Compact Air Compressor Muffler Integration

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Solution Overview

Problem

Conventional compact reciprocating piston type compressors face challenges with increased weight and manufacturing complexity due to integrally formed cylinders, leading to higher production costs and vibration noise from discharge pulsation.

Innovation Solution

A compact air compressor design where the suction and discharge mufflers are integrally formed with the block, connected via a discharge pipe to guide compressed air into a staying space within the discharge muffler, reducing discharge pulsation and vibration noise.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If the cylinder is integrally formed with the block, then the structure is simplified, but the weight and size increase

Engineering Contradiction:

Improvestructural complexityVSAvoidcompressor weight

Core Design Contradiction:

Device complexityVSWeight of moving object

Solution Approach 1:

The cylinder is separated from the block into an independent component that can be manufactured separately and then assembled. This segmentation allows each part to be optimized independently, reducing the overall weight while maintaining structural integrity through proper coupling design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The muffler is integrated with the block as a unified component, combining the functions of the block and muffler into a single structure. This merging reduces the number of separate parts, simplifies assembly, and decreases overall weight compared to having separate muffler and block components.

Inventive Principle:

Principle #5Merging (Combining)

2Device complexity

If the cylinder is integrally formed with the block, then the structure is simplified, but the manufacturing cost increases

Engineering Contradiction:

Improvestructural complexityVSAvoidmanufacturing cost

Core Design Contradiction:

Device complexityVSEase of manufacture

Solution Approach 1:

By dividing the compressor into separable components (cylinder, block, muffler), each can be manufactured using optimized processes for its specific requirements. This segmentation enables parallel production and reduces manufacturing complexity compared to producing a single monolithic structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The integration of the muffler with the block creates a unified component that can be manufactured as a single piece, reducing assembly steps and manufacturing complexity. This merging approach simplifies the production process while maintaining structural effectiveness.

Inventive Principle:

Principle #5Merging (Combining)

3Weight of moving object

If the discharge muffler is separate from the block, then the weight is reduced, but the discharge pulsation increases

Engineering Contradiction:

Improvecompressor weightVSAvoiddischarge pulsation

Core Design Contradiction:

Weight of moving objectVSObject-generated harmful factors

Solution Approach 1:

The muffler is integrated with the block as a unified structure, which helps stabilize the discharge flow and reduce pulsation. The integrated design allows for better flow management and reduces the harmful discharge pulsation effect while maintaining weight reduction benefits.

Inventive Principle:

Principle #5Merging (Combining)

4Device complexity

If the discharge pipe directly discharges compressed air, then the structure is simplified, but the vibration noise increases

Engineering Contradiction:

Improvestructural complexityVSAvoidvibration noise

Core Design Contradiction:

Device complexityVSObject-generated harmful factors

Solution Approach 1:

The discharge muffler acts as an intermediary component between the discharge valve and the external environment. It mediates the discharge flow, smoothing out pulsations and reducing vibration noise while maintaining a relatively simple overall structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 design simplifies assembly, reduces vibration noise by ensuring equal air intake and discharge, and enhances compressor performance by maintaining compressed air within the discharge muffler for efficient discharge.

Implementation Method 1

a piston 7 which is coupled to be rotatable to the connecting rod 6 to compress the refrigerant while conducting a straight reciprocating movement in the cylinder 4a

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

compressed air of high pressure is stored inside a discharge muffler and discharged to reduce discharge pulsation, thereby reducing the overall vibration noise of the air compressor

Methodology Applied

Scientific EffectAcoustic damping: Damping

Data Source

PatentUS11015588B2Compact air compressor

Publication Date: 2021.05.25 NEW MOTECH

AI summary

A cylinder coupling structure of a compact air compressor includes a block provided with a suction valve and a discharge valve to be integrally formed with a suction muffler and a discharge muffler to block a front end of the cylinder, a tubular-shaped cylinder coupled to the block, a valve cover covering the valve assembly, at least one pressurized bolt coupling the valve cover and the block, a piston reciprocating inside the cylinder, a stator coupled to the block, a rotator located to rotate relatively with respect to the stator, a crank axis coupled to the rotator to rotate integrally with the rotator to be rotatable coaxially with the block, and a connecting rod, each of both ends thereof being connected to the crank axis and the piston, respectively.