Linear Compressor Stator Assembly for Coil-Core Insulation
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Solution Overview
Problem
Conventional linear compressors face challenges in effective insulation between the coil and core blocks, leading to performance reliability issues, increased production costs, and potential deformation, which complicates the assembly process and results in a larger overall size.
Innovation Solution
A stator design featuring a bobbin set with injection-molded bodies that wind the coil and position core blocks at predetermined intervals, utilizing assembly guides, dislocation preventing means, and fixation means to ensure accurate and stable assembly, thereby insulating the coil and core blocks effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If injection-molded bodies are used to secure core blocks to the coil, then the coil and core blocks are insulated, but it is difficult to check whether the space is filled satisfactorily, leading to performance reliability issues and increased production costs
Solution Approach 1:
The patent introduces an intermediary component (the injection-molded body with integrated positioning features) that mediates between the coil and core blocks. This intermediary not only provides insulation but also includes built-in positioning protrusions that guide core block placement, making the filling process visible and inspectable during assembly, thereby resolving both the reliability and inspection difficulty issues.
Solution Approach 2:
The injection-molded body is pre-formed with positioning protrusions and cavities before assembly. This preliminary action ensures that when core blocks are inserted, their positions are automatically guided and secured, making it easy to verify proper filling and positioning during assembly inspection, thus improving both reliability and manufacturability.
2Reliability
If the coil and core blocks are spaced apart by a certain distance for insulation, then insulation is achieved, but the overall size of the linear motor increases
Solution Approach 1:
The patent merges multiple functions into the injection-molded body: it provides insulation between the coil and core blocks, positions the core blocks at predetermined intervals, and maintains the necessary air-gap spacing. This integration achieves effective insulation without requiring additional spacing components, thereby minimizing the overall size of the linear motor while maintaining reliability.
3Manufacturing precision
If core blocks are arranged at predetermined intervals using injection-molded bodies, then assembly accuracy is improved, but the assembly process becomes more complex
Solution Approach 1:
The patent segments the stator structure into modular components: the injection-molded body with positioned core blocks is assembled as a unit, which is then installed as a complete assembly. This segmentation allows for precise positioning of core blocks during the molding process, while the modular nature simplifies the overall assembly process by reducing the number of separate positioning operations required.
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
This design enhances performance reliability, reduces production costs, prevents assembly deformation, and minimizes the overall size of the linear motor and compressor by ensuring accurate and stable assembly of the core blocks, improving productivity.
Implementation Method 1
a plurality of core blocks (443), which are arranged in a circumference direction of the bobbin set (442) at predetermined intervals from an axial direction of the bobbin set (442)... injection-molded bodies 12c for securing the core blocks 12b to the coil 12a
Implementation Method 2
when the permanent magnet 13 makes a linear reciprocating motion by an interactive electromagnetic force between itself and the inner stator 11 and the outer stator 12
Data Source
AI summary
A stator for a linear compressor is provided that includes a coil winding, in which a coil is wound in a circumferential direction and current flows; a bobbin set, which is wound with the coil winding and which insulates the coil winding; and a plurality of core blocks, which is arranged in a circumferential direction of the bobbin set at predetermined intervals from an axial direction of the bobbin set, and which is advantageously used to simplify the manufacturing process, enhance the clamping force, reduce an overall production cost, and reduce a size of a product incorporating the same.