Lattice-Cored Compressor Components for Heat and Noise Isolation
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Solution Overview
Problem
Compressors face efficiency losses and increased vibrations due to heat transfer between high-pressure discharge and low-pressure suction regions, leading to reduced compressor performance and noise generation, necessitating the development of components that can effectively manage thermal and sound insulation.
Innovation Solution
The use of lightweight, high-strength compressor components with lattice structures formed via additive manufacturing, which minimize the transmission of thermal, sound, and vibrational energy by incorporating a body portion with a lattice structure that has a thermal conductivity of less than or equal to 300 mW/m·K and reduces sound or vibrational energy transmission by at least 30% compared to solid body portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If heat transfer from high-pressure discharge side to low-pressure suction side is reduced, then compressor performance and discharge line temperatures are improved, but additional insulation components and design complexity are required
Solution Approach 1:
The patent combines the structural support function with the thermal insulation function into a single integrated component. The lattice structure serves both as the mechanical framework and as the thermal barrier, eliminating the need for separate insulation components and reducing overall design complexity while improving compressor performance
Solution Approach 2:
The patent employs composite material structures combining solid matrix material with lattice geometry to achieve both mechanical strength and thermal insulation properties. This composite approach allows the single component to simultaneously provide structural support and thermal barrier functions, resolving the contradiction between performance improvement and design complexity
2Temperature
If lattice structures are used to reduce heat transfer, then thermal insulation is improved, but manufacturing complexity increases
Solution Approach 1:
The patent utilizes parameter changes in the manufacturing process, specifically employing additive manufacturing technologies that can directly create complex lattice geometries without the need for complex tooling or assembly processes. This transforms the manufacturing approach from subtractive or assembly-based methods to additive methods that simplify the production of intricate thermal insulation structures
Solution Approach 2:
The lattice structure enables local quality optimization where material distribution is tailored to specific thermal and mechanical requirements within different regions of the component. This allows enhanced thermal insulation where needed while maintaining manufacturing efficiency through standardized lattice patterns that can be replicated across the component geometry
3Adaptability or versatility
If compressor capacity is reduced due to capacity modulation, then system flexibility is improved, but undesirable vibrations and sounds are generated
Solution Approach 1:
The patent converts the harmful vibrations and noise generated during capacity modulation into beneficial damping effects. The lattice structure is designed to absorb and dissipate vibrational energy that occurs during variable capacity operation, transforming what would be harmful disturbances into controlled energy dissipation that reduces overall noise and vibration levels
Solution Approach 2:
The lattice structure functions as a porous material that provides vibration damping and noise reduction capabilities. The interconnected voids and cellular structure of the lattice absorb vibrational energy and dampen acoustic waves, converting the harmful effects of capacity modulation into beneficial vibration and noise control
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
These components enhance compressor efficiency by reducing heat transfer and noise, improving performance and operational quietness while maintaining structural integrity, through the integration of lattice structures that provide both thermal and sound insulation.
Implementation Method 1
The interior region comprising the lattice structure minimizes transmission of at least one of thermal energy or heat, sound, or vibrational energy
Implementation Method 2
The interior region comprising the lattice structure minimizes transmission of at least one of thermal energy or heat, sound, or vibrational energy
Implementation Method 3
The interior region comprising the lattice structure minimizes transmission of at least one of thermal energy or heat, sound, or vibrational energy
Data Source
Figure 1
Figure 2A~2H
Figure 2I~2K
AI summary
A light-weight, high-strength insulating compressor component formed via additive manufacturing is provided. The component may have at least one interior region comprising a lattice structure that comprises a plurality of repeating cells. A solid surface is disposed over the lattice structure. The interior region comprising the lattice structure minimizes or reduces transmission of at least one of thermal energy, sound, or vibrational energy through the component. Methods of making such compressor components via additive manufacturing processes are also provided.