Compressor Nonstick Coating for Foreign Material Removal

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Solution Overview

Problem

Forced induction internal combustion engines face premature wear and reduced efficiency due to the buildup of foreign materials such as moisture, dust, and debris on gas compressor components, which existing filtration systems are unable to fully prevent, requiring labor-intensive manual cleaning.

Innovation Solution

A compressor assembly with a nonstick coating formed from polymeric or ceramic materials, such as fluoropolymers, applied to the aerodynamic surfaces of the compressor housing and impeller, preventing foreign material accumulation and reducing wear.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If filtration devices (screen and air filter) are installed to remove foreign material, then foreign material removal capability is improved, but filtration devices cannot remove all foreign materials and build-up still occurs over time

Engineering Contradiction:

Improveforeign material removal capabilityVSAvoidcomplete prevention of build-up

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The patent converts the harmful effect of foreign material accumulation into a beneficial self-cleaning mechanism. The nonstick coating causes accumulated foreign material to automatically detach and be flushed from the compressor during operation, transforming the problem of accumulation into a self-cleaning advantage that maintains performance without manual intervention.

Inventive Principle:

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

Solution Approach 2:

The compressor system performs its own maintenance through the nonstick coating mechanism. Foreign material that accumulates on the aerodynamic surfaces is automatically removed by the compressor's own operation (airflow and rotational motion), eliminating the need for external manual cleaning operations and continuous filtration dependency.

Inventive Principle:

Principle #25Self-service

2Object-affected harmful factors

If manual cleaning of built-up foreign material is performed, then foreign material removal is achieved, but labor intensity and cost increase

Engineering Contradiction:

Improveforeign material removalVSAvoidlabor intensity

Core Design Contradiction:

Object-affected harmful factorsVSEase of operation

Solution Approach 1:

The nonstick coating enables the compressor to clean itself automatically during operation. The aerodynamic surfaces with nonstick coating cause foreign material to detach and be flushed by the compressor's own airflow and rotation, eliminating the need for manual disassembly and cleaning operations.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The self-cleaning action occurs continuously during compressor operation rather than requiring periodic manual intervention. The nonstick coating ensures that foreign material is constantly being prevented from adhering and is automatically removed as air flows through the compressor, maintaining clean surfaces throughout operation.

Inventive Principle:

Principle #20Continuity of useful action

3Reliability

If nonstick coating is applied to aerodynamic surfaces, then foreign material build-up is prevented, but manufacturing process complexity increases

Engineering Contradiction:

Improveforeign material build-up preventionVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies a nonstick coating with specific physical and chemical parameters (low surface energy, smooth surface finish) to the aerodynamic surfaces. This coating modification changes the surface properties to prevent foreign material adhesion, and the coating can be applied through standard manufacturing processes such as spraying or dipping without requiring complex assembly operations.

Inventive Principle:

Principle #35Parameter changes

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 nonstick coating effectively prevents foreign material buildup, maintaining the compressor's efficiency and volumetric flow rate, reducing the need for manual cleaning and extending the compressor's lifespan.

Implementation Method 1

A nonstick coating may be formed on the internal aerodynamic surface of the compressor housing or on the external aerodynamic surface of the compressor impeller. The nonstick coating may comprise a polymeric material, a ceramic material, or a combination thereof.

Methodology Applied

Scientific EffectNonstick coating: Coatings

Data Source

PatentUS11873724B2Compressor assembly with nonstick coating and method of manufacturing same

Publication Date: 2024.01.16 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A compressor assembly may include a compressor housing and a compressor impeller disposed within the compressor housing. The compressor housing may have an internal aerodynamic surface that defines a circumferentially extending volute, and the compressor impeller may have an external aerodynamic surface that faces toward at least a portion of the internal aerodynamic surface of the compressor housing. A nonstick coating may be formed on the internal aerodynamic surface of the compressor housing or on the external aerodynamic surface of the compressor impeller. The nonstick coating may prevent foreign material introduced into the compressor assembly from collecting on the internal aerodynamic surface of the compressor housing or on the external aerodynamic surface of the compressor impeller.