Coating layer having a conforming material for a compressor and method of using the same
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Solution Overview
Problem
Existing compressors suffer from compression leakage due to large gap distances between mating and sealing surfaces, which reduces energy efficiency, and current methods to reduce these gaps are costly and inefficient.
Innovation Solution
A coating layer with a conforming material, comprising multiple layers of crystals with different particle sizes, is applied to compressor surfaces to seal gaps and retain lubricant, effectively controlling gap distances and preventing leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple coating layers with different particle sizes are applied, then sealing effectiveness improves, but device complexity increases
Solution Approach 1:
The coating layer is segmented into multiple applied layers (first applied layer, second applied layer, etc.) with different conforming material particle sizes. Each layer serves a specific sealing function, with larger particles in outer layers and smaller particles in inner layers, creating a hierarchical structure that effectively seals gaps of varying sizes without requiring excessive complexity in the overall design
Solution Approach 2:
The coating utilizes composite material structure by combining conforming materials with different particle sizes in distinct layers. This composite approach allows each layer to contribute unique sealing properties, where the combination of materials with varying particle dimensions creates an effective multi-scale sealing system that addresses both large and small gaps
2Reliability
If conforming material with small particle size is used, then sealing of small gaps improves, but lubricant retention decreases
Solution Approach 1:
The coating is segmented into multiple layers with different particle size characteristics. Outer layers contain larger conforming material particles that provide lubricant retention through increased surface area and void spaces, while inner layers contain smaller particles that effectively seal small gaps. This segmentation allows each layer to optimize for its specific function without compromising the other
Solution Approach 2:
Different regions of the coating structure have different local qualities - outer layers have larger particle sizes optimized for lubricant retention, while inner layers have smaller particle sizes optimized for gap sealing. This local differentiation of material properties allows the coating to simultaneously achieve both lubricant retention and effective sealing of small gaps
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The coating layer enhances compressor efficiency by sealing gaps and retaining lubricant, even in large machining and assembly-induced gaps, thereby improving energy efficiency and preventing corrosion and wear.
Implementation Method 1
the conforming material in the first applied layer has a different particle size than the conforming material in the second applied layer such that a combination of the first applied layer and the second applied layer seal the contacting surface
Data Source
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Figure 3A
AI summary
A method, HVACR system (110), and positive displacement compressor (200) that includes a compressor housing (220) and a rotating component (230) and at least one second component (235). Each of the rotating component and the at least one second component have a contacting surface that define a meshing location (320, 322) between the rotating component and the at least one second component to form a compression chamber. Additionally, a coating layer (330) is provided on the contacting surface of at least one of the rotating component or the at least one second component, in which the coating layer (330) includes at least a first applied layer (432) and a second applied layer (434). The first layer and the second layer are separate layers and both the first layer and the second layer include a conforming material, in which the conforming material in the first applied layer has a different particle size than the conforming material in the second applied layer.