Lattice-Cored Compressor Components for Heat and Noise Isolation
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Solution Overview
Problem
Compressors face efficiency losses due to heat transfer between high-pressure and low-pressure regions, leading to reduced refrigerant flow and increased temperatures, which result in undesirable vibrations and noise, necessitating the development of components that can effectively manage heat transfer and sound/vibration transmission.
Innovation Solution
The use of high-strength, light-weight compressor components with lattice structures formed via additive manufacturing, which minimize thermal, sound, and vibrational energy transmission 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 energy transmission by at least 30% compared to solid components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If heat transfer between high-pressure and low-pressure regions is reduced, then compressor efficiency is improved, but thermal insulation requires additional design complexity
Solution Approach 1:
The patent applies porous materials by incorporating lattice structures with controlled porosity into compressor components. These porous structures provide thermal insulation to reduce heat transfer between high-pressure and low-pressure regions, thereby improving compressor efficiency without requiring complex multi-component insulation systems.
Solution Approach 2:
The patent uses composite materials by combining lattice structures with infill materials (such as foam or powder) to create components with optimized thermal properties. This composite approach enables effective thermal insulation while maintaining structural integrity and avoiding the need for separate insulation components.
2Loss of energy
If lattice structures are used to reduce heat transfer, then thermal insulation is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies parameter changes by optimizing lattice structure parameters (cell size, wall thickness, pattern geometry) to achieve desired thermal insulation properties. By adjusting these parameters, the patent balances thermal performance with manufacturability, enabling production through advanced manufacturing techniques like additive manufacturing.
Solution Approach 2:
The patent replaces traditional mechanical assembly methods with additive manufacturing technology. This substitution enables the direct fabrication of complex lattice structures with internal porosity, eliminating the need for complex assembly processes and tooling while achieving precise thermal insulation properties.
3Strength
If solid components are used, then structural strength is maintained, but weight increases and thermal insulation decreases
Solution Approach 1:
The patent applies segmentation by dividing solid components into lattice structures composed of repeating unit cells. This segmentation maintains structural strength through the distributed geometry of the lattice while removing excess material, thereby reducing weight and creating internal porosity for thermal insulation.
Solution Approach 2:
The patent uses porous materials by replacing solid components with lattice structures that have controlled porosity. The porous lattice structure maintains mechanical strength through its geometric configuration while significantly reducing weight and providing thermal insulation through the air gaps within 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
These components enhance compressor efficiency by reducing heat transfer and noise, improving performance and operational stability while maintaining structural integrity and reducing material usage.
Implementation Method 1
The interior region comprising the lattice structure minimizes transmission of at least one of thermal energy or heat
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
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.