Sintered Piston and Cylinder for Linear Compressor
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Solution Overview
Problem
Conventional linear compressors require extensive mechanical processing, leading to increased costs and inefficiencies due to defects and burrs generated during the manufacturing of pistons and cylinders, which complicates the production process and reduces operation efficiency.
Innovation Solution
The use of sintering molding for at least one of the piston and cylinder in a linear compressor, allowing for accurate shaping and size manufacturing without additional processing steps, and enabling the creation of complex shapes through thermal fitting or welding of individual parts, using materials with different thermal expansion coefficients for stable coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional casting and mechanical processing (turning, polishing) are used to manufacture pistons and cylinders, then the parts can be produced with basic dimensional accuracy, but the manufacturing process becomes complex, costly, and generates defects and burrs that reduce operation efficiency
Solution Approach 1:
The patent replaces conventional mechanical processing (turning, polishing) with sintering molding technology. The sintering process directly forms the piston and cylinder with precise dimensions and smooth surfaces, eliminating the need for subsequent mechanical machining operations. This substitution of manufacturing methods resolves the contradiction by simplifying the production process while maintaining high manufacturing precision and eliminating defects associated with mechanical processing.
Solution Approach 2:
The patent utilizes sintering molding to change the manufacturing parameters from conventional casting followed by mechanical processing to a direct sintering process. This parameter change enables the formation of complex geometries and precise dimensional control in a single manufacturing step, thereby simplifying the overall manufacturing process and improving operation efficiency by eliminating multiple processing stages.
2Manufacturing precision
If extensive mechanical processing (polishing, turning) is performed on pistons and cylinders, then surface finish and dimensional accuracy improve, but production costs increase and manufacturing complexity increases
Solution Approach 1:
The patent replaces mechanical processing operations (polishing, turning) with sintering molding technology. The sintering process inherently produces smooth surfaces and precise dimensions without requiring subsequent mechanical machining. This substitution eliminates the complexity of multiple processing steps while achieving the desired manufacturing precision and surface finish in a single operation.
Solution Approach 2:
The sintering molding process performs the final dimensional accuracy and surface finish preparation in advance, during the forming process itself, rather than requiring these operations to be performed subsequently through mechanical processing. This preliminary action of achieving precise dimensions and smooth surfaces during sintering eliminates the need for complex post-processing operations.
3Ease of manufacture
If mechanical processing is used to manufacture piston and cylinder, then the parts can be produced, but defects and burrs are generated during manufacturing
Solution Approach 1:
The patent substitutes mechanical processing with sintering molding to eliminate the generation of defects and burrs. The sintering process forms the parts through controlled heating and bonding of powder materials, a process that does not generate mechanical defects, burrs, or surface imperfections associated with conventional mechanical machining. This substitution maintains manufacturability while ensuring defect-free production and improving reliability.
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 reduces production costs by eliminating the need for polishing and turning, enhances mechanical characteristics with high hardness and abrasion resistance, and improves operation efficiency by simplifying the manufacturing process and ensuring accurate shapes and sizes.
Implementation Method 1
by molding at least one of a piston and a cylinder by using a sintering material
Implementation Method 2
linearly reciprocated by mutual electromagnetic force of the inner stator 12 and the outer stator 14
Implementation Method 3
using materials with different thermal expansion coefficients for stable coupling
Data Source
AI summary
A linear compressor is provided. The linear compressor may include a cylinder in which refrigerant flows in an axial direction, a piston that reciprocates within the cylinder so as to compress the refrigerant, and a linear motor that drives the piston. At least one of the cylinder or the piston may be sintering molded.