Air Compressor Cylinder with Segmented Exit Holes
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Solution Overview
Problem
Conventional air compressors with a single exit hole face resistance issues due to back pressure from stored air, leading to inefficient piston movement and potential motor overheating, which decreases performance and increases the risk of motor failure.
Innovation Solution
The air compressor features a cylinder with multiple exit holes, integrally formed with a plastic main frame, regulated by a control mechanism involving plugs and compression springs or O-rings and resilient sheets, allowing compressed air to enter the storage container quickly and smoothly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single exit hole is used in the cylinder, then the valve mechanism structure is simple, but the piston body cannot move smoothly due to high back pressure resistance
Solution Approach 1:
The single exit hole is segmented into multiple exit holes (first, second, third exit holes) distributed across the top wall of the cylinder. This segmentation reduces the resistance from back pressure by providing multiple flow paths, allowing the piston body to move more smoothly without significantly complicating the overall structure.
Solution Approach 2:
Different regions of the top wall are equipped with exit holes of different sizes and positions (first exit hole with first plug, second exit hole with second plug, third exit hole with third plug). This local differentiation optimizes air flow distribution and pressure management, improving piston movement while maintaining structural simplicity.
2Device complexity
If a single exit hole is used in the cylinder, then the device structure is simple, but the inflation speed is slow
Solution Approach 1:
The single exit hole is divided into multiple exit holes (first, second, third exit holes) with corresponding plugs. This segmentation enables parallel air flow paths, significantly increasing the volume of compressed air that can be discharged per unit time, thereby accelerating the inflation speed without requiring a completely redesigned cylinder structure.
Solution Approach 2:
Instead of increasing the size of a single exit hole (one-dimensional improvement), the solution distributes multiple exit holes across the two-dimensional top wall surface. This dimensional approach maximizes the total discharge area while maintaining structural integrity and simplicity.
3Device complexity
If a single exit hole is used in the cylinder, then the control mechanism is simple, but the motor overheats and performance decreases
Solution Approach 1:
The control mechanism is segmented into multiple independent plug-spring assemblies (first plug with first compression spring, second plug with second compression spring, third plug with third compression spring). Each assembly independently controls an exit hole, allowing for better pressure management and reduced resistance, which decreases motor load and prevents overheating while maintaining relatively simple control structures.
Solution Approach 2:
The compression springs provide automatic feedback control by adjusting plug positions based on pressure differential. When back pressure is high, springs maintain plug closure; when pressure differential favors discharge, plugs open automatically. This passive feedback mechanism optimizes motor performance without adding complex active control systems.
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
This design enhances the piston's reciprocating motion, reducing resistance and increasing the compressor's performance by allowing faster inflation and reducing motor stress, thus improving overall efficiency and safety.
Implementation Method 1
a compression spring, so that the exit hole can be opened or closed properly according to the pressure of the compressed air
Implementation Method 2
the compressed air produced in the cylinder can overcome the compressive force of the compression spring
Implementation Method 3
or O-rings and resilient sheets, allowing compressed air to enter the storage container quickly and smoothly
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An improved air compressor generally includes a cylinder (2) fitted with a piston body (14), a main frame (11) for mounting a motor (12), and an air storage container (3). The cylinder (2), which defines a plurality of exit holes (4, 5, 6) (42, 52, 62), is formed integrally with the main frame (11). The compressed air produced in the cylinder (2) can quickly enter the air storage container (3) via the exit holes (4, 5, 6) (42, 52, 62), so that the piston body (14) can conduct reciprocating motion more smoothly and thus the performance of the air compressor can be increased.