| Method of manufacturing an assembled body composed of a plurality of members, manufacturing method of electromagnetic control valve, and control valve for variable capacity compressors -> Monitor Keywords |
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Method of manufacturing an assembled body composed of a plurality of members, manufacturing method of electromagnetic control valve, and control valve for variable capacity compressorsRelated Patent Categories: Pumps, Condition Responsive Control Of Drive Transmission Or Pump Displacement, Adjustable Cam Or Linkage, Axial Cam, With Sump Pressure ActuationMethod of manufacturing an assembled body composed of a plurality of members, manufacturing method of electromagnetic control valve, and control valve for variable capacity compressors description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20060193733, Method of manufacturing an assembled body composed of a plurality of members, manufacturing method of electromagnetic control valve, and control valve for variable capacity compressors. Brief Patent Description - Full Patent Description - Patent Application Claims
BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] The present invention relates to a method of manufacturing an assembled body composed of a plurality of components comprising a metallic member made of a magnetic material, and a metallic member made of a non-magnetic material. The present invention also relates to a method of manufacturing an electromagnetic control valve which is constituted by an assembled body wherein a stator made of a magnetic metallic material is fixedly coupled by means brazing to a guide pipe made of a non-magnetic metallic material and designed to be used as a plunger guide. [0003] Further, the present invention relates to a control valve for a variable capacity compressor to be employed in air conditioners for vehicle, in particular, to a control valve for a variable capacity compressor, which is suited for use in a crutch-attached compressor wherein the transmission of rotating driving force from the engine to the rotating axis of compressor is effected by means of a crutch. [0004] 2. Description of the Related Art [0005] As shown in JP Patent Laid-open Publication (Kokai) No. 2003-166667 (2003), the electromagnetic control valve for a variable capacity compressor to be employed in air conditioners for vehicle for example is constituted by an assembled body comprising a stator made of a magnetic metallic material, a guide pipe for use as a plunger guide which is fixedly coupled to an lower end portion of the stator and made of a non-magnetic metallic material, a holder fixedly coupled to an lower end portion of the guide pipe and made of a metallic material, and a housing fixedly coupled to the holder and made of a metallic material. [0006] The manufacture of the electromagnetic control valve constituted by the aforementioned assembled body has been conventionally executed as follows for example. Namely, as shown in FIG. 5(A), a stator 33 is formed into a cylindrical body having a step portion, thereby creating a lower end portion having a smaller outer diameter. Then, a guide pipe 35 is formed into a cylindrical body having an inner diameter which is large enough to enable the guide pipe 35 to externally fit on the diametrally contracted portion (i.e. the lower end portion) 33a of the stator 33 such that an upper edge 35c of the guide pipe 35 can be butted against the annular terrace surface 33c of stator 33. Then, a brazing material 95 is interposed between the terrace surface 33c of stator 33 and the upper edge 35c of the guide pipe 35. Thereafter, the stator 33 and the guide pipe 35 are heated up to a predetermined temperature (brazing temperature) in a furnace, thereby brazing the stator 33 to the guide pipe 35. In this case, as shown in FIG. 5(B), since the brazing material 95 is caused to melt in the furnace, the fused brazing material 95 is permitted to flow into a space "Sa" of the fitted portion between the stator 33 and the guide pipe 35. As a result, the stator 33 is caused to move downward. Subsequently, when the fitted portion between the stator 33 and the guide pipe 35 is cooled sufficiently, the stator 33 and the guide pipe 35 are fixedly coupled to each other through the brazing of the fitted portion (brazing portion "Ja"). [0007] Generally, the compressor to be employed in air conditioners for vehicle is driven by means of the engine, whose rotational speed is designed to be fluctuated depending on circumstances. Because of this, a variable capacity compressor which is capable of adjusting the discharge volume of cooling medium irrespective of the rotational speed of engine is generally employed as a compressor for the air conditioner of vehicle. [0008] A control valve to be employed in this compressor for the air conditioners of vehicle is generally constructed as follows. Namely, a cooling medium exhibiting a discharge pressure "Pb" is permitted to enter into the crank chamber of compressor from the discharge chamber of compressor so as to adjust the pressure "Pc" inside the crank chamber. In this case, the flow rate of cooling medium exhibiting a discharge pressure "Pb" to the crank chamber is restricted such that the quantity of supply (throttling volume) of cooling medium to the crank chamber can be controlled depending on the sucking pressure "Ps" of compressor. For this purpose, various proposals have been suggested or put into practice, as seen from JP Patent Laid-open Publication (Kokai) No. 2002-303262 (2002), where an electromagnetic actuator (solenoid) is employed. [0009] Further, as for the variable capacity compressor to be employed in air conditioners for vehicle, there are also known a crutch-attached compressor wherein the transmission of rotating driving force from the engine to the rotating axis of compressor is effected by means of a crutch, and a crutch-less compressor wherein the rotating driving force of the engine is directly transmitted to the rotating axis of compressor without intervention of a crutch. [0010] The conventional method of manufacturing an electromagnetic control valve as described above is accompanied with the following problems. [0011] (i) Since it requires the coupling and fixing work between the guide pipe 35 and the holder as well as between the holder and the housing in addition to the brazing work between the stator 33 and the guide pipe 35, a great deal of troublesome work and time are needed for assembling these assembled bodies, thus inevitably increasing the manufacturing cost of the electromagnetic control valve. Further, the assembled body that has been once subjected to brazing process can no longer be subjected, as a matter of fact, to a heat treatment after the assembling thereof. Therefore, there is a problem that when the assembled body includes a magnetic material, the magnetic property of the magnetic material cannot be sufficiently enhanced. [0012] (ii) Since the stator 33 and the guide pipe 35 are brazed together through the employment of brazing material 95 disposed between the terrace surface 33c of stator 33 and the upper edge 35c of the guide pipe 35, the brazing material 95 is caused to melt during the step of brazing, the fused brazing material 95 is permitted to flow into a space "Sa" of the fitted portion between the stator 33 and the guide pipe 35, causing the stator 33 to move downward as shown in FIG. 5(B). However, there are problems, as the stator 33 is caused to move downward, that the stator 33 tends to incline, and that the brazing material 95 is permitted to leave between the terrace surface 33c of stator 33 and the upper edge 35c of the guide pipe 35, thereby preventing the stator 33 from sufficiently descending. As a result, the terrace surface 33c is prevented from butting against the upper edge 35c of the guide pipe 35, leaving an air gap ".beta." between the terrace surface 33c and the upper edge 35c of the guide pipe 35 even after the brazing. If the air gap ".beta." is left remained in this manner, the length of air gap between the sucking member to be secured to a lower end of the stator and the plunger becomes inappropriate, thus raising the problem that the control of flow rate cannot be appropriately performed. [0013] Further, in the case of the control valve for a variable capacity compressor, especially the control valve for a crutch-less compressor, which is provided with an electromagnetic actuator (solenoid) constituted by a coil, a sucking member, a plunger, etc., when the value of current to be fed to the coil of electromagnetic actuator (solenoid) becomes zero (OFF of electric current) or nearly zero, the sucking force of plunger by means of the sucking member is caused to decrease, thereby causing the valve rod (the main body of valve) to shift, in a stroke, to the maximum lift position due to the valve-opening force of valve spring. As a result, the valve aperture with which the valve body is retractively contacted is caused to completely open (the opening degree of valve or the magnitude of valve lift becomes maximum). As a result, the flow rate of a cooling medium to be fed from the cooling medium outlet port located on the downstream side of the valve aperture to the crank chamber of compressor is caused to increase in a stroke (maximum flow rate), thus quickly increasing the pressure "Pc" inside the crank chamber of compressor. Namely, the region where the value of current is nearly zero would be turned into an uncontrollable region. [0014] Even if this uncontrollable region is permitted to exist in this manner, almost no problem would be raised in the case of the crutch-less compressor. In the case of the crutch-attached compressor however, when the control valve is caused to bring into the uncontrollable region, the pressure "Pc" inside the crank chamber exceeds over an allowable limitation, thereby raising problems in terms of control as well as in structural viewpoints. Thus, the control valve for use in the crutch-less compressor cannot be utilized as it is in the crutch-attached compressor. BRIEF SUMMARY OF THE INVENTION [0015] The present invention has been made in view of the circumstances mentioned above and, therefore, an object of the present invention to provide a brazing method which makes it possible to rationally perform not only the brazing between a metal member such as a stator made of a magnetic material and a metal member such as a guide pipe made of a non-magnetic material but also the magnetic annealing of these metal members. Another object of the present invention is to provide a method of rationally and precisely manufacture an electromagnetic control valve provided with an assembled body comprising a stator, a guide pipe, a holder and a housing at low costs. [0016] A further object of the present invention is to provide a control valve for a variable capacity compressor which can be employed in a crutch-attached compressor and which is capable of controlling the flow rate of cooling medium to be delivered from the cooling medium outlet port disposed on a downstream side of valve aperture to the crank chamber of compressor, thereby enabling the flow rate of cooling medium to be controlled so as not to exceed over an acceptable limit. [0017] With a view to achieving the aforementioned objects, there is provided, according to one aspect of the present invention, a method of manufacturing an assembled body composed of a plurality of members including a metal member "A" made of a magnetic material and a metal member "B" made of a non-magnetic material, the method comprising the steps of: heating the metal member "A" and the metal member "B" under conditions suitable for magnetic annealing of the metal member "A" to braze the metal member "A" to the metal member "B" to obtain an assembled body comprising the metal member "A" and the metal member "B"; and gradually cooling the assembled body to perform magnetic annealing of the metal member "A". [0018] In this case, preferably, the metal member "A" is brazed to the metal member "B" by making use of a brazing material having a melting point which is lower than a magnetic annealing temperature of the metal member "A". [0019] In a preferable embodiment, the metal member "A" is formed by making use of a magnetic steel such as an electromagnetic stainless steel, the metal member "B" is formed by making use of a non-magnetic steel material such as non-magnetic stainless steel, and the brazing material is formed by making use of copper wax or bronze wax. [0020] In another preferable embodiment, the metal member "A" is formed of a step-attached columnar or cylindrical body having a diametrally contracted end portion and a terrace surface, the metal member "B" is formed of a cylindrical body having an inner diameter which is large enough to enable it to externally fit on the diametrally contracted end portion, the diametrally contracted end portion of the metal member "A" is provided, at an extended end portion thereof which is remote from the terrace surface, with an annular groove facing an inner peripheral surface of the metal member "B" for holding a brazing material therein, and the brazing is performed under conditions wherein the metal member "B" is externally fitted on the diametrally contracted end portion with an fitted end of the metal member "B" being butted against the terrace surface and the brazing material being held between the annular groove and the inner peripheral surface of the metal member "B". [0021] In a more specific embodiment, the metal member "A" is a stator of an electromagnetic control valve, and the metal member "B" is a guide pipe to be used as a plunger guide of the electromagnetic control valve. [0022] Further, according to another aspect of the present invention, there is also provided a method for manufacturing an electromagnetic control valve which is composed of an assembled body comprising a stator made of a magnetic metallic material, a guide pipe for use as a plunger guide which is fixedly coupled to an lower end portion of the stator and made of a non-magnetic metallic material, a holder fixedly coupled to an lower end portion of the guide pipe and made of a metallic material, and a housing fixedly coupled to the holder and made of a magnetic metallic material. In this manufacturing method, the stator is formed of a step-attached columnar or cylindrical body having a diametrally contracted end portion and a terrace surface, the guide pipe is formed of a cylindrical body having an inner diameter which is large enough to enable it to externally fit on the diametrally contracted end portion, the diametrally contracted end portion of the stator is provided, at an extended end portion thereof which is remote from the terrace surface, with an annular groove facing an inner peripheral surface of the guide pipe for holding a brazing material therein, the guide pipe is externally fitted on the diametrally contracted end portion with an fitted end of the guide pipe being butted against the terrace surface to thereby temporarily interconnect the stator, the guide pipe, the holder and the housing, and the brazing material is held between the annular groove and the inner peripheral surface of the guide pipe. 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