Linear Compressor Piston Flange Rib Design
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Solution Overview
Problem
Existing linear compressors face issues with interference between the cylinder and piston, leading to abrasion and efficiency loss due to magnetic flux leakage and thermal deformation, which can cause compression gas leaks and damage to components.
Innovation Solution
The linear compressor is designed with a cylinder and piston made of non-magnetic aluminum-based materials, featuring a motor assembly with a ferrite permanent magnet and a flange with reinforcing ribs to manage deformation and reduce interference, along with a supporter and springs to control piston motion and reduce abrasion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the cylinder and piston are made of magnetic materials, then the motor assembly can generate strong electromagnetic force, but magnetic flux leaks through the cylinder and piston deteriorating compressor efficiency
Solution Approach 1:
A non-magnetic coating layer is applied on the inner surface of the cylinder and outer surface of the piston, serving as an intermediary barrier that prevents magnetic flux from passing through the magnetic materials, thereby eliminating energy loss while preserving the electromagnetic force generation capability
Solution Approach 2:
The cylinder and piston are constructed as composite structures combining magnetic materials (for electromagnetic force generation) with non-magnetic coating materials (for flux prevention), allowing both magnetic force and flux containment functions to coexist
2Reliability
If the piston is coupled to peripheral constitution under predetermined pressure, then the piston can be securely fixed, but the piston deforms causing interference between cylinder and piston
Solution Approach 1:
The coupling pressure parameter is optimized to a specific range that provides sufficient coupling stability without exceeding the threshold that would cause piston deformation, balancing reliability and shape preservation
Solution Approach 2:
A cushioning element or compliant layer is introduced between the piston and peripheral constitution to absorb excess coupling pressure before it reaches the piston, preventing deformation while maintaining secure coupling
3Ease of manufacture
If a slight error occurs in piston assembly with the cylinder, then assembly is easier, but compression gas leaks to the outside causing abrasion
Solution Approach 1:
A flexible sealing ring or thin film barrier is installed between the piston and cylinder, which can deform to accommodate assembly errors and maintain effective sealing, allowing easier assembly while preventing gas leakage
Solution Approach 2:
A sealing intermediary material is placed at the interface between piston and cylinder to compensate for assembly tolerances, maintaining gas-tight sealing despite slight misalignments
4Device complexity
If the permanent magnet is directly connected to the piston, then the linear motor structure is simplified, but interference between permanent magnet and stators occurs damaging components
Solution Approach 1:
A non-magnetic coupling member or spacer is introduced between the permanent magnet and piston, serving as an intermediary that maintains the simplified direct-connect structure while preventing harmful interference and contact between the magnet and stators
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 prevents thermal deformation and magnetic flux leakage, reducing abrasion and improving efficiency by maintaining proper alignment and reducing pressure on the piston, thus enhancing the compressor's operational performance and longevity.
Implementation Method 1
The permanent magnet is linearly reciprocated by a mutual electromagnetic force between the permanent magnet and the inner (or outer) stator
Implementation Method 2
each of the cylinder or the piston may be formed of a magnetic material. Thus, a large amount of flux generated in the linear motor may leak to the outside through the cylinder and piston
Implementation Method 3
when a predetermined pressure (a coupling pressure) acts on the piston while the piston is coupled to a peripheral constitution to cause deformation of the piston due to the pressure
Data Source
AI summary
A linear compressor is provided that may include a shell including a refrigerant inlet, a cylinder provided within the shell, a piston reciprocated within the cylinder, the piston having a flow space in which a refrigerant may flow, a motor assembly that provides a drive force, the motor assembly including a permanent magnet, a flange that extends from an end of the piston in a radial direction, the flange having an opening that communicates with the flow space of the piston and a coupling hole defined outside of the opening, a support coupled to the coupling surface of the flange to support a plurality of springs, and at least one reinforcing rib that protrudes from the coupling surface to guide deformation of the flange while the flange and the support are coupled to each other.