Piston for compressor
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Solution Overview
Problem
Existing linear compressors face issues with surface treatment inefficiencies, such as unnecessary space occupation, labor costs, and potential plasma interference due to integral piston structures, and press-fitting methods that can damage components and reduce compression efficiency.
Innovation Solution
A piston design where only the bearing portion is surface-treated, and bonded to the head and flange portions using adhesives, eliminating the need for press-fitting and reducing manufacturing complexity, while enhancing abrasion resistance with DLC, Teflon, or nickel-phosphorus alloy coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If surface treatment is performed on the entire integral piston structure, then abrasion resistance is improved, but unnecessary space is occupied and manufacturing complexity increases
Solution Approach 1:
The piston is divided into separate components: a piston body and a bearing portion. Only the bearing portion requires surface treatment for abrasion resistance, while the piston body remains untreated. This segmentation allows selective surface treatment of only the necessary component, reducing manufacturing complexity and space occupation while maintaining the required abrasion resistance.
2Ease of manufacture
If press-fitting method is used to couple head portion and skirt portion, then assembly is achieved, but component damage may occur and fine gaps reduce compression efficiency
Solution Approach 1:
The mechanical press-fitting connection is replaced with a chemical bonding method using adhesive. The adhesive is injected into the coupling space between the piston body and bearing portion, creating a strong bond without mechanical force. This substitution eliminates the risk of component damage from press-fitting while maintaining assembly capability and preventing gaps that would reduce compression efficiency.
3Strength
If flange portion is inserted into coating equipment with bearing portion, then surface treatment is achieved, but plasma interference occurs at the boundary
Solution Approach 1:
By separating the piston into piston body and bearing portion, the surface treatment process can be applied only to the bearing portion in isolation. This eliminates the boundary between flange and bearing portion that would otherwise experience plasma interference during coating, as the flange portion is not present in the treatment zone.
4Device complexity
If integral piston structure is used, then manufacturing is simplified, but surface treatment requires additional space and time
Solution Approach 1:
The piston is segmented into piston body and bearing portion, allowing the bearing portion to be surface-treated separately and more efficiently. This segmentation reduces the total surface area requiring treatment compared to an integral structure, thereby reducing surface treatment time and space requirements while maintaining structural functionality.
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 simplifies the manufacturing process, prevents component damage, maintains compression efficiency, and avoids plasma interference, leading to cost savings and improved piston performance.
Implementation Method 1
enhancing abrasion resistance with DLC, Teflon, or nickel-phosphorus alloy coatings
Implementation Method 2
enhancing abrasion resistance with DLC, Teflon, or nickel-phosphorus alloy coatings
Implementation Method 3
enhancing abrasion resistance with DLC, Teflon, or nickel-phosphorus alloy coatings
Implementation Method 4
bonded to the head and flange portions using adhesives
Data Source
AI summary
A piston for a compressor includes a bearing portion having a cylindrical shape to define a suction space into which refrigerant is accommodated therein, the bearing portion being provided with a bearing surface facing an inner circumferential surface of the cylinder, a head portion coupled to a front opening of the bearing portion and provided with a plurality of suction ports which communicate with the suction space, the head portion having a compression surface configured to face a compression space to compress the refrigerant in the compression space, and a flange portion coupled to a rear opening of the bearing portion and provided with a through-passage through which the refrigerant is introduced from a muffler unit to the suction space, the flange portion being coupled to a driving portion to transmit driving force to the piston. The bearing surface is subjected to a surface treatment to improve abrasion resistance.