Rotary Compressor Intermediate Plate Direct Flow Path

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Solution Overview

Problem

Rotary compressors experience pressure loss and increased vibration noise due to the long distance refrigerant compressed in the lower cylinder must travel to reach the muffler, and overlapping noise from upper and lower compression assemblies.

Innovation Solution

An intermediate plate with openings is introduced between the upper and lower cylinders, allowing direct flow of refrigerant from the lower cylinder into the muffler, reducing the flow distance and combining the refrigerant streams, which simplifies the structure and offsets noise phases.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If the refrigerant flows through the lower muffler, lower compression assembly, intermediate plate, and upper compression assembly to reach the upper muffler, then the structure can be maintained as sequential, but the pressure of the refrigerant is reduced due to long flow distance

Engineering Contradiction:

Improvepressure loss of refrigerantVSAvoidrefrigerant flow path length

Core Design Contradiction:

Loss of energyVSLength of stationary object

Solution Approach 1:

The intermediate plate is segmented with multiple openings (first opening, second opening, third opening) that create separate flow paths. The first opening allows refrigerant from the lower cylinder to flow directly to the upper muffler, while the second and third openings handle other flow requirements. This segmentation enables direct flow path creation without increasing overall system complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The intermediate plate serves as an intermediary component with strategically positioned openings that facilitate direct refrigerant flow from the lower cylinder to the upper muffler. By acting as a mediator with controlled passages, it shortens the flow path and reduces pressure loss while maintaining structural integrity of the compression assembly.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If separate mufflers are used for upper and lower compression assemblies, then each compression assembly can be independently optimized, but noise from both compression assemblies overlaps and increases overall noise level

Engineering Contradiction:

Improvenoise levelVSAvoidmuffler configuration complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent merges the muffler function into a single common muffler that receives refrigerant from both the upper and lower compression assemblies. The intermediate plate with its openings facilitates this merging by providing a flow path that directs refrigerant from the lower cylinder directly to the common muffler, eliminating separate mufflers and reducing noise overlap.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention converts the potentially harmful effect of noise overlap into a benefit by using the common muffler design. The muffler acts as a noise dampening chamber that receives exhaust from both cylinders, and the phase difference in noise generation is exploited to reduce overall noise levels rather than amplify them.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Productivity

If the intermediate plate has multiple openings for refrigerant flow, then the refrigerant can flow directly from lower cylinder to upper muffler, but the manufacturing precision requirements increase

Engineering Contradiction:

Improverefrigerant compression efficiencyVSAvoidopening position precision in intermediate plate

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The intermediate plate exhibits local quality variations through its opening configuration. Different regions of the plate have different functions: the first opening is positioned for direct refrigerant flow, while the second and third openings serve specific flow control purposes. This localized functional differentiation optimizes refrigerant flow efficiency while maintaining manufacturability through standardized opening patterns.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS11326605B2Dual cylinder rotary compressor with intermediate plate that flows both cylinders to the muffler

Publication Date: 2022.05.10 LG ELECTRONICS INC

AI summary

A rotary compressor includes: a shell forming an internal space; a driving motor disposed in the internal space of the shell; a rotary shaft connected to the driving motor; a lower cylinder having a lower chamber for compressing a refrigerant and a lower roller disposed inside the lower chamber; an upper cylinder disposed on an upper side of the lower cylinder and having an upper chamber for compressing a refrigerant and an upper roller disposed inside the upper chamber; a muffler disposed on the upper side of the upper cylinder and receiving a refrigerant compressed in the upper chamber; and an intermediate plate disposed between the upper cylinder and the lower cylinder and having a rotary shaft hole through which the rotary shaft is disposed. The intermediate plate includes an opening formed around the rotary shaft hole and guiding a refrigerant compressed in the lower chamber to the muffler.