Compact Coolant Compressor Insulation Design
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Solution Overview
Problem
Conventional refrigerant compressors have a large volume due to the need for insulation and space between the stator windings and the cylinder housing, leading to a less compact design and increased dimensions.
Innovation Solution
A compact refrigerant compressor design where the end windings of the stator winding are pressed onto an insulating element with additional insulating sections, allowing direct placement on the coil core and reducing the insulating distance from the cylinder housing, thereby minimizing the overall height and space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional insulation arrangements are used between end windings and cylinder housing, then insulation protection is ensured, but the compressor housing volume increases
Solution Approach 1:
The insulating element is merged with the cylinder housing by integrating the insulating function directly into the housing structure through insulating coatings or insulating flange extensions. This eliminates the need for separate insulating components and reduces the overall volume required for insulation protection.
Solution Approach 2:
An insulating element is introduced as an intermediary component between the end windings and the cylinder housing. This mediator provides the necessary electrical insulation while being designed to minimize space requirements, thereby protecting against electrical discharge without increasing compressor housing volume.
2Reliability
If insulating elements are added to protect end windings from cylinder housing, then electrical insulation is improved, but device complexity increases
Solution Approach 1:
The insulating function is merged with existing components such as the cylinder housing or flange extensions by applying insulating coatings or integrating insulating features directly into the housing structure. This approach improves electrical insulation without adding separate insulating elements that would increase device complexity.
Solution Approach 2:
The cylinder housing or flange extensions are designed to serve multiple functions: structural support and electrical insulation. By making the housing multi-functional, the need for separate insulating components is eliminated, thereby improving electrical insulation while maintaining simple device architecture.
3Strength
If flange extensions are used to attach cylinder housing to coil core, then mechanical connection is ensured, but space requirements increase
Solution Approach 1:
The mechanical connection function is merged with the insulating function by designing flange extensions that provide both structural attachment and electrical insulation. This integration ensures strong mechanical connection while minimizing the area required for the stator assembly.
Solution Approach 2:
Thin insulating flange extensions or insulating coatings are used to provide both mechanical connection and electrical insulation. These thin-film solutions ensure adequate mechanical strength for attachment while minimizing the area occupied by the flange extensions.
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 achieves a significant space-saving in the compressor housing while maintaining performance, allowing for a more compact electric motor and compressor housing without compromising insulation protection.
Implementation Method 1
an insulating element which essentially covers the end face and which insulates the end windings of the stator winding which are arranged on this at least one end face from the coil core
Implementation Method 2
the alternating fields occurring in the main field winding and auxiliary field winding must be offset in terms of space and time. The rotary field speed results from the mains frequency and the number of poles. After the rotor has reached a certain operating speed, the auxiliary winding can be switched off
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a coolant compressor with a compressor housing, wherein a cylinder housing (26) (Fig. 15, 16) and an electric motor (5) (Fig. 1, 2) are fastened to each other, wherein the e-motor comprises a stator (6) with a stator bore (13) (Fig. 5, 8), the coil core (8) of which is provided with a plurality of receiving grooves (9) for receiving a stator winding (11, 12) with arbitrary windings, coil groups, and pole numbers, wherein the coil core (8) comprises a plurality of stator lamellas (16) connected to each other and wherein the stator winding (11, 12) in the region of the front sides (22, 23) (Fig. 23) of the coil core (8) comprises winding heads (11', 12'), each disposed outside of the receiving grooves (9). An insulation element (7) disposed between the coil core and the winding heads (11', 12') comprises in a peripheral edge region (7a) opposite of the stator bore (13) an arbitrary number of distant additional insulating sections (14). Said insulating sections insulate the winding heads (11', 12') disposed on the at least one front side of the stator winding (11, 12) against neighboring sections of the cylinder housing (26), particularly against a flange extension (27) that can be fastened on the coil core (8) of the cylinder housing (26).