Compressor with a discharge muffler
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Solution Overview
Problem
Linear compressors in refrigerator appliances experience pressure pulsations and noise issues due to the flow of compressed refrigerant, which are not effectively mitigated by existing mufflers, particularly because they are expensive to produce through labor-intensive brazing processes.
Innovation Solution
A discharge valve assembly with an outer shell and inner sleeve that divides the interior volume into multiple muffler cavities, reducing pressure pulsations and noise by strategically positioning the inner sleeve to create gaps that facilitate the flow of refrigerant and absorb pressure fluctuations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If traditional brazed mufflers are used to reduce pressure pulsations and noise, then noise reduction effectiveness is improved, but manufacturing cost and complexity increase due to labor-intensive brazing processes
Solution Approach 1:
The muffler is divided into multiple cavities (first muffler cavity and second muffler cavity) separated by an inner sleeve with gaps. This segmentation allows pressure pulsations to be distributed and dissipated across multiple chambers, achieving effective noise reduction while using simpler manufacturing methods without requiring complex brazing of multiple components
Solution Approach 2:
The inner sleeve is positioned within the outer shell, creating a nested structure where the inner sleeve divides the interior volume into multiple cavities. This nested design achieves complex acoustic functionality within a compact structure that can be manufactured as integrated pieces, reducing the need for labor-intensive assembly processes
2Ease of manufacture
If a simple single-chamber muffler design is used, then manufacturing simplicity is improved, but pressure pulsation dissipation effectiveness deteriorates
Solution Approach 1:
The single integrated muffler structure is segmented into multiple functional cavities by the inner sleeve, allowing pressure pulsations to be dissipated through multiple reflection and absorption paths while maintaining manufacturing simplicity as a single piece
Solution Approach 2:
The inner sleeve creates three-dimensional cavity structures within the muffler volume, utilizing spatial arrangement of gaps and cavities to enhance pressure pulsation dissipation effectiveness without increasing overall muffler size or manufacturing complexity
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 discharge valve assembly effectively limits pressure pulsations and reduces noise in linear compressors, offering a cost-effective solution by potentially reducing the need for expensive mufflers and improving operational efficiency.
Implementation Method 1
A spring is coupled to the valve head such that the spring urges the valve head towards the casing
Implementation Method 2
The inner sleeve divides the interior volume into a first muffler cavity and a second muffler cavity... Mufflers can dissipate the pressure pulsation and reduce noise
Data Source
AI summary
A discharge valve assembly includes an outer shell. An inner sleeve is positioned within the outer shell. A side wall of the inner sleeve is spaced from a side wall of the outer shell along a radial direction. A distal end of the side wall of the inner sleeve is spaced from an end wall of the outer shell by a gap along an axial direction. The inner sleeve divides an interior volume of the outer shell into a first muffler cavity and a second muffler cavity. A related compressor is also provided.