A method of casting an assembly is provided that includes forming a structural insert, over-molding the structural insert with a temporary core, and positioning the over-molded structural insert within a cavity of a casting die. The over-molded structural insert is cast within a part, to form the assembly, and the temporary core is removed. The method may also include a temporary core configured to define an alloy flash trim location or locating features to position the structural insert within the cavity of the casting die. Further, the temporary core may define shared features with the structural insert. The part and structural insert may be dissimilar materials such as a part of an aluminum alloy material and a structural insert of a steel alloy material.

One example of a gerotor pump includes an inner rotor comprising multiple teeth, the inner rotor configured to rotate about a first longitudinal gerotor pump axis. The gerotor pump also includes a hollow outer rotor including an outer surface and an inner surface having substantially identical contours, the inner surface configured to engage with the multiple teeth and to rotate about a second longitudinal gerotor pump axis. The pump includes a pump housing within which the inner rotor and the outer rotor are disposed, wherein the outer surface of the outer rotor defines gaps between the pump housing and the outer rotor.

An aluminum piston including a cooling gallery with titled inner and outer side walls is provided. The piston comprises a ring belt with a ring grooves, and an iron insert is disposed in a top one of the ring grooves. To reduce stress and mass of the piston, material located under the iron insert is removed, so that the outer side wall of the cooling gallery is tilted toward the center axis. The inner side wall of the cooling gallery is tilted away from the center axis.

A method of forming an insulated composite piston head may include: creating a preformed aluminum or aluminum alloy foam core; suspending the preformed foam core in a piston head mold; forming a molded piston head and removing it from the mold; depositing an insulating material on at least one surface of the molded piston head; performing at least one machining operation on the molded piston head so it conforms to a predetermined specification for the insulated composite piston head; and optionally applying a lubricious piston coating to at least a portion of the outer surface of the insulated composite piston head.

A light-weight, high-strength compressor component having at least one fluid delivery feature that is formed via additive manufacturing is provided. The component may have at least one interior region comprising a lattice structure that comprises a plurality of repeating cells. A solid surface is disposed over the lattice structure. The interior region comprising the lattice structure has at least one fluid delivery feature for permitting fluid flow through the body portion of the light-weight, high-strength compressor component. The fluid delivery feature may be a flow channel, a fluid delivery port, a porous fluid delivery feature, or the like that serves to transfer fluids through the component, such as refrigerant and/or lubricant oils. Methods of making such compressor components via additive manufacturing processes are also provided.

The present invention is directed to providing a pump capable of achieving improvement of a discharge efficiency. A pump configured to suck and discharge fluid includes a housing, a driving shaft rotatably supported on the housing, and a pump element contained in the housing and configured to be rotated by the driving shaft. The housing contains therein an intake passage into which the fluid delivered from outside the housing is introduced, an intake port configured to guide the fluid from the intake passage to the pump element, a discharge port into which the fluid pressurized by the pump element is introduced, and a discharge passage configured to discharge the fluid delivered from the discharge port to outside the housing. The discharge passage includes a first passage including a beginning portion connected to the discharge port and a termination portion. The first passage extends as far as the termination portion around one straight line. The discharge passage further includes a second passage connected to the termination portion of the first passage and opened to outside the housing. A shape of the first passage in cross section taken along a direction perpendicular to the straight line changes continuously from the beginning portion to the termination portion.

A light-weight, high-strength insulating compressor component formed via additive manufacturing is provided. The component may have at least one interior region comprising a lattice structure that comprises a plurality of repeating cells. A solid surface is disposed over the lattice structure. The interior region comprising the lattice structure minimizes or reduces transmission of at least one of thermal energy, sound, or vibrational energy through the component. Methods of making such compressor components via additive manufacturing processes are also provided.

A scroll compressor is provided that may include a casing; a drive motor provided at an inner space of the casing; a rotational shaft coupled to a rotor of the drive motor, and rotated together with the rotor; a frame provided below the drive motor; a fixed scroll provided below the frame, and having a fixed wrap; and an orbiting scroll provided between the frame and the fixed scroll, having an orbiting wrap so as to form a compression chamber including a suction chamber, an intermediate pressure chamber, and a discharge chamber, by being engaged with the fixed wrap. In a state in which a center of the fixed scroll and a center of the orbiting scroll are substantially the same, an interval between the fixed wrap and the orbiting wrap gradually increases towards the suction chamber from the discharge chamber.

Refrigerant compressor includes an electrical drive unit, a piston/cylinder unit which can be driven by the drive unit for the cyclical compression of refrigerant, and at least one sound-damping unit made of a thermoplastic, through which sound-damping unit refrigerant can flow and which sound-damping unit includes at least one damping chamber. The at least one sound-damping unit is connected to the piston/cylinder unit in order to enable an exchange of refrigerant between the sound-damping unit and piston/cylinder unit. The at least one sound-damping unit includes at least in sections a functional surface. The functional surface is embodied such that an emissivity of a section of the sound-damping unit includes the functional surface is less than 0.7. The at least one sound-damping unit or at least one of the sound-damping units is embodied as a discharge muffler arranged downstream of the piston/cylinder unit in the direction of flow.

In a scroll fluid machine, a thinned section (26) is provided in correspondence with a position at which the wrap height of a spiral wrap (15B, 16B) changes due to a step part. The thinned section (26) is provided on the front-side surface or the rear-side surface of a tooth tip section of at least one of the spiral wraps (15B, 16B) of at least one of partner scrolls (15, 16) respectively engaging with scrolls (15, 16). The thinned section (26) is provided in the direction in which the wrap thickness decreases so as to extend over at least a reduced-machining-accuracy area (27), which is an area where the machining becomes discontinuous due to at least a change in the wrap height. Thus, a contact failure between the spiral wraps (15B, 16B) is avoided in the area where the machining accuracy relatively decreases as a result of increasing the machining speed, thereby achieving both improved productivity and maintained performance.