Air Compressor Cylinder with Segmented Exit Holes
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Solution Overview
Problem
Conventional air compressors have a single exit hole, leading to increased resistance and reduced efficiency due to back force from stored compressed air, causing the piston body to move less smoothly and potentially overheating the motor.
Innovation Solution
The air compressor features a cylinder with multiple exit holes of different diameters, each sealed by a valve mechanism comprising a plug and compression spring, allowing for increased flow rate and reduced resistance by minimizing back force on the smallest diameter plug, enabling smoother piston movement and efficient inflation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single exit hole is used in the cylinder, then the valve mechanism structure is simple, but the back force from stored compressed air increases resistance and reduces piston movement smoothness
Solution Approach 1:
The single exit hole is segmented into multiple exit holes (first, second, and third exit holes) with different diameters. This segmentation reduces the back force on each individual plug by distributing the compressed air pressure across multiple smaller openings, thereby reducing resistance on the piston body and improving movement smoothness while maintaining a relatively simple overall structure.
Solution Approach 2:
Different exit holes are designed with different diameters to create local quality variations. The first exit hole has a larger diameter for high-flow requirements, while the second and third exit holes have smaller diameters for fine-tuned flow control and reduced back force. This local differentiation optimizes both the valve mechanism simplicity and piston movement characteristics.
2Device complexity
If a single exit hole is used in the cylinder, then the device structure is simple, but the flow rate of compressed air entering the air storage container is limited
Solution Approach 1:
The single exit hole is divided into multiple exit holes with different diameters, allowing compressed air to flow through multiple pathways simultaneously. This segmentation significantly increases the total flow rate of compressed air entering the air storage container while maintaining a relatively simple cylinder structure with minimal additional components.
Solution Approach 2:
Multiple exit holes with different flow characteristics are merged into a single valve mechanism system, where multiple plugs control multiple openings. This merging allows the system to achieve high flow rates through combined pathways while maintaining coordinated control, improving productivity without proportionally increasing device complexity.
3Device complexity
If a single exit hole is used in the cylinder, then the valve mechanism is simple, but the piston body is subjected to greater resistance causing slower inflation speed
Solution Approach 1:
The valve mechanism is segmented to control multiple exit holes with different diameters using multiple plugs. This segmentation reduces the back force on each plug by distributing the compressed air pressure, thereby reducing resistance on the piston body and increasing inflation speed while maintaining a relatively simple valve mechanism structure.
Solution Approach 2:
The parameters of the exit holes (diameters) are changed to create a distribution of sizes. This parameter variation allows the system to optimize flow characteristics and reduce back force on plugs, thereby reducing piston resistance and increasing inflation speed without significantly complicating the valve mechanism.
4Device complexity
If a single exit hole is used in the cylinder, then the overall structure is simple, but the motor may overheat and performance decreases
Solution Approach 1:
The single exit hole is segmented into multiple exit holes, reducing the back force on the valve mechanism and thereby reducing the resistance on the piston body. This reduction in resistance decreases the workload and energy consumption of the motor, preventing overheating and maintaining performance while keeping the overall structure relatively simple.
Solution Approach 2:
The back force from stored compressed air, which is normally a harmful factor causing increased resistance and motor overheating, is converted into a beneficial effect by distributing it across multiple smaller exit holes. This distribution reduces the impact on any single plug and consequently reduces the overall resistance and motor workload, preventing overheating without significantly complicating the structure.
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 design enhances the flow rate of compressed air into the storage container, reduces piston resistance, and allows for the use of a lower-power motor for faster inflation, improving overall efficiency and motor performance.
Implementation Method 1
a valve mechanism including a plug and a compression spring, so that the exit hole can be opened or closed properly according to the pressure of the compressed air
Implementation Method 2
the compressed air produced in the cylinder can overcome the compressive force of the compression spring to enter the inner space of the air compressor
Implementation Method 3
the compressed air stored in the air storage container can exert a back force on the plug, thus restraining the plug being moved away from the exit hole
Data Source
Figure 1
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AI summary
An improved air compressor includes a cylinder (2) that is fitted with a piston body (14) and defines at its top wall (21) a plurality of exit holes having different diameters and communicating between the cylinder (2) and an air storage container (3). The exit holes are sealed by plugs (7, 8, 9) and compression springs (71, 81, 91). The exit holes allow the compressed air produced in the cylinder (2) to enter the air storage container (3) more quickly. When the piston body (14) approaches the top wall (21) of the cylinder (2), one exit hole, with a smaller diameter, allows the compressed air to enter the air storage container (3) more easily. The exit holes with different diameters allow the piston body (14) to move in the cylinder more smoothly, and thus the efficiency of inflating an object can be increased.