Stator for compressor motor

A stator for a compressor motor may include a stator body having a hollow therein, a plurality of coil winding portions that protrudes inward from an inner circumferential surface of the stator body and spaced apart from each other, a coil wound around each of the plurality of coil winding portions, and an insulation portion that extends in an axial direction of the stator body, disposed between a first coil winding portion and a second coil winding portion of the plurality of coil winding portions, and coupled to the inner circumferential surface of the stator body to surround a portion of the coil. The insulation portion may be made of polyether ether ketone, which is a plastic-based material, or one of polyurethane rubber or silicone rubber, which are rubber-based materials.

CROSS-REFERENCE TO RELATED APPLICATION(S)

The present application claims priority under 35 U.S.C. 119 and 35 U.S.C. 365 to Korean Patent Application No. 10-2018-0051898, filed in Korea on May 4, 2018, which is hereby incorporated by reference in its entirety.

BACKGROUND

A stator for a compressor motor is disclosed herein.

In general, compressors are machines that receive power from a power generation device, such as an electric motor or a turbine, to compress air, a refrigerant, or various working gases, thereby to increase a pressure. Compressors are being widely used in home appliances, such as refrigerators or air conditioners, or in various industrial fields.

Compressors may be largely classified into reciprocating compressors in which a compression space into and from which a working gas, such as a refrigerant, is suctioned and discharged is defined between a piston and a cylinder to allow the piston to be linearly reciprocated into the cylinder, thereby compressing the working gas, rotary compressors in which a compression space into and from which a working gas, such as a refrigerant, is suctioned or discharged is defined between a roller that eccentrically rotates and a cylinder to allow the roller to eccentrically rotate along an inner wall of the cylinder, thereby compressing the working gas, and scroll compressors in which a compression space into and from a working gas, such as a refrigerant, is suctioned or discharged is defined between an orbiting scroll and a fixed scroll to compress the working gas while the orbiting scroll rotates along the fixed scroll.

A structure of a stator used in a compressor according to related art is disclosed in Korean Patent Publication No. 10-2006-0027704, which is hereby incorporated by reference. According to the related art, disclosed are features in which an insulator is coupled to upper and lower portions of a stator, an insulation film member having a film shape is coupled to a slot, and a coil is wound around the insulator and the insulation film member.

According to the related art, the insulator and the insulation film member have limitations in reducing electromagnetic noise generated in the wound coil. Also, if a component for reducing the electromagnetic noise is additionally installed, an amount of coil capable of being wound around the stator is reduced, deteriorating drive efficiency of the compressor motor.

DETAILED DESCRIPTION

Hereinafter, embodiments will be described with reference to the accompanying drawings. It should be noted that when components in the drawings are designated by reference numerals, the same or like components have the same or like reference numerals as far as possible even though the components are illustrated in different drawings. Further, in description of embodiments, when it is determined that detailed descriptions are well-known configurations or functions reduce understanding, the detailed descriptions have been omitted.

Also, in the description of the embodiments, terms such as first, second, A, B, (a) and (b) may be used. Each of these terms is merely used to distinguish the corresponding component from other components, and does not delimit an essence, an order or a sequence of the corresponding component. It should be understood that when one component is “connected”, “coupled” or “joined” to another component, the former may be directly connected or jointed to the latter or may be “connected”, coupled” or “joined” to the latter with a third component interposed therebetween.

Hereinafter, a compressor according to an embodiment will be described with reference to the accompanying drawings. A rotary compressor will be described as an example of the compressor.

FIG. 1is a view illustrating a configuration of a compressor according to an embodiment. Referring toFIG. 1, a rotary compressor100according to an embodiment may include a case110defining an inner space and a top cover112coupled to an upper portion of the case110.

A motor may be provided in the case110. The motor may include a stator120that generates magnetic force by applied power and a compression mechanism130that compresses a refrigerant by induced electromotive force generated through an interaction with the stator120.

The compression mechanism130may include a rotor131provided inside the stator120. The stator120and the rotor131may be understood as components of the compressor motor. The compression mechanism130may further include a rotational shaft135coupled to the rotor131to rotate according to rotation of the rotor131.

The rotary compressor100may further include a roller141eccentrically coupled to a lower portion of the rotational shaft135to rotate along a predetermined eccentric trajectory according to the rotation of the rotational shaft135, a cylinder142in which the roller141is accommodated, and a main bearing143and a sub bearing144, which may be provided on or at upper and lower portions of the cylinder142to support the cylinder142. Each of the main bearing143and the sub bearing144may have an approximately disc shape. The main bearing9and the sub bearing10may support the upper and lower portions of the cylinder142, respectively.

The rotary compressor100further includes a vane (not shown) that separates a suction chamber and a compression chamber while reciprocating within a slot defined in the cylinder142according to rotation of the roller141, a suction hole145and a discharge hole, which provide a flow passage for a refrigerant suctioned into or discharged from the cylinder142, and a muffler146provided on or at an upper portion of the discharge hole to reduce discharge noise of the refrigerant.

An effect due to the above-described components will be briefly described hereinafter. When the rotational shaft135rotates, the roller141may rotate and revolve along an inner circumferential surface of the cylinder142while drawing a predetermined eccentric trajectory. The refrigerant may be introduced into the suction chamber of the cylinder142through the suction hole145. Then, the refrigerant may be compressed in a compression chamber while the roller141rotates.

When a pressure within the compression chamber is equal to or greater than a discharge pressure, a discharge valve (not shown) provided on or at one side of the discharge hole may be opened, and the compression refrigerant may be discharged to the discharge hole through the opened discharge valve. The discharge valve may be disposed on the main bearing143above the cylinder142.

The refrigerant discharged through the discharge hole may be introduced into the muffler146disposed on the main bearing143. The muffler146may serve to reduce noise of the discharged refrigerant.

The main bearing143may be disposed above the cylinder142to disperse compression force of the refrigerant, which is generated in the cylinder142, or force generated in the compressor motors120and131toward the case110.

FIG. 2is a perspective view illustrating a state in which a coil is wound around the stator according to the embodiment ofFIG. 1.FIG. 3is a plan view of the stator according to the embodiment ofFIG. 1.FIG. 4is an exploded view of the stator according to the embodiment ofFIG. 1.

Referring toFIGS. 2 to 4, the rotary compressor100according to this embodiment may include the case110(seeFIG. 1) having an approximately cylindrical shape and defining the inner space, the stator120installed in the case110, the rotor131installed to rotate in the stator120, and the rotational shaft135coupled to the rotor131to rotate according to the rotation of the rotor131. The stator120may be one component of the compressor motor and generate magnetic force by applied power. The stator120may include a stator body121having an approximately hollow cylindrical shape and a coil winding part or portion125protruding inward from an inner circumferential surface of the stator body121.

The stator body121may be inserted into the case110. At least a portion of an outer circumferential surface of the stator body121may be coupled to contact an inner circumferential surface of the case110.

A plurality of the coil winding part125may be provided, and the plurality of coil winding parts125may be disposed to be spaced apart from each other. A coil160may be wound around each of the plurality of winding parts125. At least a portion of the coil160may be disposed between one or a first coil winding part125and the other or a second coil winding part125.

The coil winding part125may include a body122that protrudes from the inner circumferential surface of the stator body121toward a center and an extension part or portion123that extends from an end of the body122toward each of both sides thereof. The extension parts123may extend from the two coil winding parts125adjacent to each other, respectively. That is, two extension parts123respectively extending to left and right or lateral sides may be disposed on one coil winding part125. The extension part123may be understood as a “separation prevention rib” that prevents the coil wound around the coil winding part125from being separated. An insertion space124into which the coil160may be inserted may be defined between the extension parts123of the two coil winding parts125adjacent to each other.

The stator120may further include an insulation part or portion or layer170. The insulation part170may reduce electromagnetic noise that may be generated in the stator120. The insulation part170may reduce electromagnetic noise generated when power is applied to the coil160to generate electromagnetic force, and the compressor motors120and131are driven by the electromagnetic force.

The insulation part170may be disposed between the two coil winding parts125adjacent to each other. Also, the insulation part170may be disposed on the inner circumferential surface of the stator body121. The insulation part170may surround a portion of the coil160disposed between one or a first coil winding part125and the other or a second coil winding part125.

That is, the insulation part170may surround a portion of the coil160disposed between two coil winding parts125adjacent to each other to reduce the electromagnetic noise generated between the coil160and the stator120. The insulation part170may surround a portion of the coil160to insulate the coil160and the stator120from each other.

The insulation part170may be made of a plastic-based or rubber-based material, for example. Also, the insulation part170may be made of an insulation material, a damping material, or a vibration damper material, for example.

When the insulation part170is made of the plastic-based material, the insulation part170may be made of a material which is excellent in at least one of heat resistance, chemical resistance, abrasion resistance, or workability. For example, the insulation part170may be made of polyether ether ketone (PEET). Also, the insulation part170may be processed by a processing device and then mounted on the inner circumferential surface of the stator body121.

When the insulation part170is made of the rubber-based material, the insulation part170may be made of a material which is excellent in at least one of durability (hardness, tensile strength, etc.), use temperature, heat resistance, and chemical resistance (acid resistance, etc.). For example, the insulation part170may be made of polyurethane rubber or silicone rubber. For example, the insulation part170may be made of liquid rubber and then applied to the inner circumferential surface of the stator body121and hardened so as to be fixed to the inner circumferential surface of the stator body121. Alternatively, the insulation part170may be made of plate-shaped rubber and then inserted into the inner circumferential surface of the stator body121so as to be fixed to the inner circumferential surface of the stator body121.

Hereinafter, a structure of the insulation part170will be described.

The insulation part170may include an insulation part body171, a first extension part or portion172, and a second extension part or portion173.

The insulation part body171may be coupled to the inner circumferential surface of the stator body121. The insulation part body171may be coupled to the inner circumferential surface of the stator body121disposed between one coil winding part125and the other coil winding part125. Also, the insulation part body171may move in a vertical direction of the stator body121and be coupled to the inner circumferential surface of the stator body121. The vertical direction of the stator body121may be understood as an axial direction of the stator body121.

The first extension part172may extend from one or a first side surface of the insulation part body171. Also, the second extension part173may extend from the other or a second side surface of the insulation part body171. In this embodiment, the first extension part172may extend from a left side of the insulation part body171, and the second extension part173may extend from a right side of the insulation part body171.

The first extension part172may extend from one side of the insulation part body171toward the extension part123of one coil winding part125. The first extension part172may extend from the insulation part body171and then be coupled to one coil winding part125. A portion of one coil160wound around the adjacent coil winding part125may contact the first extension part172.

The second extension part173may extend from the other side of the insulation part body171toward the extension part123of the other coil winding part125. Also, the second extension part173may extend from the insulation part body171and then be coupled to the other coil winding part125. A portion of the other coil160wound around the adjacent coil winding part125may contact the second extension part173.

In this embodiment, when the insulation part170is viewed in a plane, the insulation part170may have an approximately ‘⊏’ shape. Thus, the insulation part170may be inserted between one coil winding part125and the other coil winding part125of the stator120.

The insulation part body171may extend in the axial direction of the stator body121. The insulation part body171that extends in the axial direction may further protrude than the stator body121. The first extension part172and the second extension part173may extend in the axial direction of the stator body121. The first extension part172and the second extension part173, which extend in the axial direction, may further protrude than the stator body121. That is, upper and lower ends of the insulation part170may further protrude than upper and lower ends of the stator body121. The upper end of the insulation part170may be defined as “one protrusion portion” or a “first protrusion portion”, the lower end of the insulation part170may be defined as “the other protrusion portion” or a “second protrusion portion”, and a portion accommodated in the stator body121may be defined as an “internal fixing portion”.

When the insulation part170is disposed to further protrude than the stator body121, the coil160may be prevented from directly contacting the stator120when the coil160is wound around one coil winding part125and the other coil winding part125. The coil160wound around the stator body121may be wound around the stator120in a state of being spaced apart from the upper and lower ends of the stator120by one protrusion portion and the other protrusion portion of the insulation part170, which are disposed to further protrude than the stator body121. Also, the coil160may be stably fixed to the stator body121by the internal fixing portion of the insulation part170.

As the insulation part170increases in thickness, the number of turns of the coil160wound between one coil winding part125and the other coil winding part125may decrease. Also, as the insulation part170decreases in thickness, a reduction effect of the noise generated in the coil160may be reduced. Thus, the insulation part170may have a set thickness.

Due to this configuration, the insulation part170may be disposed between the coil winding parts125adjacent to each other, and the coil160may be wound around the insulation part170to reduce the electromagnetic noise, which may be generated in the coil160, by the insulation part170. As a portion of the coil160wound around the coil winding part125is surrounded by the insulation part170, vibration of the electromagnetic noise generated in the coil160may be attenuated by the insulation part170to reduce the electromagnetic noise. Further, the electrical limitation that may occur due to direct contact between the coil160wound around the coil winding part125and the stator120may be prevented by the insulation part170.

FIG. 5is a perspective view of an insulation part according to another embodiment. An insulation part according to this embodiment has a feature in which a portion of the insulation part according to the previous embodiment is deformed. Thus, descriptions of components which are the same or similar to those according to the previous embodiment will be omitted.

Referring toFIG. 5, the insulation part according to this embodiment may include a first insulation part or portion270and a second insulation part or portion280. The first insulation part270and the second insulation part280may be disposed to be spaced apart from each other. The first insulation part270and the second insulation part280may be disposed to be spaced apart from each other in a vertical direction with respect to an axial direction of a stator body. The first insulation part270may be disposed on an upper portion of the stator body, and the second insulation part280may be disposed on a lower portion of the stator body.

The first insulation part270may be disposed above the second insulation part280. The first insulation part270may include a first insulation part body271, a first extension part or portion272, and a second extension part or portion273.

The first insulation part body271may be coupled to an inner circumferential surface of the stator body disposed between coil winding parts adjacent to each other. The first extension part272may extend from one or a first side surface of the first insulation part body271in a direction of an extension part or portion of one or a first coil winding part or portion and then be coupled to a body of the one coil winding part. The second extension part273may extend from the other or a second side surface of the first insulation part body271in a direction of an extension part or portion of the other or a second coil winding part or portion and then be coupled to a body of the other coil winding part. The first extension part272may be referred to as “one side extension part” or a “first side extension portion” and the second extension part273may be referred to as “the other side extension part” or a “second side extension portion”.

The second insulation part280may be disposed below the first insulation part270. Also, the second insulation part280may include a second insulation part body281, a third extension part282, and a fourth extension part283.

The second insulation part body281may be coupled to the inner circumferential surface of the stator body disposed between the coil winding parts adjacent to each other. The second extension part282may extend from one or a first side surface of the second insulation part body281in a direction of an extension part or portion of one or a first coil winding part or portion and then be coupled to a body of the one coil winding part. The fourth extension part283may extend from the other or a second side surface of the second insulation part body281in a direction of an extension part or portion of the other or a second coil winding part or portion and then be coupled to a body of the other coil winding part. The second extension part282may be referred to as “one side extension part” or a “first side extension portion”, and the fourth extension part283may be referred to as “the other side extension part” or a “second side extension portion”.

The first insulation part270may be disposed to further protrude upward than an upper end of the stator body. The second insulation part280may be disposed to further protrude downward than a lower end of the stator body. That is, a portion of the first insulation part270and a portion of the second insulation part280may be disposed to further protrude from than the upper and lower ends of the stator body. A remaining portion of the first insulation part270and a remaining portion of the second insulation part280may be disposed inside the stator body and then coupled to the stator body.

Due to this configuration, while the coil is wound around the stator, direct contact between the stator and the coil may be prevented by the first insulation part270and the second insulation part280. Also, the insulation part coupled to the stator may be provided to be divided into the first insulation part270and the second insulation part280, thereby reducing manufacturing cost required for manufacturing the insulation part. Also, since the first insulation part270and the second insulation part280are easily mounted on the stator body, the method for coupling the insulation part to the stator body may be easily performed.

FIG. 6is a perspective view of a stator according to another embodiment.FIG. 7is a perspective view of an insulator according to the embodiment ofFIG. 6.

An insulation part according to this embodiment has a feature in which a portion of the insulation part according to this embodiment is deformed. Thus, descriptions of components which are the same or similar to those according to the previous embodiment have been omitted.

Referring toFIGS. 6 and 7, stator120according to this embodiment may include an upper insulator370and a lower insulator380. The upper insulator370and the lower insulator380may be disposed to be spaced apart from each other. The upper insulator370and the lower insulator380may be spaced apart from each other in a vertical direction with respect to an axial direction of stator body121.

The upper insulator370may be disposed on an upper end of the stator body121. Also, the upper insulator370may be understood as one insulation in which a plurality of insulation parts according to the previous embodiment are connected to each other.

The upper insulator370may include a first insulation part body371, a first extension part or portion372, a second extension part or portion373, and a first connection part or portion374.

The first insulation part body371may be coupled to an inner circumferential surface of the stator body121disposed between coil winding parts adjacent to each other. The first extension part372may extend from one or a first side surface of the first insulation part body371and then be coupled to a body of the one coil winding part. The second extension part373may extend from the other or a second side surface of the first insulation part body371and then be coupled to a body of the other coil winding part.

The first connection part374may form the upper insulator370which is integrated by connecting the first extension part372of the first insulation part body, which is disposed on one side, of the plurality of first insulation part bodies disposed adjacent to each other to the second extension part373of the first insulation part body, which is disposed at the other side. The first connection part374may be disposed on upper ends of the first extension part372and the second extension part373to connect the first extension part372to the second extension part383.

The first connection part374may be seated on the stator body121while the upper insulator370is coupled to the stator body121. That is, the first connection part374may be seated on the stator body121while the upper insulator370is coupled to the upper end of the stator body121so that a portion of the upper insulator370is coupled to the inside of the stator body121, and a remaining portion of the stator body121is exposed to the outside.

The lower insulator380may be disposed on a lower end of the stator body121. Also, the lower insulator380may be understood as one insulation in which a plurality of insulation parts according to the previous embodiment is connected to each other.

The lower insulator380may include a second insulation part body381, a third extension part or portion382, a fourth extension part or portion383, and a second connection part or portion384. The second insulation part body381may be coupled to an inner circumferential surface of the stator body121disposed between coil winding parts adjacent to each other. The third extension part382may extend from one or a first side surface of the second insulation part body281and then be coupled to a body of the one coil winding part. The fourth extension part383may extend from the other or a second side surface of the second insulation part body381and then be coupled to a body of the other coil winding part.

The second connection part384may form the lower insulator380which is integrated by connecting the third extension part382of the second insulation part body, which is disposed on one side, of the plurality of second insulation part bodies disposed adjacent to each other to the fourth extension part383of the second insulation part body, which is disposed at the other side. The second connection part384may be disposed on lower ends of the third extension part382and the fourth extension part383to connect the third extension part382to the fourth extension part383.

The second connection part384may be seated on the stator body121while the lower insulator380is coupled to the stator body121. That is, the second connection part384may be seated on the stator body121while the lower insulator380is coupled to the lower end of the stator body121so that a portion of the lower insulator380is coupled to the inside of the stator body121, and a remaining portion of the stator body121is exposed to the outside.

Due to this configuration, the upper insulator370and the lower insulator, which may be integrated with each other, may be easily coupled to the stator120. Also, the coils wound around one coil winding part and the other coil winding part may be prevented from directly contacting the upper and lower ends of the stator120by the first connection part374of the upper insulator370and the second connection part384of the lower insulator380.

FIG. 8is a graph illustrating a noise analysis result of the stator according to an embodiment. Referring toFIG. 8, the graph that shows results obtained by analyzing noise generated in the stator according to embodiments and noise generated in the stator according to the related art.

In the stator according to embodiments, electromagnetic noise generated in a state in which the insulation part is disposed between one coil winding part and the other coil winding part, and a portion of the coils wound around the one coil winding part and the other coil winding part is surrounded by the insulation part is measured. Also, in the stator according to the related art, electromagnetic noise generated in a state in which the insulation film member having the thin film and the insulator are disposed between one coil winding part and the other coil winding part, and a portion of the coil is surrounded by the insulation film member is measured.

Referring to the graph, the electromagnetic noise generated in the stator according to embodiments may be reduced by efficiently attenuating vibration of the noise through the insulation part surrounding a portion of the coil. Thus, it may be confirmed that the electromagnetic noise generated in the stator according to embodiments is significantly reduced when compared to that generated in the stator according to the related art.

Embodiments provide a stator for a compressor motor, in which electromagnetic noise generated in a wound coil is capable of being reduced. Embodiments further provide a stator for a compressor motor, in which manufacturing costs of the stator is capable of being reduced.

In one embodiment, a stator for a compressor motor may include an insulation part or portion disposed between one or a first coil winding part or portion and the other or a second coil winding part or portion of a plurality of coil winding parts or portions and configured to surround a portion of a coil to reduce electromagnetic noise generated in the coil. The stator for a compressor motor may be made of a rubber-based material having heat resistance, chemical resistance, abrasion resistance, and durability or a plastic-based material having heat resistance, chemical resistance, abrasion resistance, and workability to suppress vibration of the electromagnetic noise generated in the coil, thereby reducing electromagnetic noise.

In the stator for the compressor motor according to embodiments, the insulation parts may extend in an axial direction of a stator body so as to be integrated with each other, or the insulation parts may be disposed to be spaced apart from each other in the axial direction of the stator body, thereby simplifying a process of providing the insulation part.

In the stator for the compressor motor according to embodiments, cost required for the process of providing the insulation part may be reduced in the process of manufacturing the stator, and the insulation part may be optimally disposed. The insulation part made of the plastic-based material or rubber-based material having heat resistance, chemical resistance, and abrasion resistance may be provided in the stator to reduce electromagnetic noise generated in the coil wound around the stator. The insulation part provided in the stator may be optimally disposed to reduce the cost required for the process of providing the insulation part.