Integrated Piston Valve Structure to Reduce Compressor Dead Volume
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Solution Overview
Problem
Existing cylinder pistons for air compressors require significant installation space and result in dead volume due to separate inlet and outlet valves, limiting efficiency and increasing assembly complexity.
Innovation Solution
Integration of dual channel openings in the piston surface with a flexible bending sealing element that can function as both an inlet and outlet valve, allowing independent operation and reducing the need for additional valve components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate inlet and outlet valves are arranged in the compressor housing or cylinder head, then the valves can be designed as separate components, but the installation space required increases and dead space volume is created
Solution Approach 1:
The patent integrates both inlet and outlet valves directly into the piston structure, merging previously separate valve components into a single integrated component. This eliminates the need for separate valve installations in the compressor housing or cylinder head, thereby reducing installation space and dead space volume while maintaining separate valve functionality
Solution Approach 2:
The piston is designed to serve multiple functions: it not only compresses the medium but also incorporates both inlet and outlet valve functions. This multi-functional design allows the piston to control fluid flow in both directions (inlet and outlet) while maintaining mechanical separation of the valve functions through different opening directions
2Device complexity
If all openings are opened or closed simultaneously via a rigid cover or single valve mechanism, then the valve structure is simple, but independent control of inlet and outlet valves is not possible
Solution Approach 1:
The piston incorporates multiple separately controllable openings (first opening for inlet valve, second opening for outlet valve) that can be opened and closed independently of each other. This segmentation allows independent control of inlet and outlet flows while maintaining a relatively simple integrated piston structure
Solution Approach 2:
The valve openings are designed with asymmetric orientations: the first opening is oriented at a first angle to the piston movement direction, while the second opening is oriented at a second angle. This asymmetric design enables independent valve operation through directional control mechanisms while keeping the overall piston structure compact
3Volume of stationary object
If valves are integrated into the piston surface, then installation space is reduced and dead space volume is minimized, but the piston structure becomes more complex
Solution Approach 1:
The valve structures are merged into the piston body itself, with inlet and outlet openings formed directly in the piston surface. This integration eliminates separate valve housings and reduces dead space volume, while the openings are designed to maintain reasonable structural complexity through their geometric configuration and orientation
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 reduces dead space volume, enhances efficiency, and simplifies assembly by integrating valves directly onto the piston, improving response time and reducing moving mass.
Implementation Method 1
a flexible bending sealing element (22) is provided inside or covering the channel openings (12), wherein the sealing element for the at least two or a plurality of channel openings (12) enables an inflow into a channel opening (12) or outflow from a channel opening (12)
Data Source
AI summary
A cylinder piston for an air compressor, in particular for a two-stage air compressor, has at least two channel openings integrated in the piston surface of the cylinder piston, which are designed as an inlet valve and/or as an outlet valve for air in a compression chamber of the cylinder. A coherent, one-piece and flexible bending sealing element is provided inside or covering the channel openings. The sealing element for the at least two or a plurality of channel openings enables an inflow into a channel opening or outflow from a channel opening, wherein the at least two channel openings through the flexible bending sealing element can be designed independently of one another as an inlet valve or as an outlet valve. Also provided is a cylinder with at least one cylinder piston and an air compressor with such a cylinder.