Scroll Compressor Pretreatment for NVH Reduction
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Solution Overview
Problem
Conventional scroll compressors face challenges in minimizing Noise, Vibration, Harshness (NVH) levels due to friction and wear, requiring additional sealing elements and costly coating processes, which increase production complexity and costs, and can lead to thermal expansion issues.
Innovation Solution
A method for manufacturing scroll compressors using a common aluminum alloy for both spirals, with a pretreatment process involving degreasing, etching, and applying a zincate layer followed by a nickel coating, eliminating the need for additional sealing elements and steel sheets, ensuring optimal adhesion and reducing thermal expansion differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional sealing elements and steel sheets are used to ensure sealing function, then sealing reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The invention extracts and eliminates the additional sealing elements (C-shaped springs, O-rings, steel sheets) from the compressor design. By using different materials for the orbiter and stator that naturally form a sealing interface through their inherent properties, the patent removes the need for separate sealing components while maintaining the sealing function.
Solution Approach 2:
The invention applies homogeneity by using consistent material pairing (aluminum orbiter with nickel coating and zincate pretreatment, stainless steel stator) across the sealing interface. This uniform material combination ensures reliable sealing through controlled friction and wear characteristics without requiring additional sealing elements.
2Reliability
If different materials are used for orbiter and stator to reduce friction and wear, then reliability is improved, but thermal expansion differences cause manufacturing and operational issues
Solution Approach 1:
The invention changes the surface parameters of the aluminum orbiter by applying a nickel coating with specific thickness and properties. This surface modification provides the desired low friction and wear resistance while the underlying aluminum material maintains compatible thermal expansion characteristics with the stainless steel stator.
Solution Approach 2:
The invention uses a composite structure for the orbiter: an aluminum base material providing lightweight properties and thermal expansion compatibility, combined with a nickel surface coating providing low friction and wear resistance. This composite approach resolves the contradiction between material performance and thermal expansion stability.
3Reliability
If coating processes are applied to protect contacting surfaces, then wear protection is improved, but manufacturing cost and process complexity increase
Solution Approach 1:
The invention applies preliminary surface treatment (zincate etching) to the aluminum orbiter before coating. This pretreatment creates a surface that enhances nickel coating adhesion, ensuring durable wear protection. By preparing the surface in advance, the coating process becomes more efficient and reliable.
Solution Approach 2:
The invention changes the surface parameters of the aluminum orbiter through zincate etching, creating a micro-roughened surface with improved chemical reactivity. This parameter change at the surface level enables better coating adhesion and wear protection without affecting the bulk material properties or requiring complex manufacturing processes.
4Productivity
If high rotary speeds are used to meet cooling demands, then productivity is improved, but NVH level increases due to friction oscillations
Solution Approach 1:
The invention changes the surface parameters of the contacting surfaces through nickel coating and zincate pretreatment. This modification reduces the coefficient of friction and stabilizes the friction characteristics at high speeds, thereby reducing self-excited friction oscillations and NVH levels while allowing the compressor to operate at high rotary speeds for maximum cooling capacity.
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 approach minimizes NVH levels, reduces production costs and complexity, and extends the service life of the compressor by using a uniform material and simplified manufacturing processes, while providing effective wear protection and lubrication.
Implementation Method 1
etching of the area using an alkaline etching agent
Implementation Method 2
etching of the area using an acidic etching agent
Implementation Method 3
applying a zincate layer as an intermediate layer onto the area to be coated
Implementation Method 4
coating the treated area using a coating material
Implementation Method 5
coating the treated area using a coating material
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
The invention relates to a method of manufacture of a scroll compressor (1), in particular for pretreatment for the coating of areas in contact with one another during operation of the scroll compressor (1). The scroll compressor (1) is developed with a non-movable spiral (3) with a base plate (3a) and a spiral-form wall (3b) extending from one side of the base plate (3a), as well as with a movable spiral (4) with a base plate (4a) and a spiral-form wall (4b) extending from a front side of the base plate (4a). The spirals (3, 4) are developed out of a basis material.