Linear Compressor Piston Surface Treatment for Friction and Abrasion
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Solution Overview
Problem
The existing linear compressor has a large volume, which reduces the inner storage space of refrigerators, and its miniaturization leads to performance deterioration due to increased friction from oil circulation, while the manufacturing method is costly and prone to surface treatment errors causing abrasion.
Innovation Solution
A compact linear compressor design with a gas bearing system between the cylinder and piston, and a surface treatment process using chromium nitride and diamond-like carbon to reduce friction and abrasion, performed in a single chamber to simplify and reduce manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If the linear compressor is miniaturized to increase storage space, then the volume of the machine room is reduced, but the friction force due to oil circulation increases and performance deteriorates
Solution Approach 1:
The patent replaces the traditional oil-based mechanical lubrication system with a gas bearing system that uses refrigerant gas for lubrication. This substitution eliminates the harmful friction force caused by oil circulation while maintaining the compact size of the compressor, thereby resolving the contradiction between miniaturization and performance degradation.
Solution Approach 2:
The patent changes the lubrication parameter from liquid oil to gaseous refrigerant. By introducing a gas bearing that supplies refrigerant gas to the compression chamber, the system achieves effective lubrication without the negative effects of oil circulation, allowing the compressor to maintain high performance in a miniaturized configuration.
2Volume of stationary object
If the linear compressor is miniaturized to increase storage space, then the volume of the machine room is reduced, but the compressor performance deteriorates
Solution Approach 1:
The replacement of oil-based lubrication with a gas bearing system eliminates the friction and performance deterioration associated with miniaturization. The gas bearing provides effective lubrication in the compressed refrigerant environment, maintaining compressor reliability and performance even in a compact design.
Solution Approach 2:
The refrigerant gas acts as an intermediary substance that provides lubrication between the moving parts of the compressor. This intermediary gas bearing mechanism enables effective lubrication without the harmful effects of oil, thereby maintaining compressor performance in a miniaturized configuration.
3Manufacturing precision
If traditional manufacturing methods are used for surface treatment, then multiple processes are required, but the manufacturing cost increases and surface treatment errors cause abrasion
Solution Approach 1:
The patent merges multiple surface treatment processes (buffer formation, polishing, and surface treatment layer deposition) into a single integrated manufacturing step. This consolidation reduces manufacturing complexity and costs while ensuring high surface treatment quality that prevents abrasion, thereby resolving the contradiction between manufacturing precision and ease of manufacture.
Solution Approach 2:
The manufacturing process described in the patent performs multiple functions simultaneously: forming the buffer part, polishing the surface, and depositing the surface treatment layer in one continuous operation. This multi-functional approach ensures high surface quality for abrasion prevention while simplifying the manufacturing process and reducing costs.
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 compact design increases storage space by reducing the machine room volume, maintains performance with reduced friction, and enhances abrasion resistance through effective surface treatment, thereby improving the compressor's operational efficiency and reducing manufacturing costs.
Implementation Method 1
a gas bearing system between the cylinder and piston
Implementation Method 2
a surface treatment process using chromium nitride and diamond-like carbon
Implementation Method 3
diamond-like carbon to reduce friction and abrasion
Data Source
AI summary
A linear compressor and a method for manufacturing a linear compressor are provided. A piston of a linear compressor may include a surface treatment body made of aluminum or an aluminum alloy; a first surface treatment provided on an outer surface of the surface treatment body by a first vacuum deposition process; and a second surface treatment provided on an outer surface of the first surface treatment by a second vacuum deposition process.