Inner Iron Lamination Assembly for Compact Linear Compressor Motors
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Solution Overview
Problem
Conventional linear compressors have complex motor assemblies that result in increased assembly time, maintenance costs, and poor efficiency, with a large footprint.
Innovation Solution
A motor assembly for a linear compressor comprising a stacked inner iron lamination assembly with a permanent magnet, front and back ring assemblies, and a method of assembly that includes attaching these components to form a compact and efficient motor structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional motor assemblies with multiple components are used, then the motor can provide sufficient power, but the assembly time, maintenance costs, and design complexity increase
Solution Approach 1:
The patent merges the motor assembly into a single integrated component where the stator and rotor are combined as one piece. The motor assembly includes a stator with winding coils and a rotor with permanent magnets, all integrated into a unified structure that eliminates the need for separate motor components, thereby reducing assembly complexity while maintaining power output
Solution Approach 2:
The integrated motor assembly serves multiple functions within a single component: it provides electromagnetic force generation, structural support for the piston, and magnetic field containment. The motor assembly acts as both the actuator and a structural element of the compressor, reducing the overall number of parts needed
2Power
If conventional motor assemblies with multiple components are used, then the motor can provide sufficient power, but the assembly time and maintenance costs increase
Solution Approach 1:
The motor assembly is merged into a single pre-assembled unit that is installed as one component rather than multiple separate parts. This integration significantly reduces assembly time during manufacturing and service operations, as the entire motor assembly can be installed in a single step without requiring multiple alignment and fastening operations
Solution Approach 2:
The motor assembly is pre-assembled and pre-tested as a complete unit before installation into the compressor. The stator, rotor, and associated components are configured and secured together in advance, allowing for rapid installation without requiring on-site assembly of multiple discrete motor parts
3Power
If conventional motor assemblies are used, then the motor can provide sufficient power, but the footprint and size increase
Solution Approach 1:
The rotor is nested within the stator, with the permanent magnets on the rotor positioned inside the magnetic field generated by the stator windings. This nested configuration allows the motor to generate sufficient power in a compact radial arrangement, minimizing the overall footprint while maintaining electromagnetic performance
4Power
If conventional motor assemblies are used, then the motor can provide sufficient power, but the efficiency decreases
Solution Approach 1:
The patent uses permanent magnets with specific magnetic properties and optimizes the winding coil configuration to improve the electromagnetic conversion efficiency. The motor assembly is designed with parameters optimized for high efficiency operation, including the arrangement of permanent magnets and winding coils to minimize energy losses
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 reduces the size and number of components, leading to a smaller footprint and improved efficiency while maintaining high operational performance.
Implementation Method 1
The driving coil generates a force for sliding the piston forward and backward within a chamber
Implementation Method 2
a permanent magnet assembly attached to the inner iron lamination assembly
Data Source
AI summary
A motor assembly for a linear compressor defines an axial direction and a radial direction and includes an inner iron lamination assembly comprising a plurality of laminations stacked along the axial direction, a permanent magnet assembly attached to the inner iron lamination assembly, a front ring assembly attached to a first end of the inner iron lamination assembly, a back ring assembly attached to a second end of the inner iron lamination assembly, a plurality of bosses mounted to the first end and the second end of the inner iron lamination assembly, and a planar spring assembly attached to the plurality of bosses of the inner iron lamination assembly.