Reciprocating compressor and manufacturing method thereof

Inactive Publication Date: 2006-02-02

LG ELECTRONICS INC

10 Cites 60 Cited by

AI-Extracted Technical Summary

Problems solved by technology

However, it is difficult to stack the thin stator cores 32a, 32b and 32c in the radial direction, which results in the high p...

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Method used

[0043] Referring to FIG. 4, an inner stator 110 of a reciprocating motor is formed in an integral cylindrical shape by a powder metallurgy process using a soft magnetic composite that is a kind of metal powder and is coated with an insulation coating material to improve electric magnetic properties for application to an electromagnetic system such as a motor. Here, the powder metallurgy process produces a material having a special property or a product having a special shape by using a phenomenon that metal powder or composite powder is hardened at a high temperature.

[0044] The inner stator 110 is incorporated with a cylinder 120. The outside portion composing the inner stator 110 is sintered to have magnetism, but the inside portion composing the cylinder 120 is sintered to have abrasion resistance. The inner stator 110 can be made of magnetic metal powder or mixture of general metal powder and magnetic metal powder. The rate of the magnetic metal powder to the general metal powder (hereinafter, referred to as ‘powder rate’) in the portion composing the inner stator 110 is set higher than the powder rate of the cylinder 120 to improve magnetic density of the inner stator 110.

[0045] The cylinder 120 is manufactured by a powder metallurgy process using the same material as that of the inner stator 110, namely, metal powder such as a soft magnetic composite. In addition, as shown in FIG. 6, only the cylinder 120 can be manufactured by the powder metallurgy process using general metal powder. In this case, since the g...

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Benefits of technology

[0021] Therefore, an object of the present invention is to provide a reciprocating compressor which can be easily manufactured by simplifying a manufacturing process o...

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Abstract

The present invention discloses a reciprocating compressor and a manufacturing method thereof. The reciprocating compressor includes a frame installed in a casing, an outer stator having a winding coil and being fixed to the frame, an inner stator disposed in the outer stator with a predetermined gap, and sintered by a powder metallurgy process using metal powder, a rotor having a permanent magnet between the outer stator and the inner stator, a cylinder disposed inside the inner stator of the reciprocating motor for forming a compression chamber, and sintered by a powder metallurgy process using metal powder, a piston slidably inserted into the inner circumference of the cylinder, for sucking and compressing gas by linear reciprocation, and a plurality of resonance springs for elastically supporting the connection part of the piston and the rotor, and inducing resonance of the piston. Accordingly, the cylinder is not deformed by the inner stator, and thus abrasion of the piston and the cylinder by deformation of the cylinder is prevented in advance. Moreover, the reciprocating compressor is easily manufactured by considerably simplifying the manufacturing process.

Application Domain

Reciprocating/oscillating/vibrating magnetic circuit partsEngine manufacture +6

Technology Topic

Powder metallurgyStator +8

Image

Examples

Experimental program(1)

Example

[0040] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.

[0041] A stator structure of a reciprocating motor in accordance with the present invention will now be explained in detail with reference to the accompanying drawings. A casing, a frame unit and a resonance spring unit identical to the conventional ones will not be described.

[0042]FIG. 4 is a perspective diagram illustrating disassembly of an inner stator and a cylinder of a reciprocating compressor in accordance with a first embodiment of the present invention, FIG. 5 is a cross-sectional diagram illustrating the inner stator and the cylinder of the reciprocating compressor in accordance with the first embodiment of the present invention, and FIG. 6 is a cross-sectional diagram illustrating an inner stator and a cylinder of a reciprocating compressor in accordance with a second embodiment of the present invention.

[0043] Referring to FIG. 4, an inner stator 110 of a reciprocating motor is formed in an integral cylindrical shape by a powder metallurgy process using a soft magnetic composite that is a kind of metal powder and is coated with an insulation coating material to improve electric magnetic properties for application to an electromagnetic system such as a motor. Here, the powder metallurgy process produces a material having a special property or a product having a special shape by using a phenomenon that metal powder or composite powder is hardened at a high temperature.

[0044] The inner stator 110 is incorporated with a cylinder 120. The outside portion composing the inner stator 110 is sintered to have magnetism, but the inside portion composing the cylinder 120 is sintered to have abrasion resistance. The inner stator 110 can be made of magnetic metal powder or mixture of general metal powder and magnetic metal powder. The rate of the magnetic metal powder to the general metal powder (hereinafter, referred to as ‘powder rate’) in the portion composing the inner stator 110 is set higher than the powder rate of the cylinder 120 to improve magnetic density of the inner stator 110.

[0045] The cylinder 120 is manufactured by a powder metallurgy process using the same material as that of the inner stator 110, namely, metal powder such as a soft magnetic composite. In addition, as shown in FIG. 6, only the cylinder 120 can be manufactured by the powder metallurgy process using general metal powder. In this case, since the general metal powder is cheaper than the magnetic metal powder, the prime cost of production can be cut down without seriously reducing efficiency of the motor.

[0046] When the cylinder 120 is manufactured by mixing general metal powder and magnetic metal powder, the powder rate of the cylinder 120 is set lower than the powder rate of the inner stator 110 to reduce expenses and improve intensity.

[0047] Preferably, an abrasion resistance coating layer is formed on the inner circumference of the cylinder 120 to reduce abrasion in sliding motion with a piston, and the thickness thereof is sufficiently large to reinforce the intensity.

[0048] On the other hand, the inner stator 110 and the cylinder 120 can be individually manufactured by sintering magnetic metal powder or another metal powder, and bonded to each other by diffusion bonding. FIG. 7 is a cross-sectional diagram illustrating an inner stator and a cylinder of a reciprocating compressor in accordance with a third embodiment of the present invention. As depicted in FIG. 7, the inner stator 110 and the cylinder 120 are individually manufactured, and the inner stator 110 is inserted onto the outer circumference of the cylinder 120.

[0049] The manufacturing method of the present invention will now be explained.

[0050] Generally, when magnetic metal powder is heated at a high temperature, the bonding strength of particles is improved to increase abrasion resistance. However, when the magnetic metal powder is heated at a high temperature over 500° C. in the sintering process, the magnetic metal powder may be demagnetized. It is thus very important to perform the sintering process without demagnetizing the inner stator 110 and reducing abrasion resistance of the cylinder 120. Preferably, the sintering temperature of the inner stator 110 ranges from 330 to 500° C., and the sintering temperature of the cylinder 120 ranges from 900 to 1100° C.

[0051] For this, as shown in FIG. 8, the cylinder 120 is temporarily formed by putting primary metal powder into a die.

[0052] The cylinder 120 is manufactured by primarily sintering the primary metal powder in the die at a high temperature of about 1000° C.

[0053] The inner stator 110 is temporarily manufactured by putting secondary metal powder onto the outer circumference of the cylinder 120 in the die in which the cylinder 120 has been manufactured. The inner stator 110 is manufactured by secondarily sintering the secondary metal powder at a temperature of about 400° C. Thus, the inner stator 110 and the cylinder 120 are incorporated.

[0054]FIG. 9 is a block diagram illustrating the manufacturing method of the reciprocating compressor in accordance with the second embodiment of the present invention.

[0055] As illustrated in FIG. 9, the inner stator 110 and the cylinder 120 are temporarily formed in a single form by supplying primary metal powder and secondary metal powder to a predetermined shape of die. The outside portion of the temporary product composing the inner stator 110 is heated and primarily sintered at a temperature of about 400° C., and the inside portion of the temporary product composing the cylinder 120 is locally heated and secondarily sintered at a temperature of about 1000° C. As a result, the inner stator 110 and the cylinder 120 are manufactured in a single form.

[0056]FIG. 10 is a block diagram illustrating the manufacturing method of the reciprocating compressor in accordance with the third embodiment of the present invention.

[0057] Referring to FIG. 10, the inner stator 110 and the cylinder 120 are temporarily formed in a single form by supplying primary metal powder and secondary metal powder to a predetermined shape of die. The temporary product is collectively sintered at a temperature of maintaining magnetism of the inner stator 100, namely, at a temperature of about 400° C., and the portion composing the cylinder 120 is locally heated and sintered at a temperature of about 1000° C. to improve abrasion resistance. Accordingly, the inner stator 110 and the cylinder 120 are manufactured in a single form.

[0058]FIG. 11 is a block diagram illustrating the manufacturing method of the reciprocating compressor in accordance with the fourth embodiment of the present invention.

[0059] As shown in FIG. 11, the inner stator 110 and the cylinder 120 are individually manufactured by supplying primary metal powder and secondary metal powder to different dies, and heating and sintering the primary metal powder and the secondary metal powder at a necessary temperature for the inner stator 110 (about 400° C.) and a necessary temperature for the cylinder 120 (about 1000° C.), respectively. Thereafter, the inner stator 110 is bonded onto the outer circumference of the cylinder 120 by diffusion bonding.

[0060] As another example, although not illustrated, the inner stator 110 and the cylinder 120 are formed in a predetermined shape of die by using magnetic metal powder, and heated and sintered at a necessary temperature for the inner stator 110 (about 400° C.). An abrasion resistance coating surface can be formed on the inner circumference of the cylinder 120.

[0061] The effects of the present invention will now be described.

[0062] As compared with the conventional inner stator formed by stacking a few hundreds of thin stator cores sheet by sheet in the radial direction, the inner stator of the present invention can be easily manufactured by considerably simplifying the manufacturing process.

[0063] Since the inner stator and the cylinder are manufactured by sintering the same metal powder, the cylinder is not deformed by the inner stator. Therefore, abrasion of the piston and the cylinder by deformation of the cylinder is prevented in advance, which results in high reliability of the compressor.

[0064] As the present invention may be embodied in several forms without departing from the spirit or essential characteristics thereof, it should also be understood that the above-described embodiments are not limited by any of the details of the foregoing description, unless otherwise specified, but rather should be construed broadly within its spirit and scope as defined in the appended claims, and therefore all changes and modifications that fall within the metes and bounds of the claims, or equivalence of such metes and bounds are therefore intended to be embraced by the appended claims.

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PUM

Property	Measurement	Unit
Temperature	300.0 ~ 500.0	°C
Temperature	900.0 ~ 1100.0	°C
Temperature
tensile		MPa
Particle size		Pa
strength	10

Description & Claims & Application Information

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Classification and recommendation of technical efficacy words

Prevent abrasion
Easily manufacture

Reciprocating compressor and manufacturing method thereof

AI-Extracted Technical Summary

Problems solved by technology

Method used

Benefits of technology

Abstract

Image

Examples

Example

PUM

Description & Claims & Application Information

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