Metal working – Method of mechanical manufacture – Prime mover or fluid pump making
Reexamination Certificate
2000-07-27
2002-01-22
Cuda Rosenbaum, I (Department: 3726)
Metal working
Method of mechanical manufacture
Prime mover or fluid pump making
C417S417000
Reexamination Certificate
active
06339876
ABSTRACT:
BACKGROUND OF THE INVENTION
(a) Field of the Invention
The present invention relates to a method for assembling an inner core/cylinder block assembly for a linear compressor.
(b) Description of the Related Art
In general, a linear compressor is used in a refrigeration system that provides refrigeration energy by undergoing a refrigerant the successive process of compressing, condensing, expanding and evaporating. The linear compressor has a linear motor, which is driven by electromagnetic force created by the alternate direction change of magnetic flux, to compress the refrigerant at high temperature and pressure.
FIG. 1
shows a conventional linear compressor, and
FIG. 2
shows an inner core of the conventional linear compressor.
As shown in the drawings, the conventional linear compressor comprises an airtight container
10
, a driving part generating a driving force in the airtight container
10
, and a compressing part inhaling, compressing and discharging a refrigerant by using the driving force of the driving part.
The compressing part comprises a piston
11
and a cylinder block
13
provided with a compressing chamber
12
in which the piston
11
is slidably disposed. On one end of the cylinder block
13
is mounted a cylinder head
16
in which an inhaling chamber
14
and a discharging chamber
15
are provided for guiding the refrigerant to the inside and outside of the compressing chamber
12
, respectively.
The driving part comprises an inner core
20
coupled on an outer surface of the cylinder block
13
, a stator
30
spaced away from the inner core
20
at a predetermined distance, a permanent magnet
22
disposed between the inner core
20
and the stator
30
to interact with an electric field formed by the stator
30
.
The stator
30
includes a cylindrical bobbin
31
, coils
32
wound around the bobbin
31
, and outer core
33
inserted into the bobbin
31
.
On the lower end of the piston
11
is provided a fixing shaft
11
a
with a frame
40
for fixing the permanent magnet
22
. A resonant spring
41
for elastically supporting the piston
11
is connected to the lower end of the fixing shaft
11
a
to raise compressing force of the piston
11
.
The inner core
20
is made by piling up rectangular-shaped electric steel plates
21
and is arranged radially along the outer circumference of the cylinder block
13
. Korean laid-open patent No. 96-39553 discloses a method for piling the steel plates
21
and assembling the inner core
20
and the cylinder block
13
. This will be described hereinafter with reference to FIG.
2
.
Each steel plate is first magnetized by a magnetic flux generating device (not shown), then the magnetized steel plates
21
are radially disposed about a holder
50
.
The holder
50
includes a cylindrical main body
51
, an inner extending portion
52
extending inwardly at the lower end of the main body
51
, and an outer extending portion
53
extending outwardly at the lower end of the main body
51
. The inner extending portion
52
is provided with a plurality of screw holes
52
a
so that the holder
50
can be coupled on the lower end of the cylinder block
13
by a screw
54
. Each magnetized steel plate
21
is disposed on the outer extending portion
53
.
The magnetized steel plates
21
disposed on the holder
50
are fixed by an adhesive, thereby obtaining a radially piled inner core
20
. And, the holder
50
is coupled to the cylinder block
13
by screw-coupling the screws
54
through the screw holes
52
a
, thereby completing the coupling process of the holder
50
to the cylinder block
13
.
However, in the conventional compressor, to dispose the steel plate
21
on the holder
50
, a special magnetic flux generating device is required, making the manufacturing process complicated. In addition, since the steel plates
21
are attached on the holder
50
by an adhesive, the same may be easily removed by external force, deteriorating the performance of the compressor. Furthermore, to assemble the inner core
20
on the cylinder block
13
, additional fastening members such as the holder
50
and the screws
54
are required, lowering the productivity and increasing the manufacturing costs.
SUMMARY OF THE INVENTION
The present invention has been made in an effort to solve the above problems.
It is an objective of the present invention to provide a method for manufacturing a linear compressor easily and with the low costs.
To achieve the above objective, the present invention provides a linear compressor comprising a cylinder block in which a compressing chamber is formed; and an inner core having a plurality of electric steel plates disposed around the cylinder block, wherein the cylinder block extends into spaces between the electric steel plates so that the cylinder block is integrally formed with the inner core.
Each of the electric steel plates comprises an insertion projection extending from a surface toward the cylinder block and an insertion step extending upward and downward from the insertion projection to form a concave between the surface and the insertion step, the cylinder block extending into the concave to interlock with the inner core.
According to another aspect of the present invention, a method for manufacturing the linear compressor comprising the steps of punching each of the electric steel plates; radially stacking the electric steel plates; welding the electric steel plates to form the inner core; inserting the inner core into a cast mold for casting the cylinder block; pouring molten material into the cast mold and applying pressure to the cast mold so that the molten material is filled into spaces between the electric steel plates, thereby making the inner core integral with the cylinder block.
The punching step further comprises the steps of forming an insertion projection on a surface of the electric steel plate; and forming an insertion step on the insertion projection. The stacking step further comprises the steps of preparing a jig having an insertion groove; and stacking the electric steel plates along the jig in a semi-cylindrical shape by inserting the insertion step into the insertion groove.
The welding step further comprises the step of welding the electric steel plates along the insertion steps. The method further comprises the step of making a pair of inner cores inserted into the cast mold.
The punching step further comprises the steps of forming an insertion projection on a surface of the electric steel plate and forming an insertion step on the insertion projection to form a concave between the insertion step and the surface.
The molten material is filled into the concave during the pouring step.
REFERENCES:
patent: 5003212 (1991-03-01), Ibe et al.
patent: 5704771 (1998-01-01), Fujisawa et al.
patent: 6077054 (2000-06-01), Lee et al.
patent: 6084320 (2000-07-01), Morita et al.
Cuda Rosenbaum I
Larson & Taylor PLC
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