Compressor Rotor Magnet Support Structure for Secure Insert Molding
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Solution Overview
Problem
Existing methods for manufacturing motors for compressors face challenges in securely fixing magnets to the rotor core during insert molding, leading to potential escape-off issues and reduced productivity.
Innovation Solution
A motor design featuring magnet support structures on the rotor core with pass holes for resin flow, allowing magnets to be fixed and secured before molding, preventing escape and enhancing productivity through integrated component coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnets are fixed to the rotor core using conventional insert molding methods, then the motor can be manufactured, but the magnets may escape during the molding process due to insufficient fixing structures
Solution Approach 1:
The magnet support structures are pre-formed on the rotor core before the insert molding process. These structures include positioning features and retaining walls that prepare the rotor core in advance to securely hold the magnets during subsequent molding operations, preventing magnet escape without requiring complex additional fixing mechanisms
Solution Approach 2:
The magnet support structures act as intermediary elements between the rotor core and the magnets. These structures provide a dedicated interface that facilitates secure magnet attachment while maintaining simplicity in the overall rotor design, serving as a mediating component that resolves the conflict between reliable fixation and structural simplicity
2Reliability
If magnets are securely fixed before molding using complex fixing structures, then magnet escape is prevented, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The magnet support structures are integrated directly into the rotor core as a unified component rather than being separate attachments. This merging of the support structures with the rotor core eliminates additional assembly steps and simplifies the manufacturing process, maintaining high productivity while ensuring reliable magnet fixation through the integrated design
3Ease of manufacture
If conventional insert molding is used without dedicated magnet support structures, then the manufacturing process is simpler, but resin penetrates into gaps between magnets and rotor core reducing quality
Solution Approach 1:
The magnet support structures provide localized quality enhancement at specific regions of the rotor core where magnets are positioned. The structures include tailored positioning features and retaining walls that precisely control magnet placement and prevent resin penetration at critical interfaces, achieving high manufacturing precision without compromising overall manufacturing simplicity
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
The solution effectively prevents magnet escape during molding, improves productivity by reducing component insertion time, and enhances rotor quality by minimizing resin penetration gaps.
Implementation Method 1
The rotor may include a rotor core and a magnet, and may be configured to interact electromagnetically with the stator having a coil. The rotor may be rotated by the force acting between the magnetic field by the rotor's magnet and the current flowing through the coil of the stator.
Data Source
AI summary
A motor for a compressor, according to one embodiment of the present disclosure, may comprise one or more magnets. The motor may comprise a rotor core having a plurality of magnet support structures, which define one or more magnet-mounting spaces, disposed on the inner circumferential surface of the rotor core. The motor may comprise a rotor housing that is injection molded to be integrally coupled to the magnets and the rotor core. The magnet-mounting spaces may have one of the magnets inserted and arranged along a first direction. The magnet support structures may have, on the inner side thereof, a pass hole through which resin flows based on the injection molding of the rotor housing.