Suction silencer for reciprocating compressor

Abstract

A reciprocating compressor includes a piston (130) slidably mounted within a compression chamber and defining a suction port for receiving a flow of gas. A flexmount (160) is mechanically coupled to the piston (130) and has an inner surface (202) defining a suction cavity (204). A suction silencer (210) for a reciprocating compressor is disposed at least partially within the suction cavity (204) and includes an inlet tube (212) extending axially within the suction cavity (204) and defining an inlet passage (214) configured to receive the flow of gas (238), and a plurality of chamber plates (220) extending radially from an outer surface (222) of the inlet tube (212), the plurality of chamber plates (220) and the flexmount (160) defining a plurality of resonance chambers (224) to reduce compressor noise.

Description

Technical Field

[0001] The present invention relates generally to reciprocating compressors, and more particularly to an intake muffler for use in a reciprocating compressor. Background Technology

[0002] Some refrigeration appliances include a sealed system for cooling the refrigeration compartment of the appliance. The sealed system typically includes a compressor that generates compressed refrigerant during operation of the sealed system. The compressed refrigerant flows to an evaporator, where heat exchange between the refrigeration compartment and the refrigerant cools the refrigeration compartment and the food contained therein. More recently, some refrigeration appliances include reciprocating compressors, such as linear compressors, for compressing the refrigerant. A linear compressor typically includes a piston and a drive coil. The drive coil generates a force to propel the piston forward within the compartment. During the piston's movement within the compartment, the piston compresses the refrigerant.

[0003] Reciprocating compressors typically include a one-way valve that allows gas to flow into the compression chamber when the piston moves to the retracted position during the suction stroke and prevents gas from escaping from the compression chamber when the piston moves to the extended position during the compression stroke. For example, the valve may include a baffle valve mounted to the compression face of the piston. The baffle valve may be thin enough to bend under the force of gas pressure from the suction line. It is worth noting that the continuous opening and closing of the suction valve can generate significant noise. Conventional reciprocating compressors may include silencers to reduce noise from the pulsating suction valve; however, these silencers are complex to install, may be inefficient in reducing noise, and may impair compressor efficiency.

[0004] Therefore, reciprocating compressors with features designed to improve noise reduction are desirable. More particularly, reciprocating compressors with an intake muffler that is easy to install and effectively reduces compressor noise without compromising compressor performance will be especially beneficial. Summary of the Invention

[0005] Various aspects and advantages of the present invention will be set forth in the description which follows, or will be apparent from the description, or may be learned by practicing the invention.

[0006] In one exemplary embodiment, a reciprocating compressor defining axial and radial directions is provided. The reciprocating compressor includes: a cylindrical housing defining a compression chamber; a piston disposed within the compression chamber and axially movable, the piston defining an intake port for receiving a gas flow; a flexible mount mechanically coupled to the piston, the flexible mount having an inner surface defining an intake chamber; and an intake muffler at least partially disposed within the intake chamber of the flexible mount. The intake muffler includes: an inlet pipe extending axially within the intake chamber and defining an inlet passage configured to receive a gas flow; and a plurality of chamber plates extending radially from an outer surface of the inlet pipe, the plurality of chamber plates and the flexible mount defining a plurality of resonant chambers.

[0007] In another exemplary embodiment, an intake muffler for a reciprocating compressor is provided. The reciprocating compressor defines axial and radial directions and includes: a piston disposed within a compression chamber; a flexible mount mechanically coupled to the piston and having an inner surface defining an intake chamber; and a locking flange extending radially from the inner surface of the flexible mount toward the intake muffler. The intake muffler includes: an inlet pipe extending axially within the intake chamber and defining an inlet passage configured to receive a gas flow; a plurality of chamber plates extending radially from an outer surface of the inlet pipe, the chamber plates and the flexible mount defining a plurality of resonant chambers; and a latching feature engaging the locking flange to secure the intake muffler within the intake chamber.

[0008] These and other features, aspects, and advantages of the invention will become more readily understood with reference to the following description and the appended claims. Embodiments of the invention are illustrated in conjunction with the accompanying drawings, which are incorporated in and form a part of this specification, and together with the description serve to explain the principles of the invention. Attached Figure Description

[0009] Referring to the accompanying drawings, the specification sets forth a complete disclosure of the invention for those skilled in the art, which enables them to implement the invention, including the preferred embodiments thereof.

[0010] Figure 1 This is a front elevation view of a refrigeration appliance according to an exemplary embodiment of the present invention.

[0011] Figure 2 yes Figure 1 A schematic diagram of the refrigeration system of an exemplary refrigeration appliance.

[0012] Figure 3 This is a perspective sectional view of a linear compressor according to an exemplary embodiment of the present invention.

[0013] Figure 4 This is an exemplary embodiment of the present invention. Figure 3 Another perspective sectional view of an exemplary linear compressor.

[0014] Figure 5 This is a perspective view of a linear compressor according to an exemplary embodiment of the present invention, wherein the compressor housing has been removed for clarity.

[0015] Figure 6 This is an exemplary embodiment of the present invention. Figure 3 A cross-sectional view of an exemplary linear compressor, wherein the piston is in the extended position.

[0016] Figure 7 This is an exemplary embodiment of the present invention. Figure 3 A cross-sectional view of an exemplary linear compressor, with the piston in the retracted position.

[0017] Figure 8 Provided with an exemplary embodiment of the present invention Figure 3 A perspective view of a piston, flexible mount, and intake muffler used in conjunction with an exemplary linear compressor.

[0018] Figure 9 This is an exemplary embodiment of the present invention. Figure 8 Cross-sectional views of an exemplary piston, flexible mount, and intake muffler.

[0019] Figure 10 Exemplary embodiments of the present invention are provided. Figure 8 A perspective view of an exemplary inhalation muffler.

[0020] Figure 11 Exemplary embodiments of the present invention are provided. Figure 8 A close-up perspective view of the latching feature of an exemplary inhalation muffler.

[0021] Figure 12 Exemplary embodiments of the present invention are provided. Figure 8 A close-up perspective view of the locking flange of an exemplary flexible mount.

[0022] Figure 13 The latching feature of an intake muffler with a locking flange of an engaging flexible mount according to an exemplary embodiment of the present invention is illustrated.

[0023] The repeated use of reference numerals in this specification and the accompanying drawings is intended to indicate the same or similar features or elements of the invention. Detailed Implementation

[0024] Referring now to embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. Each example is given by way of explanation and does not constitute a limitation thereof. Indeed, it will be apparent to those skilled in the art that various modifications and variations can be made to the invention without departing from its scope or spirit. For example, features shown or described as part of one embodiment can be used in another embodiment, thereby producing yet another embodiment. Therefore, it is desired that the invention cover such modifications and variations falling within the scope of the appended claims and their equivalents.

[0025] As used herein, the term "or" is generally intended to be inclusive (i.e., "A or B" is intended to mean "A or B or both"). As used throughout the specification and claims, approximate language is applied to modify any quantitative representation that may vary without altering its associated essential function. Therefore, values ​​modified by terms such as "approximately," "approximately," and "roughly" are not limited to the specified precise values. In at least some cases, approximate language may correspond to the accuracy of the instrument used to measure the value. For example, approximate language may refer to a margin of 10%.

[0026] Figure 1 It describes the integration of a sealed refrigeration system 60 ( Figure 2 10. Refrigeration appliance. It should be understood that the term "refrigeration appliance" is used in a general sense herein to include refrigeration appliances of any kind, such as freezers, refrigerator / freezer combinations, and conventional refrigerators of any style or model. Furthermore, it should be understood that the invention is not limited to use in electrical appliances. Therefore, the invention can be used for any other suitable purpose, such as vapor compression in an air conditioning unit or air compression in an air compressor.

[0027] exist Figure 1 In the illustrated example embodiment, the refrigeration appliance 10 is described as a vertical refrigerator having a cabinet or outer casing 12 defining a plurality of internal cooling storage compartments. Specifically, the refrigeration appliance 10 includes an upper food preservation compartment 14 with a door 16 and a lower freezer compartment 18 with an upper drawer 20 and a lower drawer 22. Drawers 20 and 22 are "pull-out" drawers because they can be manually moved in and out of the freezer compartment 18 via a suitable sliding mechanism.

[0028] Figure 2This is a schematic diagram of certain components of a refrigeration appliance 10, including its hermetically sealed refrigeration system 60. The machine compartment 62 contains components for performing a known vapor compression cycle for compressed air. These components include a compressor 64, a condenser 66, an expander 68, and an evaporator 70, connected in series and filled with refrigerant. As those skilled in the art will understand, the refrigeration system 60 may include additional components, such as at least one additional evaporator, compressor, expander, and / or condenser. As an example, the refrigeration system 60 may include two evaporators.

[0029] Within the refrigeration system 60, refrigerant flows into a compressor 64, which operates to increase the pressure of the refrigerant. This compression raises the temperature of the refrigerant, which is then lowered by passing the refrigerant through a condenser 66. Within the condenser 66, heat exchange occurs with the surrounding air to cool the refrigerant. As illustrated by arrow AC, a fan 72 is used to draw air through the condenser 66 to provide forced convection for faster and more efficient heat exchange between the refrigerant within the condenser 66 and the surrounding air. Thus, as those skilled in the art will know, increasing the airflow through the condenser 66 can, for example, improve the efficiency of the condenser 66 by enhancing the cooling of the refrigerant contained therein.

[0030] An expansion device 68 (e.g., a valve, capillary tube, or other limiting device) receives refrigerant from the condenser 66. The refrigerant enters the evaporator 70 from the expansion device 68. As it leaves the expansion device 68 and enters the evaporator 70, the refrigerant pressure decreases. Due to the pressure drop and phase change of the refrigerant, the evaporator 70 is cool relative to chambers 14 and 18 of the refrigeration appliance 10. This generates cooling air and cools chambers 14 and 18 of the refrigeration appliance 10. Thus, the evaporator 70 acts as a heat exchanger, transferring heat from the air passing through it to the refrigerant flowing through it.

[0031] In general, the vapor compression cycle components, associated fans, and associated compartments in the refrigeration circuit are sometimes referred to as operable to force cold air through compartments 14, 18 ( Figure 1 ) sealed refrigeration system. Figure 2 The refrigeration system 60 described herein is provided by way of example only. Therefore, other configurations using the refrigeration system are also within the scope of this invention. Furthermore, it should be understood that terms such as "refrigerant," "gas," "fluid," etc., are generally intended to refer to a moving fluid used to facilitate the operation of the refrigeration system 60, and may include fluids, liquids, gases, or any combination thereof in any state.

[0032] See now for the overall overview. Figures 3 to 7 The following describes a linear compressor 100 according to an exemplary embodiment of the present invention. Specifically, Figure 3 and Figure 4 A three-dimensional sectional view of the linear compressor 100 is provided. Figure 5 A perspective view of the linear compressor 100 with the compressor housing or casing 102 removed for clarity is provided, and Figure 6 and Figure 7 Cross-sectional views of the linear compressor with the piston in the extended and retracted positions are provided. It should be understood that the linear compressor 100 is used herein only as an exemplary embodiment to facilitate the description of aspects of the invention. Modifications and variations of the linear compressor 100 can be made while remaining within the scope of the invention. In fact, aspects of the invention are applicable to any suitable piston-actuated or reciprocating compressor.

[0033] like Figure 3 and Figure 4 For example, housing 102 may include a lower or lower housing 104 and an upper or upper housing 106, which join together to form a generally enclosed cavity 108 for accommodating various components of the linear compressor 100. Specifically, for example, cavity 108 may be an airtight or hermetically sealed shell that can accommodate the working parts of the linear compressor 100 and prevent or inhibit refrigerant leakage or escape from the refrigeration system 60. Additionally, the linear compressor 100 generally defines an axial direction A, a radial direction R, and a circumferential direction C. V in the figures indicates the vertical direction. It should be understood that the linear compressor 100 is described herein only and exemplified as an aspect describing the invention. Changes and modifications to the linear compressor 100 can be made while remaining within the scope of the invention.

[0034] See now for the overall overview. Figures 3 to 7 This section will describe various parts and operating components of a linear compressor 100 according to an exemplary embodiment. As shown, the linear compressor 100 includes a housing 110 that extends, for example, along an axial direction A between a first end 112 and a second end 114. The housing 110 includes a cylinder 117 defining a chamber 118. The cylinder 117 is disposed at or adjacent to the first end 112 of the housing 110. The chamber 118 extends longitudinally along the axial direction A. As discussed in more detail below, the linear compressor 100 is operable to increase the pressure of a fluid within the chamber 118 of the linear compressor 100. The linear compressor 100 can be used to compress any suitable fluid, such as a refrigerant or air. In particular, the linear compressor 100 can be used in refrigeration appliances, such as compressor 64 (…). Figure 2 10 ( ) refrigeration appliances Figure 1 ).

[0035] The linear compressor 100 includes a stator 120 of a motor mounted or fixed to a housing 110. For example, the stator 120 typically includes an outer back iron 122 extending circumferentially C within the housing 110 and a drive coil 124. The linear compressor 100 also includes one or more valves that allow refrigerant to enter and exit the chamber 118 during operation of the linear compressor 100. For example, an exhaust muffler 126 is disposed at one end of the chamber 118 to regulate the outflow of refrigerant from the chamber 118, while an intake valve 128 (only shown for clarity) is also present. Figures 6 to 7 (As shown in the figure) regulate the inflow of refrigerant into chamber 118.

[0036] A piston 130, having a piston head 132, is slidably received within a chamber 118 of a cylinder 117. Specifically, the piston 130 is slidable along an axial direction A. During the sliding of the piston head 132 within the chamber 118, the piston head 132 compresses the refrigerant within the chamber 118. As an example, the piston head 132 can be positioned from the top dead center position (see, for example...) Figure 6 ) Along axis A toward the bottom dead center position (see example) Figure 7 The piston head 132 slides within chamber 118, which is the expansion stroke of the piston head 132. When the piston head 132 reaches the bottom dead center position, it changes direction and slides back towards the top dead center position within chamber 118, which is the compression stroke of the piston head 132. It should be understood that the linear compressor 100 may include additional piston heads and / or additional chambers at opposite ends of the linear compressor 100. Thus, in an optional exemplary embodiment, the linear compressor 100 may have multiple piston heads.

[0037] As illustrated in the figure, the linear compressor 100 also includes a mover 140, typically driven by a stator 120, for compressing the refrigerant. Specifically, for example, the mover 140 may include an inner back iron 142 disposed within the stator 120 of the motor. In particular, the outer back iron 122 and / or drive coil 124 may extend, for example, around the inner back iron 142 along a circumferential direction C. The inner back iron 142 also has an outer surface facing the outer back iron 122 and / or drive coil 124. At least one drive magnet 144 is mounted to the inner back iron 142, for example, mounted on the outer surface of the inner back iron 142.

[0038] The drive magnet 144 may face and / or be exposed to the drive coil 124. Specifically, the drive magnet 144 may be spaced apart from the drive coil 124 by an air gap, for example, along a radial direction R. This defines an air gap between the opposing surfaces of the drive magnet 144 and the drive coil 124. The drive magnet 144 may also be mounted or secured to the inner back iron 142 such that the outer surface of the drive magnet 144 is substantially flush with the outer surface of the inner back iron 142. This allows the drive magnet 144 to be inserted within the inner back iron 142. Thus, during operation of the linear compressor 100, the magnetic field from the drive coil 124 may only need to pass through a single air gap between the outer back iron 122 and the inner back iron 142, and the linear compressor 100 may be more efficient than a linear compressor with air gaps on both sides of the drive magnet.

[0039] As in Figure 3 As can be seen, the drive coil 124 extends, for example, circumferentially C, around the inner back iron 142. In another example embodiment, the inner back iron 142 may extend circumferentially C around the drive coil 124. The drive coil 124 is operable to move the inner back iron 142 along the axial direction A during operation of the drive coil 124. As an example, a current source (not shown) may induce a current within the drive coil 124 to generate a magnetic field that attracts the drive magnet 144 and pushes the piston 130 along the axial direction A to compress the refrigerant within the chamber 118 as described above and as those skilled in the art will understand. In particular, during operation of the drive coil 124, the magnetic field of the drive coil 124 may attract the drive magnet 144 to move the inner back iron 142 and the piston head 132 along the axial direction A. Thus, during operation of the drive coil 124, the drive coil 124 may cause the piston 130 to slide between a top dead center position and a bottom dead center position, for example, by moving the inner back iron 142 along the axial direction A.

[0040] The linear compressor 100 may include various components for enabling and / or regulating the operation of the linear compressor 100. Specifically, the linear compressor 100 includes a controller (not shown) configured to regulate the operation of the linear compressor 100. The controller is operatively in communication with a motor (e.g., a drive coil 124 of the motor). Thus, the controller can selectively activate the drive coil 124, for example, by inducing a current in the drive coil 124, to compress the refrigerant with the piston 130 as described above.

[0041] The controller includes memory and one or more processing devices, such as a microprocessor, CPU, etc., such as a general-purpose or special-purpose microprocessor, operable to execute programming instructions or microcontroller code related to the operation of the linear compressor 100. The memory may represent random access memory such as DRAM or read-only memory such as ROM or FLASH. The processor executes programming instructions stored in the memory. The memory may be a separate component from the processor or may be included on a board within the processor. Alternatively, the controller may be constructed to perform control functions without using a microprocessor, for example using a combination of discrete analog and / or digital logic circuits (such as switches, amplifiers, integrators, comparators, flip-flops, AND gates, etc.), rather than relying on software.

[0042] The inner backplate 142 also includes an outer cylinder 146 and an inner sleeve 148. The outer cylinder 146 defines the outer surface of the inner backplate 142 and also has an inner surface disposed opposite to the outer surface of the outer cylinder 146. The inner sleeve 148 is disposed on or at the inner surface of the outer cylinder 146. A first interference fit between the outer cylinder 146 and the inner sleeve 148 can connect or fix the outer cylinder 146 and the inner sleeve 148 together. In an alternative exemplary embodiment, the inner sleeve 148 may be welded, glued, fastened or attached to the outer cylinder 146 via any other suitable mechanism or method.

[0043] The outer cylinder 146 can be constructed from or using any suitable material. For example, the outer cylinder 146 can be constructed from or using multiple (e.g., ferromagnetic) laminations. The laminations are distributed along a circumferential direction C to form the outer cylinder 146, and are mounted to each other or fixed together, for example, by rings pressed onto the ends of the laminations. The outer cylinder 146 may define a recess that extends inward from the outer surface of the outer cylinder 146, for example, along a radial direction R. A drive magnet 144 is disposed in the recess on the outer cylinder 146, for example, such that the drive magnet 144 is embedded within the outer cylinder 146.

[0044] The linear compressor 100 also includes a pair of flat springs 150. Each flat spring 150 may be coupled to a corresponding end of the inner back iron 142, for example, along the axial direction A. During operation of the drive coil 124, the flat springs 150 support the inner back iron 142. Specifically, the inner back iron 142 is suspended within the stator or motor of the linear compressor 100 by the flat springs 150, such that movement of the inner back iron 142 along the radial direction R is impeded or restricted, while movement along the axial direction A is relatively unimpeded. Thus, the flat springs 150 may be approximately stiffer along the radial direction R than along the axial direction A. In this way, during operation of the motor and movement of the inner back iron 142 along the axial direction A, the flat springs 150 may, for example, help maintain the uniformity of the air gap between the drive magnet 144 and the drive coil 124 along the radial direction R. The flat springs 150 may also help prevent the lateral pull of the motor from being transmitted to the piston 130 and reacting as frictional losses in the cylinder 117.

[0045] A flexible mount 160 is mounted to and extends through the inner backplate 142. Specifically, the flexible mount 160 is mounted to the inner backplate 142 via an inner sleeve 148. Thus, the flexible mount 160 can be coupled (e.g., threaded) to the inner sleeve 148 at an intermediate portion to mount or secure the flexible mount 160 to the inner sleeve 148. The flexible mount 160 can help form a coupling 162. The coupling 162 connects the inner backplate 142 and the piston 130, such that movement of the inner backplate 142 is transmitted, for example, along the axial direction A, to the piston 130.

[0046] Coupling 162 can be a compliant or flexible compliant coupling along the radial direction R. In particular, coupling 162 can be fully compliant along the radial direction R, such that little or no movement of the inner back iron 142 along the radial direction R is transmitted to the piston 130 through coupling 162. In this way, the lateral pull of the motor is separated from the piston 130 and / or cylinder 117, and the friction between the piston 130 and cylinder 117 can be reduced.

[0047] As can be seen in the figure, the piston head 132 of the piston 130 has a cylindrical sidewall 170. This cylindrical sidewall 170 extends axially A from the piston head 132 toward the inner backplate 142. The outer surface of the cylindrical sidewall 170 can slide on the cylinder 117 at the chamber 118, and the inner surface of the cylindrical sidewall 170 can be disposed opposite to the outer surface. Thus, the outer surface of the cylindrical sidewall 170 can be radially opposite to the center of the cylindrical sidewall 170, and the inner surface of the cylindrical sidewall 170 can be radially facing the center of the cylindrical sidewall 170.

[0048] The flexible mount 160 extends, for example, along axial direction A between a first end 172 and a second end 174. According to an exemplary embodiment, the inner surface of the cylindrical sidewall 170, near the first end, defines a ball seat 176. Additionally, the coupling 162 includes a ball head 178. Specifically, for example, the ball head 178 is disposed at the first end 172 of the flexible mount 160, and the ball head 178 can contact the flexible mount 160 at the first end 172. Additionally, the ball head 178 can contact the piston 130 at the ball seat 176 of the piston 130. In particular, the ball head 178 can rest on the ball seat 176 of the piston 130, such that the ball head 178 can slide and / or rotate on the ball seat 176 of the piston 130. For example, the ball head 178 may have a truncated spherical surface disposed close to the ball seat 176 of the piston 130, and the ball seat 176 may be shaped to be complementary to the truncated spherical surface of the ball head 178. The truncated spherical surface of the ball head 178 can slide and / or rotate on the ball seat 176 of the piston 130.

[0049] For example, compared to a fixed connection between the flexible mount 160 and the piston 130, the relative movement between the flexible mount 160 and the piston 130 at the interface between the ball head 178 and the ball seat 176 of the piston 130 can reduce friction between the piston 130 and the cylinder 117. For example, when the axis of the piston 130 sliding within the cylinder 117 is angled relative to the axis of the reciprocating motion of the inner back iron 142, the truncated spherical surface of the ball head 178 can slide on the ball seat 176 of the piston 130 to reduce friction between the piston 130 and the cylinder 117 relative to the rigid connection between the inner back iron 142 and the piston 130.

[0050] The flexible mount 160 is connected to the inner back iron 142 at its first end 172. For example, the flexible mount 160 may be connected to the inner back iron 142 at its second end 174 or between its first and second ends. Conversely, the flexible mount 160 is disposed at or within the piston 130 at its first end 172, as discussed in more detail below.

[0051] See also Figures 8 to 13 The flexible mount 160 and the internal muffler according to an exemplary embodiment of the invention will be described in more detail below. In this regard, for example, the flexible mount 160 includes a tubular wall 200 disposed between the inner back iron 142 and the piston 130 and mechanically connecting them. Additionally, the tubular wall 200 has an inner surface 202 defining a suction chamber 204, which is typically used to receive refrigerant or air (hereinafter and...) Figure 9 The compressible fluid (marked as gas flow 238) is directed to the piston head 132 and / or piston 130 via the flexible mounting 160.

[0052] The inner back iron 142 may be mounted to the flexible mount 160, for example, at the intermediate portion of the flexible mount 160 between the first end 172 and the second end 174, such that the inner back iron 142 extends around the tubular wall 200. The suction chamber 204 may extend within the tubular wall 200 between the first end 172 and the second end 174 of the flexible mount 160, such that compressible fluid can flow through the suction chamber 204 from the second end 174 (e.g., gas inlet) to the first end 172 (e.g., gas outlet) of the flexible mount 160. Thus, during operation of the linear compressor 100, compressible fluid can flow through the inner back iron 142 within the flexible mount 160.

[0053] The piston head 132 also defines at least one opening 206. The opening 206 of the piston head 132 extends through the piston head 132, for example, along the axial direction A. Thus, during operation of the linear compressor 100, the flow of fluid can pass through the piston head 132 via the opening 206 of the piston head to reach the chamber 118. In this way, during operation of the linear compressor 100, the flow of fluid (compressed by the piston head 132 within the chamber 118) can pass through the flexible mounting 160 and the inner back iron 142 to flow into the piston 130 within the suction chamber 204. As described above, the suction valve 128 ( Figures 6 to 7 It can be set on piston head 132 to regulate the flow of compressible fluid through opening 206 into chamber 118.

[0054] like Figures 3 to 4 and Figures 6 to 13 As a best example, the linear compressor 100 may also include an intake silencer 210, at least partially disposed within the intake chamber 204 within the tubular wall 200, for example, to reduce noise generated during operation of the linear compressor 100. In this regard, for example, the intake valve 128 generates a popping sound each time it opens or closes. The intake silencer 210 may be designed to attenuate such compressor noise. Additionally, or alternatively, the intake silencer 210 may generally be used to reduce noise generated by the compressible fluid flowing through the intake chamber 204 or any other noise generated during operation of the linear compressor 100.

[0055] As briefly mentioned above, the intake muffler 210 may be substantially, at least partially, disposed within the intake chamber 204 of the flexible mount 160. The intake muffler 210 may include an inlet pipe 212 that extends substantially along the axial direction A within the intake chamber 204, for example, coaxial with the tubular wall 200 of the flexible mount 160. The inlet pipe 212 may substantially define an internal inlet passage 214 for receiving a gas flow from the second end of portion 174 and directing the gas flow to the first end 172 and through the opening 206 in the piston head 132 into the chamber 118. Specifically, the inlet passage 214 may be designed to have a sufficient cross-sectional flow area to not restrict the gas flow through the flexible mount 160 and the piston head 132. Therefore, the presence of the intake muffler 210 may have little or no negative impact on the efficiency and performance of the linear compressor 100.

[0056] Additionally, the inhalation muffler 210 typically includes multiple chamber plates (e.g., generally identified herein by reference numeral 220). As illustrated in the example, each chamber plate 220 may extend generally radially R outward from the outer surface 222 of the inlet pipe 212. Specifically, the chamber plate 220 may extend from the inlet pipe 212 to contact the inner surface 202 of the tubular wall 200. For example, according to an exemplary embodiment, the chamber plate 220 may form a seal against the tubular wall 200 to define multiple resonant chambers (e.g., generally identified herein by reference numeral 224). According to the illustrated embodiment (e.g., as shown in the example), Figure 9 and Figure 10 (As best shown herein), the intake muffler 210 includes four chamber plates 220 arranged and oriented to define three resonant chambers 224, for example, to attenuate three specific harmonics of compressor noise. However, it should be understood that, according to alternative embodiments, the intake muffler 210 may include any suitable number, size, and arrangement of chamber plates 220 to define any suitable number of resonant chambers for attenuating any suitable noise generated by the linear compressor 100. Therefore, the intake muffler 210 as described herein is intended only for the purpose of discussing various aspects of the invention and is not intended to be limiting in any way.

[0057] See now for details. Figures 8 to 10 This section will describe an exemplary configuration of the flexible mount 160 and the intake muffler 210 according to an exemplary embodiment of the present invention. As shown, the chamber plate 220 typically includes a first chamber plate 230 disposed near the piston head 132. Additionally, the plate 220 may include a second chamber plate 232, a third chamber plate 234, and a fourth chamber plate 236, each chamber plate being further spaced from the first chamber plate 230. In this respect, for example, the fourth chamber plate 236 may be disposed adjacent to the second end 174 of the flexible mount 160 (e.g., disposed as an inlet plate). Similarly, the second chamber plate 232 and the third chamber plate 234 may be disposed along axial direction A between the first chamber plate 230 and the fourth chamber plate 236.

[0058] As described above, the intake muffler 210 is typically used to receive refrigerant gas and direct it toward the piston head 132 to facilitate compressor operation. Specifically, as Figure 9As best illustrated, the gas flow 238 is typically delivered to an inlet passage 214 near the fourth chamber plate 236 (e.g., inlet plate 236). The gas flow 238 can then flow downwards along the inlet passage 214 toward the piston head 132 along the axial direction A. According to the illustrated embodiment, the inlet pipe 212 may further define a plurality of chamber ports 240 defined to extend through the inlet pipe 212. According to the illustrated embodiment, one chamber port 240 is positioned adjacent to the first chamber plate 230 and allows the gas flow 238 to exit the inlet pipe 212. Additionally, the first chamber plate 230 may define a suction gap 242 through which the gas flow 238 can pass toward the piston 130, through the opening 206 of the piston head 132, and into the chamber 118.

[0059] See still Figure 9 The first or main resonance chamber 250 may be defined between the flexible mount 160 and the intake muffler 210. More specifically, the main resonance chamber 250 is at least partially defined by the outer surface 222 of the first chamber plate 230, the second chamber plate 232, the inlet pipe 212, and the inner surface 202 of the tubular wall 200. Similarly, the auxiliary or second resonance chamber 252 is at least partially defined by the outer surface 222 of the second chamber plate 232, the third chamber plate 234, the inlet pipe 212, and the inner surface 202 of the tubular wall 200. Another auxiliary or third resonance chamber 254 is at least partially defined by the outer surface 222 of the third chamber plate 234, the fourth chamber plate 236, the outer surface 222 of the inlet pipe 212, and the inner surface 202 of the tubular wall 200. As explained in more detail below, each of these resonant chambers 224 can be sized as a chamber port 240 with a specific length, diameter, volume, and / or cross-sectional dimensions to facilitate noise reduction at a specific frequency or frequency range.

[0060] As described above, the inlet pipe 212 may define a plurality of chamber ports 240, wherein at least one chamber port is used to direct the gas flow 238 toward the piston head 132. However, as illustrated in the example figure, the inlet pipe 212 may define at least one chamber port 240 for each of the plurality of resonant chambers 224. In this respect, at least one chamber port 240 provides fluid communication between the inlet passage 214 and each of the plurality of resonant chambers 224. Thus, pulsations within the suction chamber 204 can propagate through the inlet passage 214 and through or into the respective resonant chambers 224, which can be used to attenuate noise of a specific frequency or frequency range.

[0061] Therefore, resonant chamber 224 can typically operate as a Helmholtz resonator. In this respect, as is known in the art, a Helmholtz resonator or oscillator is typically an air container or chamber with an orifice or neck. The Helmholtz resonant frequency can be defined by the size and dimensions of the chamber and the neck of a particular chamber, such that the Helmholtz resonator is used to attenuate noise or vibration at that particular frequency. In other words, the intake silencer 210 can be designed such that chamber plate 220 defines resonant chamber 224 for absorbing acoustic vibrations at a specific frequency. For example, the primary resonant chamber 250 can have a quarter-wavelength Helmholtz resonator frequency tuned to the primary pulsating frequency of the intake valve 128. Similarly, auxiliary resonant chamber 252 and third resonant chamber 254 can be tuned to higher harmonics of the noise generated by the linear compressor 100.

[0062] It should be understood that the intake muffler 210 and the flexible mounting member 160 can be formed from any suitable rigid material. For example, according to an exemplary embodiment, the intake muffler 210 can be formed by injection molding, for example, using suitable plastic materials such as injection-molded polybutylene terephthalate (PBT), nylon 6, high-impact polystyrene (HIPS), or acrylonitrile butadiene styrene (ABS). Alternatively, according to an exemplary embodiment, these components can be compression molded, for example, using sheet molding compound (SMC) thermosetting plastics or other thermoplastic plastics. According to other embodiments, the intake muffler 210 can be formed from any other suitable rigid and / or flexible material suitable for absorbing acoustic vibrations.

[0063] In particular, it may be desirable to secure the intake muffler 210 within the intake chamber 204 in a manner that results in simple assembly, minimal maintenance, and little or no vibration or movement between the two parts. Conventional mufflers are attached to linear compressors by welding or mechanical fasteners, leading to complex assembly, potentially weak joints, and shorter muffler life. Therefore, aspects of the invention also relate to features for quickly and securely mounting the intake muffler 210 within the flexible mount 160. While exemplary mounting features are described below, it should be understood that variations and modifications can be made to these features while remaining within the scope of the invention.

[0064] For example, such as Figures 8 to 13As a best example, the flexible mount 160 may generally define one or more locking flanges 260, which are typically used to engage complementary latching features 262 defined on the intake muffler 210. Specifically, according to the illustrated embodiment, the flexible mount 160 includes four locking flanges 260 circumferentially spaced around the tubular wall 200 (e.g., one flange in each quadrant, with circumferential gaps between the flanges). Similarly, the intake muffler 210 defines four complementary latching features, which are also circumferentially spaced around the intake muffler 210, for example, extending from the fourth chamber plate 236.

[0065] In this respect, each locking flange 260 may extend radially R toward the intake muffler 210 from the inner surface 202 of the tubular wall 200, and / or the latching feature 262 may extend radially outward toward the tubular wall 200. Thus, a user can insert the intake muffler 210 into the intake cavity 204 at a first angular orientation where the latching feature 262 and the locking flange 260 are misaligned. The user can slide the intake muffler 210 into the intake cavity 204 along axis A until it reaches its lowest point within the flexible mount 160, and then rotate the intake muffler 210 about axis A to engage the locking flange 260 and the latching feature 262.

[0066] More specifically, according to the exemplified embodiment, latching features 262 may be defined on the inlet plate of chamber plate 220, for example, a fourth chamber plate 236 disposed near the second end 174 of tubular wall 200, as exemplified herein. Additionally, each latching feature 262 may extend axially away from the fourth chamber plate 236 and may have a spring-like structure for deflecting and snapping into place as the intake muffler 210 rotates. In this respect, for example, latching features 262 may define an inclined surface 264 that engages the locking flange 260 as the intake muffler 210 rotates. Thus, latching features 262 may deflect as the intake muffler 210 rotates until the locking flange 260 is located within the locking recess 266 defined by latching features 262. Once the locking flange 260 is located within the locking recess 266, the intake muffler 210 is securely fixed along the axial direction A and further rotation along the circumferential direction C is prevented. It should be understood that other latching and / or locking mechanisms are feasible and within the scope of this invention.

[0067] The aspects of the invention described above relate to a linear compressor with an integrated intake muffler in a refrigeration system. Specifically, the multi-chamber intake muffler is integrated into a flexible mount and a piston ball joint assembly, allowing these structures to move uniformly and providing improved compressor performance and effective noise reduction. The muffler may be a single part inserted into a tubular piston flexible mount and may snap-fit ​​and lock securely with mating features in the piston flexible mount. This snap-fit ​​may be spring-loaded to prevent any jitter or loosening of the intake muffler insert during compressor operation.

[0068] The multi-chamber muffler design utilizes a primary resonant chamber, a secondary resonant chamber, and a tertiary resonant chamber branching from the main inlet pipe to address typical harmonics in the intake pulsation. Once the muffler components are inserted into the piston flexible mount, the outer plate of the muffler design defines three separate chambers. The primary chamber can have a quarter-wavelength Helmholtz resonator frequency tuned to the primary pulsation frequency of the intake valve, with its internal volume maximized for fitting into the piston flexible mount. The intake gas inlet pipe can be sized to avoid dynamic restriction of the incoming intake gas, and the muffler insert can be made of relatively flexible and stretchable nylon (PA6) or any other flexible material.

[0069] This written description discloses the invention (including the best mode) by way of example and enables those skilled in the art to practice the invention (including making and using any apparatus or system and performing any of the included methods). The patentable scope of the invention is defined by the claims and may include other examples that may be conceived by those skilled in the art. Such other examples are expected to fall within the scope of the claims if they include structural elements that are not distinct from the literal language of the claims, or if they include equivalent structural elements that are not substantially distinct from the literal language of the claims.

Claims

1. A reciprocating compressor defining axial and radial directions, characterized in that, The reciprocating compressor includes: A cylindrical outer casing that defines a compression chamber; A piston disposed within the compression chamber and movable axially, the piston defining an intake port for receiving a gas flow; A flexible mount mechanically coupled to the piston, the flexible mount having an inner surface defining an intake chamber, the flexible mount defining a locking flange; and An inhalation muffler, at least partially disposed within the inhalation cavity of the flexible mount, wherein the locking flange extends radially from the inner surface of the flexible mount toward the inhalation muffler, the inhalation muffler comprising: An inlet pipe extending axially within the suction chamber and defining an inlet passage configured to receive the gas flow; and Multiple chamber plates extending radially from the outer surface of the inlet pipe, the multiple chamber plates and the flexible mounting member defining multiple resonant chambers; A latching feature is defined to engage the locking flange when the inhalation muffler is rotated, wherein the latching feature deflects until the locking flange is located in the locking recess defined by the latching feature to secure the inhalation muffler within the inhalation cavity.

2. The reciprocating compressor according to claim 1, characterized in that, The plurality of chamber plates include a first chamber plate and a second chamber plate, and wherein the plurality of resonant chambers include a main resonant chamber defined by the inner surfaces of the first chamber plate, the second chamber plate, the inlet pipe, and the flexible mounting member.

3. The reciprocating compressor according to claim 2, characterized in that, The main resonance chamber is defined by a main resonance frequency corresponding to the main pulsation frequency of the suction valve of the reciprocating compressor.

4. The reciprocating compressor according to claim 2, characterized in that, The plurality of chamber plates includes a third chamber plate, and wherein the plurality of resonant chambers includes an auxiliary resonant chamber defined by the inner surface of the second chamber plate, the third chamber plate, the inlet pipe, and the flexible mounting member.

5. The reciprocating compressor according to claim 4, characterized in that, The plurality of chamber plates includes a fourth chamber plate, and wherein the plurality of resonant chambers includes a third resonant chamber defined by the inner surface of the third chamber plate, the fourth chamber plate, the inlet pipe, and the flexible mounting member.

6. The reciprocating compressor according to claim 3, characterized in that, The main resonant chamber has a quarter-wavelength Helmholtz resonator frequency tuned to the main pulsating frequency of the intake valve.

7. The reciprocating compressor according to claim 1, characterized in that, Each of the multiple resonant chambers is a Helmholtz resonator.

8. The reciprocating compressor according to claim 1, characterized in that, The inlet pipe defines a plurality of chamber ports, at least one of which provides fluid communication between the inlet passage and each of the plurality of resonant chambers.

9. The reciprocating compressor according to claim 1, characterized in that, Each of the plurality of chamber plates extends outward from the inlet pipe along the radial direction to contact the inner surface of the flexible mount.

10. The reciprocating compressor according to claim 1, characterized in that, The inhalation muffler is injection molded from nylon, polyamide, or flexible plastic.

11. The reciprocating compressor according to claim 1, characterized in that, The latching feature is defined on the inlet plate of the plurality of chamber plates and extends along the axial direction away from the remaining plates of the plurality of chamber plates.

12. The reciprocating compressor according to claim 1, characterized in that, The flexible mount defines a plurality of locking flanges, and the intake muffler defines a plurality of latching features.

13. The reciprocating compressor according to claim 1, characterized in that, Also includes: A valve, disposed above the intake port, is used to selectively allow the gas flow through the intake port and into the compression chamber.

14. The reciprocating compressor according to claim 1, characterized in that, Also includes: An electric motor for reciprocating a mover along the axial direction, wherein the flexible mount is mechanically connected to the mover to reciprocate the piston along the axial direction.

15. An intake silencer for a reciprocating compressor, characterized in that, The reciprocating compressor defines axial and radial directions, and includes: a piston disposed within a compression chamber; a flexible mount mechanically coupled to the piston and having an inner surface defining an intake chamber; and a locking flange extending radially from the inner surface of the flexible mount toward the intake muffler, the intake muffler including: An inlet tube extends along the axial direction within the suction chamber and defines an inlet passage configured to receive a gas flow. Multiple chamber plates extending radially from the outer surface of the inlet pipe, the multiple chamber plates and the flexible mounting member defining multiple resonant chambers; and A latching feature engages the locking flange to secure the inhalation muffler within the inhalation chamber. The latching feature defines an inclined surface for engaging the locking flange during rotation of the inhalation muffler, wherein the latching feature deflects until the locking flange is located in a locking recess defined by the latching feature.

16. The inhalation muffler according to claim 15, characterized in that, The plurality of chamber plates include a first chamber plate and a second chamber plate, and wherein the plurality of resonant chambers include a main resonant chamber defined by the inner surfaces of the first chamber plate, the second chamber plate, the inlet pipe, and the flexible mounting member.

17. The inhalation muffler according to claim 16, characterized in that, The main resonance chamber is defined by a main resonance frequency corresponding to the main pulsation frequency of the suction valve of the reciprocating compressor.

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