COMPRESSOR

Description

[0001] The present invention relates to a compressor.

[0002] One of the biggest challenges faced with electric motors is keeping the components of the electric motor cool during use. In the case of compressors, the airflow generated by the compressor can be utilised to cool some of the components of the motor. However, it is often the case that the airflow through the compressor is restricted, and is not able to flow past all the components effectively. Therefore the efficiency and performance of the compressor may be limited by the restricted cooling available to a small number of the components.

[0003] EP 2 247 838 A2 discloses a compressor according to the preamble of claim 1. Further relevant prior art documents are WO 98 / 30790 A2, DE 37 10 622 A1 and US 2012 / 128512 A1.

[0004] There is a general desire to improve compressors, such as the motors found in vacuum cleaners, in a number of ways. In particular, improvements may be desired in terms of size, weight, manufacturing cost, performance, efficiency, reliability and noise.

[0005] This invention provides a compressor according to claim 1.

[0006] Such a compressor comprises, inter alia, a stator assembly comprising a plurality of stator elements; a rotor assembly comprising a shaft to which is mounted at least one bearing, a permanent magnet and an impeller; a support body; and an outer can comprising an air inlet. The support body comprises a hollow elongate central part to which is mounted the at least one bearing, and inside which the magnet is positioned, the elongate central part comprising a plurality of openings, and the air inlet of the outer can is axially aligned at least partially with the plurality of openings in the elongate central part.

[0007] As a result, airflow generated by the compressor during use is able to flow into the compressor through the air inlet of the outer can and through the opening of the elongate central part of the support body to cool the magnet during use. Accordingly, more of the components of the compressor can be cooled effectively, and the performance and efficiency of the compressor can be improved.

[0008] The air inlet comprises at least one large opening such that air enters the compressor in a direction having both axial and radial components. As such, cooling airflow is better able to enter the compressor in a way that provides cooling to all internal components of the compressor, both inside the elongate central part of the support body, and outside.

[0009] The outer can is spaced radially from the support body to form an annular airflow pathway. As a result, cooling airflow passes through the annular pathway to cool components positioned within the annular airflow pathway in addition to the airflow flowing through the elongate central part of the support body.

[0010] The stator elements extend partially through the plurality of openings and at least a portion of the plurality of openings is still open, and the stator elements are fixed to the support body such that they extend into the annular airflow pathway. As a result the stator elements are cooled by both the airflow inside the elongate central part of the support body, and also the annular airflow pathway between the support body and the outer can. This provides all-round cooling for windings wound around the stator elements. As a result, the windings can be kept cooler, and the performance and efficiency of the compressor is improved.

[0011] A printed circuit board may be mounted to an end of the outer can proximate the air inlet. Larger electronic components may be mounted to the printed circuit board extend from the PCB into an air pathway for air entering the compressor through the air inlet. As a result, electrical components on the PCB, and in particular the larger components, are cooled by the airflow into the compressor during use. This may further improve the performance and efficiency of the compressor.

[0012] In use, air flows axially through the compressor both inside the support body, and outside the support body.

[0013] In order that the present invention may be more readily understood, embodiments of the invention will now be described, by way of example, with reference to the following accompanying drawings, in which: Figure 1 shows an exploded perspective view of parts of a compressor; Figure 2 shows a cross section through a compressor; and Figure 3 shows an assembled compressor including the parts shown in Figure 1.

[0014] Figure 1 shows an exploded perspective view of a compressor 10. Certain components, such as control electronics and an external housing, are not shown for clarity. The compressor 10 includes a rotor assembly 12, a support body 14 and a stator assembly comprising four stator elements 16, 18, 20 and 22. When the compressor 10 is assembled, the rotor assembly 12 is located within and mounted to the support body 14, and the stator elements are located in respective openings or slots in the support body 14. The stator element 20 is located within opening 24 in the support body. The support body 14 may be a one-piece construction, for example moulded as a single object, and includes an impeller shroud 26 that covers the impeller. The compressor 10 also includes a diffuser 28.

[0015] The rotor assembly 12 comprises a shaft 30 on which is mounted a magnet 32, a first balancing ring 34 and a second balancing ring 36. When the rotor assembly 12 is assembled, a pair of bearings are mounted on the shaft 30 on either side of the core 32 and balancing rings 34, 36. In Figure 1, only one of the pair of bearings is visible: bearing 38. An impeller 42 is mounted at one end of the shaft 30.

[0016] When the stator elements 16, 18, 20 and 22 are located in respective openings in the support body 14, at least a portion of the opening is still open, and not restricted by the stator element. This allows an airflow to pass the stator element, through the opening, and into the support body. When the compressor is in use, this airflow is used to cool the rotor assembly 12 located inside the support body 14, and in particular the magnet 32.

[0017] Figure 2 shows a cross section through a compressor 100. The compressor 100 comprises a stator assembly having a number of stator elements 102, 104. A rotor assembly is also provided which comprises a shaft 106 to which is mounted a magnet 108, first and second bearings 110, 112 mounted to the shaft 106 at either end of the magnet 108, and an impeller 114. A support body 116 comprising a hollow elongate central part is provided. A number of openings 118 are provided in the hollow elongate body, through which the stator elements 102, 104 partially extend. The rotor assembly is housed within the support body 116, and the bearings 110, 112 are mounted to bearings seats 120, 122 formed as part of the support body 116 at each end of the openings 118. The magnet 108, being between the bearings, therefore is located within the elongate central part of the support body 116, and aligns with the stator elements 102, 104.

[0018] An outer can 130 is positioned around the outside of the compressor 100. It is supported by the support body 116 by being mounted via hub 132 to the outside surface of the bearing seat 120. An air inlet 134 is provided in the outer can 130 to allow air to be drawn in by the compressor 100 during use. Mounted to the outer surface of the other bearing seat 122 is a shroud 136 which surrounds the impeller 114. The outer casing 130 is also mounted to shroud 136. Air passages are provided around or through the shroud 136 to allow air to be drawn through the compressor 100 by the impeller 114. The hub 132 also acts as a winding termination block to which windings of the stator elements 102, 104 can be connected in order to receive current.

[0019] As can be seen from Figure 2, the air inlet 134 of the outer can 130 is axially aligned with the openings 118 in the support body 116. This encourages air flowing into the compressor 100 to flow into the support body 116 to help cool the magnet 108 positioned therein during use. Indeed, the inlet 134 is relatively large, which encourages air flowing into the compressor in a direction that has both radial and axial components. This allows for a cooling airflow through the compressor 100 as indicated by arrows A and B. Cooling airflow A passes through an annular channel between the support body 116 and the outer can 130. Cooling airflow B passes into the support body, and passes between the magnet 108 and the support body 116. Because the stator elements 102, 104 extend partially through the openings 118, the windings on the stator elements are cooled by both airflows on both the inside and the outside of the support body 116.

[0020] After passing the stator elements 102, 104, airflow B passes back out of the support body 116 and rejoins airflow A. The combined airflows are then drawn past the shroud 136 by the impeller 114, and out of the compressor 100 as airflow C.

[0021] Figure 3 shows an assembled compressor 200 including the parts shown in Figure 1. The compressor 200 comprises an outer can 202 which has a number of large air inlets 204 through which the compressor 200 draws air during use. A printed circuit board (PCB) 210 is mounted to an end of the outer can 202 proximate to the air inlets 204. This proximity of the PCB 210 to the cooling airflow being drawn into the compressor 200 helps to keep the PCB 210 and the electronic components mounted to it cool.

[0022] As can be seen from Figure 3, a number of the larger electronic components for example those marked as references 212 and 214 are large enough to actually extend from the PCB into the air pathway for air entering the compressor 200 through the inlet 204, thus providing even better cooling thereto. These larger components may be components for which the improved cooling may be particularly beneficial, for example large capacitors, or heat sinks for electronic switches.

[0023] Whilst particular embodiments have thus far been described, it will be understood that various modifications may be made without departing from the scope of the invention as defined by the claims.

Claims

1. A compressor comprising: a stator assembly comprising a plurality of stator elements (16, 18, 20, 22); a rotor assembly (12) comprising a shaft (30) to which is mounted at least one bearing, a permanent magnet and an impeller; a support body; and an outer can (130) comprising an air inlet (134); wherein the support body (14, 116) comprises a hollow elongate central part to which is mounted the at least one bearing and inside which the magnet is positioned, the elongate central part comprising a plurality of openings, and the air inlet of the outer can (130) is axially aligned at least partially with the plurality of openings in the elongate central part; characterized in that : the outer can (130) is spaced radially from the support body to form an annular airflow pathway; the stator elements (16, 18, 20, 22) extend partially through the plurality of openings and at least a portion of the plurality of openings is still open and wherein the stator elements (16, 18, 20, 22) are fixed to the support body such that they extend into the annular airflow pathway; and the air inlet (134) comprises at least one large opening such that air enters the compressor in a direction having both axial and radial components; thereby, in use, air flows axially through the compressor both inside the support body, and outside the support body.

2. A compressor as claimed in claim 1, wherein a printed circuit board (210) is mounted to an end of the outer can proximate the air inlet.

3. A compressor as claimed in claim 2, wherein larger electronic components mounted to the printed circuit board (PCB) extend from the PCB into an air pathway for air entering the compressor through the air inlet.