Reciprocating Compressor Integral Discharge Muffler and Hose
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Solution Overview
Problem
Existing reciprocating compressors face refrigerant leakage and complex manufacturing challenges due to the connection between the discharge muffler and hose, leading to increased costs and inefficiencies.
Innovation Solution
The discharge muffler and hose are integrally formed using gas injection molding, with a connector system that includes rounded or tapered sections to maintain strength and prevent leakage, and an overflow injection method to ensure uniform inner diameters, simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the discharge muffler and discharge hose are connected using an adhesion method, then the components can be assembled separately, but refrigerant leakage occurs at the connection part and the manufacturing process becomes complicated
Solution Approach 1:
The discharge muffler and discharge hose are merged into a single integrally formed component through injection molding. This eliminates the separate connection interface that caused leakage, while simplifying the manufacturing process by reducing the number of assembly steps and connections required.
2Device complexity
If the discharge muffler and discharge hose are integrally formed using injection molding, then manufacturing complexity is reduced and leakage is prevented, but the structural strength at connection points may be compromised
Solution Approach 1:
Rounded portions are incorporated into the integral structure at the discharge hose connection points. These curved transitions eliminate sharp corners and stress concentration points, distributing mechanical loads more evenly throughout the structure and maintaining structural strength while preserving the benefits of integral formation.
3Ease of manufacture
If gas injection molding is used to form the discharge hose, then the manufacturing process is simplified, but the inner diameter uniformity may be compromised
Solution Approach 1:
The gas injection molding process incorporates feedback control mechanisms where the injection pressure and gas flow are dynamically adjusted based on real-time monitoring of the molding process. This ensures uniform inner diameter throughout the discharge hose while maintaining the simplified manufacturing process benefits of gas injection molding.
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 configuration effectively prevents refrigerant leakage and reduces manufacturing complexity, enhancing the reliability and cost-effectiveness of the compressor.
Implementation Method 1
The discharge hose and the connector may be formed integrally with each other using gas injection molding
Data Source
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AI summary
A reciprocating compressor and a method of manufacturing a reciprocating compressor. The reciprocating compressor may include a discharge muffler (410) forming a discharge chamber in which refrigerant compressed in a compression chamber flows and a discharge hose (520) that extends from the discharge muffler (410) to guide discharge of the refrigerant and coupled to the discharge pipe (130). At least a portion of the discharge muffler (410) and the discharge hose (130) are integrally formed using injection molding.