comparison with FCD
having the same tensile strength (tensile strength is high at the same level of hardness), the
preform also has higher tensile strength than a conventional preform. When the slider
preform is cut, a counterpart slider (Oldham ring, seal, and the like in the case that the slider
is a movable scroll) is not damaged because the surface roughness is more easily reduced in
comparison with an FC material. In summary of the above, this compressor slider preform
has high tensile strength and exhibits good machinability when machining is required.
The compressor according to a seventeenth aspect comprises a slider having a carbon content

of 2.0 wt% to 2.7 wt%, a silicon content of 1.0 wt% to 3.0 wt%, a balance of iron that
includes unavoidable impurities, graphite that is smaller than the flake graphite of flake
graphite cast iron, and a hardness that is greater than HRB 90 but less than HRB 100 in at
least a portion of the slider. As used herein, the phrase "compressor" refers to, e.g., a scroll
compressor, a swing compressor, a rotary compressor, or the like. It is preferred that the
hardness be greater than HRB 90 but less than HRB 95. A range in which the hardness is
greater than HRB 90 but less than HRB 100 substantially corresponds to a range in which the
ferrite surface area ratio of the base composition is from 50% to 5%. The graphite surface
area ratio of the base composition substantially corresponds to a range from 6% to 2%. The
range in which the hardness is greater than HRB 90 but less than HRB 95 substantially
corresponds to a range in which the ferrite surface area ratio of the base composition is less
than 50% and greater than 25%. The graphite surface area ratio of the base composition
substantially corresponds to a range that is less than 6% and greater than 3%. The hardness
can be adjusted by a heating treatment that follows molding.
The tensile strength of a molded article can be freely adjusted by heat treatment for a molded
article obtained by subjecting iron having the components described above to semi-molten or
semi-solid die casting and metal-mold casting, and thereafter rapidly cooling the molded
material to convert the entire material to white iron. It has been made apparent that the
tensile strength of a molded article manufactured via the heat treatment is in a proportional
relationship with the hardness of the molded article. The range in which the hardness is
greater than HRB 90 but less than HRB 100 substantially corresponds to a range in which the
tensile strength is from 600 MPa to 900 MPa. In other words, control of the tensile strength
of the molded article can be substituted with control of the hardness, which is easy to
measure. Another merit is that when the slider is a scroll, the freedom of designing the
scroll portion is considerably expanded to allow a smaller diameter or greater capacity to be
achieved. Therefore, the compressor slider demonstrates higher tensile strength than a slider
composed of flake graphite cast iron. Based on experimental results obtained by the present
inventor, it is apparent that when the hardness is in a range that is greater than HRB 90 but
less than HRB 100, the slider can demonstrate sufficient durability during compressor
operation, "breaking-in" can occur as soon as possible, and seizing during abnormal operation
does not occur. Accordingly, in this compressor, tensile strength is high, sufficient
durability is demonstrated during compressor operation, "breaking-in" can occur as soon as
possible, and seizing during abnormal operation can be prevented. In this compressor, the
slider has a carbon content of 2.0 wt% to 2.7 wt%, a silicon content of 1.0 wt% to 3.0 wt%, a

balance of iron that includes unavoidable impurities, and graphite that is smaller than the
flake graphite of flake graphite cast iron. Therefore, merits and other advantages can be
obtained in that thrust loss can be reduced due to a smaller diameter, and higher capacity
obtained by reducing the thickness of the components, and damage is less likely to occur with
regard to inclusion of foreign matter and a sudden increase in internal pressure because of the
higher toughness in comparison with FC material. Even if damage were to occur, small
scrapings are not produced and pipes do not need to be cleaned. Such a compressor can be
regarded to be suitable in cases in which an upgrade is required.
The compressor according to an eighteenth aspect is the compressor according to the
seventeenth aspect, and is capable of accommodating a carbon dioxide (CO2) refrigerant.
This compressor is capable of accommodating a carbon dioxide (CO2) refrigerant.
Accordingly, the compressor can contribute to global environmental problems.
EFFECT OF THE INVENTION
The compressor slider according to the first aspect has high tensile strength, demonstrates
sufficient durability during operation, can be "broken in" as early as possible, and does not
undergo seizing during abnormal operation. This compressor slider has a carbon content of
2.0 wt% to 2.7 wt%, a silicon content of 1.0 wt% to 3.0 wt%, a balance of iron that includes
unavoidable impurities, and graphite that is smaller than the flake graphite of flake graphite
cast iron. Therefore, merits and other advantages can be obtained in that thrust loss can be
reduced due to a smaller diameter, and higher capacity obtained by reducing the thickness of
the components, and damage is less likely to occur with regard to inclusion of foreign matter
and a sudden increase in internal pressure because of the higher toughness in comparison
with FC material. Even if damage were to occur, small scrapings are not produced and
pipes do not need to be cleaned. Such a compressor can be regarded to be suitable in cases
in which an upgrade is required.
The compressor slider according to the second aspect is one in which a slider preform can be
made into a near-net shape. Therefore, the compressor slider can reduce machining costs
and can be manufactured at lower cost.
The compressor slider according to the third aspect is one in which the pressure required
during the molding step is reduced. Therefore, a press apparatus or a heating apparatus in
die casting is not required, and equipment costs can be reduced. As a result, the compressor
slider reduces molding costs and can be manufactured at lower cost.
In the fourth aspect, when the compressor slider is a scroll part, the ratio of the tensile
strength in relation to Young's modulus of the scroll part after heat processing is determined

so that costs are not incurred to achieve excessive strength in heat treatment. The
determination is based on research to determine the level of tensile strength that is sufficient
from the viewpoint of fatigue strength. In this determination, the ratio (H/T) of the scroll
portion is determined with consideration given to the required upper limit of the deformation
amount of the scroll portion from the viewpoint of the machining time, performance
reduction, and noise. Specifically, the increase in strength by heat treatment is limited so
that the ratio of the tensile strength in relation to Young's modulus is set to be 0.0046 or less.
Since the ratio of the tensile strength in relation to Young's modulus is determined in this
manner, a situation is avoided in which the scroll portion in the scroll according to the present
invention is subjected to an excessive increase in strength via a heat treatment that involves
costs and time, and the heat treatment can be suitably performed.
In the compressor slider according to the fifth aspect, sufficient fatigue strength and abrasion
resistance can be imparted to a stress concentration area, sliding portion, or the like. Since
the strength of the partially heat-treated portions is increased, the partially heat-treated
portions can be made thinner and more lightweight.
In the compressor slider according to the sixth aspect, in the case a bearing portion or another
portion that requires hardness in particular exists, abrasion in this portion can be sufficiently
reduced by setting the hardness of the portion to be greater than HRC 50 but less than HRC
65.
The compressor slider according to the seventh aspect is one in which good breaking-in
characteristics are imparted to the slider area that require slidability, and sufficient fatigue
strength is imparted to the stress concentration area.
In the compressor slider according to the eighth aspect, the occurrence of blowholes is
reduced.
In the compressor slider according to the ninth aspect, the occurrence of blowholes is reduced.
Also, blowholes inside a slider are unlikely to become exposed to the exterior when a
through-hole is formed in the opening formation portion, and degradation in fatigue strength
can be reduced.
The compressor scroll part according to the tenth aspect has high tensile strength,
demonstrates sufficient durability during operation, can be "broken in" as early as possible,
and does not undergo seizing during abnormal operation.
In the compressor scroll part according to the eleventh aspect, the shape of the scroll portion
is determined in accordance with strength and quality, and wasted material can be eliminated.
In accordance with the twelfth aspect, stress applied to the mold in the vicinity of the center

of the scroll can be reduced during mold release in which the scroll is released from the mold.
As a result, the service life of the mold can be extended.
In accordance with the thirteenth aspect, the precision in the external peripheral portion of the
scroll portion can be assured even when the thickness of the scroll portion is reduced.
In the scroll and the scroll compressor provided with the scroll according to the fourteenth
and fifteenth aspects, the slope angle is reduced with priority given to increasing the capacity
rather than strength and the amount of deformation of the scroll portion because pressure is
relatively low in portions other than the portion of the scroll portion adjacent to where the
winding starts. In the first internal peripheral surface of the portion of the scroll portion
adjacent to where the winding starts, the slope angle is increased with priority given to
increasing strength and reducing the amount of deformation because pressure is relatively
high. In the external peripheral surface of the portion of the s scroll portion that is adjacent
to where winding starts, the slope angle is reduced with consideration given to surface
precision control and the airtightness of the compression chamber. It can be assured that the
thickness of the scroll portion overall is reduced and capacity is increased. On the other
hand, in the portion of the high-pressure scroll portion that is adjacent to where winding starts,
a slope having a first angle is used, whereby strength can be assured and the amount of
deformation can be reduced to an acceptable level.
The compressor slider preform according to the sixteenth aspect has high tensile strength and
exhibits good machinability when machining is required.
In the compressor according to the seventeenth aspect, a slider is used that has higher tensile
strength than a slider composed of flake graphite cast iron. Based on experimental results
obtained by the present inventor, it is apparent that when the hardness is in a range that is
greater than HRB 90 but less than HRB 100, the slider can demonstrate sufficient durability
during compressor operation, "breaking-in" can occur as soon as possible, and seizing during
abnormal operation does not occur. Accordingly, in this compressor, tensile strength is high,
sufficient durability is demonstrated during compressor operation, "breaking-in" can occur as
soon as possible, and seizing during abnormal operation can be prevented. In this
compressor, the slider has a carbon content of 2.0 wt% to 2.7 wt%, a silicon content of 1.0
wt% to 3.0 wt%, a balance composed of iron having unavoidable impurities, and graphite that
is smaller than the flake graphite of flake graphite cast iron. Therefore, merits and other
advantages can be obtained in that thrust loss can be reduced due to a smaller diameter, and
higher capacity obtained by reducing the thickness of the components, and damage is less
likely to occur with regard to inclusion of foreign matter and a sudden increase in internal

pressure because of the higher toughness in comparison with FC material. Even if damage
were to occur, small scrapings are not produced and pipes do not need to be cleaned.
The compressor according to the eighteenth aspect can contribute to global environmental
problems.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal sectional view of a high-low pressure dome-type scroll
compressor according to a first embodiment of the present invention;
FIG. 2 is a bottom view of a fixed scroll incorporated in a high-low pressure
dome-type scroll compressor according to the first embodiment of the present invention;
FIG. 3 is a cross-sectional view along the line III-III of the fixed scroll incorporated
in a high-low pressure dome-type scroll compressor according to the first embodiment of the
present invention;
FIG. 4 is a top view of a movable scroll incorporated in a high-low pressure
dome-type scroll compressor according to the first embodiment of the present invention;
FIG. 5 is cross-sectional view along the line V-V of the movable scroll incorporated
in a high-low pressure dome-type scroll compressor according to the first embodiment;
FIG. 6 is a top view of an Oldham ring incorporated in a high-low pressure
dome-type scroll compressor according to the first embodiment;
FIG. 7 is a side view of an Oldham ring incorporated in a high-low pressure
dome-type scroll compressor according to the first embodiment;
FIG. 8 is a bottom view of an Oldham ring incorporated in a high-low pressure
dome-type scroll compressor according to the first embodiment;
FIG. 9 is a cross-sectional view showing a metal-mold to produce a fixed scroll
incorporated in a high-low pressure dome-type scroll compressor according to the first
embodiment and a fixed scroll preform molded by semi-molten die casting;
FIG. 10 is an enlarged view of the opening formation area of the preform of the fixed
scroll incorporated in a high-low pressure dome-type scroll compressor according to the first
embodiment;
FIG. 11 is a longitudinal-sectional view showing a metal-mold to produce a movable
scroll incorporated in a high-low pressure dome-type scroll compressor according to the first
embodiment and a movable scroll preform molded by semi-molten die casting;
FIG. 12 is an enlarged view of the center portion of a preform of a movable scroll
incorporated in a high-low pressure dome-type scroll compressor according to the first
embodiment;

FIG. 13 is a longitudinal sectional view showing a convention fixed scroll preform;
FIG. 14 is a longitudinal sectional view of a convention movable scroll preform;
FIG. 15 is a longitudinal sectional view of a crankshaft incorporated in a high-low
pressure dome-type scroll compressor according to the first embodiment;
FIG. 16(a) is a diagram showing the partition surface area in a conventional fixed
scroll;
FIG. 16(b) is a diagram showing the compression work area in a conventional fixed
scroll;
FIG. 16(c) is a diagram showing the thrust area in a conventional fixed scroll;
FIG. 16(d) is a diagram showing the partition surface area in the fixed scroll of the
first embodiment;
FIG. 16(e) is a diagram showing the compression work area in the fixed scroll of the
first embodiment;
FIG. 16(f) is a diagram showing the thrust area in the fixed scroll of the first
embodiment;
FIG. 17(a) is a diagram showing the partition surface area in a conventional movable
scroll;
FIG. 17(b) is a diagram showing the compression work area in a conventional
movable scroll;
FIG. 17(c) is a diagram showing the thrust area in a conventional movable scroll;
FIG. 17(d) is a diagram showing the partition surface area in the movable scroll of
the first embodiment;
FIG. 17(e) is a diagram showing the compression work area in the movable scroll of
the first embodiment;
FIG. 17(f) is a diagram showing the thrust area in the movable scroll of the first
embodiment;
FIG. 18(a) is a diagram showing the intake capacity formed by a conventional scroll;
FIG. 18(b) is a diagram showing the intake capacity formed by the scroll of the first
embodiment;
FIG. 19 is a schematic diagram of a test apparatus used for testing the abrasion
resistance and seizing resistance of a molded article manufactured using semi-molten die
casting;
FIG. 20 is a graph showing the relationship between the hardness and the abrasion
resistance of a molded article manufactured using semi-molten die casting;

FIG. 21 is a graph showing the relationship between the hardness and the
"breaking-in" of a scroll manufactured using semi-molten die casting;
FIG. 22 is a graph showing the relationship between the hardness and the seizing
resistance of a molded article manufactured using semi-molten die casting;
FIG. 23 is a graph showing the relationship between the hardness and the tensile
strength of a molded article manufactured using semi-molten die casting;
FIG. 24 is a graph showing the relationship between the notching distance and the
cutting resistance of a molded article manufactured using semi-molten die casting;
FIG. 25 is a graph showing a comparison of the cutting tool abrasion in relation to a
molded article manufactured using semi-molten die casting;
FIG. 26 is a simple process chart of the metal-mold casting step according to a
modified example (J) of the first embodiment;
FIG. 27 is an enlarged view of the opening formation area of the fixed scroll preform
according to a modified example (K) of the first embodiment;
FIG. 28 is an enlarged view of the opening formation area of the fixed scroll preform
according to a modified example (K) of the first embodiment;
FIG. 29 is a cross-sectional view of the movable scroll according to a modified
example (L) of the first embodiment;
FIG. 30 is an enlarged view of the opening formation area of the movable scroll
according to a modified example (L) of the first embodiment;
FIG. 31 is an enlarged view of the opening formation area of the movable scroll
according to a modified example (L) of the first embodiment;
FIG. 32(a) is a diagram showing the intake capacity formed by a conventional scroll;
FIG. 32(b) is a diagram showing the intake capacity formed by the scroll of a
modified example (O) of the first embodiment;
FIG. 33 is a cross-sectional view of an inner drive-type movable scroll according to
the second embodiment;
FIG. 34 is a cross-sectional view showing the metal-mold for manufacturing the
movable scroll according to the second embodiment, and the movable scroll preform molded
by semi-molten die casting;
FIG. 35 is a cross-sectional view of the metal-mold for manufacturing the movable
scroll incorporated in a high-low pressure dome-type scroll compressor according to the third
embodiment, and the movable scroll molded by semi-molten die casting;
FIG. 36 is an enlarged view of the wrap mold portion of a metal-mold for

manufacturing the movable scroll incorporated in a high-low pressure dome-type scroll
compressor according to the third embodiment;
FIG. 37 is a top view of the movable scroll incorporated in a high-low pressure
dome-type scroll compressor according to the third embodiment;
FIG. 38 is a cross-sectional view along the line A-A of the movable scroll
incorporated in a high-low pressure dome-type scroll compressor according to the third
embodiment;
FIG. 39 is a graph showing the relationship between the winding angle a and the
draft angle 9 of the movable scroll incorporated in a high-low pressure dome-type scroll
compressor according to the third embodiment;
FIG. 40 is a bottom view of the fixed scroll incorporated in a high-low pressure
dome-type scroll compressor of the third embodiment;
FIG. 41 is a cross-sectional view along the line B-B of the fixed scroll incorporated
in a high-low pressure dome-type scroll compressor according to the third embodiment;
FIG. 42 is a graph showing the relationship between the winding angle a and the
draft angle 0 of the movable scroll according to a modified example (A) of the third
embodiment;
FIG. 43 is a graph showing the relationship between the winding angle a and the
draft angle 6 of the movable scroll according to a modified example (B) of the third
embodiment;
FIG. 44 is a graph showing the relationship between the winding angle a and the
draft angle 8 of the movable scroll according to a modified example (C) of the third
embodiment;
FIG. 45 is a cross-sectional view of a movable scroll manufactured by coating a resin
onto the movable scroll according to a modified example (D) of the third embodiment;
FIG. 46 is a longitudinal sectional view of the fixed scroll according to a modified
example (F) of the third embodiment;
FIG. 47 is a longitudinal sectional view of the movable scroll according to a
modified example (F) of the third embodiment;
FIG. 48 is a longitudinal sectional view of a metal mold for manufacturing the
movable scroll incorporated in a high-low pressure dome-type scroll compressor according to
the fourth embodiment, and the movable scroll preform molded by semi-molten die casting;
FIG. 49 is a bottom view of the fixed scroll incorporated in a high-low pressure
dome-type scroll compressor according to the fourth embodiment;

FIG. 50 is a bottom view of the fixed scroll preform according to the fourth
embodiment;
FIG. 51 is a cross-sectional view along the line C-C of the fixed scroll preform
according to the fourth embodiment;
FIG. 52 is a cross-sectional view along the line D-D of the fixed scroll incorporated
in a high-low pressure dome-type scroll compressor according to the fourth embodiment;
FIG. 53 is a partial enlarged view of the cross section along the line D-D of the fixed
scroll incorporated in a high-low pressure dome-type scroll compressor according to the
fourth embodiment;
FIG. 54 is a longitudinal sectional view of the movable scroll incorporated in a
high-low pressure dome-type scroll compressor according to the fourth embodiment;
FIG. 55 is a diagram showing a state in which a gas refrigerant is compressed by
varying the state of the meshing of the wrap of the two scrolls in a high-low pressure
dome-type scroll compressor according to the fourth embodiment;
FIG. 56 is a diagram showing a state in which a gas refrigerant is compressed by
varying the state of the meshing of the wrap of the two scrolls in a high-low pressure
dome-type scroll compressor according to the fourth embodiment;
FIG. 57 is a diagram showing a state in which a gas refrigerant is compressed by
varying the state of the meshing of the wrap of the two scrolls in a high-low pressure
dome-type scroll compressor according to the fourth embodiment;
FIG. 58(a) is a diagram showing the range of the internal peripheral surface of the
portion of the wrap of the fixed scroll adjacent to where winding starts according to the fourth
embodiment;
FIG. 58(b) is a diagram showing the range of the internal peripheral surface of the
portion of the wrap of the movable scroll adjacent to where winding starts according to the
fourth embodiment;
FIG. 59 is a longitudinal sectional view of a swing compressor according to the fifth
embodiment;
FIG. 60 is a top view of a cylinder block according to the fifth embodiment;
FIG. 61 is a lateral cross-sectional view of a cylinder chamber of the swing
compressor according to the fifth embodiment;
FIG. 62 is a top view of a piston of the swing compressor according to the fifth
embodiment;
FIG. 63 is a top view of a cylinder block of a rotary compressor according to a

modified example (A) of the fifth embodiment; and
FIG. 64 is a lateral cross-sectional view of a cylinder chamber of a rotary compressor
according to a modified example (A) of the fifth embodiment.
DESCRIPTION OF THE REFERENCE SYMBOLS
1 High-low pressure dome-type scroll compressor (compressor)
17, 817 Crankshafts (sliders)
17a Eccentric shaft (partial heat treatment location)
17b Main shaft (partial heat treatment location)
23 Housing (slider)
24, 525, 644, 734 Fixed scrolls (sliders, scrolls)
24a, 26a, 96a, 184, 186 End plates (flat plate portions)
24b, 26b, 96b, 524b, 526b, 185, 187 Wraps (scroll portion)
24P, 26P, 96P, 184a, 186a End surfaces (first plate surfaces)
26, 96, 526, 646, 736 Movable scrolls (sliders, scrolls)
39 Oldham ring (slider)
39a, 39b Movable scroll-side key portions (partial heat treatment locations)
39c, 39dHousing-side key portions (partial heat treatment locations)
60 Lower main bearing (slider)
70, 80, 90, 180, 280 Metal-molds
71 a, 72a, 81a, 91a Convexities
124, 724 Fixed scroll preform (slider preforms)
126, 196, 626, 726 Movable scroll preform (slider preforms)
185a Portion of the wrap of the fixed scroll adjacent to where winding starts (portion
adjacent to where winding starts near the center)
187a Portion of the wrap of the movable scroll adjacent to where winding starts (portion
adjacent to where winding starts near the center)
310b Final product (slider)
821 Piston
823 Front head (slider)
824 First cylinder block (slider)
825 Middle plate (slider)
826 Second cylinder block (slider)
827 Rear head (slider)
801 Swing compressor (compressor)

901 Rotary compressor (compressor)
921 Roller (slider)
924 Cylinder block (slider)
IS85a, IS87a Internal peripheral surfaces of the portion of the wrap adjacent to where
winding starts (first surfaces)
SC1 Peripheral portion of the base of the wrap of the fixed scroll (partial heat treatment
location, stress concentration area)
SC2 Innermost portion of the wrap of the fixed scroll (partial heat treatment location,
stress concentration area)
SC3 Peripheral portion of the base of the wrap of the movable scroll (partial heat
treatment location, stress concentration area)
SC4 Peripheral portion of the base of the bearing portion of the movable scroll (partial
heat treatment location, stress concentration area)
SC5 Notched portion formed in the vicinity of the design center of the end plate of the
bearing portion of the movable scroll (partial heat treatment location, stress concentration
area)
SC6 Innermost portion of the wrap of the movable scroll (partial heat treatment location,
stress concentration area)
SC7 Peripheral portion of the notched portion between the main shaft portion and the
eccentric shaft portion of the crankshaft (partial heat treatment location, stress concentration
area)
SC8 Peripheral portion of the base of the blade portion in the piston (partial heat
treatment location, stress concentration area)
BEST MODE FOR CARRYING OUT THE INVENTION
First embodiment
A compressor in which the slider according to a first embodiment is used will be
described using a high-low pressure dome-type scroll compressor as an example. The
high-low pressure dome-type compressor of the first embodiment is designed so as to be
capable of withstanding carbon dioxide refrigerant (CO2), R410A, or another high-pressure
refrigerant.
The high-low pressure dome-type scroll compressor 1 according to the first
embodiment constitutes a refrigerant circuit together with an evaporator, a condenser, an
expansion mechanism, and the like; acts to compress a gas refrigerant in the refrigerant
circuit; and is primarily composed of a hermitically sealed cylindrical dome-type casing 10, a

scroll compression mechanism 15, an Oldham ring 39, a drive motor 16, a lower main
bearing 60, a suction tube 19, and a discharge tube 20, as shown in FIG. 1. The constituent
elements of the high-low pressure dome-type scroll compressor 1 will be described in detail
below.
(Details of the constituent elements of a high-low pressure dome-type scroll compressor)
(1) Casing
The casing 10 primarily has a substantially cylindrical trunk casing 11, a
saucer-shaped upper wall portion 12 welded in an airtight manner to an upper end of the
trunk casing 11, and a saucer-shaped lower wall portion 13 welded in an airtight manner to a
lower end of the trunk casing 11. Primarily accommodated in the casing 10 are the scroll
compression mechanism 15 for compressing gas refrigerant, and the drive motor 16 disposed
below the scroll compression mechanism 15. The scroll compression mechanism 15 and the
drive motor 16 are connected by a crankshaft 17 disposed so as to extend in the vertical
direction inside the casing 10. As a result, a clearance space 18 is formed between the scroll
compression mechanism 15 and the drive motor 16.
(2) Scroll compression mechanism
The scroll compression mechanism 15 is primarily composed of a housing 23, a
fixed scroll 24 provided in close contact above the housing 23, and a movable scroll 26 for
meshing with the fixed scroll 24, as shown in FIG. 1. The constituent elements of the scroll
compression mechanism 15 will be described in detail below,
a) Housing
The housing 23 is press-fitted and secured to the trunk casing 11 in peripheral
direction across the entire external peripheral surface of the housing. In other words, the
trunk casing 11 and the housing 23 are in kept close contact in an airtight manner across the
entire periphery. For this reason, the interior of the casing 10 is partitioned into a
high-pressure space 28 below the housing 23, and a low-pressure space 29 above the housing
23. Also, the fixed scroll 24 is fixedly fastened by a bolt 38 to the housing 23 so that the
upper end surface of the housing 23 is in close contact with the lower end surface of the fixed
scroll 24. A housing concavity 31 concavely disposed in the center of the upper surface of
the housing 23, and a bearing portion 32 that extends downward from the center of the lower
surface of the housing 23, are formed in the housing 23. A bearing hole 33 that passes
through in the vertical direction is formed in the bearing portion 32, and a main shaft portion
17b of the crankshaft 17 is rotatably fitted to the bearing hole 33 via the a shaft bearing 34.
In the first embodiment, the housing 23 is manufactured using a novel and special

manufacturing method. The manufacturing method is described in detail below in the
section titled "Method for manufacturing a slider."
b) Fixed scroll
The fixed scroll 24 is primarily composed of an end plate 24a and a scroll (involute
shape) wrap 24b that extends downward from the lower surface 24P of the end plate 24a, as
shown in FIGS. 1 to 3. A discharge hole 41 that is in communication with a later-described
compression chamber 40, and an enlarged concave portion 42 that is in communication with
the discharge hole 41, are formed in the end plate 24a. The discharge hole 41 is formed so
as to extend in the vertical direction in the center portion of the end plate 24a. The enlarged
concave portion 42 is a concavity that is formed so as to widen in the horizontal direction on
the upper surface of the end plate 24a. An opening formation area P (see FIG. 9) provided
with the discharge hole 41 is thinly formed in advance in the fixed scroll 24, as shown in the
manufacturing method described below, whereby the generation of blowholes CN (see FIG.
9) is reduced. The ratio of the height of the wrap 24b in relation to the thickness of wrap
24b is 15 or more. The angle portion and the corner portion of the wrap 24b have a rounded
shape that fits into the angle portion and corner portion of the wrap 26b of the movable scroll.
A lid body 44 is fixedly fastened with a bolt 44a to the upper surface of the fixed
scroll 24 so as to straddle the enlarged concave portion 42. A muffler space 45 for muffling
the operating noise of the scroll compression mechanism 15 is formed by covering the
enlarged concave portion 42 with a lid body 44. The fixed scroll 24 and the lid body 44 are
sealed by close contact via packing, which is not depicted.
In the first embodiment, the fixed scroll 24 is manufactured using a novel and
special manufacturing method. The manufacturing method is described in detail below in
the section titled "Method for manufacturing a slider."
c) Movable scroll
The movable scroll 26 is an outer drive-type movable scroll and is primarily composed of an
end plate 26a, a scroll (involute shape) wrap 26b that extends upward from the end surface
26P of the end plate 26a, a bearing portion 26c that extends downward from the lower surface
of the end plate 26a and is fitted to the outer side of the crankshaft 17, and a groove portion
26d (see FIG. 5) formed in the two ends of the end plate 26a, as shown in FIGS. 1, 4 and 5.
The movable scroll 26 is supported by the housing 23 via an Oldham ring 39 fitted into the
groove portion 26d (see FIG. 1). An eccentric shaft portion 17a of the crankshaft 17 is fitted
into the bearing portion 26c. The movable scroll 26, by being incorporated into the scroll
compression mechanism 15 in this manner, non-rotatably orbits the interior of the housing 23

due to the rotation of the crankshaft 17. The wrap 26b of the movable scroll 26 meshes with
the wrap 24b of the fixed scroll 24, and the compression chamber 40 is formed between the
contact portions of the two wraps 24b, 26b (see FIG. 18(b)). In the compression chamber 40,
the two wraps are displaced toward the center in accompaniment with the orbiting of the
movable scroll 26, and the capacity of the compression chamber decreases. In the high-low
pressure dome-type scroll compressor 1, gas refrigerant in the compression chamber 40 is
compressed in this manner.
In the first embodiment, the movable scroll 26 is manufactured using a novel and special
manufacturing method. The manufacturing method is described in detail below in the
section titled "Method for manufacturing a slider."
d) Other
A communication channel 46 is formed in the scroll compression mechanism 15 across the
fixed scroll 24 and the housing 23. The communication channel 46 is composed of a
scroll-side channel 47 formed as a notch in the fixed scroll 24, and a housing-side channel 48
formed as a notch in the housing 23. The upper end of the communication channel 46, i.e.,
the upper end of the scroll-side channel 47, opens to the enlarged concave portion 42, and the
lower end of the communication channel 46, i.e., the lower end of the housing-side channel
48, opens to the lower end surface of the housing 23. In other words, the lower end opening
of the housing-side channel 48 is a discharge port 49 through which refrigerant in the
communication channel 46 flows to the clearance space 18.
(3) Oldham ring
An Oldham ring 39 is a member for preventing the movable scroll 26 from rotating, and is
primarily composed of a main body 39e, movable scroll-side key portions 39a, 39b, and
housing-side key portions 39c, 39d, as shown in FIGS. 6 to 8. The main body 39e is a
substantially annular molded article, as shown in FIGS. 6 and 8. The movable scroll-side
key portions 39a, 39b face in opposing directions, with the axis of the main body 39e
disposed therebetween, and are a pair of projections that extend to one side along the axial
direction from projection portions that extend to the external peripheral side in the radial
direction of the main body 39e. The housing-side key portions 39c, 39d face in opposing
directions, with the axis of the main body 39e disposed therebetween; are a pair of
projections that extend to the opposite side of the movable scroll-side key portions 39a, 39b
along the axial direction from projection portions that extend to the external peripheral side in
the radial direction of the main body 39e; and are disposed in a position that is inclined
substantially 90° from the movable scroll-side key portions 39a, 39b about the center of the

axis. The movable scroll-side key portions 39a, 39b are fitted into a grove portion 26d of
the movable scroll 26, and the housing-side key portions 39c, 39d are fitted into an Oldham
groove (not shown) formed in the housing 23. The Oldham grooves are elliptical grooves
disposed in positions so that the grooves face each other in the housing 23.
In the first embodiment, the Oldham ring 39 is manufactured using a novel and special
manufacturing method. The manufacturing method is described in detail below in the
section titled "Method for manufacturing a slider."
(4) Drive motor
The drive motor 16 is a DC motor in the first embodiment, and is primarily composed of an
annular stator 51 secured to the inner wall surface of the casing 10, and a rotor 52 rotatably
accommodated with a small gap (air gap channel) inside the stator 51. The drive motor 16
is disposed so that the upper end of a coil end 53 formed at the upper end of the stator 51 is at
substantially the same height position as the lower end of the bearing portion 32 of the
housing 23.
A copper wire is wrapped around a tooth portion of the stator 51, and a coil end 53 is formed
above and below the stator. The external peripheral surface of the stator 51 is provided with
core cut portions that have been formed as notches in a plurality of locations from the upper
end surface to the lower end surface of the stator 51 at prescribed intervals in the peripheral
direction. A motor cooling channel 55 that extends in the vertical direction is formed by the
core cut portions between the trunk casing 11 and the stator 51.
A rotor 52 is drivably connected to the movable scroll 26 of the scroll compression
mechanism 15 via the crankshaft 17 disposed in the axial center of the trunk casing 11 so as
to extend in the vertical direction. A guide plate 58 for guiding the refrigerant that has
flowed out of the discharge port 49 of the communication channel 46 to the motor cooling
channel 55 is disposed in the clearance space 18.
(5) Crankshaft
The crankshaft 17 is a substantially cylindrical integrally molded article, as shown in FIG. 1,
and is primarily composed of an eccentric shaft portion ] 7a, a main shaft portion 17b, a
balance weight portion 17c, and a secondary shaft portion 17d. The eccentric shaft portion
17a is accommodated in the bearing portion 26c of the movable scroll 26. The main shaft
portion 17b is accommodated in the bearing hole 33 of the housing 23 via the shaft bearing
34. The secondary shaft portion 17d is accommodated in the lower main bearing 60.
In the first embodiment, the crankshaft 17 is manufactured using a novel and special
manufacturing method. The manufacturing method is described in detail below in the

section titled "Method for manufacturing a slider."
(6) Lower main bearing
The lower main bearing 60 is disposed in a lower space below the drive motor 16. The
lower main bearing 60 is secured to the trunk casing 11, constitutes the lower end-side
bearing of the crankshaft 17, and accommodates the secondary shaft portion 17d of the
crankshaft 17.
In the present embodiment, the lower main bearing 60 is manufactured using a novel and
special manufacturing method. The manufacturing method is described in detail below in
the section titled "Method for manufacturing a slider."
(7) Suction tube
The suction tube 19 is used for guiding the refrigerant of the refrigerant circuit to the scroll
compression mechanism 15 and is fitted in an airtight manner in the upper wall portion 12 of
the casing 10. The suction tube 19 passes through the low-pressure space 29 in the vertical
direction, and the inside end portion is fitted into the fixed scroll 24.
(8) Discharge tube
The discharge tube 20 is used for discharging the refrigerant inside the casing 10 to the
exterior of the casing 10, and is fitted in an airtight manner into the trunk casing 11 of the
casing 10. The discharge tube 20 has an inside end portion 36 formed in the shape of a
cylinder extending in the vertical direction, and is secured to the lower end portion of the
housing 23. The inside end opening of the discharge tube 20, i.e., the inlet, is opened
downward.
(Method for manufacturing a slider)
In the high-low pressure dome-type scroll compressor 1 according to the first
embodiment, a crankshaft 17, a housing 23, a fixed scroll 24, a movable scroll 26, an Oldham
ring 39, and a lower main bearing 60 constitute sliders. These sliders are manufactured
using the manufacturing method described below.
(1) (Raw material)
The iron material as the raw material of the sliders according to the first embodiment
is a billet to which the following components have been added: C: 2.3 to 2.4 wt%, Si: 1.95 to
2.05 wt%, Mn: 0.6 to 0.7 wt%, P: O.035 wt%, S: to 1.00 wt%. As used herein, weight ratios are ratios in relation to the entire amount. Also,
the term "billet" refers to a pre-molded material in which an iron material having the
above-described components has been temporarily melted in a melting furnace and thereafter
molded into a cylindrical shape or the like using a continuous casting apparatus. Here, the

content of C and Si is determined so as to satisfy two objects: to achieve a tensile strength
and tensile modulus of elasticity that are greater than those of flake graphite cast iron, and to
provide a suitable fluidity for molding a slider preform having a complex shape. The Ni
content is determined so as to achieve a metal structure that improves the toughness of the
metal structure and is suitable for preventing surface cracks during molding.
(2) Manufacturing step
The sliders according to the first embodiment are manufactured via a semi-molten
die casting step, a heat treatment step, a finishing step, and a partial heat treatment step. The
steps will be described in detail below.
a) Semi-molten die casting step
In the semi-molten die casting step, first, a billet is brought to a semi-molten state by
high-frequency heating. Next, the semi-molten billet is introduced into a prescribed metal
mold, and is then molded into a desired shape while a prescribed pressure is applied using a
die casting machine to obtain a slider preform. The metal structure of the slider preform
becomes white iron overall when the slider preform is removed from the mold and rapidly
cooled. The slider preform is slightly larger than the slider that will be ultimately obtained,
and the slider preform becomes the final slider when the machining tolerance has been
removed in a later final finishing step.
In the first embodiment, the preform 124 of the fixed scroll 24 is molded using the
metal mold 70 shown in FIG. 9, and the preform 126 of the movable scroll 26 is molded using
the metal mold 80 shown in FIG. 11.
(Molding of the fixed scroll)
The metal mold 70 for obtaining a preform 124 of the fixed scroll 24 by semi-molten
die casting is composed of a first mold portion 71 and a second mold portion 72. The shape
of a space portion 73 that is formed when the first mold portion 71 and the second mold
portion 72 are combined corresponds to the shape of the external appearance of the fixed
scroll 24 (i.e., the preform 124) prior to cutting.
A convexity 71a and a convexity 72a are formed on the first mold portion 71 and the
second mold portion 72, respectively, so as to face each other in order to form an opening
formation area P, which is an area in which a discharge hole 41 will be formed in the vicinity
of the center of the preform 124 of the fixed scroll 24. The spacing between the convexity
71a and the convexity 72a is set to 4 mm or less. Therefore, the generation of blowholes
CN can be further reduced because the thickness t2 (see FIGS. 9 and 10) of the opening
formation area P is reduced to 4 mm or less.

Here, as a comparative example, the thickness of an opening formation area Q in the
vicinity of the center of the preform 224 is kept about the same as the thickness of the
peripheral portions when the preform 224 of a conventional fixed scroll formed by
semi-molten die casting shown in FIG. 13 is considered. Therefore, blowholes CN may be
generated over a broad range inside a part 224a that corresponds to an end plate because
blowholes are also generated in the vicinity of the center of the part 224a that corresponds to
an end plate. Accordingly, the blowholes CN are exposed to the exterior from the discharge
hole 241 when the discharge hole 241 (portion surrounded by two imaginary lines in FIG. 13)
is formed by drilling into the opening formation area Q in the vicinity of the center of the
preform 224. As a result, the fatigue strength of the fixed scroll after manufacture is
considerably reduced.
(Molding of the movable scroll)
The metal mold 80 used in semi-molten die casting of a preform 126 of a movable
scroll 26 is composed of a first mold portion 81 and a second mold portion 82, as shown in
FIG. 11. The shape of the space 83 formed when the first mold portion 81 and the second
mold portion 82 are combined corresponds to the shape of the external appearance of the
movable scroll 26 (i.e., the preform 126) prior to cutting.
A convexity 81a for forming an internal space 26f (see FIG. 5) of the bearing portion
26c of the movable scroll 26 is formed in the first mold portion 81. The spacing of the
convexity 81a and the second mold portion 82 is set to 4 mm or less. Therefore, the
thickness t1 (see FIGS. 11 and 12) of the center portion of the art that corresponds to an end
plate in the preform 126 of the movable scroll 26 is 4 mm or less. Accordingly, the
occurrence of blowholes CN can be reduced in this portion.
The preform 126 of the movable scroll 26 has a thickness tl in a center portion 26e
of the part that corresponds to an end plate. This thickness is less than the thickness of the
preform of a movable scroll of an inner drive; i.e., a movable scroll in which a bearing unit
composed of a solid rounded rod fits inside the drive shaft. Accordingly, with this movable
scroll 26, the occurrence of blowholes CN can be reduced In comparison with the movable
scroll of an inner drive.
Here, when a conventional movable scroll preform 226 formed by semi-molten die
casting shown in FIG. 14 is considered as a comparative example, the thickness of the center
portion 226e is about the same as that of the peripheral portions. Therefore, numerous
blowholes CN are generated in the vicinity of the center of the part 226a that corresponds to
an end plate. Accordingly, the strength of the movable scroll formed in such a manner is

reduced. In particular, since the largest gas load (or pressure) occurs in the center portion
226e during operation of the scroll compressor, the end plate is likely to deform when the
strength of the center portion 226e is reduced. Furthermore, when the end plate deforms,
the sliding state between the movable scroll and the fixed scroll is degraded, and this results
in abrasion and seizing.
b) Heat treatment step
In the heat treatment step, the slider preform after the semi-molten die casting step is
heat treated. In this heat treatment step, the metal structure of the slider preform changes
from a white iron structure to a metal structure composed of a pearlite/ferrite base and
granular graphite. The graphitization and pearlite transformation of the white iron structure
can be adjusted by adjusting the heat treatment temperature, the holding time, the cooling rate,
and the like. As described in, e.g., "Research of Semi-molten Iron Molding Techniques,"
Honda R&D Technical Review, Vol. 14, No. 1, a metal structure having a tensile strength of
about 500 MPa to 700 MPa and a hardness of about HB 150 (HRB 81 (converted value from
the SAE J 417 hardness conversion table)) to HB 200 (HRB 96 (converted value from the
SAE J 417 hardness conversion table)) can be obtained by holding the metal for 60 minutes at
950°C and thereafter gradually cooling the metal in the furnace at a cooling rate of 0.05 to
0.10°C/sec. Such a metal structure is primarily ferrite, and is therefore soft and has
excellent machinability. However, a built-up edge of a blade during machining may be
formed, and the service life of the blade tool may be reduced. The metal is held for 60
minutes at 1000°C, then air cooled, held for a prescribed length of time at a temperature that
is slightly lower than the initial temperature, and thereafter air cooled, whereby a metal
structure having a tensile strength of about 600 MPa to 900 MPa and a hardness of about HB
200 (HRB 96 (converted value from the SAE J 417 hardness conversion table)) to HB 250
(HRB 105, HRC 26 (converted value from the SAE J 417 hardness conversion table; HRB
105 is a reference value for extending beyond the effective practical range of a test type)) can
be obtained. In such a metal structure, a substance whose hardness is equal to that of flake
graphite cast iron has the same machinability as flake graphite cast iron, and better
machinability than spheroidal graphite cast iron having the same ductility and toughness.
Also possible is a method in which the metal is held for 60 minutes at 1000°C, cooled in oil,
held for a prescribed length of time at a temperature that is slightly lower than the initial
temperature, and thereafter air cooled, whereby a metal structure having a tensile strength of
about 800 MPa to 1300 MPa and a hardness of about HB 250 (HRB 105, HRC 26 (converted
value from the SAE J 417 hardness conversion table; HRB 105 is a reference value for

extending beyond the effective practical range of a test type)) to HB 350 (HRB 122, HRC 41
(converted value from the SAE J 417 hardness conversion table; HRB 122 is a reference
value for extending beyond the effective practical range of a test type)) can be obtained.
Such a metal structure is primarily pearlite, and is therefore hard and has poor machinability
but possesses excellent abrasion resistance. However, there is a possibility that the metal
will damage the other member of the sliding pair due to excessive hardness.
In the heat treatment step in the first embodiment, the slider preform is heat treated
under conditions that cause the hardness to be greater than HRB 90 (HB 176 (converted value
from the SAE J 417 hardness conversion table) but less than HRB 100 (HB 219 (converted
value from the SAE J 417 hardness conversion table). It is apparent that when the slider
preform is manufactured using semi-molten die casting, the hardness of the slider preform is
in a proportional relationship with the tensile strength of the slider preform, and therefore
substantially corresponds to a range in which the tensile strength of the slider preform in this
case is from 600 MPa to 900 MPa.
In the heat treatment step in the first embodiment, the slider preform is heat treated
under conditions that cause the hardness to be greater than HRB 90 (HB 176 (converted value
from the SAE J 417 hardness conversion table) but less than HRB 100 (HB 219 (converted
value from the SAE J 417 hardness conversion table). It is apparent that when the slider
preform is manufactured using semi-molten die casting, the hardness of the slider preform is
in a proportional relationship with the tensile strength of the slider preform, and therefore
substantially corresponds to a range in which the tensile strength of the slider preform in this
case is from 600 MPa to 900 MPa.
In the heat treatment step of the preform 124 of the fixed scroll 24 and the preform 126 of the
movable scroll 26, heat treatment is carried out so that the ratio of the tensile strength in
relation to Young's modulus is 0.0046 or less. Heat treatment is carried out so that the ratio
of the tensile strength in relation to Young's modulus is 0.0033 or more, so that the ferrite
ratio is reduced to a level that allows abrasion resistance to be assured and so that a built-up
edge is less likely to be formed during cutting. Since Young's modulus is 175 to 190 GPa
regardless of the heat treatment, the heat treatment is carried out so that the tensile strength is
about 600 MPa to 900 MPa.
c) Finishing step
In the finishing step, the slider preform is machined and the slider is completed.
In the finishing step of the preform 124 of the fixed scroll 24, the discharge hole 41, which is
a through-hole in the opening formation area P, is formed by conventionally known drilling

or the like, and the portion corresponding to the warp is cut by end milling or the like. The
height H from the end plate 24P to the distal end, as well as the thickness T, are given
prescribed design values, as shown in FIG. 3.
In the finishing step of the preform 126 of the movable scroll 26, the portion corresponding to
the warp is cut by end milling or the like, and a notched portion (counterbore) SC5 for
dispersing the stress of a gas load is formed by end milling or the like. The height H from
the end plate 26P to the distal end, as well as the thickness T, are given prescribed design
values, as shown in FIG. 5. The notched portion (counterbore) SC5 acts to disperse stress of
the base portion of the wrap 26b, which is the portion in which stress is maximally
concentrated.
When the high-low pressure dome-type scroll compressor 1 according to the first
embodiment is incorporated in a refrigerant circuit of a refrigerant apparatus in which R410A
is used as a refrigerant, the height H and thickness T of the wraps 24b and 26b are designed
so that the ratio (H/T) is 10 to 19, assuming that the ratio of tensile strength in relation to
Young's modulus of the fixed scroll 24 and the movable scroll 26 is 0.0033 to 0.0046. The
amount of flexing (deformation amount) at the distal end of the end portion (end portion
where winding starts) at the scroll center of the wraps 24b, 26b can be kept within an
acceptable range by using such a design, and there is no problem in terms of strength, even
when R410A, which is a gas refrigerant used in the refrigerant apparatus, is at maximal
pressure.
When the high-low pressure dome-type scroll compressor 1 according to the first
embodiment is incorporated in a refrigerant circuit of a refrigerant apparatus in which carbon
dioxide is used as a refrigerant, the height H and thickness T of the wraps 24b and 26b are
designed so that the ratio (H/T) is 2 to 8, assuming that the ratio of tensile strength in relation
to Young's modulus of the fixed scroll 24 and the movable scroll 26 is 0.0033 to 0.0046.
The amount of flexing (deformation amount) at the distal end of the end portion (end portion
where winding starts) at the scroll center of the wraps 24b, 26b can be kept within an
acceptable range by using such a design, and there is no problem in terms of strength, even
when carbon dioxide, which is a gas refrigerant used in the refrigerant apparatus, is at
maximal pressure.
d) Partial heat treatment step
In the partial heat treatment step, laser heating treatment or high-frequency heating treatment
is carried out in specific locations of the slider, and the fatigue strength and abrasion
resistance of the specific locations is improved. In laser heating treatment or high-frequency

heating treatment, a laser beam or a high frequency wave is irradiated so that the surface
hardness of the heated portions is HRC 50 to HRC 65.
In the partial heat treatment step of the fixed scroll 24, laser heating treatment is performed
on the peripheral portion SC1 of the base of the wrap 24b in which stress is concentrated
during operation of the high-low pressure dome-type scroll compressor 1, and high-frequency
heating treatment is performed on the innermost portion SC2 of the wrap 24b (see FIGS. 2
and 3; in the diagrams, the laser heating treatment locations are shaded).
In the partial heat treatment step of the movable scroll 26, laser heating treatment is
performed on the peripheral portion SC3 of the base of the wrap 26b and in the peripheral
portion SC4 of the base of the bearing portion 26c in which stress is concentrated during
operation of the high-low pressure dome-type scroll compressor 1, and high-frequency
heating treatment is performed on the notched portion SC5 formed in the vicinity of the
design center of the end plate 26a and on the innermost portion SC6 of the wrap 26b (see
FIGS. 4 and 5; in the diagrams, the laser heating treatment locations are shaded).
In the partial heat treatment step of the crankshaft 17, high-frequency heating treatment is
performed on the eccentric shaft portion 17a and the main shaft portion 17b, which require
abrasion resistance. Laser heating treatment is performed on the peripheral portion SC7 of
the notched portion that is present between the eccentric shaft portion 17a and the main shaft
portion 17b in which stress is concentrated during operation of the compressor (see FIG. 15;
in the diagram, the laser heating treatment locations are shaded.)
In the partial heat treatment step of the Oldham ring 39, high-frequency heating treatment is
performed on the movable scroll-side key portions 39a, 39b and the housing-side key
portions 39c, 39d, which require abrasion resistance (see FIGS. 6, 7, and 8; in the diagrams,
the high-frequency heating treatment locations are shaded).
(Operation of a high-low pressure dome-type scroll compressor)
Next, the operation of the high-low pressure dome-type scroll compressor 1 will be briefly
described. First, when the drive motor 16 is driven, the drive shaft 17 rotates, and the
movable scroll 26 orbits without rotation. At this point, low-pressure gas refrigerant passes
through the suction tube 19, is suctioned from the peripheral edge of the compression
chamber 40 into the compression chamber 40, is compressed as the capacity of the
compression chamber 40 changes, and becomes a high-pressure gas refrigerant (see FIG.
18(b)). The high-pressure gas refrigerant passes from the center portion of the compression
chamber 40 through the discharge channel 41; is discharged to the muffler space 45; then
passes through communication channel 46, the scroll-side channel 47, the housing-side

channel 48, and the discharge port 49; flows out to the clearance space 18; and flows
downward between the guide plate 58 and the inner surface of the trunk casing 11. A
portion of the gas refrigerant branches off and flows in the peripheral direction between the
guide plate 58 and the drive motor 16 when the gas refrigerant flows downward between the
guide plate 58 and the inner surface of the trunk casing 11. At this point, lubricating oil
mixed with the gas refrigerant separates off. On the other hand, the other portion of the
branched gas refrigerant flows downward through the motor cooling channel 55 to the space
below the motor, and then reverses course and flows upward through the motor cooling
channel 55 on the side (left side in FIG. 1) facing the communication channel 46 or the air
gap channel between the stator 51 and the rotor 52. Thereafter, the gas refrigerant that has
passed through the guide plate 58 and the gas refrigerant that has flowed from the air gap
channel or the motor cooling channel 55 merge at the clearance space 18. The merged gas
refrigerant flows from the inside-end portion 36 of the discharge tube 20 to the discharge tube
20, and is then discharged to the exterior of the casing 10. The gas refrigerant discharged to
the exterior of the casing 10 circulates through the refrigerant circuit, then passes through the
suction tube 19 again, and is suctioned and compressed in the scroll compression mechanism
15.
(Comparison of a conventional scroll in which an FC material is used, and the scroll of first
embodiment)
Next, a comparison is made with reference to FIGS. 16 to 18 between a conventional fixed
scroll 324 and movable scroll 326 that use FC250, and the fixed scroll 24 and movable scroll
26 of the compressor 1 according to the first embodiment. In this case, the height H of the
wraps 285, 287, 24b, 26b of the scrolls 324, 326, 24, 26 are all set to be the same. The
thickness T of the wraps 285, 287 are set based on design guidelines for conventional
strength in the conventional fixed scroll 324 and movable scroll 326, and the thickness T of
the wraps 24b, 26b are set based on the design guidelines described above for the fixed scroll
24 and the movable scroll 26. A semi-molten die casting material is used for the fixed scroll
24 and the movable scroll 26, and since the strength is increased in comparison with
conventional FC250, the thickness T of the wraps is reduced in comparison with the
conventional fixed scroll 324 and movable scroll 326.
The shaded portions of FIGS. 16(a), 16(b), and 16(c) indicate the partition surface area,
compression work area, and thrust area, respectively, in a conventional fixed scroll 324.
The partition surface area is a lateral cross section surface area of a wrap (wrap 285, in this
case). In contrast, shaded portions of FIGS. 16(d), 16(e), and 16(f) indicate the partition

surface area, compression work area, and thrust area, respectively, in the fixed scroll 24.
When FIGS. 16(a) and 16(d) are compared, the partition surface area is reduced in the fixed
scroll 24 in comparison with the conventional fixed scroll 324. This is because the ratio
(H/T) of the height H to the thickness T of the wrap 24b is increased in association with
higher strength. When a comparison is made with reference to FIGS. 16(c) and 16(f)
between the effective compression surface areas obtained by subtracting the partition surface
area from the surface area of compression work area, the effective compression surface area
is 48 cm , or about 20% greater in the fixed scroll 24, in comparison with the 40 cm of the
conventional fixed scroll 324.
The shaded portions of FIGS. 17(a), 17(b), and 17(c) indicate the partition surface area,
compression work area, and thrust area, respectively, in a conventional movable scroll 326.
The partition surface area is a lateral cross section surface area of a wrap (wrap 287, in this
case). In contrast, shaded portions of FIGS. 17(d), 17(e). and 17(f) indicate the partition
surface area, compression work area, and thrust area, respectively, in the movable scroll 26.
When FIGS. 17(a) and 17(d) are compared, the partition surface area is reduced in the
movable scroll 26 in comparison with the conventional movable scroll 326. This is because
the ratio (H/T) of the height H to the thickness T of the wrap 26b is increased in association
with higher strength. When a comparison is made with reference to FIGS. 17(c) and 17(f)
between the effective compression surface areas obtained by subtracting the partition surface
area from the surface area of compression work area, the effective compression surface area
is 32 cm , or about 15% greater in the movable scroll 26, in comparison with the 28 cm of
the conventional movable scroll 326.
The shaded portion of FIG. 18(a) shows the suction capacity formed by the conventional
fixed scroll 324 and movable scroll 326 having wraps 285, 287 in which the thickness T is
relatively thick; and the shaded portion of FIG. 18(b) shows the suction capacity formed by
the fixed scroll 24 and movable scroll 26 having wraps 24b, 26b in which the thickness T is
relatively small (thin). In the compressor 1, the thickness T of the wraps 24b, 26b is
reduced and the ratio (H/T) is increased. The suction capacity is thereby made about 1.5
times greater in comparison with a compressor in which the conventional scrolls 324, 326 are
adopted.
(Tests)
(1) Abrasion resistance test and "breaking-in" test
First, a pin-shaped test piece 412a and a disc-shaped test piece 412b such as those shown in
FIGS. 19 were manufactured from a material fabricated by semi-molten die casting, and test

pieces 412a, 412b having different levels of hardness were fabricated by varying the heat
treatment conditions of the material fabricated by semi-molten die casting. The test pieces
412a, 412b were set in a pin/disc test apparatus 401 such as that shown in FIG. 19, the
pin-shaped test piece 412a that was set in a holder 413 was made to slide for two hours
against the disc-shaped test piece 412b under conditions of an average sliding speed of 2.0
m/s and a constant surface pressure load of 20 MPa in a liquid mixture 416 composed of
ethereal oil (100°C) and R410A refrigerant stored in a container 410, and the amount
abrasion was measured. The surface pressure in this case was adjusted by using the load
applied to the lower-side shaft 411b. A mechanical seal 414 was provided between an
upper-side rotor shaft 411a and the container 410. The amount of abrasion in this was
obtained by adding the pin abrasion amount and the disc abrasion amount.
The data obtained from this experiment is summarized in the bar graph shown in FIG. 20.
The relationship between the abrasion amount and the hardness of the test pieces
manufactured by semi-molten die casting (hereinafter referred to as semi-molten die cast test
pieces) is shown in the left-side area facing the graph. For reference, the abrasion amount
and the hardness of the test pieces composed of FC250 (hereinafter referred to as FC250 test
pieces), which is a conventional material, are shown in the right-side area facing the graph.
The test pieces composed of FC250 have a level of hardness (HRB 101.0) that indicates good
"breaking-in" characteristics in a conventional compressor. Also, the base structure of
FC250 test piece exhibiting such a level of hardness contains 95% or higher pearlite
structure.
Here, in view of the left-side area, it is apparent that the hardness and abrasion amount of the
semi-molten die casting test pieces have a substantially proportional relationship. When the
semi-molten die casting test pieces and the FC250 test piece are compared, it is apparent that
the semi-molten die casting test piece having a hardness of HRB 103.7 has dramatically less
abrasion amount than the FC250 test piece, the semi-molten die casting test piece having a
hardness of HRB 98.0 has substantially the same abrasion amount as the FC250 test piece,
and the semi-molten die casting test piece having a hardness of HRB 87.4 has dramatically
more abrasion amount than the FC250 test piece. In other words, it is apparent that the
semi-molten die casting test piece having a hardness of HRB 98.0 has about the same
"breaking-in" characteristic as the FC250 test piece having a hardness of HRB 100 or higher.
This suggests that the abrasion phenomenon depends on not only on the hardness, but also on
the base structure. In other words, when the ratio of the pearlite structure constituting the
base structure is high, the "breaking-in" characteristic of the molded article is poor, even

when the hardness is the same. In this case, hardness that can demonstrate good
"breaking-in" characteristics is a hardness that is empirically determined to have an abrasion
amount of greater than 5 μm but less than 13 μm. Accordingly, a semi-molten die casting
test piece that has a level of hardness greater than HRB 90 but less than HRB 100 has
excellent "breaking-in characteristics." This is supported by the "breaking-in" curve of a
semi-molten die cast article shown in FIG. 21. It is apparent from FIG 21 that 100 hours is
required for sufficient breaking-in when the hardness is HRB 100 or higher, but "breaking-in"
is substantially completed in ten or so hours when the hardness is HRB 100 or less.
(2) Seizing resistance test
First, a pin-shaped test piece 412a and a disc-shaped test piece 412b such as those shown in
FIGS. 19 were manufactured from a material fabricated by semi-molten die casting, and test
pieces 412a, 412b having different levels of hardness were fabricated by varying the heat
treatment conditions of the material fabricated by semi-molten die casting. The test pieces
412a, 412b were set in a pin/disc test apparatus 401 such as that shown in FIG. 19, and a load
(surface pressure) was applied in steps of 15.6 MPa under conditions of an average sliding
speed of 2.0 m/s in a liquid mixture 416 composed of ethereal oil (100°C) and R410A
refrigerant stored in a container 410. The point at which the frictional torque, as detected by
a torque detector 415, rapidly increased was determined to be the point at which seizing
occurs, and the surface pressure at this time was used as the surface pressure at which seizing
occurs. The surface pressure in this case was adjusted by using the load applied to the
lower-side shaft 411b. A mechanical seal 414 was provided between an upper-side rotor
shaft 411a and the container 410.
The data obtained from this experiment is summarized in the bar graph shown in FIG. 22.
The relationship between the surface pressure at which seizing occurs and the hardness of the
test pieces manufactured by semi-molten die casting (hereinafter referred to as semi-molten
die cast test pieces) is shown in this graph.
It is apparent from FIG. 22 that the surface pressure at which seizing occurs is dramatically
reduced when the hardness of the semi-molten die cast test piece is between HRB 98.0 and
HRB 103.8. In other words, this shows that seizing more readily occurs when the hardness
of the semi-molten die cast molded test piece is HRB 100 or higher. When the movable
scroll and fixed scroll are manufactured using semi-molten die casting, the hardness of the
movable scroll and the fixed scroll must be less than HRB 100 in order to prevent the
movable scroll and the fixed scroll from seizing during abnormal operation of the
compressor.

(3) Ductility test
FIG. 23 shows the relationship between the tensile elongation and the hardness of a molded
article manufactured using semi-molten die casting. The tensile elongation was measured in
accordance with the test method described in JIS Z2241. In this tensile test, the shape of the
test piece was that of test piece #4 or #5 described in JIS Z2201.
It is apparent from FIG. 23 that the elongation and the hardness of a molded article
manufactured by semi-molten die casting (hereinafter referred to as a semi-molten die cast
article) are in an inverse proportional relationship. When compared with a conventional
FC250 or FCD600 molded article (hereinafter referred to as a conventional molded article), it
is apparent that the semi-molten die cast article exhibits dramatically higher ductility than a
conventional molded article. In the case of a semi-molten die cast article, the fact is that a
built-up edge is readily formed during machining, and grinding processability is degraded,
when the tensile elongation is 14% or higher; fine scrapings are readily produced in the case
that cracking has occurred when the tensile elongation is 8% or lower (possibly due to fluid
backflow (hydraulic compression), which may occur when the semi-molten die cast article is
a movable scroll or a fixed scroll); and the effect of preventing such situations cannot be
sufficiently provided by improving the ductility. For this reason, the semi-molten die cast
article preferably ideally has a tensile elongation that is greater than 8% but less than 14%.
Therefore, the hardness of the semi-molten die cast article is ideally greater than HRB 90 but
less than HRB 100.
(4) Cutting test
FIG. 24 shows the relationship between the notching distance and the cutting resistance of a
molded article manufactured using semi-molten die casting. The cutting test was carried out
using a down cut method with the aid of an end mill as a cutting blade under dry conditions at
an end mill rotational speed of 6000 rpm and a feed rate of 1800 mm/min - 0.05/blade. The
hardness of the semi-molten die cast article at this time was HRB 98, and the hardness of the
reference FC250 molded article was HRB 101.
It is apparent from FIG. 24 that with a semi-molten die cast article, cutting resistance
increases in a proportional fashion as the notching distance increases in the same manner as
for an FC250 molded article, but the absolute value is less than that of an FC250 molded
article.
(5) Tool abrasion test
FIG. 25 shows a comparison of the cutting tool abrasion for a molded article manufactured
using semi-molten die casting. The tool abrasion test was carried out in the same manner as

the cutting test by using a down cut method with the aid of an end mill as a cutting blade
under dry conditions at an end mill rotational speed of 8000 rpm and a feed rate of 1920
mm/min - 0.04/blade. The data in FIG. 25 is composed of values obtained by rotating a tool
to the cutting distance noted above the bars. The hardness of the semi-molten die cast
articles at this time was HRB 93 to 95 and HRB 98 to 100, and the hardness of the reference
FC250 molded article was HRB 101.
It is apparent from FIG. 25 that when the FC250 molded article and the semi-molten die cast
article having a hardness of 93 to 95 are compared, the tool abrasion amount for the two
molded articles is substantially the same at the external peripheral portion of the blade and
the base of the blade regardless of the fact that the semi-molten die cast article having a
hardness of 93 to 95 has a longer cutting distance than the FC250 molded article. Therefore,
the semi-molten die cast article having a hardness of 93 to 95 has about the same or better
machinability than the FC250 molded article. When a comparison is made between the
semi-molten die cast article having a hardness of 93 to 95 and the semi-molten die cast article
having a hardness of 98 to 100, the semi-molten die cast article having a hardness of 93 to 95
has a lower abrasion amount at the base of the blade than the semi-molten die cast article
having a hardness of 98 to 100 regardless of the fact that the semi-molten die cast article
having a hardness of 93 to 95 has a longer cutting distance than the semi-molten die cast
article having a hardness of 98 to 100. In other words, the semi-molten die cast article
having a hardness of 93 to 95 has dramatically better machinability than the semi-molten die
cast article having a hardness of 98 to 100.
(Characteristics of the high-low pressure dome-type scroll compressor according to
first embodiment)
(1)
In the first embodiment, the movable scroll 26 and fixed scroll 24 are manufactured via a
semi-molten die casting step and a heat treatment step. Accordingly, a movable scroll and
fixed scroll can be readily provided by this manufacturing method with higher tensile
strength and hardness than a movable scroll and fixed scroll composed of flake graphite cast
iron manufactured using conventional sand casting.
(2)
In the first embodiment, the movable scroll preform and the fixed scroll preform are
manufactured via a semi-molten die casting step and a heat treatment step, and the hardness is
adjusted to be greater than HRB 90 but less than HRB 100. The tensile strength of the
movable scroll preform and the fixed scroll preform substantially corresponds to the range

from 600 MPa to 900 Mpa. Accordingly, when this method for manufacturing a compressor
slider is adopted, the end plates 24a, 26a of the movable scroll 26 and the fixed scroll 24, as
well as the wraps 24b, 26b, can be made thinner. Therefore, the scroll compressor 1 can be
given a smaller diameter, and, consequently, thrust loss can be reduced and capacity can be
increased. Also, the stress generated in the scroll is greater than during normal operation
(during full load) when the capacity is controlled during an operation characterized by a high
compression ratio, even in a capacity controller based on an unloader piston, but since
strength is improved and toughness is enhanced, the possibility that the scroll will be
damaged or the like can be reduced. Such a movable scroll 26 and fixed scroll 24 have
excellent toughness in comparison with an FC material, and damage is not likely to occur
from a sudden increase in internal pressure or the inclusion of foreign matter. Even if
damage were to occur, fine scrapings are not likely to be produced and the pipes do not need
to be washed. When a movable scroll preform and fixed scroll preform composed of flake
graphite cast iron manufactured by sand casting are machined and the final movable scroll
and fixed scroll are formed, the movable scroll preform and fixed scroll preform are
ordinarily re-gripped a number of times in order to remove distortions produced by
machining. However, there in no concern for distortions caused by machining when a
movable scroll preform and fixed scroll preform having such a high tensile strength are
machined. Therefore, adopting the present manufacturing method allows the cost of
re-gripping to be reduced.
(3)
It is apparent that when a slider manufactured by semi-molten die casting is heat treated, the
tensile strength of the slider is in a proportional relationship with the hardness of the slider.
Therefore, tensile strength can be assured in the slider according to the first embodiment by
merely measuring the hardness.
(4)
In the heat treatment step of the first embodiment, the heat treatment is carried out so that the
hardness of the movable scroll preform and the fixed scroll preform is greater than HRB 90
but less than HRB 100. For this reason, a movable scroll 26 and fixed scroll 24 that can
demonstrate sufficient durability during compressor operation, that readily undergo
"breaking-in" as early as possible, and that do not seize during abnormal operation can be
manufactured when the method for manufacturing the compressor slider is adopted. When
the hardness is in this range, machining of the movable scroll preform and the fixed scroll
preform is improved, the movable scroll preform and fixed scroll preform are less likely to be

damaged, and handling is facilitated. For this reason, tool abrasion and tool chipping are
less likely to occur, tool service life is extended, a built-up edge is less likely to form, the
grinding processability is good, machining time can be reduced, and machining costs can
therefore be reduced. Regardless the scrolls have superior tool abrasion and machining time
because of lower hardness in relation to FCD having the same tensile strength (tensile
strength is high at the same level of hardness), it can be said that higher tensile strength can
be achieved. Also, the movable scroll 26, the Oldham ring 39, the seal (not shown), and the
like are unlikely to be damaged because surface roughness of them is readily reduced in
comparison with an FC material.
(5)
In the first embodiment, the fixed scroll 24 is manufactured by molding a metal material by
semi-molten die casting using a metal mold 70 having convexities 71a, 72a in which an
opening formation area P can be thinly formed in the vicinity of the center of the preform 124,
and thereafter forming a discharge hole 41 in the thin opening formation area P. An opening
formation area P of the discharge hole 41 can be formed with the aid of the convexities 71a,
72a to a thickness of 4 mm or less in the vicinity of the center of the portion that corresponds
to the end plate in the preform 124 of the fixed scroll 24. Accordingly, the occurrence of
blowholes CN can be reduced in the preform 124 of the fixed scroll 24. Therefore, only
small divided blowholes CN are present in the periphery away from the vicinity of the center
inside the end plate 24a in the fixed scroll 24. As a result, the likelihood that a blowhole CN
inside the preform 124 will be exposed to the exterior is eliminated even if a discharge hole
41 is formed in the opening formation area P of the preform 124, and a reduction in fatigue
strength can be inhibited.
(6)
In the first embodiment, the movable scroll 26 is manufactured by molding a metal material
by semi-molten die casting using a metal mold 80 having a convexity 81a in which a
prescribed portion can be formed to a thickness of 4 mm or less in the vicinity of the center of
the preform 126. Accordingly, the occurrence of blowholes CN in the preform 126 of the
movable scroll 26 can be reduced. Therefore, only small divided blowholes CN are present
in the periphery away from the vicinity of the center inside the end plate 26a in the movable
scroll 26.
(?)
Constituent elements having very few defects are adopted in the high-low pressure dome-type
scroll compressor 1 of the first embodiment. For this reason, the high-low pressure

dome-type compressor 1 can also compress carbon dioxide and other high-pressure
refrigerants.
(8)
There are problems in that near-net shaping is difficult and machinability is poor with
high-carbon steel and ductile iron as high-strength materials. Therefore, a scroll is often
manufactured using FC250 or another ordinary cast iron in a conventional scroll compressor.
In contrast, in the high-low pressure dome-type scroll compressor 1 according to the first
embodiment, the fixed scroll 24 and movable scroll 26 can endowed with high strength by
molding with the aid of semi-molten die casting.
For this reason, capacity can be increased considerably without substantially changing the
outside diameter in the compressor 1, as shown in FIG. 18 and other diagrams.
(9)
In comparison with a conventional material such as FC250, an article produced by die casting
(referred to herein as semi-molten die casting), in which an iron material In a semi-molten
(semi-solid) state is pressed into a mold to manufacture a casting, has high strength even
without performing special heat treatment, but tensile strength can be further improved by
performing heat treatment that involves holding the article at a prescribed temperature for a
prescribed length of time and adjusting the cooling speed.
However, when the tensile strength is increased to a level that is not conventionally used,
other problems occur when the ratio (H/T), i.e., ratio of the height (H) to thickness (T) of the
wrap, is determined solely from the conventional viewpoint of strength based on whether
fatigue damage will occur or not. In other words, when the ratio (H/T) is made excessively
high because of the strength, drawbacks occur even if there is no problem in terms of strength.
That is, because the deformation of the wraps 24b, 26b is too great when cutting is performed,
the result is that the machining allowance and cutting feeding of end milling or the like
cannot be increased and machining time is extended, that the deformation amount (flexing
amount) of the wraps 24b, 26b is increased and performance is reduced during operation of
the compressor 1, and that noise is increased by contact with a counterpart scroll.
Furthermore, in the case wraps 24b, 26b, which are shaped in the same manner as the scrolls
24, 26, are existed, distortions tend to appear when strength is considerably increased by heat
treatment. When the strength is excessively high, machining speed during cutting is
reduced and costs are increased.
In view of the above, in the compressor 1, the ratio of the tensile strength in relation to
Young's modulus of the scrolls 24, 26 after heat treatment is determined so that added costs

are not incurred due to excessively increasing the strength by heat treatment. This is the
result of research to determine the sufficient level of tensile strength from the viewpoint of
fatigue strength when the ratio (H/T) of the wrap is determined with consideration given to
the upper limit of the deformation amount of the wraps 24b, 26b that is required from the
viewpoint of machining time, lost performance, and noise. Specifically, the ratio of tensile
strength to Young's modulus is set to 0.0046 or less, as described above, so as to limit the
amount of increased strength by heat treatment.
As described above, in the design of the scrolls 24, 26 in this case, problems during operation,
such as a higher level of noise and reduced performance due to flexing of the wraps 24b, 26b,
can be reduced while satisfying strength requirements because a balance has been achieved
with the Young's modulus (toughness) without excessive strengthening. Since flexing of the
wraps 24b, 26b during cutting is reduced, manufacturing costs can be reduced by shortening
machining time and obtaining other benefits.
As described above, the tensile strength of the scrolls 24, 26 can be set to 1000 MPa or higher
depending on the heat treatment, but in this case, the increase in strength by heat treatment is
limited.
On the other hand, the tensile strength of the scrolls 24, 26 can be set to about 500 MPa by
reducing the cooling speed. Conversely, it is illogical to spend time in heat treatment in
order to limit the level of strength, and since drawbacks arise in that abrasion resistance is
reduced when the ferrite ratio of the metal structure is increased, heat treatment is carried out
so that the ratio of the tensile strength to Young's modulus is 0.0033 or higher in the
compressor 1.
(10)
In the first embodiment, the crankshaft 17, the movable scroll 26, the fixed scroll 24, and the
Oldham ring 39 are manufactured via a semi-molten die casting step and a heat treatment step.
Accordingly, raw material costs, machining costs, and tool abrasion expenses can be kept low
in comparison with conventional sand casting, and grinding waste, liquid machining waste,
and other types of waste can be reduced. Also, the crankshaft 17, fixed scroll 24, movable
scroll 26, and Oldham ring 39 can easily be provided with higher tensile strength and higher
hardness than a crankshaft, movable scroll, fixed scroll, and Oldham ring composed of flake
graphite cast iron and manufactured by conventional sand casting.
(H)
In the first embodiment, the crankshaft preform, the movable scroll preform, the fixed scroll
preform, and the Oldham ring preform were manufacture via a semi-molten die casting step

and a heat treatment step, and the hardness of these preforms was adjusted so as to be greater
than HRB 90 but less than HRB 100. In this case, the tensile strength of the crankshaft
preform, the movable scroll preform, the fixed scroll preform, and the Oldham ring preform
substantially corresponds to a range from 600 MPa to 900 MPa. Accordingly, adoption of
this method for manufacturing a compressor slider allows the end plates 24a, 26a of the
movable scroll 26 and the fixed scroll 24, as well as the wraps 24b, 26b (*9), to be made
thinner, and the Oldham ring 39 to be made thinner as well. Also, the diameter of the
crankshaft 17 can be reduced. Therefore, the diameter of the scroll compressor 1 can be
reduced, and the thrust loss can consequently be reduced and capacity increased. Also, the
stress generated in the scroll is greater than during normal operation (during full load) when
the capacity is controlled during high-compression ratio operation, even in a capacity
controller based on an unloader piston, but since strength is improved and toughness is
enhanced, the possibility that the scroll will be damaged or the like can be reduced. Such a
crankshaft 17, movable scroll 26, fixed scroll 24, and Oldham ring 39 have excellent
toughness in comparison with an FC material, and damage is not likely to occur from a
sudden pressure increase due to the inclusion of foreign matter. Even if damage were to
occur, fine scrapings are not likely to be produced and the pipes do not need to be washed.
When a crankshaft preform, a movable scroll preform, a fixed scroll preform, and an Oldham
ring preform composed of flake graphite cast iron and manufactured by sand casting are
machined and the final crankshaft 17, movable scroll 26, fixed scroll 24, and the Oldham ring
39 are formed, the crankshaft preform, the movable scroll preform, the fixed scroll preform,
and the Oldham ring preform are ordinarily re-gripped a number of times in order to remove
distortions produced by machining. However, there in no concern for distortions caused by
machining when a crankshaft preform, a movable scroll preform, a fixed scroll preform, and
an Oldham ring preform having such a high tensile strength are machined. Therefore,
adopting the present manufacturing method allows the cost of re-gripping to be reduced.
(12)
It is apparent that when a slider manufactured by semi-molten die casting is heat treated, the
tensile strength of the slider is in a proportional relationship with the hardness of the slider.
Therefore, tensile strength can be assured in the slider according to the first embodiment by
merely measuring the hardness.
(13)
In the heat treatment step of the first embodiment, heat treatment is carried out so that the
hardness of the crankshaft preform, the movable scroll preform, the fixed scroll preform, and

the Oldham ring preform is greater than HRB 90 but less than HRB 100. For this reason, a
crankshaft 17, a movable scroll 26, a fixed scroll 24, and an Oldham ring 39 that can
demonstrate sufficient durability during compressor operation, that readily undergo
"breaking-in" as early as possible, and that do not seize during abnormal operation can be
manufactured when this method for manufacturing the compressor slider is adopted. When
the hardness is in this range, machining of the crankshaft preform, the movable scroll preform,
the fixed scroll preform, and the Oldham ring preform is improved; the crankshaft preform,
the movable scroll preform, the fixed scroll preform, and the Oldham ring preform are less
likely to be damaged; and handling is facilitated. For this reason, tool abrasion and tool
chipping are less likely to occur, tool service life is extended, a built-up edge is less likely to
form, the grinding processability is good, machining time can be reduced, and machining
costs can therefore be reduced. It should also be noted that Regardless the scrolls have
superior tool abrasion and machining time because of lower hardness in relation to FCD
having the same tensile strength (tensile strength is high at the same level of hardness), it can
be said that higher tensile strength can be achieved. Also, the movable scroll 26 is unlikely
to damage the Oldham ring 39, the seal (not shown), and the like because surface roughness
of them can be more readily obtained in comparison with an FC material.
(14)
In the partial heat treatment step of the first embodiment, a stress concentration area
(peripheral portion SC1 of the base of the wrap 24b and the innermost portion SC2 of the
wrap 24b) of the fixed scroll 24 is subjected to partial heat treatment. Accordingly,
sufficient fatigue strength can be imparted to the stress concentration area in the fixed scroll
24 while the slider, which requires slidability, retains good "breaking-in" characteristics.
(15)
In the partial heat treatment step of the first embodiment, the stress concentration area
(peripheral portion SC3 of the base of the wrap 26b, the notched portion SC5 formed in the
vicinity of the design center of the end plate 26a, the peripheral portion SC4 of the base of the
bearing portion 26c, and the innermost portion SC6 of the wrap 26b) of the movable scroll 26
is subjected to partial heat treatment. Accordingly, sufficient fatigue strength can be
imparted to the stress concentration area in the movable scroll 26 while the slider, which
requires slidability, retains good "breaking-in" characteristics.
(16)
In the partial heat treatment step of the first embodiment, the eccentric shaft portion 17a and
the main shaft portion 17b of the crankshaft 17 are subjected to high-frequency heating

treatment. Accordingly, the eccentric shaft portion 17a and the main shaft portion 17b can
be endowed with sufficient abrasion resistance. Therefore, the service life of the crankshaft
17 can be extended.
(17)
In the partial heat treatment step of the first embodiment, the peripheral portion SC7 of the
notched portion that is present between the eccentric shaft portion 17a and the main shaft
portion 17b of the crankshaft 17 is subjected to laser heating treatment. Accordingly, the
stress concentration portion of the crankshaft 17 can be endowed with sufficient fatigue
strength.
(18)
In the semi-molten die casting of the first embodiment, the balance weight portion 17c is
integrally formed with the crankshaft 17. Accordingly, a separate ring portion or the like as
a balance weight is not required. Therefore, material costs associated with a balance weight
can be reduced. Also, in the manufacture of a balance weight, the balance weight is cored to
a rough shape and then a machining step was required to adjust or otherwise modify the
balance, but the crankshaft 17 according to the present invention is manufactured by
semi-molten die casting. Therefore, material can be molded to a shape that is very
approximate to the final shape, and the number of steps for manufacturing a compressor can
be reduced. Therefore, the compressor crankshaft 17 can contribute to a reduction in the
costs to manufacture a compressor.
(19)
In the partial heat treatment step of the first embodiment, the movable scroll-side key
portions 39a, 39b and the housing-side key portions 39c, 39d of the Oldham ring 39 are
subjected to high-frequency heating treatment. Accordingly, the movable scroll-side key
portions 39a, 39b and the housing-side key portions 39c, 39d can be endowed with sufficient
abrasion resistance. Therefore, the service life of the Oldham ring 39 can be extended.
(Modified example of first embodiment)
(A)
An airtight high-low pressure dome-type scroll compressor 1 was adopted in the first
embodiment, but the compressor may be a high-pressure dome-type compressor or a
low-pressure dome-type compressor. The compressor may also be a semi-airtight or open
compressor.
(B)
A scroll compression mechanism 15 was used in the scroll compressor 1 according

to the first embodiment, but the compression mechanism may be a rotary compression
mechanism, a reciprocating compression mechanism, a screw compression mechanism, or the
like. The scroll compression mechanism 15 may be a double-toothed or co-rotation-type
scroll.
(C)
In the first embodiment, a billet was used in which the following components were
added: C: 2.3 to 2.4 wt%, Si: 1.95 to 2.05 wt%, Mn: 0.6 to 0.7 wt%, P: wt%, Cr: 0.00 to 0.50 wt%, Ni: 0.50 to 1.00 wt%. The elemental ratio of the iron material
may be arbitrarily determined as long as the ratio does not depart from the spirit of the
present invention.
(D)
In the first embodiment, an Oldham ring 39 was used as the rotation-preventing
mechanism, but a pin, a ball coupling, a crank, or any other mechanism may be used as the
rotation-preventing mechanism.
(E)
In the first embodiment, an example was given of the case in which the scroll
compressor 1 was used in a refrigerant circuit, but the application is not limited to air
conditioning, and can also be made to a compressor used alone or incorporated into a system,
or to a blower, a supercharger, a pump, or the like.
(F)
A lubricating oil is present in the compressor 1 according to the first embodiment,
but an oilless or oil-free (which may or may not contain oil) compressor, blower,
supercharger, or pump may also be used.
(G)
The high-low pressure dome-type scroll compressor 1 according to the first embodiment was
an outer drive-type scroll compressor, but the scroll compressor according to the present
embodiment may be an inner drive-type scroll compressor, Also, in such a case, the pin
shaft portion for the inner drive of the movable scroll may be selectively heated by
high-frequency heating or another method after the heat treatment step, and the surface
hardness of the pin shaft portion may be set to be greater than HRC 50 but less than HRC 65.
In this manner, the abrasion resistance of the pin shaft portion of the inner drive can be
considerably improved.
(H)
In the first embodiment, the slider preform was formed into a final slider via a final finishing

step, but the finishing step may be omitted in the case that near-net shaping to a substantially
completed article is possible in the semi-molten die casting step.
(I)
In the heat treatment step of the first embodiment, the entire slider preform was heat treated,
but when the slider preform is the movable scroll 26 or the fixed scroll 24, the hardness may
be set to be greater than HRB 90 but less than HRB 100 for only the distal ends of the wraps
24b, 26b and the surface (thrust surface) portion of the end plate side, which are important
locations in terms of seizing resistance, abrasion resistance, and "breaking-in" characteristics.
The ferrite surface area ratio may be set to be greater than 5% but less than 50%, and the
graphite surface area ratio may be set to be greater than 2% but less than 6%.
(J)
The slider according to the first embodiment was manufactured via a semi-molten die casting
step, a heat treatment step, a finishing step, and a partial heat treatment step, but such a slider
may be manufactured via a metal-mold casting molding step, a heat treatment step, a
finishing step, and a partial heat treatment step. The raw materials may be the same.
In the metal-mold casting step, a raw material liquefied by high-temperature heating is
poured into a cast mold space 303 formed by a fixed mold 302 and a movable mold 301, as
shown in FIG. 26. Thereafter, the liquid raw material inside the cast mold space 303 is
rapidly cooled via the fixed mold 302 and the movable mold 301. At this point, the liquid
raw material inside the cast mold space 303 solidifies to become a solid molded material 310.
In this case, the molded material 310 undergoes heat contraction. For this reason, the
molded material 310 can be readily released from the mold. The unnecessary portions of
the solid molded material 310 are thereafter cut away (hereinbelow, the cut molded material
310 is referred to as a preform material 301a). Next, the preform material 301a is heat
treated in the heat treatment step, and the hardness of the material is adjusted to be greater
than HRB 90 but less than HRB 100. At this point, the target hardness may be set to a range
of HRB 90 to HRB 95. In the final finishing step, the preform material 301a that has
undergone the heat treatment step is finely machined to form a final product 310b. In the
present modified example, the heat treatment step and the final finishing step are carried out
in the same manner as the heat treatment step and the final finishing step according to the
first embodiment.
(K)
In the first embodiment, mutually facing convexities 71a and 72a form concavities from the
two sides, above and below, in the end plate 24a to reduce the thickness of the end plate 24a,

as shown in FIGS. 9 and 10, when the preform 124 of the fixed scroll 24 is molded.
However, the present invention is not limited thereby.
As a modified example of the first embodiment, the portion corresponding to the end plate
may be depressed only from the top side, as shown in FIG. 27, for example. The portion
corresponding to the end plate portion may be depressed only from the bottom side, as shown
in FIG. 28, whereby the portion corresponding to the end plate may be molded so as be have a
prescribed thickness t2 (e.g., 4 mm or less). Either of these cases reduces the occurrence of
blowholes CN in the same manner as in the first embodiment.
(L)
In the first embodiment, a space between a second mold portion 82 and a convexity 81a in
which an internal space 26f of the bearing portion 26c is formed is set to a prescribed
distance (e.g., 4 mm or less) when the preform 126 of the movable scroll 26 is molded, as
shown in FIGS. 11 and 12, whereby the thickness tl in the center portion of the portion
corresponding to the end plate is brought via the molding process to a prescribed level (e.g., 4
mm or less). However, the present invention is not limited thereby.
As a modified example of the first embodiment, it is also possible to consider a case in which,
e.g., a discharge hole 26h is formed in the end plate 26a of the movable scroll 26, as shown in
FIG. 29, instead of a discharge hole 41 being in the fixed scroll 24. When the movable
scroll 26 having such a discharge hole 26h is manufactured, convexities that face each other
are provided to the first mold portion 81 and the second mold portion 82 of the metal mold 80
(see FIG. 11) for manufacturing the preform 126 of the movable scroll 26, in the same
manner as the metal mold 70 for manufacturing the preform 124 of the fixed scroll 24.
Semi-molten die casting can be carried out using a metal mold 80 having such opposing
convexities. By molding in such a manner, the preform 126 of the movable scroll 26 having
a thin opening formation area R is formed in the vicinity of the center of the portion
corresponding to the end plate such as those shown in FIGS. 30 and 31. In this case, the
occurrence of blowholes CN is reduced and the likelihood that a blowhole CN inside the
preform 126 will be exposed to the exterior is eliminated when a discharge hole is formed in
the opening formation area R by drilling.
Here, in the case of the preform 126 of the movable scroll 26 in FIG. 30, the opening
formation area R is made thinner by depressing the portion corresponding to the end plate
from above and setting the height of the bottom of the internal space 26f of the bearing
portion 26c to be slightly higher than that of the existing movable scroll in the lower side of
the portion that corresponds to the end plate. The occurrence of blowholes CN can thereby

be reduced.
In the case of the preform 126 of the movable scroll 26 of FIG. 31, the height of the bottom of
the internal space 26f is set to be about the same as that of the existing movable scroll, and
the opening formation area R is made thinner by enlarging the concavity of the portion
corresponding to the end plate from above. The occurrence of blowholes CN can thereby be
reduced.
(M)
A notched portion SC5 was formed by an end mill or the like in the movable scroll 26
according to the first embodiment, but a notched portion (counterbore) SC5 may be also
formed in advance in the semi-molten die casting step in the upper surface of the center
portion of the end plate 26a of the movable scroll 26 shown in FIGS. 4 and 5.
In such a case, the notched portion (counterbore) SC5 and the internal space 26f of the
bearing portion 26c are formed at the same time, the thickness of the center portion of the
portion corresponding to the end plate is made thinner, and the occurrence of blowholes CN
is further reduced.
Also, labor can be reduced and shavings are not produced because the notched portion
(counterbore) SC5 is not required to be formed by cutting with an end mill or the like after
semi-molten die casting, in the same manner as in the method for manufacturing the movable
scroll 26 according to the first embodiment.
(N)
In the first embodiment, an iron material was used as the raw material of the slider, but a
metal material other than iron may be used as long as the material does not depart from the
spirit of the present invention.
(0)
In the first embodiment, the suction capacity is increased by a factor of about 1.5 using the
fixed scroll 24 and movable scroll 26 in which the wraps 24b, 26b having a thickness T that is
less than a conventional fixed scroll 324 and movable scroll 326 are adopted, as shown in FIG.
18(b). However, it is also possible to reduce the thickness of the wrap of only one of the
scrolls. For example, in the case that the movable scroll 26 of the first embodiment and the
conventional fixed scroll 324 are combined, the suction capacity can be increased by about
1.25 times higher than conventionally possible, as shown in FIG. 32(b).
Second embodiment
A compressor in which the slider according to a second embodiment is used will be
described using a high-low pressure dome-type scroll compressor as an example. The

high-low pressure dome-type scroll compressor of the second embodiment is one in which
the outer drive-type movable scroll 26 of the high-low pressure dome-type scroll compressor
1 of the first embodiment is substituted with an inner drive-type movable scroll. Therefore,
only the movable scroll will be described below.
(Configuration of the movable scroll)
The movable scroll 96 is primarily composed of an end plate 96a, a scroll (involute shape)
wrap 96b that extends upward from the end surface 96P of the end plate 96a, a bearing
portion 96c that extends downward from the lower surface of the end plate 96a, and a groove
portion 96d formed in the two ends of the end plate 96a, as shown in FIG. 33.
The movable scroll 96 is an inner drive-type movable scroll. In other words, the movable
scroll 96 has a bearing portion 96c that fits inside a concave portion formed in the distal end
of the crankshaft 17.
The vicinity of the center of the end plate 96a is formed to a thickness t3 that is less than the
thickness of the other portions (e.g., the portion near the periphery of the end plate 96a), as
shown in FIG. 33. In other words, a cored concave portion 96f cored during semi-molten
die casting is formed inside the bearing portion 96c. Therefore, the occurrence of blowholes
CN (see FIG. 34) in the portion corresponding to the end plate in the preform 196 is reduced.
The thickness t3 in the vicinity of the center of the portion corresponding to the bearing unit
is set to 4 mm or less in the preform 196.
The thickness of the bearing portion 96c is such that the thickness t4 would increase
considerably without the cored concave portion 96f, and blowholes CN would more readily
occur inside the bearing portion 96c. The thickness t5 of the bearing portion 96c is reduced
because of the presence of the cored concave portion 96f. Therefore, the occurrence of
blowholes CN inside the bearing portion 96c is reduced and a reduction in the strength of the
bearing portion 96c limited. The thickness t5 of the bearing portion 96c is set to 4 mm or
less.
(Molding of the movable scroll)
A mold 90 for the semi-molten die casting of the preform 196 of the movable scroll 96 is
composed of a first mold portion 91 and a second mold portion 92, as shown in FIG. 34.
The shape of a space portion 93 that is formed when the first mold portion 91 and the second
mold portion 92 are combined corresponds to the shape of the external appearance of the
preform 196 of the movable scroll 96 to be molded.
A convexity 91a for forming a cored concave portion 96f of the bearing portion 96c of the
movable scroll 96 is formed in the first mold portion 91. The spacing between the

convexity 91a and the second mold portion 92 is set to 4 mm or less. Therefore, the
thickness t3 in the center portion 96e of the end plate 96a is reduced to 4 mm or less.
A preform 196 of the movable scroll 96 having a thickness t3 in the center portion of the
portion that corresponds to the end plate of 4 mm or less can be manufactured by the
semi-molten die casting of iron or another metal material using the mold 90 configured in the
manner described above.
(Characteristics of the high-low pressure dome-type scroll compressor according to second
embodiment)
(1)
In the second embodiment, a cored concave portion 96f is formed in at least a portion of the
interior of a bearing portion 96c with the aid of a concave portion 91a of a mold 90 when a
preform 196 of a movable scroll 96 is formed by semi-molten die casting, and a center
portion of the portion that corresponds to the end plate of the preform 196 of the movable
scroll 96 is thereby formed to be 4 mm or less. As a result, the occurrence of blowholes CN
in the movable scroll 96 is reduced.
The cored concave portion 96f is formed in the bearing portion 96c of the movable scroll 96,
whereby the weight of the movable scroll 96 can be considerably reduced and the movable
scroll 96 can be made more lightweight.
(2)
In the second embodiment, the cored concave portion 96f is formed in the portion
corresponding to the bearing portion of the preform 196 of the movable scroll 96, whereby
the portion that corresponds to the bearing portion is formed to be 4 mm or less. As a result,
the occurrence of blowholes CN in the bearing portion 96c is reduced, and degradation in
strength of the bearing portion 96c is also reduced.
Third embodiment
A compressor in which the slider according to a third embodiment is used will be described
below using a high-low pressure dome-type scroll compressor as an example. The
difference between the high-iow pressure dome-type compressor of the third embodiment and
the high-low pressure dome-type scroll compressor of the first embodiment is the shape of
the wrap of the fixed scroll and the movable scroll. Therefore, only the fixed scroll and the
movable scroll will be described below.
A preform 626 of the movable scroll 526 according to the third embodiment is formed by
semi-molten die casting using a mold 180 shown in FIG. 35, for example.
A specific description is provided below.

The mold 180 for semi-molten die casting the preform 626 of the movable scroll 526 is
composed of a first mold portion 181 and a second mold portion 182, as shown in FIG. 35.
The shape of a space portion 183 that is formed when the first mold portion 181 and the
second mold portion 182 are combined together corresponds to the shape of the external
appearance of the preform 626 of the movable scroll 526 to be molded.
The mold 180 is provided with a wrap mold portion 182a. The wrap mold portion 182a has
an external shape that is set so that the draft angle of the portion Q0 where winding starts near
the center of the wrap-corresponding portion of the preform 626 of the movable scroll 526 is
greater than the draft angle of the portion Q4 where winding ends at the outer side (see draft
angles 91, 92 of the movable scroll 26 of the FIG. 36).
The side surface 182b and the side surface 182c of the wrap mold portion 182a have a portion
Q1 that is nearer to the center than the portion Q3 between the portion Q1 and portion Q3 of
the wrap-corresponding portion, as shown in FIGS. 35 and 36, for example. Therefore, the
draft angle 91 of the portion Q1 is set so as to be greater than the draft angle 93 of the portion
Q3 on the outer side.
The preform 626 is made into the movable scroll 526 via a finishing step. The shape of the
wrap of the movable scroll 526 is described below.
In the movable scroll 526, the shape of the scroll of the wrap 526b has a draft angle in the
portion Q10 where winding starts near the center. This angle is greater than the draft angle
of the portion Q14 where winding ends at the outer side, as shown in FIGS. 37 and 38, and
the draft angle from where winding starts to where winding ends is set so as to gradually and
continuously change. Specifically, the portion Q11 of the wrap 526b where winding starts is
set to be a maximum draft angle (e.g., 2 degrees), the draft angle in the intermediate portions
(Q11 to Q13) is set so as to continuously decrease as the winding angle a changes, and the
draft angle of the portion Q14 where winding ends is set to the minimum angle (e.g., 0.5
degree). In other words, the relationship between the winding angle a and the draft angle θ
of the wrap is set so that the draft angle θ has the maximum value of 2 degrees when the
winding angle a is the angle where winding starts, the draft angle θ decreases in proportion to
the increase the winding angle a, and the draft angle θ has the minimum value of 0.5 degree
when the winding angle a is the angle where winding ends, as shown in the graph of FIG. 39.
The fixed scroll 524 is manufactured in the same manner as the movable scroll 526. The
shape of the wrap of the movable scroll after the finishing step is described below.
In the fixed scroll 524, the shape of the scroll of the wrap 524b has a draft angle in the
portion PO where winding starts near the center. The draft angle is greater than the draft

angle of the portion P4 where winding ends at the outer side, as shown in FIGS. 40 and 41,
and the draft angle from where winding starts to where winding ends is set so as to gradually
and continuously change. Specifically, the portion PO of the wrap 524b where winding
starts is set to be a maximum draft angle (e.g., 2 degrees), the draft angle in the intermediate
portions (P1 to P3) is set so as to continuously decrease as the winding angle a changes, and
the draft angle of the portion P4 where winding ends is set to the minimum angle (e.g., 0.5
degree). In other words, the relationship between the winding angle a and the draft angle θ
of the wrap is set so that the draft angle θ has the maximum value of 2 degrees when the
winding angle a is the angle where winding starts, the draft angle 0 decreases in proportion to
the increase the winding angle a, and the draft angle θ has the minimum value of 0.5 degree
when the winding angle a is the angle where winding ends, as shown in the graph of FIG. 39.
(Characteristics of the high-low pressure dome-type scroll compressor according to
third embodiment)
(1)
In the preform 626 of the movable scroll 526 according to the third embodiment, the draft
angle in relation to the mold in the wrap-corresponding portion varies in accordance with the
winding angle of the wrap-corresponding portion according to the present invention.
Therefore, the shape of the wrap is determined in accordance with strength and quality, and
wasted material can be eliminated.
(2)
In the preform 626 of the movable scroll 526 in the third embodiment, the scroll shape of the
wrap-corresponding portion is set so that the draft angle in the portion Q0 where winding
starts near the center of the wrap-corresponding portion is greater than the draft angle of the
portion Q4 where winding ends at the outer side, and so that the draft angle gradually and
continuously changes from where winding starts in the center of the wrap-corresponding
portion to the location where winding ends. Therefore, the stress applied to the mold in the
vicinity of the center of the scroll during mold release is reduced when the preform 626 of the
movable scroll 526 is molded by semi-molten die casting. As a result, normal cracking can
be reduced and the service life of the mold can be extended. Therefore, the mold costs can
be reduced and manufacturing costs of the fixed scroll 24 and movable scroll 26 can be
curtailed in association therewith.
(3)
In the third embodiment, the draft angle in the portion Q0 where winding starts near the
center of the wrap-corresponding portion of the preform 626 of the movable scroll 526 is

greater than the draft angle of the portion Q4 where winding ends at the outer side. For this
reason, the adverse effect on the near-net shaping of the wrap overall (i.e., molding
approximate to the final shape) can be reduced even if the draft angle in the center portion of
the wrap-corresponding portion is increased.
In other words, when the draft angle for the entire wrap-corresponding portion is increased,
the stress applied to the mold in the wrap-corresponding portion overall is reduced during
mold release, but the adverse effect on near-net shaping is increased. However, in the third
embodiment, the adverse effect on the near-net shaping is reduced by increasing the draft
angle in the vicinity of the center of the wrap-corresponding portion to be greater than the
draft angle of the portion where winding ends at the outer side.
(Modified example of third embodiment)
(A)
In the preform 626 of the movable scroll 526 according to the third embodiment, the draft
angle is set so as to gradually and continuously change from where winding starts in the
center of the wrap-corresponding portion to the location where winding ends, but the present
invention is not limited to this configuration. The change in the draft angle θ in relation to
the winding angle a of the wrap-corresponding portion may be set so that the rate of decrease
in the draft angle θ is greater in a range near where winding starts, as shown in the graph of
FIG. 42, and so that the rate of decrease of the draft angle 0 is reduced in a range near where
winding ends (the maximum value of the draft angle 0 is 2 degrees, and the minimum value is
0.5 degree). In this case as well, stress applied to the mold in the vicinity of the center of
the scroll is reduced during mold release, and the service life of the mold is extended when
the preform 626 of the movable scroll 526 is molded by semi-molten die casting.
In the case of the change in the draft angle 0 in relation to the winding angle a of the
wrap-corresponding portion shown in the graph of FIG. 42, the draft angle 0 is set to be a low
angle in portions other than the portions where winding starts and winding ends, in
comparison with the case of the graph of FIG. 39 (change in which the draft angle 0 decreases
in linear fashion in proportion to an increase in winding angle a). Therefore, any adverse
effect on near-net shaping of the wrap-corresponding portion overall can be further reduced.
(B)
In the preform 626 of the movable scroll 526 according to the third embodiment, the shape of
the wrap-corresponding portion is set so that the draft angle gradually and continuously
changes from where winding starts to where winding ends, but the present invention is not
limited to this configuration. The change in the draft angle θ in relation to the winding

angle a of the wrap-corresponding portion may be set so that the draft angle 9 decreases in a
stepwise fashion from where winding starts to where winding ends, as shown in the graph of
FIG. 43 (the maximum value of the draft angle 9 is 2 degrees, and the minimum value is 9.5
degrees). In this case as well, stress applied to the mold in the vicinity of the center of the
scroll is reduced during mold release, and the service life of the mold is extended when the
preform 626 of the movable scroll 526 is molded by semi-molten die casting. Also, the
setting of the draft angle 9 in a range of individual winding angles a of the
wrap-corresponding portion is facilitated.
(C)
In the preform 626 of the movable scroll 526 according to the third embodiment, the shape of
the wrap-corresponding portion is set so that the draft angle from where winding starts to
where winding ends gradually and continuously changes, but the present invention is not
limited to this configuration. The change in the draft angle 9 in relation to the winding
angle a of the wrap-corresponding portion is set so that the draft angle 9 in a prescribed range
of winding angles a near where winding starts has the maximum value (2 degrees), and so
that the draft angle 9 in other angle ranges is set to the minimum value (9.5 degree), as shown
in the graph of FIG. 44. In this case as well, stress applied to the mold in the vicinity of the
center of the scroll is reduced during mold release, and the service life of the mold is
extended when the preform 626 of the movable scroll 526 is molded by semi-molten die
casting. Also, any adverse effect on near-net shaping of the wrap-corresponding portion
overall can be further reduced.
(D)
Although not particularly mentioned in the third embodiment, the surface of the scroll may be
coated with a resin. For example, leakage of refrigerant gas compressed by a compressor
can be reduced and noise suppressed when the entire surface of the movable scroll 536 is
coated with a resin RS in the manner shown in FIG. 45. Noise and leakage of the refrigerant
gas can be reduced when at least the wrap 536b of the movable scroll 536 is coated with a
resin RS.
When the scroll is coated with a resin in this manner, the strength of the scroll inside the resin
coating can be improved only in required locations by increasing the draft angle of the
portion where winding starts near the center of the wrap 536b.
Furthermore, when the surface of the resin RS is machined by cutting after the wrap 536b of
the movable scroll 536 has been coated with resin RS, the movable scroll 536 can be
machined with good precision to a prescribed external shape.

The fixed scroll may be coated with the resin RS in the same manner as the movable scroll
536. In this case as well, noise and leakage of the refrigerant gas can be reduced when at
least the wrap of the fixed scroll is coated with a resin RS.
(E)
In the third embodiment, a compressor scroll is manufactured by semi-molten die casting or
another semi-molten molding method, but the present invention is not limited thereto, and the
service life of a mold can be extended in the present invention when the compressor scroll is
one in which the material is injected into the mold and then molded. For example, the
service life of a mold can be extended by making the draft angle in the portion where winding
starts near the center of the wrap of the scroll to be greater than the draft angle of the portion
where winding ends at the outer side, even when the scroll is one in which high-temperature
molten metal material is injected into the mold and then cast.
(F)
In the preform 626 of the movable scroll 526 according to the third embodiment, the draft
angle of the portion Q0 where winding starts near the center of the wrap-corresponding
portion is greater than the draft angle of the portion Q4 where winding ends at the outer side,
but the present invention is not limited thereto, and the draft angle on the outer side may be
greater.
In other words, in the fixed scroll preform 644 and the movable scroll preform 646, the draft
angle in the portions P23, Q24 where winding ends at the outer side of the
wrap-corresponding portion may be greater than the draft angle of the portions P21, Q21
where winding starts near the center, as shown in FIGS. 46 and 47.
This configuration is effective for the case in which the thickness of the external peripheral
portion of the wrap-corresponding portion is thin and precision is difficult to achieve during
machining. For example, since the external peripheral edge of the wrap-corresponding
portion is a cantilever shape, the strength of the external peripheral portion of the
wrap-corresponding portion is reduced when the thickness of the entire wrap-corresponding
portion is reduced. For this reason, the external peripheral portion of the
wrap-corresponding portion readily deforms during machining. In view of this situation,
precision can be assured by making the draft angle of the external peripheral portion of the
wrap-corresponding portion to be greater than that of the center portion.
The wrap-corresponding portion may be set so that the draft angle from where winding starts
to where winding ends gradually and continuously changes (i.e., continuously increases from
where winding starts near the center to where winding ends at the outer side) in the same

manner as in the third embodiment. In this case, the waste of material can be more
effectively eliminated.
The wrap-corresponding portion may also be set so that the draft angle from where winding
starts to where winding ends changes in a stepwise fashion (i.e., increases in a stepwise
fashion from where winding starts near the center to where winding ends at the outer side) in
the same manner as in the modified example (B) of the third embodiment. In this case, the
waste of material can be more effectively eliminated.
In a prescribed angle range between where winding starts to where winding ends (i.e., a
prescribed range near the portion where winding ends), the wrap-corresponding portion may
be set so that the draft angle is greater than the draft angle in other angle ranges in the same
manner as in the modified example (C) of the third embodiment. In this case, the waste of
material can be more effectively eliminated.
At least the wrap-corresponding portion may be coated with a resin in the same manner as in
the modified example (D) of the third embodiment. In this case, noise and leakage of the
gas refrigerant can be reduced.
Fourth embodiment
A compressor in which the slider according to a fourth embodiment is used will be described
below using a high-low pressure dome-type scroll compressor as an example. The
difference between the high-low pressure dome-type scroll compressor of the fourth
embodiment and the high-low pressure dome-type scroll compressor of the first embodiment
is the shape of the wrap of the fixed scroll and the movable scroll. Therefore, only the fixed
scroll and the movable scroll will be described below.
A movable scroll preform 726 according to the fourth embodiment is formed by semi-molten
die casting using a mold 280 shown in FIG. 48, for example.
A specific description is provided below.
The mold 280 for the semi-molten die casting of the movable scroll preform 726 is composed
of a first mold portion 281 and a second mold portion 282, as shown in FIG. 48. The shape
of a space portion that is formed when the first mold portion 281 and the second mold portion
282 are combined together corresponds to the shape of the external appearance of the
movable scroll preform 726 to be molded. In the wrap-corresponding portion of the second
mold portion 282 of the mold 280, the external shape is set so as to maintain the required
draft angle when the movable scroll preform 726 is released from the mold 280.
Specifically, the shape of the wrap-corresponding portion of the second mold portion 282 is
determined so that the entire surface of the wrap-corresponding portion 87 is sloped at the

first angle 6 with respect to a line orthogonal to the portion 86a corresponding to the end plate.
The thickness of the wrap-corresponding portion 87 of the movable scroll preform 726 in the
boundary with the portion 86a corresponding to the end plate is t + t1 + t1, where t is the
thickness of the distal end.
The fixed scroll preform 724 is also manufactured in the same manner as the movable scroll
preform 726.
The fixed scroll preform 724 and the movable scroll preform 726 molded by semi-molten die
casting are further machined by cutting, whereby the final fixed scroll 734 and movable scroll
736 to be incorporated into a compressor are formed.
The fixed scroll 734 shown in FIG. 49 is manufactured by machining the fixed scroll preform
724 shown in FIGS. 50 and 51. A cutting operation for forming a wrap 185 from the wrap
85 will be described at this point. This operation is one of the machining processes that may
be used. These processes also include drilling of a discharge hole 741.
In this case, the wrap 85 is differentiated into surfaces OS85a, IS85b, OS85b, which are in
close contact with the wrap 187 of the movable scroll 36 as the other element of the meshing
pair and which can form an. end portion of the compression chamber 740, and into an internal
peripheral surface IS85a of the portion 85a where winding starts (portion near the center of
the wrap 85), which is not in close contact with the wrap 187 of the movable scroll 736 as the
other element of the meshing pair. The former surfaces OS85a, IS85b, OS85b are machined
by cutting, and the latter surface IS85a is not machined by cutting. Among the surfaces
OS85a, IS85b, OS85b, the external peripheral surface OS85a of the portion 85a is near where
winding starts; and the internal peripheral surface IS85b and the external peripheral surface
OS85b of the portion 85b are nearer to where winding ends than the portion 85a near where
winding starts. The surfaces OS85a, IS85b, OS85b are machined by cutting in an end mill
process, the slopes shown in FIGS. 50 and 51 are removed, and the surfaces OS 185a, IS 185b,
OS 185b shown in FIGS. 49 and 52 are formed. The surfaces OS85a, IS85b, OS85b
indicated by the broken lines in FIG. 52 are cut, and the surfaces OS 185a, IS 185b, OS185b
indicated by solid lines are formed. The slope angle of the surfaces OS 185a, IS185b,
OS 185b in relation to the line orthogonal to the end plate surface 184a is 0 degrees. On the
other hand, the internal peripheral surface IS85a of the portion 85a of the wrap 85 near where
winding starts is left unchanged as the internal peripheral surface of the portion 185a near
where winding starts in the final wrap 185 as well. FIG. 53 shows an enlarged view of the
portion 185a near where winding starts in FIG. 52. In the portion 185a of the wrap 185 near
where winding starts, the external peripheral surface OS 185a is orthogonal to the end plate

surface 184a, whereas the internal peripheral surface IS85a slopes by a first angle 0 with
respect to the line orthogonal to the end plate surface 184a. The portion 85a of the wrap 185
near where winding starts is thereby given a thickness ta in the boundary with the end plate
surface 184a, and this thickness is greater than that of the other portions 85b of the wrap 185.
The portions 85b of the wrap 185 other than the portion 85a near where winding starts are
machined by cutting so as to have the same thickness from the boundary with the end plate
surface 184a to the distal end, and the thickness is set to be the same as the thickness t of the
distal end of the portion 85a near where winding starts shown in FIG. 53.
The movable scroll 736 shown in FIG. 54 is manufactured by machining the movable scroll
preform 726 shown in FIG. 48. Among the machining processes, the cutting operation for
forming a wrap 187 from the wrap 87 will be described at this point.
In this case, the wrap 87 is differentiated into surfaces OS87a, IS87b, OS87b, which are in
close contact with the wrap 185 of the fixed scroll 734 as the other element of the meshing
pair and which can form an end portion of the compression chamber 740, and into an internal
peripheral surface IS87a of the portion 87a where winding starts (portion near the center of
the wrap 87), which is not in close contact with the wrap 185 of the fixed scroll 734 as the
other element of the meshing pair. The former surfaces OS87a, IS87b, OS87b are machined
by cutting, and the latter surface IS87a is not machined by cutting. Among the surfaces
OS87a, IS87b, OS87b, the external peripheral surface OS87a of the portion 87a is near where
winding starts; and the internal peripheral surface IS87b and the external peripheral surface
OS85b of the portion 87b are nearer to where winding ends than the portion 87a near where
winding starts. The surfaces OS87a, IS87b, OS87b are machined by cutting in an end mill
process, the slopes shown in FIG. 48 are removed, and the surfaces OS187a, IS187b, OS187b
shown in FIG. 54 are formed. The surfaces OS87a, IS87b, OS87b indicated by the broken
lines in FIG. 54 are cut, and the surfaces OS 187a, IS187b, OS187b indicated by solid lines
are formed. The slope angle of the surfaces OS187a, IS187b, OS187b in relation to the line
orthogonal to the end plate surface 186a is 0 degrees. On the other hand, the internal
peripheral surface IS87a of the portion 87a of the wrap 87 near where winding starts is left
unchanged as the internal peripheral surface of the portion 187a near where winding starts in
the final wrap 187 as well. In the portion 187a of the wrap 187 near where winding starts,
the external peripheral surface OS 187a is orthogonal to the end plate surface 186a, whereas
the internal peripheral surface IS87a slopes by a first angle θ with respect to the line
orthogonal to the end plate surface 186a. The portion 87a of the wrap 187 near where
winding starts is thereby given a thickness ta in the boundary with the end plate surface 186a,

and this thickness is greater than that of the other portions 87b of the wrap 187. The
portions 87b of the wrap 187 other than the portion 87a near where winding starts are
machined by cutting so as to have the same thickness from the boundary with the end plate
186a to the distal end, and the thickness is set to the thickness t, which is less than the
thickness ta, as shown in FIG. 54.
(Movement of the scroll during compression operation)
FIGS. 55 to 57 are diagrams showing a state in which a gas refrigerant is compressed in
association with variation in the capacity of the compression chamber 740. FIGS. 55 to 57
are lateral cross-sectional views of the meshing portion of the wrap 185 of the fixed scroll
734 and the wrap 187 of the movable scroll, and are views from above. The movable scroll
736 turn with respect to the fixed scroll 734, whereby the state changes in the sequence of
FIGS. 55(a), 55(b), 56(a), 56(b), 57(a), and 57(b). The internal peripheral surfaces IS85a,
IS87a of the portions 185a, 187a of the wraps 185, 187 near where winding starts (surfaces
with thick lines in the diagrams; see FIG. 58) are surfaces that do not make contact with the
counterpart wrap, do not constitute end portions of the compression chamber 740, and do not
contribute to compression work. Therefore, although these surfaces are sloped at a first
angle θ, the surface precision of the surfaces IS85a and IS87a does not affect the airtightness
of the compression chamber 740.
(Characteristics of the high-low pressure dome-type scroll compressor according to fourth
embodiment)
(1)
Using ductile cast iron and high-carbon steel, which are high-strength materials, makes it
difficult to achieve a near-net shape and results in low machinability. Therefore, the scroll
in a conventional scroll compressor is often manufactured using FC250 or another ordinary
cast iron.
In contrast, in the compressor according to the fourth embodiment, the fixed scroll preform
724 and the movable scroll preform 726 are molded by semi-molten die casting, whereby
high strength and high rigidity are achieved and the final fixed scroll 734 and movable scroll
736 are molded to a near-net shape.
However, the scroll preforms 724, 726, which are semi-molten die cast materials, are given
higher strength by heat treatment, but the rigidity (Young's modulus) is fixed and cannot be
adjusted. Therefore, the amount of deformation (flexing) of the wraps 185, 187 during
operation increases when the wraps 185, 187 are merely made thinner as strength is increased,
and noise and abrasion tend to be generated. When the gap between the two wraps 185, 187

is increased so as to allow a considerable amount of deformation in order to avoid this noise
and abrasion, airtightness of the compression chamber is reduced and compression
performance is degraded.
In order to avoid these drawbacks, it is possible to consider increasing the rigidity of the
wraps 185, 187 overall by increasing the thickness of the base portion of the portion near the
end plates 184, 186 and reducing the thickness of the distal end portion, rather than merely
reducing the thickness of the wraps 185, 187. However, demerits occur in that the capacity
of the compression chamber is reduced when the thickness of the base portion is increased
overall. Also, it is possible that quality control (control of surface precision) will be made
more difficult and performance will be compromised by leaving a slope on the wraps 185,
187 in which high precision is required.
In view of the above, in the compressor according to the fourth embodiment, a slope having a
first angle 0 is provided to the surfaces IS85a, IS87a of the internal peripheral side to increase
strength and to considerably reduce the amount of deformation in the portions 185a, 187a
near where winding starts in the wraps 185, 187. In these wraps, there is an increase in the
pressure applied by the refrigerant gas compressed near the center. On the other hand, the
slope is eliminated from the portions 185b, 187b that are set at a distance from the center of
the wraps 185, 187, and a reduction in capacity is avoided. Also, the external peripheral
surfaces OS 185a, OS187a of the portions 185a, 187a of the wraps 185, 187 near where
winding starts are surfaces that make contact with the counterpart scroll and that perform
compression work. The slope is eliminated because control of the surface precision
becomes difficult when a large slope is provided, and refrigerant gas leakage is likely to
increase in the contact portions of the two scrolls 734, 736. A slope having a first angle 0
is provided to the internal peripheral surfaces IS85a, IS87a of the portions 185a, 187a of the
wraps 185, 187 near where winding starts, but there is no demerit because these surfaces
IS85a, IS87a are not surfaces that make contact with a counterpart: scroll and does not affect
the airtightness of the compression chamber 740.
In this manner, in the compressor according to the fourth embodiment, the pressure is
relatively low in the portions 185b, 187b other than the portions 185a, 187a of the wraps 185,
187 near where winding starts. Therefore, priority is placed on increasing capacity rather
than increasing strength and reducing the amount of deformation, and the slope angle is set to
zero. The pressure is relatively high in the internal peripheral surfaces IS85a, IS87a of the
portions 185a, 187a of the wraps 185, 187 near where winding starts. Therefore, a slope
angle (first angle 0) is provided with the aim of increasing strength and reducing the amount

of deformation. In the external peripheral surfaces OS 185a, OS187a of the portions 185a,
187a of the wraps 185, 187 near where winding starts, the slope angle is set to zero with
consideration given to control of the surface precision and the airtightness of the compression
chamber 740. For this reason, the thickness of the wraps 185, 187 is reduced overall and the
capacity is assured, but a slope having a first angle 0 is provided to the portions 185a, 187a
near where winding starts of the wraps 185, 187, which received high-pressure, whereby
strength can be assured and the amount of deformation can be kept within acceptable levels.
There is an advantage in that control of surface precision and airtightness of the compression
chamber 740 are assured because the slope angle is set to zero also for the portions 185b,
187b other than the portions 185a, 187a of the wraps 185, 187 near where winding starts.
(2)
In the compressor according to the fourth embodiment, all of the surfaces OS 182a, IS 185b,
OS185b, OS187a, IS 187b, OS187b in the scroll 124, 126 have a slope angle of zero, except
for the surfaces IS85a, IS87a, which are provided with a slope having a first angle θ. In this
manner, the surfaces that make contact with the wrap of the meshing counterpart scroll and
perform compression work all have a slope angle of zero. Therefore, control of the surface
precision for these surfaces is facilitated, and there is less of a drawback in which gas
refrigerant leaks from the meshing portion of the wraps 185, 187 of the two scroll 124, 126 to
the compression chamber 740 on the outer side during operation of the compressor.
(3)
In the compressor according to the fourth embodiment, the internal peripheral surfaces IS85a,
IS87a of the portions 185a, 187a of the wraps 185, 187 near where winding starts are surfaces
that do not make contact with meshing counterpart wraps 187, 185. In view of that fact that
high surface precision is not required for these surfaces, machining by cutting the surfaces
IS85a and IS87a is omitted. Reduced costs can thereby be assured and the time required for
machining by cutting is reduced.
(4)
In the compressor according to the fourth embodiment, the draft angle maintained during
mold release is provided to the preforms 724, 726 of the uncut scrolls 734, 736, and the draft
angle is directly used as the slope of the surfaces IS85a, IS87a of the wraps 185, 187.
Therefore, the surfaces IS85a, IS87a of the wraps 185, 187 are set to the first angle θ without
cutting.
(5)
In the compressor according to the fourth embodiment, the portions 185a, 187a of the wraps

185, 187 near where winding starts in the scrolls 734, 736 have internal peripheral surfaces
lS85a, IS87a that are sloped by a first angle 9 with respect to the line orthogonal to the end
plate surfaces 184a, 186a in contrast to the external peripheral surfaces OS 185a, OS187a that
are orthogonal to the end plate surfaces 184a, 186a. The portions 85a, 87a of the wraps 185,
187 near where winding starts have a thickness ta in the boundary with the end plate surfaces
184a, 186a, and this thickness is greater than that of the other portions 85b, 87b of the wraps
185, 187. Strength is therefore increased in the portions 185a, 187a of the wraps 185, 187
near where winding starts in the scrolls 734, 736 of this compressor. Therefore, the scrolls
734, 736 of this compressor can withstand an increase in pressure due to a high pressure
difference even when carbon dioxide or another high-pressure refrigerant is compressed. In
addition, the height of the teeth of the scrolls 734, 736 can be increased by this effect. In
other words, the capacity of the compression chamber 740 can be increased even while the
wraps 185, 187 are reduced in diameter. The trunk casing 11 is reduced in diameter when
the diameter of the compressor can be reduced in this manner. The trunk casing 11 having a
reduced diameter can demonstrate the same compression strength with less thickness than a
conventional trunk casing. Accordingly, the raw material costs and the like of the trunk
casing 11 can be reduced. The diameter of the wraps 185, 187 of the scrolls 734, 736 can
also be reduced. For this reason, the sliding surface area of the thrust portion, which is
subject to rigorous conditions, can be increased.
(6)
In the compressor according to the fourth embodiment, the scrolls 734, 736 are manufactured
by semi-molten die casting. Accordingly, the scrolls 734, 736 have a surface roughness that
is less than that of scrolls obtained by conventional iron casting. For this reason, cracks are
unlikely to occur from the surface of the scrolls 734, 736 even when carbon dioxide or
another high-pressure refrigerant is compressed in this compressor.
(Modified example of fourth embodiment)
In the fourth embodiment, the preforms 724, 726 of the compressor scrolls 734, 736 are
manufactured by semi-molten die casting or another semi-molten molding method, but the
present invention is not limited thereby. For example, only the slope angle of the internal
peripheral surfaces of the portion near where winding starts in the center of the wrap, which
does not make contact with the counterpart scroll during compressor operation, may be
increased, and the capacity of the compression chamber can be increased while reducing the
amount of deformation and increasing the strength. This is true even in the case of a scroll
that has been cast by injecting high-temperature molten metal material into the mold.

However, the problem of the deformation amount (flexing) in the portion near where winding
starts in the center of the wrap is mainly considered in the case of a scroll in which relatively
higher rigidity is not desired as much as the desired for higher strength obtained using a
high-strength material. Therefore, the present invention is made more useful in that the
rigidity of this portion alone can be improved.
Fifth embodiment
A compressor in which the slider according to a fifth embodiment is used will be described
below using a swing compressor as an example.
The swing compressor 801 according to the fifth embodiment is a two-cylinder swing
compressor, as shown in FIG. 59, and is primarily composed of a cylindrical airtight
dome-type casing 810, a swing compression mechanism 815, a drive motor 816, a suction
tube 819, a discharge tube 820, and a muffler 860. The swing compressor 801 has an
accumulator (vapor-liquid separator) 895 mounted on the casing 810. The constituent
elements of the swing compressor 801 are described below.
(Details of the constituent elements of the swing compressor)
(1) Casing
The casing 810 has a substantially cylindrical trunk casing 811, a saucer-shaped upper wall
portion 812 welded in an airtight manner to an upper end of the trunk casing 811, and a
saucer-shaped lower wall portion 813 welded in an airtight manner to a lower end of the
trunk casing 811. Primarily accommodated in the casing 810 are the swing compression
mechanism 815 for compressing a gas refrigerant, and the drive motor 816 disposed above
the swing compression mechanism 815. The swing compression mechanism 815 and the
drive motor 816 are connected by a crankshaft 817 disposed so as to extend in the vertical
direction inside the casing 810.
(2) Swing compression mechanism
The swing compression mechanism 815 is primarily composed of a crankshaft 817, a piston
821, a bushing 822, a front head 823, a first cylinder block 824, a middle plate 825, a second
cylinder block 826, and a rear head 827, as shown in FIGS. 59 and 61. In the fifth
embodiment, the front head 823, first cylinder block 824, middle plate 825, second cylinder
block 826, and rear head 827 are integrally fastened by a plurality of bolts 890. Also, in the
fifth embodiment, the swing compression mechanism 815 is immersed in lubricating oil L
pooled in the bottom portion of the casing 810, and the lubricating oil L is fed to the swing
compression mechanism 815 by differential pressure. The constituent elements of the swing
compression mechanism 815 will be described in detail below.

a) First cylinder block
A cylinder hole 824a, a suction hole 824b, a discharge channel 824c, a bushing
accommodation hole 824d, and a blade accommodation hole 824e are formed on the first
cylinder block 824, as shown in FIG. 60. The cylinder hole 824a is a cylindrical hole that
passes along the plate thickness direction, as shown in FIGS. 59 and 60. The suction hole
824b passes through the cylinder hole 824a from the external peripheral wall surface. The
discharge channel 824c is formed by notching a portion of an internal peripheral part of the
cylindrical portion that forms the cylinder hole 824a. The bushing accommodation hole
824d is a hole that extends in the plate thickness direction and is disposed between the
suction hole 824b and the discharge channel 824c when viewed in the plate thickness
direction. The blade accommodation hole 824e is a hole that extends in the plate thickness
direction and is in communication with the bushing accommodation hole 824d.
The first cylinder block 824 is fitted into the front head 823 and the middle plate 825 so that
the discharge channel 824c faces the front head 823 in a state in which an eccentric shaft
portion 817a of the crankshaft 817 and a roller portion 821a of the piston 821 are
accommodated in the cylinder hole 824a, a blade portion 821b of the piston 821 and the
bushing 822 are accommodated in the bushing accommodation hole 824d, and the blade
portion 821b of the piston 821 is accommodated in the blade accommodation hole 824e (see
FIG. 61). As a result, a first cylinder chamber Rc1 is formed on the swing compression
mechanism 815; and the first cylinder chamber Rcl is partitioned by the piston 821 into a
suction chamber that is in communication with the suction hole 824b, and a discharge
chamber that is communication with the discharge channel 824c.
b) Second cylinder block
A cylinder hole 826a, a suction hole 826b, a discharge channel 826c, a bushing
accommodation hole 826d, and a blade accommodation hole 826e are formed on the second
cylinder block 826 in the same manner as the first cylinder block 824, as shown in FIG. 60.
A cylinder hole 826a is a cylindrical hole that extends in the plate thickness direction, as
shown in FIGS. 59 and 60. The suction hole 826b passes from the external peripheral wall
surface to the cylinder hole 826a. The discharge channel 826c is formed by notching a
portion of an internal peripheral portion of the cylinder part that forms the cylinder hole 826a.
The bushing accommodation hole 826d is a hole that extends in the plate thickness direction
and is disposed between the suction hole 826b and the discharge channel 826c when viewed
in the plate thickness direction. The blade accommodation hole 826e is a hole that extends
in the plate thickness direction and is in communication with the bushing accommodation

hole 826d.
The second cylinder block 826 is fitted into the rear head 827 and the middle plate 825 so that
the discharge channel 826c faces the rear head 827 in a state in which an eccentric shaft
portion 817b of the crankshaft 817 and a roller portion 821a of the piston 821 are
accommodated in the cylinder hole 826a, a blade portion 821b of the piston 821 and the
bushing 822 are accommodated in the bushing accommodation hole 826d, and the blade
portion 821b of the piston 821 is accommodated in the blade accommodation hole 826e (see
FIG. 61). As a result, a second cylinder chamber Rc2 is formed on the swing compression
mechanism 815; and the second cylinder chamber Rc2 is partitioned by the piston 821 into a
suction chamber that is in communication with the suction hole 826b, and a discharge
chamber that is communication with the discharge channel 826c.
c) Crankshaft
The crankshaft 817 has two eccentric shaft portions 817a, 817b provided to one of the end
portions. The two eccentric shaft portions 817a, 817b are formed so that the eccentric axes
face each other across the center axis of the crankshaft 817. The crankshaft 817 is secured
to the rotor 852 of the drive motor 816 on the side in which the eccentric shaft portions 817a,
817b are not provided.
d) Piston
The piston 821 has a substantially cylindrical roller portion 821a, and a blade portion 821b
that protrudes outward in the radial direction of the roller portion 821a, as shown in FIGS. 59
and 62. The roller portion 821a is fitted into the eccentric shaft portions 817a, 817b of the
crankshaft 817, and is inserted in this state into the cylinder holes 824a, 826a of the cylinder
blocks 824, 826. The roller portion 821a thereby moves in an orbiting fashion about the
rotational axis of the crankshaft 817 when the crankshaft 817 rotates. The blade portion
821b is accommodated in bushing accommodation holes 824d, 826d and blade
accommodation holes 824e, 826e. The blade portion 821b thereby swings and
simultaneously moves in a reciprocating fashion in the lengthwise direction.
e) Bushing
The bushing 822 is a substantially semicylindrical member and is accommodated in the
bushing accommodation holes 824d, 826d so as to hold the blade portion 821b of the piston
821 on both sides.
f) Front head
The front head 823 is a member that covers the first cylinder block 824 on the side of the
discharge channel 824c and is fitted into the casing 810. A bearing portion 823a is formed

on the front head 823, and the crankshaft 817 is inserted into the bearing portion 823a. Also,
formed in the front head 823 is an opening 823 b for feeding to the discharge tube 820 a
refrigerant gas that flows in through the discharge channel 824c formed in the first cylinder
block 824. The opening 823b is opened and closed by a discharge valve (not shown) for
preventing the backflow of refrigerant gas.
g) Rear head
The rear head 827 covers the second cylinder block 826 on the side of the discharge channel
826c. A bearing portion 827a is formed on the rear head 827, and the crankshaft 817 is
inserted into the bearing portion 827a. Also, an opening (not shown) for feeding to the
discharge tube 820 a refrigerant gas that flows in through the discharge channel 826c formed
in the second cylinder block 826 is formed in the rear head 827. The opening is opened and
closed by a discharge valve (not shown) for preventing the backflow of refrigerant gas.
h) Middle plate
The middle plate 825 is disposed between the first cylinder block 824 and the second cylinder
block 826, and partitions the first cylinder chamber Rc1 and the second cylinder chamber
Rc2.
(3) Drive motor
The drive motor 816 is a DC motor in the fifth embodiment, and is primarily composed of an
annular stator 851 secured to the internal wall surface of the casing 810, and a rotor 852
rotatably accommodated with a slight gap (air gap channel) on the inner side the stator 851.
Copper wire is wound about a tooth portion (not shown) of the stator 851, and a coil end 853
is formed above and below the stator. The external peripheral surface of the stator 851 is
provided with core cut portions (not shown) that have been formed as a notch in a plurality of
locations from the upper end surface to the lower end surface of the stator 851 at prescribed
intervals in the peripheral direction.
A crankshaft 817 is secured along the rotational axis to the rotor 852.
(4) Suction tube
The suction tube 819 is provided so as to pass through the casing 810, and has one end that is
fitted into the suction holes 824b, 826b formed in the first cylinder block 824 and the second
cylinder block 826, and another end that is fitted into the accumulator 895.
(5) Discharge tube
The discharge tube 820 is provided so as to pass through the upper wall portion 812 of the
casing 810.
(6) Muffler

The muffler 860 is used to muffle the discharge noise of the refrigerant gas, and is mounted
on the front head 823.
(Method for manufacturing a slider)
In the swing compressor 801 according to the fifth embodiment, the cylinder blocks 824, 826,
the piston 821, and the crankshaft 817 are manufactured by the same manufacturing method
as the one used to manufacture the slider of the first embodiment. In this case, the piston
821 and the crankshaft 817 are heat treated in the heat treatment step under conditions at
which the hardness is greater than HRB 90 but less than HRB 100.
In the fifth embodiment, after the finishing step, high-frequency heaters are inserted into the
bushing accommodation holes 824d, 826d of the cylinder blocks 824, 826, and the cylinder
blocks 824, 826 are subjected to a high-frequency heating treatment so that the hardness of
the portions on the periphery of the bushing accommodation holes 824d, 826d is set to be
greater than HRC 50 but less than HRC 65. The cylinder blocks 824, 826 prior to the
high-frequency heating treatment are heat treated under conditions at which the hardness is
greater than HRB 90 but less than HRB 100. After finishing, the crankshaft 817 is subjected
to high-frequency heating treatment in the main shaft and secondary shaft portions
accommodated in the front head 823 and the rear head 827.
In the fifth embodiment, after the finishing step, the peripheral portion SC8 of the base of the
blade portion 821b of the piston 821 in which stress is readily concentrated (see FIG. 62; the
partial heating treatment locations are shaded) is subjected to partial heat treatment.
(Operation of the swing compressor)
When the drive motor 816 is driven, the eccentric shaft portions 817a, 817b rotate
eccentrically about the crankshaft 817, and the roller portion 821a fitted into the eccentric
shaft portions 817a, 817b orbits while the external peripheral surface of the roller portion
821a makes contact with the internal peripheral surface of the cylinder chambers Rc1, Rc2.
The blade portion 821b reciprocates while the two side surfaces are held by the bushing 822,
in accompaniment with the orbiting of the roller portion 821a inside the cylinder chambers
Rcl, Rc2. At this point, a low-pressure refrigerant gas is suctioned from the suction port
819 into the suction chamber and is compressed to a high pressure in the discharge chamber,
and the high-pressure refrigerant gas is thereafter discharged from the discharge channels
824c, 826c.
(Characteristics of the swing compressor)
(1)
In the fifth embodiment, the cylinder blocks 824, 826 and the piston 821 are manufactured

via a semi-molten die casting step and a heat treatment step. Accordingly, a cylinder block
and piston can be readily provided with higher tensile strength and hardness than a cylinder
block and piston composed of flake graphite cast iron manufactured using conventional sand
casting (because higher strength and rigidity than FC250 can be achieved by performing heat
treatment).
(2)
In the fifth embodiment, the cylinder blocks 824, 826 and the piston 821 are manufactured
via a semi-molten die casting step and a heat treatment step, and the hardness of these
components is adjusted so as to be greater than HRB 90 but less than HRJB 100. In this case,
the hardness of the cylinder blocks 824, 826 and the piston 821 substantially corresponds to a
tensile strength within a range of 600 MPa to 900 MPa. Accordingly, the cylinder blocks
824, 826 and the piston 821 can be made thinner by adopting this method for manufacturing a
compressor slider. Therefore, the swing compressor 801 can be reduced in diameter, and the
abrasion of the cylinder blocks 824, 826 and the piston 821 can consequently be reduced and
the compression capacity increased.
(3)
In the heat treatment step of the fifth embodiment, the cylinder block preform and the piston
preform are heat treated to a hardness greater than HRB 90 but less than HRB 100.
Accordingly, when this method for manufacturing a compressor slider is adopted, the
cylinder blocks 824, 826 and the piston 821 can be manufactured so that sufficient durability
can be demonstrated during compressor operation, "breaking-in" occurs as early as possible,
and seizing during abnormal operation does not occur. When the hardness is in this range,
the machinability of the cylinder block preform and the piston preform is good, the cylinder
block preform and the piston preform are not readily damaged, and handling is facilitated.
Accordingly, tool abrasion and tool chipping is less likely to occur, tool service life is
extended, a built-up edge is less likely to form, grinding processability is good, and
machining costs are reduced because machining time can be reduced. Regardless the scrolls
have superior tool abrasion and machining time because of lower hardness in relation to FCD
having the same tensile strength (tensile strength is high at the same level of hardness), it can
be said that higher tensile strength can be achieved.
(4)
In the fifth embodiment, the cylinder blocks 824, 826 are manufactured by a semi-molten die
casting and a heat treatment step, after which high-frequency heaters are inserted into the
bushing accommodation holes 824d, 826d, and hardening is carried out so that the hardness

of the portions of the periphery of the bushing accommodation holes 824d, 826d is greater
than HRC 50 but less than HRC 65. For this reason, the abrasion of the portions of the
periphery of the bushing accommodation holes 824d, 826d is reduced even when CO2 or
another natural refrigerant is suctioned in.
(5)
In the fifth embodiment, the main shaft portion, the secondary shaft portion accommodated in
the front head 823 and the rear head 827, and the eccentric shaft portion of the crankshaft 817
are subjected to high-frequency heating treatment. Accordingly, sufficient abrasion
resistance can be imparted to the main shaft portion, the secondary shaft portion, and the
eccentric shaft portion. Therefore, the service life of the crankshaft 817 can be extended.
(6)
In the fifth embodiment, the peripheral portion SC8 of the base of the blade portion 821b of
the piston 821 in which stress is readily concentrated is partially heat treated. Accordingly,
the piston 821 is not likely to be destroyed even if a somewhat large load is applied to the
blade portion 821b.
(Modified example of fifth embodiment)
(A)
In the fifth embodiment, the cylinder blocks 824, 826 and the piston 821 were heat treated so
that the hardness of the cylinder blocks 824, 826 and the piston 821 of the swing compressor
801 was greater than HRB 90 but less than HRB 100, after which high-frequency heaters
were inserted in the bushing accommodation holes 824d, 826d and a hardening treatment was
performed so that the hardness of the portions in the periphery of the bushing accommodation
holes 824d, 826d was made to be greater than HRC 50 but less than HRC 65. In this case,
such a hardness adjustment technique may be applied to a cylinder block 924 and a roller 921
of a rotary compressor 901 such as that shown in FIG. 64. In other words, the roller 921 and
the cylinder block 924 of the rotary compressor 901 are heat treated so that the hardness of
the cylinder block 924 and the roller 921 is greater than HRB 90 but less than HRB 100.
Thereafter, a high-frequency heater is inserted into a vane accommodation hole 924d, and the
cylinder block 924 is subjected to a hardening treatment so that the hardness of the portions
in the periphery of the vane accommodation hole 924d is greater than HRC 50 but less than
HRC 65 (see FIG. 63). A vane 922 may be manufactured using the same method. In FIGS.
63 and 64, the reference numeral 924a indicates a cylinder hole, 924c is a discharge channel,
924b is a suction hole, 917 is a crankshaft, 917a is an eccentric shaft of the crankshaft, 923 is
a spring, and Rc3 is a cylinder chamber. The roller 921 and the cylinder block 924 may be

manufactured in accordance with the manufacturing method described in modified example
(H) of the first embodiment.
(B)
The swing compressor 801 according to the fifth embodiment was a two-cylinder swing
compressor, but the swing compressor may also be a single-cylinder swing compressor.
(C)
In the swing compressor 801 according to the fifth embodiment, the cylinder blocks 824, 826
and the piston 821 were manufactured via a semi-molten die casting step and a heat treatment
step, but the crankshaft 817, the front head 823, the rear head 827, the middle plate 825, and
other sliders may be manufactured via the same steps.
INDUSTRIAL APPLICABILITY
The compressor slider according to the present invention has high tensile strength, can
demonstrate sufficient durability during operation, is readily "broken in" as early as possible,
does not seize during abnormal operation, and can therefore be useful as a compressor
designed for upgrade demand.

Claims
1. A compressor slider having a carbon content of 2.0 wt% to 2.7 wt%; a
silicon content of 1.0 wt% to 3.0 wt%; a balance of iron that includes unavoidable
impurities; a metal structure primarily composed of a pearlite structure, a ferrite
structure, and granular graphite; and a hardness that is greater than HRB 90 and
less than HRB 100 in at least a portion of the slider.
2. The compressor slider as recited in Claim 1, being manufactured by semi-
molten die casting or semi-solid die casting, then rapid cooling, and then a heat
treatment.
3. The compressor slider as recited in Claim 1, being manufactured by metal-
mold casting, then rapid cooling, and then a heat treatment.
4. The compressor slider as recited in any of Claims 1 to 3, wherein the ratio
of tensile strength to Young's modulus is 0.0046 or less.
5. The compressor slider as recited in any of Claims 1 to 4, wherein a portion
thereof is partially heat treated.
6. The compressor slider as recited in Claim 5, wherein the hardness of a
location that has been partially heat treated is greater than HRC 50 and less than
HRC 65.
7. The compressor slider as recited in Claim 5 or 6, wherein a location that is
partially heat treated is a stress concentration area.
8. The compressor slider as recited in any of Claims 1 to 7, being
manufactured using a mold having a convexity that allows a prescribed portion in the
vicinity of a center to be thinly formed, and being provided with a thin prescribed
portion in the vicinity of the center.

9. The compressor slider as recited in any of Claims 1 to 7, wherein a slider
preform provided with a thin prescribed portion in the vicinity of a center is molded
using a mold having a convexity that allows a prescribed portion in the vicinity of the
center to be thinly formed, and a through-hole is formed in the thin prescribed portion
in the preform.
10. A compressor scroll having a carbon content of 2.0 wt% to 2.7 wt%, a
silicon content of 1.0 wt% to 3.0 wt%, a balance of iron that includes unavoidable
impurities, and a metal structure primarily composed of a pearlite structure, a ferrite
structure, and granular graphite, the compressor scroll comprising:
a plate portion; and
a scroll portion that extends from a first plate surface of the plate portion in a
direction perpendicular to the first plate surface while a scroll shape is maintained,
wherein
the plate portion and the scroll portion have a hardness that is greater than
HRB 90 and less than HRB 100.
11. The compressor scroll part as recited in Claim 10, wherein a draft angle of
the scroll portion in relation to a mold varies in accordance with a winding angle.
12. The compressor scroll part as recited in Claim 11, wherein the scroll
portion presents a scroll shape in which a draft angle in relation to the mold in the
portion where winding starts near a center is larger than the draft angle of an outside
portion where winding ends.
13. The compressor scroll as recited in Claim 11, wherein the scroll portion
presents a scroll shape in which a draft angle in relation to the mold in the portion
where winding ends at the outer side is larger than a draft angle of the portion where
winding starts near the center.

14. The compressor scroll as recited in Claim 10, wherein
the scroll portion has a first surface that slopes at a first angle with respect to
a line that is orthogonal to the flat surface portion, the first surface being positioned
on the internal peripheral side of the portion in the vicinity of the start of winding near
the center; and
a surface other than the first surface has a slope angle in relation to the line
orthogonal to the flat plate portion that is less than the first angle.
15. The compressor scroll as recited in Claim 14, wherein the portion of the
wrap near where winding starts has a thickness at the boundary with the flat portion
that is greater than in other portions of the wrap.
16. A compressor slider preform having a carbon content of 2.0 wt% to 2.7
wt%; a silicon content of 1.0 wt% to 3.0 wt%; a balance of iron that includes
unavoidable impurities; a metal structure primarily composed of a pearlite structure,
a ferrite structure, and granular graphite; and a hardness that is greater than HRB 90
and less than HRB 100 in at least a portion of the slider.
17. A compressor, comprising a slider having a carbon content of 2.0 wt% to
2.7 wt%; a silicon content of 1.0 wt% to 3.0 wt%; a balance of iron that includes
unavoidable impurities; a metal structure primarily composed of a pearlite structure,
a ferrite structure, and granular graphite; and a hardness that is greater than HRB 90
and less than HRB 100 in at least a portion of the slider.
18. The compressor as recited in Claim 17, being capable of accommodating
a carbon dioxide (CO2) refrigerant.

An object of the present invention is to provide a compressor slider that has high tensile strength, is capable of demonstrating sufficient durability during operation, can be
easily "broken in" in the shortest possible period, and is free of seizing during abnormal
operation. The compressor slider (17, 23, 24, 26, 39, 60, 96, 310b, 524, 526, 644, 646, 724,
726, 734, 736, 817, 821, 823, 824, 825, 826, 827, 921, 924) has a carbon content of 2.0 wt%
to 2.7 wt%, a silicon content of 1.0 wt% to 3.0 wt%, a balance of iron that includes
unavoidable impurities, graphite that is smaller than the flake graphite of flake graphite cast
iron, and a hardness that is greater than HRB 90 but less than HRB 100 in at least a portion of
the slider.

Documents:

http://ipindiaonline.gov.in/patentsearch/GrantedSearch/viewdoc.aspx?id=Q68mENDLt2PzvUrtMfWtkw==&loc=wDBSZCsAt7zoiVrqcFJsRw==


Patent Number 277202
Indian Patent Application Number 3815/KOLNP/2008
PG Journal Number 48/2016
Publication Date 18-Nov-2016
Grant Date 15-Nov-2016
Date of Filing 18-Sep-2008
Name of Patentee DAIKIN INDUSTRIES, LTD.
Applicant Address UMEDA CENTER BUILDING, 4-12, NAKAZAKI-NISHI 2-CHOME, KITA-KU, OSAKA-SHI, OSAKA
Inventors:
# Inventor's Name Inventor's Address
1 HIROYUKI YAMAJI C/O RINKAI FACTORY, SAKAI PLANT, DAIKIN INDUSTRIES, LTD., 12, CHIKKOU-SHINMACHI, 3-CHO, NISHI-KU, SAKAI-SHI, OSAKA 592-8331
2 MIE ARAI 5-110, HAMADERA FUNAO-CHO NISHI, NISHI-KU, SAKAI-SHI, OSAKA 592-8342
3 MITSUHIKO KISHIKAWA C/O RINKAI FACTORY, SAKAI PLANT, DAIKIN INDUSTRIES, LTD., 12, CHIKKOU-SHINMACHI, 3-CHO, NISHI-KU, SAKAI-SHI, OSAKA 592-8331
4 SATOSHI YAMAMOTO C/O RINKAI FACTORY, SAKAI PLANT, DAIKIN INDUSTRIES, LTD., 12, CHIKKOU-SHINMACHI, 3-CHO, NISHI-KU, SAKAI-SHI, OSAKA 592-8331
5 MIKIO KAJIWARA C/O RINKAI FACTORY, SAKAI PLANT, DAIKIN INDUSTRIES, LTD., 12, CHIKKOU-SHINMACHI, 3-CHO, NISHI-KU, SAKAI-SHI, OSAKA 592-8331
6 TAKASHI HIROUCHI C/O RINKAI FACTORY, SAKAI PLANT, DAIKIN INDUSTRIES, LTD., 12, CHIKKOU-SHINMACHI, 3-CHO, NISHI-KU, SAKAI-SHI, OSAKA 592-8331
7 YASUHIRO MURAKAMI C/O RINKAI FACTORY, SAKAI PLANT, DAIKIN INDUSTRIES, LTD., 12, CHIKKOU-SHINMACHI, 3-CHO, NISHI-KU, SAKAI-SHI, OSAKA 592-8331
8 MASANORI MASUDA C/O KANAOKA FACTORY, SAKAI PLANT, DAIKIN INDUSTRIES, LTD., 1304, KANAOKA-CHO, KITA-KU, SAKAI-SHI, OSAKA 591-8511
9 KAZUHIRO FURUSHO C/O KANAOKA FACTORY, SAKAI PLANT, DAIKIN INDUSTRIES, LTD., 1304, KANAOKA-CHO, KITA-KU, SAKAI-SHI, OSAKA 591-8511
PCT International Classification Number F04C 29/00
PCT International Application Number PCT/JP2007/053551
PCT International Filing date 2007-02-26
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 2006-269128 2006-09-29 Japan
2 2006-074692 2006-03-17 Japan
3 2006-114819 2006-04-18 Japan
4 2006-069141 2006-03-14 Japan
5 2006-056276 2006-03-02 Japan