Variable displacement compressors and methods for manufacturing such compressors

Abstract

Variable displacement compressors 30 may include a rotor 7 that is press-formed from a plate W. The rotor 7 is fixedly mounted on a drive shaft 6 and is coupled to a swash plate 8 via a hinge device 20 . The hinge device 20 preferably permits the swash plate 8 to rotate with the rotor 7 as well as the drive shaft 6 and also may permit the swash plate 8 to change its inclination angle relative to the rotor 7 as well as the drive shaft 6 . The swash plate 8 may be coupled to a piston(s) 11 that reciprocates within a cylinder bore(s) 2 a.

1 . A variable displacement compressor, comprising: 
 a drive shaft having a rotational axis,    a press-formed rotor having a base portion and at least one support arm, the base portion being fixedly coupled to the drive shaft,    a swash plate pivotally mounted on the drive shaft in an inclined position relative to the drive shaft, the at least one support arm being coupled to the swash plate, wherein the inclination angle of the swash plate can change relative to the drive shaft when the rotor rotates with the swash plate, and    a piston coupled to the swash plate, whereby the piston reciprocates within a cylinder bore when the swash plate rotates, wherein the stroke length of the piston varies in response to changes in the inclination angle of the swash plate.    
     
     
         2 . A variable displacement compressor as in  claim 1 , wherein the at least one support arm is bent relative to a planer surface of the base portion, such that the at least one support arm is substantially positioned within a plane that is (a) parallel or substantially parallel to the rotational axis L of the drive shaft and is (b) perpendicular, or substantially perpendicular, to the planar surface of the base portion.  
     
     
         3 . A variable displacement compressor as in  claim 1 , further including a counterbalancing device that is arranged and constructed to adjust the center of gravity of the rotor so as to position the center of gravity at the rotational axis of the rotor.  
     
     
         4 . A variable displacement compressor as in  claim 3 , wherein the counterbalancing device includes at least one perforation formed in the base portion.  
     
     
         5 . A variable displacement compressor as in  claim 4 , wherein the counterbalancing device includes a counterweight disposed on the base portion, the counterweight being positioned opposite to the support arm with respect to the rotational axis.  
     
     
         6 . A variable displacement compressor as in  claim 5 , wherein the at least one support arm is bent relative to a planer surface of the base portion, such that the at least one support arm is substantially positioned within a plane that is (a) parallel or substantially parallel to the rotational axis L of the drive shaft and is (b) perpendicular, or substantially perpendicular, to the planar surface of the base portion.  
     
     
         7 . A variable displacement compressor as in  claim 6 , wherein an elongated slot is defined in the at least one support arm and a hinge pin slidably couples the at least one support arm to the swash plate.  
     
     
         8 . A variable displacement compressor as in  claim 3 , wherein the counterbalancing device includes a counterweight disposed on the base portion, the counterweight being positioned opposite to the support arm with respect to the rotational axis.  
     
     
         9 . A variable displacement compressor as in  claim 1 , wherein an elongated slot is defined in the at least one support arm and a hinge pin slidably couples the at least one support arm to the swash plate.  
     
     
         10 . A method for making a variable displacement compressor, comprising; 
 press-forming a single plate in order to form a rotor having at least one support arm integrally formed with a base portion,    fixedly coupling the base portion to a drive shaft of the variable displacement compressor, and    slidably coupling the at least one support arm to a swash plate of the variable displacement compressor, the swash plate being coupled to a piston slidably received within a cylinder bore.    
     
     
         11 . A method as in  claim 10 , further including: 
 punching the plate in order to form the rotor with two support arms extending outwardly from the base portion, and    bending a base of each support arm proximal to the base portion, wherein the support arms are bent so as to be disposed in a plane that is (a) parallel, or substantially parallel, to a rotational axis of the drive shaft and (b) perpendicular, or substantially perpendicular to a planar surface of the rotor.    
     
     
         12 . A method as in  claim 10 , further including forming at least one perforation in the base portion, the at least one perforation serving to adjust the center of gravity of the rotor.  
     
     
         13 . A method as in  claim 12 , further including forming a counterbalance weight on the base portion on the side opposite to the at least one support arm with respect to a rotational axis of the drive shaft.  
     
     
         14 . A method as in  claim 13 , further including: 
 punching the plate in order to form the rotor with two support arms extending outwardly from the base portion, and    bending a base of each support arm proximal to the base portion, wherein the support arms are bent so as to be disposed in a plane that is (a) parallel, or substantially parallel, to a rotational axis of the drive shaft and (b) perpendicular, or substantially perpendicular to a planar surface of the rotor.    
     
     
         15 . A method as in  claim 10 , further including forming a counterbalance weight on the base portion on the side opposite to the at least one support arm with respect to a rotational axis of the drive shaft.  
     
     
         16 . An apparatus for making a variable displacement compressor, comprising: 
 means for press-forming a single plate in order to form a rotor having at least one support arm integrally formed with a base portion,    means for fixedly coupling the base portion to a drive shaft of the variable displacement compressor, and    means for slidably coupling the at least one support arm to a swash plate of the variable displacement compressor, the swash plate being coupled to a piston slidably received within a cylinder bore.    
     
     
         17 . An apparatus as in  claim 16 , further including: 
 means for punching the plate in order to form the rotor with two support arms extending outwardly from the base portion, and    means for bending a base of each support arm proximal to the base portion, wherein the support arms are bent so as to be disposed in a plane that is (a) parallel, or substantially parallel, to a rotational axis of the drive shaft and (b) perpendicular, or substantially perpendicular to a planar surface of the rotor.