U.S. patent application number 11/312536 was filed with the patent office on 2006-05-18 for drum type washing machine.
Invention is credited to Kang Mo Choi, Chi Wan Hur, Sang Man Je, Yu Beom Kang, Gon Kim, Jae Kyum Kim, Ho Cheol Kwon.
Application Number | 20060101866 11/312536 |
Document ID | / |
Family ID | 36314935 |
Filed Date | 2006-05-18 |
United States Patent
Application |
20060101866 |
Kind Code |
A1 |
Kim; Gon ; et al. |
May 18, 2006 |
Drum type washing machine
Abstract
Drum type washing machine including a tub of plastic having a
wall for holding washing water therein and mounting a driving part
thereon, a drum rotatably arranged inside of the tub, a shaft
passed through the tub and connected to the drum for transmission
of a driving power from a motor to the drum, at least one bearing
for supporting the shaft, a bearing housing having a sleeve form of
bearing supporting part, and a stator fastening part extended in a
radial direction from the bearing supporting part, wherein both of
the bearing supporting part and the stator fastening part are
inserted in a tub rear wall, while stator fastening holes in the
stator fastening part are exposed, a rotor engaged to a rear end
part of the shaft to form the motor together with the stator, and
the stator mounted on the stator fastening part of the bearing
housing with fastening members on an inner side of the rotor to
form the motor together with the rotor, wherein the stator includes
an annular helical type core having multiple layers formed by
winding a steel plate having tooth portions and a base part in a
helix starting from a bottom layer to a top layer, an insulator
having the helical type core encapsulated therein, a coil wound on
the tooth portions, and fastening parts formed as a unit with the
insulator, having fastening holes projected toward an inside of the
helical type core for fastening the stator to the bearing housing,
thereby reducing a weight of required material, simplifying an
assembly process, and assure stable mounting of the stator on the
tub.
Inventors: |
Kim; Gon; (Changwon-si,
KR) ; Hur; Chi Wan; (Changwon-si, KR) ; Kang;
Yu Beom; (Changwon-si, KR) ; Je; Sang Man;
(Koje-si, KR) ; Choi; Kang Mo; (Masan-si, KR)
; Kim; Jae Kyum; (Gimhae-si, KR) ; Kwon; Ho
Cheol; (Changwon-si, KR) |
Correspondence
Address: |
MCKENNA LONG & ALDRIDGE LLP
1900 K STREET, NW
WASHINGTON
DC
20006
US
|
Family ID: |
36314935 |
Appl. No.: |
11/312536 |
Filed: |
December 21, 2005 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
10730281 |
Dec 9, 2003 |
|
|
|
11312536 |
Dec 21, 2005 |
|
|
|
Current U.S.
Class: |
68/3R |
Current CPC
Class: |
D06F 37/304 20130101;
H02K 1/187 20130101; D06F 37/264 20130101; H02K 1/30 20130101; H02K
7/085 20130101; D06F 37/206 20130101; H02K 1/2786 20130101; D06F
37/262 20130101; H02K 1/148 20130101; D06F 37/269 20130101 |
Class at
Publication: |
068/003.00R |
International
Class: |
D06F 37/00 20060101
D06F037/00 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 10, 2002 |
KR |
10-2002-0078337 |
Dec 2, 2003 |
KR |
10-2003-0086841 |
Claims
1-40. (canceled)
41. A drum type washing machine comprising: a tub for holding
washing water therein; a motor secured to one side of the tub, the
motor having a stator and a rotor; and a bushing mounted to one end
of a shaft coupled to the rotor, the bushing configured for
preventing the shaft.
42. The drum type washing machine as claimed in claim 41, wherein
the bushing is formed of brass.
43. The drum type washing machine as claimed in claim 41, wherein a
sealing member is mounted to the other end of the shaft for
preventing infiltration of water.
44. The drum type washing machine as claimed in claim 43, wherein
the sealing member is positioned on an outside surface of the
bushing.
45. The drum type washing machine as claimed in claim 42, further
comprising: a bearing housing having a bearing support which has
bearings for supporting a shaft coupled to the motor and a stator
fastening part for securing the stator of the motor thereto.
46. The drum type washing machine as claimed in claim 45, wherein
the bearing support and the stator fastening part are formed as one
unit with the tub.
47. The drum type washing machine as claimed in claim 46, wherein
the bearing housing is formed with the tub by injection molding.
Description
[0001] This application claims the benefit of the Korean
Application Nos P2002-0078337 filed on Dec. 10, 2002, and
P2003-0086841 filed on Dec. 2, 2003, which are hereby incorporated
by references.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to drum type washing machines,
and more particularly, to an improved structure of a driving part
of a direct drive type drum type washing machine which employs an
outer rotor type brushless DC motor.
[0004] 2. Background of the Related Art
[0005] In general, a drum type washing washes laundry by using a
friction force between a drum rotated by a driving power of a motor
and the laundry in a state detergent, washing water, and the
laundry are introduced into the drum, shows almost no damage to,
and entangling of the laundry, and has pounding, and rubbing
washing effects.
[0006] In the related art drum type washing machines, there are an
indirect drive type in which the driving power of the motor is
transmitted to the drum through a belt wound on a motor pulley and
a drum pulley indirectly, and a direct drive type in which the
brushless DC (BLDC) motor is connected to the drum directly, to
transmit the driving power of the motor to the drum, directly.
[0007] The type in which the driving power of the motor is
transmitted to the drum, not directly, but indirectly through the
motor pulley and the drum pulley, has much energy loss in the
course of power transmission, and causes much noise in the course
of power transmission.
[0008] According to this, it is the present trend that use of the
direct drive type drum type washing machines with the BLDC motor is
increasing, for solving the problems of the indirect drive type
drum type washing machines. A related art direct drive type drum
type washing machine will be described with reference to FIG. 1,
briefly. FIG. 1 illustrates a longitudinal section of a related art
drum type washing machine.
[0009] Referring to FIG. 1, the related art drum type washing
machine is provided with a tub 2 mounted inside of a cabinet 1, and
a drum 3 rotatably mounted on a central part of an inside of the
tub 2. There is a motor in rear of the tub 2, wherein a stator 6 is
fixed to a rear wall of the tub, and a rotor 5 surrounds the stator
6, and is connected to the drum 3 with a shaft passed through the
tub.
[0010] Together with these, there is a metallic tub supporter
between a tub rear wall and the stator having a shape almost the
same with an outer shape of the tub rear wall fixed to the tub rear
wall in fastening the stator for supporting a load of the stator,
and maintaining a concentricity of the stator.
[0011] In the meantime, there are a door 21 mounted on a front part
of the cabinet 1, and a gasket 22 between the door 21 and the tub
2.
[0012] There are a hanging spring 23 between an inside surface of
an upper part of the cabinet 1, and an upper part of an outside
circumferential surface of the tub 2, and a friction damper 24
between the inside surface of a lower part of the cabinet 1, and a
lower part of the outside circumferential surface of the tub 2.
[0013] FIG. 2 illustrates a perspective outside view of the stator
in FIG. 1, and FIG. 3 illustrates a perspective view of a sectional
type core SC applied to the stator in FIG. 2.
[0014] In a related art method for fabricating the stator core, a
sheet of metal plate is pressed to form a unit core having tooth
portions 151, a base part 150, and a round part 500 opposite to the
tooth portions 151 for forming fastening hole 500a therein, the
unit cores are stacked to form a unit core assembly, and the unit
core assemblies are connected to each other in a circumferential
direction, to complete fabrication of the stator core, called the
sectional type core SC.
[0015] The round part provides the fastening hole 500a for fixing
the stator 6 to the rear wall of the tub, and enduring a fastening
force of a bolt.
[0016] However, the method for fabricating the stator 6 by means of
the sectional type cores SC has, not only a complicate fabrication
process, but also loss of much material.
[0017] Therefore, even if a helical type core HC is favorable, in
which a sheet of steel plate having the tooth portions 151 and the
base part 150 is'stacked turning in a helix, since it is required
to bend the sheet of metal punched out in a form of a band into the
helix, the helical type core has a drawback in that the round part
for fixing the stator to the tub can not be formed on an inner side
of the core.
[0018] This is because, if the round part 500 is formed on the
inner side of the core in fabrication of the helical core HC, a
large width of the core at a part having the round part formed
thereon impedes bending of the core.
[0019] Therefore, currently, a stator structure is required, in
which a function the same with the round part of the sectional type
core SC is made to be carried out, not by the core itself, but by
other part, for employing the helical type core HC.
[0020] For reference, a reason why it is important to secure an
adequate rigidity of the round part having the fastening hole
formed in for fixing the stator to the tub is as follows.
[0021] The washing machine that rotates the drum directly by using
the BLDC motor has the stator mounted on a rear part of the tub,
directly. In a case of the motor for a large capacity drum type
washing machine with more than 1.5 kg of stator net weight, and a
spinning speed in a range of 600.about.2000 RPM, it is liable that
a bolt fastened part of the stator 6 is broken due to the stator
weight, vibration in the high speed rotation, and shaking and
deformation of the rotor 5.
[0022] Particularly, in a case of the drum type washing machine, in
which the BLDC motor is used, and the stator 6 is fixed to the tub
rear wall, where an axis direction of the stator 6 is substantially
parallel to ground, the vibration generated in operation of the
washing machine causes intensive damage to the fastening part of
the stator 6 to the tub rear wall.
[0023] Thus, an adequate rigidity of the round part having the
fastening hole formed therein is very important in fixing the
stator 6 to the tub.
[0024] In the meantime, in a trend a capacity of the drum type
washing machine becomes larger as the time goes by, there have been
many problems, such as even the tub to which the stator is fastened
is damaged in a case the stator has a weight more than 1.5 kg in a
structure the axis of the stator is parallel to the ground like the
drum type washing machine.
[0025] Therefore, in order to prevent occurrence of the damage, in
the related art structure, in general a metal tub supporter is
lined, when a process for fastening the tub supporter to the tub
rear wall is required in addition to an assembly line, that drops a
productivity.
SUMMARY OF THE INVENTION
[0026] Accordingly, the present invention is directed to a drum
type washing machine that substantially obviates one or more of the
problems due to limitations and disadvantages of the related
art.
[0027] An object of the present invention is to provide a drum type
washing machine, which has an outer rotor type motor with a stator
of which material and weight required for fabrication can be
reduced, fabrication of which can be simplified, and secure
mounting of which on the tub is possible.
[0028] Other object of the present invention is to provide a drum
type washing machine, in which a tub can sustain weight and
vibration of a BLDC motor for a washing machine mounted on a tub
wall directly, which motor has a net stator weight more than 1.5
kg, and variable rotational speed of 0.about.2000 RPM or over.
[0029] Another object of the present invention is to provide a drum
type washing machine, which can dispense with a tub supporter
fastening process from an assembly line, that can secure a
supporting force of the tub rear wall to the stator, and simplifies
an assembly process.
[0030] Further object of the present invention is to provide a drum
type washing machine, which enables a service man to carry out
maintenance in repair and replacement of components.
[0031] Additional features and advantages of the invention will be
set forth in the description which follows, and in part will be
apparent to those having ordinary skill in the art upon examination
of the following or may be learned from practice of the invention.
The objectives and other advantages of the invention will be
realized and attained by the structure particularly pointed out in
the written description and claims hereof as well as the appended
drawings.
[0032] To achieve these objects and other advantages and in
accordance with the purpose of the present invention, as embodied
and broadly described herein, the drum type washing machine
includes a tub of plastic having a wall for holding washing water
therein and mounting a driving part thereon, a drum rotatably
arranged inside of the tub, a shaft passed through the tub and
connected to the drum for transmission of a driving power from a
motor to the drum, at least one bearing for supporting the shaft, a
bearing housing having a sleeve form of bearing supporting part,
and a stator fastening part extended in a radial direction from the
bearing supporting part, wherein both of the bearing supporting
part and the stator fastening part are inserted in a tub rear wall,
while stator fastening holes in the stator fastening part are
exposed, a rotor engaged to a rear end part of the shaft to form
the motor together with the stator, and the stator mounted on the
stator fastening part of the bearing housing with fastening members
on an inner side of the rotor to form the motor together with the
rotor, wherein the stator includes an annular helical type core
having multiple layers formed by winding a steel plate having tooth
portions and a base part in a helix starting from a bottom layer to
a top layer, an insulator having the helical type core encapsulated
therein, a coil wound on the tooth portions, and fastening parts
formed as a unit with the insulator, having fastening holes
projected toward an inside of the helical type core for fastening
the stator to the bearing housing.
[0033] In other aspect of the present invention, there is provided
a drum type washing machine including a tub of plastic having a
wall for holding washing water therein and mounting a driving part
thereon, a drum rotatably arranged inside of the tub, a shaft
passed through the tub and connected to the drum for transmission
of a driving power from a motor to the drum, at least one bearing
for supporting the shaft, a bearing housing having a sleeve form of
bearing supporting part, and a stator fastening part extended in a
radial direction from the bearing supporting part, wherein both of
the bearing supporting part and the stator fastening part are
inserted in a tub rear wall, while stator fastening holes in the
stator fastening part are exposed, a rotor engaged to a rear end
part of the shaft to form the motor together with the stator, and
the stator mounted on the stator fastening part of the bearing
housing with fastening members on an inner side of the rotor to
form the motor together with the rotor, wherein the stator includes
an annular helical type core having multiple layers formed by
winding a steel plate having tooth portions and a base part in a
helix starting from a bottom layer to a top layer, an insulator
having the helical type core encapsulated therein, a coil wound on
the tooth portions, and fastening parts formed as a unit with the
insulator, having three or more than three fastening holes
projected toward an inside of the helical type core for fastening
the stator to the bearing housing.
[0034] In another aspect of the present invention, there is
provided a drum type washing machine including a tub of a plastic
having a wall for holding washing water therein and mounting a
driving part thereon a drum rotatably arranged inside of the tub, a
shaft passed through the tub and connected to the drum for
transmission of a driving power from a motor to the drum, at least
one bearing for supporting the shaft, a bearing housing having a
sleeve form of bearing supporting part inserted in the tub rear
wall, and a stator fastening part formed as a unit with the bearing
supporting part extended from the bearing supporting part exposed
to an outside of the tub, with stator fastening holes formed in an
exposed part of the stator fastening part, a rotor engaged to a
rear end part of the shaft to form the motor together with the
stator, and the stator mounted on the stator fastening part of the
bearing housing with fastening members on an inner side of the
rotor to form the motor together with the rotor, wherein the stator
includes an annular helical type core having multiple layers formed
by winding a steel plate having tooth portions and a base part in a
helix starting from a bottom layer to a top layer, an insulator
having the helical type core encapsulated therein, a coil wound on
the tooth portions, and fastening parts formed as a unit with the
insulator, having fastening holes projected toward an inside of the
helical type core for fastening the stator to the bearing
housing.
[0035] In further object of the present invention, there is
provided a drum type washing machine including a tub of a plastic
having a wall for holding washing water therein and mounting a
driving part thereon, a drum rotatably arranged inside of the tub,
a shaft passed through the tub and connected to the drum for
transmission of a driving power from a motor to the drum, at least
one bearing for supporting the shaft, a bearing housing having a
sleeve form of bearing supporting part inserted in the tub rear
wall, and a stator fastening part formed as a unit with the bearing
supporting part extended in a radial direction from the bearing
supporting part exposed to an outside of the tub, with stator
fastening holes formed in an exposed part of the stator fastening
part, a rotor engaged to a rear end part of the shaft to form the
motor together with the stator, and the stator mounted on the
stator fastening part of the bearing housing with fastening members
on an inner side of the rotor to form the motor together with the
rotor, wherein the stator includes an annular helical type core
having multiple layers formed by winding a steel plate having tooth
portions and a base part in a helix starting from a bottom layer to
a top layer, an insulator having the helical type core encapsulated
therein, a coil wound on the tooth portions, and fastening parts
formed as a unit with the insulator, having three or more than
three fastening holes projected toward an inside of the helical
type core for fastening the stator to the bearing housing.
[0036] In still further object of the present invention, there is
provided a drum type washing machine including a tub of plastic
having a wall for holding washing water therein and mounting a
driving part thereon, a drum rotatably arranged inside of the tub,
a shaft passed through the tub and connected to the drum for
transmission of a driving power from a motor to the drum, at least
one bearing for supporting the shaft, a bearing housing having a
sleeve form of bearing supporting part, and a stator fastening part
extended in a radial direction from the bearing supporting part,
wherein both of the bearing supporting part and the stator
fastening part are inserted in a tub rear wall, while stator
fastening holes in the stator fastening part are exposed, a rotor
engaged to a rear end part of the shaft to form the motor together
with the stator, and the stator mounted on the stator fastening
part of the bearing housing with fastening members on an inner side
of the rotor to form the motor together with the rotor.
[0037] In yet further aspect of the present invention, there is
provided a drum type washing machine including a tub of plastic
having a wall for holding washing water therein and mounting a
driving part thereon, a drum rotatably arranged inside of the tub,
a shaft passed through the tub and connected to the drum for
transmission of a driving power from a motor to the drum, at least
one bearing for supporting the shaft, a bearing housing having a
sleeve form of bearing supporting part inserted in the tub rear
wall, and a stator fastening part formed as a unit with the bearing
supporting part extended in a radial direction from the bearing
supporting part exposed to an outside of the tub, with stator
fastening holes formed in an exposed part, a rotor engaged to a
rear end part of the shaft to form the motor together with the
stator; and the stator with a weight heavier than 1.5 kg mounted on
the stator fastening part of the bearing housing with fastening
members on an inner side of the rotor to form the motor together
with the rotor.
[0038] In still yet further aspect of the present invention, there
is provided a drum type washing machine including a tub having a
wall for holding washing water therein and mounting a driving part
thereon, and a sleeve form of bearing supporting part for
supporting bearings, in which both the tub and the bearing
supporting part are formed as one unit, a drum rotatably arranged
inside of the tub, a shaft passed through the tub and connected to
the drum for transmission of a driving power from a motor to the
drum, at least one bearing inside of the bearing supporting part
for supporting the shaft, a rotor engaged to a rear end part of the
shaft to form the motor together with the stator, and the stator
mounted on the tub on an inner side of the rotor and an outer side
of the bearing supporting part with fastening members, wherein the
stator includes an annular helical type core having multiple layers
formed by winding a steel plate having tooth portions and base part
in a helix starting from a bottom layer to a top layer, an
insulator having the helical type core encapsulated therein, a coil
wound on the tooth portions, and fastening parts formed as a unit
with the insulator, having fastening holes projected toward an
inside of the helical type core for fastening the stator to the
bearing housing.
[0039] It is to be understood that both the foregoing description
and the following detailed description of the present invention are
exemplary and explanatory and are intended to provide further
explanation of the invention claimed.
BRIEF DESCRITPION OF THE DRAWINGS
[0040] The accompanying drawings, which are included to provide a
further understanding of the invention and are incorporated in and
constitute a part of this application, illustrate embodiment(s) of
the invention and together with the description serve to explain
the principle of the invention. In the drawings;
[0041] FIG. 1 illustrates a longitudinal section of a related art
direct drive, drum type washing machine, schematically;
[0042] FIG. 2 illustrates a perspective view of a related art
stator;
[0043] FIG. 3 illustrates a perspective view of a sectional type
core;
[0044] FIG. 4 illustrates a longitudinal section of a direct drive,
drum type washing machine in accordance with a preferred embodiment
of the present invention, schematically;
[0045] FIG. 5 illustrates an enlarged longitudinal sectional view
of an `A` part in FIG. 4 of the drum type washing machine of the
present invention;
[0046] FIG. 6 illustrates a cut away perspective view of a tub rear
wall;
[0047] FIG. 7 illustrates a perspective view of the unitary bracket
and bearing housing in FIG. 5;
[0048] FIG. 8 illustrates a backside perspective view of FIG.
7;
[0049] FIG. 9 illustrates a section across a line I-I in FIG.
7;
[0050] FIG. 10 illustrates a perspective view of the stator in FIG.
5;
[0051] FIG. 11 illustrates a perspective view of the helical type
core in FIG. 10;
[0052] FIG. 12A illustrates a plan view of key parts of the stator
in FIG. 10, and FIG. 12B illustrates a perspective view of key
parts of the stator in FIG. 10;
[0053] FIG. 13 illustrates a perspective view of a stator in a
driving part of a drum type washing machine in accordance with
another preferred embodiment of the present invention; and
[0054] FIG. 14 illustrates a longitudinal section of a drum type
washing machine in accordance with another preferred embodiment of
the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0055] Reference will now be made in detail to the preferred
embodiments of the present invention, examples of which are
illustrated in the accompanying drawings FIGS. 4.about.14.
[0056] FIG. 4 illustrates a longitudinal section of a direct drive,
drum type washing machine in accordance with a preferred embodiment
of the present invention schematically, and FIG. 5 illustrates an
enlarged longitudinal sectional view of an `A` part in FIG. 4 of
the drum type washing machine of the present invention.
[0057] FIG. 6 illustrates a cut away perspective view of a tub rear
wall, FIG. 7 illustrates a perspective view of the unitary bracket
and bearing housing in FIG. 5, FIG. 8 illustrates a backside
perspective view of FIG. 7, and FIG. 9 illustrates a section across
a line I-I in FIG. 7.
[0058] FIG. 10 illustrates a perspective view of the stator in FIG.
5, FIG. 11 illustrates a perspective view of the helical type core
in FIG. 10, FIG. 12A illustrates a plan view of key parts of the
stator in FIG. 10, and FIG. 12B illustrates a perspective view of
key parts of the stator in FIG. 10.
[0059] The drum type washing machine of the present invention,
having a tub 2 inside of a cabinet 1 for holding washing water,
with a wall for fixing a driving part thereto, a drum 3 inside of
the tub 2, a shaft 4 connected to the drum 3 with a shaft for
transmission of a driving power from a motor to the drum 3, and a
bearing for supporting the shaft 4, wherein the tub 2 is formed of
a plastic, and includes a metal bearing housing 7 at a central part
of a rear wall of the tub 2 both for supporting the bearings at
both ends of an outside circumferential surface of the shaft 4 and
fastening the stator 6.
[0060] The bearing housing 7 is formed of an aluminum alloy and the
like, and integrated with the tub rear wall by inserting the
bearing housing 7 in a mold in an injection molding of the tub 2 of
plastic.
[0061] In the meantime, referring to FIG. 5, the bearing housing 7
includes a bearing supporting part 7a of a sleeve form for
supporting the bearings, a stator fastening part 7b formed as a
unit with the bearing supporting part 7a extended form a rear end
of the bearing supporting part 7a in a radial direction, and stator
fastening holes 700b in the stator fastening part 7b, wherein both
the bearing supporting part 7a and the stator fastening part 7b are
inserted in the tub 2 rear wall, when only the stator fastening
holes 700b are exposed.
[0062] Referring to FIGS. 7 and 8, the stator fastening part 7b,
extended from the sleeve form of bearing supporting part 7a in the
radial direction outwardly, includes stepped areas 70b-1 each
having at least one step in the outward extension in a direction of
the outward extension, and flat areas 70b-2 each between adjacent
stepped areas 70b-1, wherein the stepped areas 70b-1 and the flat
areas 70b-2 are connected to each other, respectively.
[0063] That is, the stator fastening part 7b includes the stepped
areas 70b-1 each having steps as the stepped area 70b-1 extends in
an outward radial direction, and flat areas 70b-2 between the
stepped areas 70b-1, wherein each of the areas 70b-1 extended from
an upper end of the bearing supporting part 7a in the outward
radial direction is bent down at preset intervals as the stepped
area 70b-1 extends in the outward radial direction, and each of the
areas 70b-2 connected to a lower end of the bearing housing 7 is
flat.
[0064] There is a resin stuffing groove 750a around the upper part
of the bearing housing 7 for enhancing a bonding force with the tub
2 in the insert injection molding.
[0065] Referring to FIGS. 6 and 7, there is a positioning hole 710b
formed adjacent to a stator fastening hole 700b of the stator
fastening part 7b in correspondence to a positioning projection on
the stator 6.
[0066] Referring to FIG. 6, there is a boss 200 at a part of the
tub rear wall opposite to each of the stator fastening holes 700b
for preventing the stator fastening part 7b from coming into direct
contact with the stator 6, thereby preventing an insulator of the
stator 6 from being broken due to a fastening force applied thereto
in mounting the stator 6.
[0067] It is also preferable that the stator fastening part 7b has
a circumferential rib 720b at a position spaced a distance from an
axis of the bearing supporting part 7a for increasing a bonding
force with the plastic in the injection molding of the tub 2.
Though it is preferable that there are fastening bosses 70b each
with a stator fastening hole 700b on the rib 720, it is not
necessarily required to form the fastening holes 700b on the rib
720b.
[0068] In addition to this, there are circumferential and radial
reinforcing ribs 201 on a region excluding the bearing housing
stepped area of the tub rear wall for reinforcing the tub rear
wall.
[0069] In the meantime, different from the foregoing stator
fastening part 7b, the stator fastening part 7b may be an extension
from the sleeve form of the bearing supporting part 7a the same
with the foregoing stator fastening part 7b, but separated at
regular intervals in a circumferential direction to form a
plurality of separated radial segments.
[0070] Referring to FIGS. 5 and 6, the bearing housing 7 of metal
has a step 8a in an inside circumferential surface for supporting,
and preventing the bearings 600a on the inside circumferential
surface from breaking away from the bearing housing 7.
[0071] A front part of the shaft 4 is fixed to a spider 10 in a
rear wall of the drum 3, and a section of the shaft 4 from an
exposed part in rear of the spider 10 to a front bearing 600a has a
brass bushing 11 press fit thereon for preventing the shaft 4 from
rusting, with a sealing member 12 fitted on an outside surface of
the bushing 11 for preventing infiltration of water toward the
bearing.
[0072] The shaft 4 has the rotor 5 of the direct drive motor
mounted at a center of rear end thereof, on an inner side of which
the stator 14 is positioned, that is mounted on the tub rear wall
to form the direct drive motor together with the rotor 5.
[0073] Referring to FIG. 5, the rotor 5, formed of steel plate, has
a circumferential bent part with a seating surface 130 for seating
magnets M placed on an inside surface of a side wall 13b extended
forward from an edge of a rear wall of the rotor 5, and a hub 132
in a center part of the rear wall 13a having through holes for
passing fastening members 15a, such as bolts, in mounting the rotor
5 on the shaft 4.
[0074] It is preferable that the rotor 5 is formed by pressing.
[0075] The rotor 5 has a plurality of radial cooling fins 133
around the hub 132 for blowing air toward the stator 6 when the
rotor 5 rotates, to cool down heat from the stator 6. Each of the
cooling fins 133 has a length in the radial direction.
[0076] The cooling fin 133 is formed by lancing to be bent at
90.degree. from the rear wall to direct an opened side of the rotor
5, and a through hole 134 formed in the lancing serves as an air
hole.
[0077] The rotor 5 has embossing 135 between adjacent cooling fins
133 of the rear wall 13a for reinforcing the rotor 5, and drain
holes 136 in the embossing 135.
[0078] The rotor 5 has fastening holes 137 for fastening a
connector 16 engaged with a rear end part of the shaft 4 in rear of
a rear bearing 600b by means of serration, and positioning holes
138 for positioning the connector in mounting the connector on the
shaft 4, both of which fastening holes 137 and positioning holes
138 are formed around the through hole 131 in the hub 132 at
regular intervals.
[0079] The connector 16 is formed of plastic having a vibration
mode different from the rotor 5 of steel plate, and serves as a
bushing for the rotor, too. The connector 16 has serration 164 fit
to the serration 400 in the rear end part of the shaft 4.
[0080] The tub rear wall has a hub part for putting the bearing
supporting part 7a of the bearing housing 7 therein in the
injection molding of the tub 2.
[0081] According to this, the present invention permits to dispense
with the tub supporter which is essential in the related art, to
reduce assembly man power in an assembly line, and improve a
productivity.
[0082] That is, the present invention permits to dispense with the
tub supporter, which is a separate part having an almost same
outside shape with the tub rear wall, fixed to, and holds the tub
rear wall in mounting the stator 6, and maintains a concentricity
of the stator 6.
[0083] Referring to FIG. 10, the stator 6 includes a helical type
core HC, an insulator 144 having the helical type core HC
encapsulated therein, a coil wound around tooth portions 151 of the
helical type core HC, and fastening parts 143 molded as a unit with
the insulator 144 projected toward an inside of the helical type
core HC from three, or more than three places, and in general
weighs more than 1.5 kg as the capacity of the drum type washing
machine becomes larger.
[0084] The helical type core HC has multiple layers formed by
winding a steel plate having the tooth portions and the base part
in a helix starting from a bottom layer to a top layer, with the
tooth portions 151 projected outwardly in a radial direction from
the base part. The base part 150 has recesses 152 for reducing
stress in the winding of the helical type core.
[0085] The multiple layers of the helical type core HC are fastened
with rivets 153 passed through through holes in the base part 150.
A starting part and an end part of the helical type core HC may be
welded at the base parts 150 in contact thereto. The recess 152 in
the base part 150 may be rectangular, trapezoidal, or an arc.
[0086] Referring to FIGS. 12A and 12B, in the stator 6 having three
or more than three fastening parts 143 formed as a unit with the
insulator so as to be projected in a radial direction toward inside
from the inside circumferential surface of the helical type core,
each of the fastening parts 143 is formed to meet a condition of
a.gtoreq.b, where "a" denotes a length of the tooth portion 151
from an outer edge of the base part 150, and "b" denotes a distance
from an inner edge of the base part 150 to a center of the
fastening hole 143a.
[0087] The fastening part 143 has a height greater than 20% of a
total core stack height, and preferably equal to the total core
stack height.
[0088] The fastening part 143 has at least one cavity 143c for
damping vibration at the time of motor driving, and a positioning
pin 143b fit to the positioning hole 710b in the stator fastening
part exposed in a state inserted in the tub rear wall.
[0089] In the meantime, there is a metal tube 143p or a spring pin
forcibly inserted in the fastening hole 143a of the fastening part
143.
[0090] The operation of the driving part of the drum type washing
machine of the present invention will be described.
[0091] Under the control of a controller (not shown) attached to a
panel for driving the motor, if current flows to the coils 142 in
the stator 6 in succession, to rotate the rotor 5, the shaft 4
engaged with the connector 16 having the rotor 5 fixed thereto by
means of serration rotates. According to this, the power is
transmitted to the drum 3 through the shaft 4, to rotate the drum
3.
[0092] In the meantime, performance of the foregoing drum type
washing machine will be described.
[0093] At first, since the tub 2 is formed of a heat resistant
plastic, the tub 2 is light, and since the tub 2 is injection
molded, the tub 2 is easy to fabricate.
[0094] Since the bearing housing 7 is formed of a metal, such as an
aluminum alloy, which shows little thermal deformation even at a
high temperature, the bearing housing 7 can be used in the drum
type washing machine having the spinning cycle.
[0095] Since the bearing housing 7 of metal is inserted in the hub
of the tub rear wall at the time of injection molding of the tub 2
of plastic, to form an integrated type tub 2 and bearing housing 7,
that permits to dispense with the additional process of mounting
the bearing housing 7 on the tub rear wall, thereby simplifying the
assembly process, and reduce an assembly man power.
[0096] Referring to FIG. 11, the recess 152 in the base part 150 of
the stator 6 reduces a stress in winding the core, thereby
permitting an easy and small power winding.
[0097] Especially, referring to FIG. 12A, in the stator 6 having
three or more than three fastening parts 143 formed as a unit with
the insulator so as to be projected in a radial direction toward
inside from the inside circumferential surface of the helical type
core, each of the fastening parts 143 is formed to meet a condition
of a.gtoreq.b, where "a" denotes a length of the tooth portion 151
from an outer edge of the base part 150, and "b" denotes a distance
from an inner edge of the base part 150 to a center of the
fastening hole 143a.
[0098] The condition is set taking a case into account, in which,
even though the closer the position of the fastening hole 143a to a
point a load exerts thereon, the better in view of reduction of a
torque, the position of the fastening hole 143a set at a position
close excessively to the point a load exerts thereon leads to a
bolt of smaller diameter, to require an excessively many number of
bolts.
[0099] Referring to FIG. 12B, the fastening part 143 has a height
greater than 20% of a total core stack height, otherwise the
fastening part 143 is liable to break due to vibration caused by
motor driving. Especially, the fastening par 143 may have a height
equal to or higher than the total core stack height.
[0100] However, because an excessively high fastening part 143
increases a total width of the driving part, and reduces a washing
capacity of the washing machine, the height of the fastening part
143 is limited not to exceed two times of the total core stack
height.
[0101] The cavity 143c in the fastening part 143 dampens vibration
at the time of motor driving, to improve mechanical reliability of
the stator 6.
[0102] The positioning pin 143b on the fastening part 143 fits to
the positioning hole 710b in the tub 2, thereby permitting an easy
mounting of the stator 6 on the tub 2.
[0103] The sleeve form of bearing supporting part 7a for supporting
bearings fitted therein, and the stator fastening part 7b for
fastening the stator 6 thereto, of the bearing housing 7, both of
which are formed as a unit, can dispense with the related art tub
supporter.
[0104] The boss 200 at a part of the tub rear wall opposite to each
of the stator fastening holes 700b prevents the stator fastening
part 7b from coming into direct contact with the stator 6, thereby
preventing the insulator of the stator 6 from being broken due to a
fastening force applied thereto in mounting the stator 6.
[0105] The stepped areas 70b-1 each having steps at preset
intervals as the stepped area 70b-1 extends in an outward radial
direction of the cylindrical bearing supporting part 7a, and the
flat areas 70b-2 between adjacent stepped areas 70b-1 and connected
to the stepped areas 70b-1 in a circumferential direction with flat
parts perpendicular thereto permit to increase bonding force to the
tub 2 in the injection molding of the tub 2.
[0106] In addition to this, the circumferential rib 720b at a
position spaced a distance from an axis of the bearing supporting
part 7a also increases a bonding force with the plastic in the
injection molding of the tub 2.
[0107] Moreover, the through holes 730b in the stator fastening
part 7b increases the bonding force with the plastic in the insert
injecting molding of the bearing housing 7.
[0108] The fastening boss 70b with the stator fastening hole 700b
in the bearing housing 7 can dispense with formation of fastening
holes in the tub 2, additionally.
[0109] That is, according to the present invention, the stator 6 is
fastened to the stator fastening holes 700b in the fastening boss
70b of the stator fastening part 7b buried in the tub rear wall
with bolts.
[0110] The positioning hole 710b formed adjacent to the stator
fastening hole 700b of the stator fastening part 7b in
correspondence to a positioning projection on the insulator of the
stator 6 improves workability in mounting the stator 6 on the tub
rear wall.
[0111] Of course, the positioning hole 710b in the stator fastening
part 7b is formed, not covered with plastic, but exposed, and in a
case the positioning hole is formed in the insulator, the
positioning projection will be formed on the stator fastening part
7b.
[0112] Since the front end of the shaft 4 is fixed to the spider 10
in the rear wall of the drum 3, and a section of the shaft 4 from a
part exposed to an outside of the spider 10 to the front bearing
600a has the brass busing 11 forcibly press fit thereon, rusting of
the shaft 4 is prevented.
[0113] The sealing member 12 on the outside surface of the bushing
11 prevents infiltration of water toward the bearing.
[0114] The circumferential bent part with a seating surface 130 for
seating magnets M placed on an inside surface of a side wall 13b
extended forward from an edge of a rear wall of the rotor 5 permits
an easy fabrication of the rotor since the seating surface 130
supports the magnet M easily when the magnet M is attached to the
inside surface of the rotor 5.
[0115] The hub 132 in a center part of the rear wall 13a having
through holes 131 permits to pass fastening members 15a, such as
bolts, in mounting the rotor 5 on the shaft 4, and the plurality of
radial cooling fins 133 each with a length permits blowing of air
toward the stator 6 to cool heat from the stator 6 when the rotor 5
rotates.
[0116] The cooling fin 133 is formed by lancing to direct an opened
side of the rotor 5, and a through hole 134 formed in the lancing
serves as an air hole.
[0117] The rotor 5 formed of steel plate by pressing reduces a time
period required for fabrication of the rotor 5, and improves
productivity.
[0118] The embossing 135 between adjacent cooling fins 133 on the
rear wall 13a of the rotor 5 improves an overall strength of the
rotor 5, and the drain hole 136 in the embossing 135 permits to
discharge water through the drain hole 136.
[0119] The connector 16, formed by a plastic injecting molding, has
a vibration mode different from a vibration mode of the rotor 5 of
steel plate, to attenuate vibration transmitted from the rotor 5 to
the shaft 4.
[0120] The serration 164 in the inside circumferential surface of
the hub of the connector 16 engaged with the serration 400 in the
rear end part of the shaft 4 enables transmission of a rotation
power from the rotor 5 to the shaft 4 through the connector 16 as
it is.
[0121] FIG. 13 illustrates a perspective view of a stator in a
driving part of a drum type washing machine in accordance with
another preferred embodiment of the present invention.
[0122] Referring to FIG. 13, the stator 6 of the present invention
includes a helical type core HC, an insulator 144 having the
helical type core HC encapsulated therein, a coil wound on tooth
portions 151 of the helical core HC, and fastening parts 143 formed
as a unit with the insulator 144 so as to be projected toward an
inside of the helical type core HC.
[0123] That is, the stator 6 in the embodiment has, not a structure
in which the fastening parts are projected in a radial direction
toward an inside of the helical type core HC from more than three
positions, but a structure in which the fastening parts form a unit
with the insulator 144 extended in a radial direction toward an
inside of the helical type core HC.
[0124] Alike the foregoing embodiment, the helical type core HC has
multiple layers formed by winding a steel plate in a helix starting
from a bottom layer to a top layer, with a plurality of tooth
portions 151 projected outwardly in a radial direction from a base
part 150 of the helical type core HC, and recesses 152 in the base
part 150 for reducing a stress in winding the helical type core
HC.
[0125] There is a positioning hole 143g adjacent to the fastening
hole 143a in the fastening part 143, if there is a positioning pin
on the tub rear wall, for fitting in mounting the stator. Opposite
to this, of course, the positioning pin may be formed adjacent to
the fastening hole 143a, and the positioning hole may be formed in
the tub rear wall.
[0126] Other parts and performances thereof of the embodiment are
the same with the foregoing embodiment, of which repetitive
descriptions are omitted.
[0127] In the meantime, the present invention is not limited to
above embodiments, it is of course possible that dimensions,
shapes, and materials may be changed as far as the changes do not
depart from the spirit or scope of the invention.
[0128] For an example, the stator fastening part 7b may only have
an outward radial direction extension from the cylindrical bearing
supporting part 7a with stepped areas 70b-1 at preset intervals
along a radial direction. Or, alternatively, the stator fastening
part 7b may have alternate outward radial direction extensions from
front part and rear part of the cylindrical bearing supporting part
7a in a circumferential direction connected at edges of the
extensions substantially perpendicular to the extensions, without
the stepped areas.
[0129] FIG. 14 illustrates a longitudinal section of a drum type
washing machine in accordance with another preferred embodiment of
the present invention.
[0130] Referring to FIG. 14, the drum type washing machine includes
a tub 2 having a wall for holding washing water therein and
mounting a driving part thereon, and a sleeve form of bearing
supporting part 17 for supporting bearings, in which both the tub 2
and the bearing supporting part 17 are formed as one unit, a drum 3
rotatably arranged inside of the tub 2, a shaft 4 passed through
the tub 2 and connected to the drum 3 for transmission of a driving
power from a motor to the drum, at least one bearing 600a inside of
the bearing supporting part 17 for supporting the shaft 4, a rotor
5 engaged to a rear end part of the shaft 4 to form the motor
together with the stator 6, and the stator 6 mounted on the tub 2
on an inner side of the rotor 5 and an outer side of the bearing
supporting part 17 with fastening members. The stator 6 includes an
annular helical type core HC having multiple layers formed by
winding a steel plate having tooth portions 151 and base part in a
helix starting from a bottom layer to a top layer, an insulator
having the helical type core HC encapsulated therein, a coil wound
on the tooth portions 151, and fastening parts formed as a unit
with the insulator 144, having fastening holes projected toward an
inside of the helical type core HC for fastening to the bearing
supporting part 17.
[0131] Of course, there are a plurality of fastening holes in an
outer region of the bearing supporting part 17 of the tub 2 for
mounting the stator 6 of motor with fastening members. There is a
metal tube 143p or a spring pin forcibly inserted in the fastening
hole 143a of the fastening part 143.
[0132] Both the tub 2 and the bearing supporting part 17 may be
formed by plastic injection molding, or the tub 2 may be formed of
plastic, and the bearing supporting part 17 may be formed of a
metal, such as an aluminum alloy.
[0133] More preferably, in the plastic injection molding of the tub
2, the tub 2 is injection molded in a state a tub supporting plate
18 of a metal formed as a separate piece from the bearing
supporting part is buried in an outer region of the bearing
supporting part 17.
[0134] Other parts not described herein are the same with the
foregoing embodiment, and repetitive description of which will be
omitted.
[0135] The performance of the embodiment will be described.
[0136] When a current flows to the stator 6, to rotate the rotor 5,
the shaft 4 connected to the rotor 5 rotates. The shaft 4 rotates
supported on a front bearing 600a and a rear bearing 600b inside of
the bearing supporting part 17.
[0137] That is, a load on the shaft 4 is transmitted to the front,
and rear bearings 600a, and 600b, and, therefrom, to the bearing
supporting part 17. Since the bearing supporting part 17 is formed
as a unit with the tub rear part, the bearing supporting part 17
can support the shaft 4, more stably.
[0138] The tub supporting plate 18 of a metal formed as a separate
piece from the bearing supporting part, and buried in an outer
region of the bearing supporting part 17 in the injection molding
of the tub 2 permits to dispense with a separate reinforcing liner
attached to the tub rear wall, enough to secure a supporting force
for the stator 6 mounted on the tub rear wall even if the BLDC
motor is mounted on the tub wall directly.
[0139] It will be apparent to those skilled in the art that various
modifications and variations can be made in the present invention
without departing from the spirit or scope of the invention. Thus,
it is intended that the present invention cover the modifications
and variations of this invention provided they come within the
scope of the appended claims and their equivalents.
[0140] The drum type washing machine of the present invention has
the following advantages.
[0141] First, the direct drive type motor reduces noise, out of
order, and power loss, and the bearing housing of a metal can be
applied to a product with a drying function, as the bearing housing
has no thermal deformation.
[0142] Second, the rotor 5 of a steel plate formed by pressing
reduces a fabrication time period, and improves a productivity.
[0143] Third, the helical type core permits to reduce waste of
material, easy fabrication, and increase a rigidity of the
fastening part of the stator 6 to reduce noise and vibration, and
improve mechanical reliability, and a lifetime.
[0144] Fourth, the difference of vibration modes of the rotor and
the connector permits to reduce vibration transmitted from the
rotor to the shaft, and the stator fastening part 7b permits rigid
mounting of the stator 6 on the tub rear wall, and maintenance of
concentricity of the stator 6, without damage of the tub rear
wall.
[0145] Fifth, the elimination of tub supporter fitting work from
the assembly line permits to simplify an assembly process, and easy
maintenance by a serviceman in repair and replacement of
component.
[0146] Sixth, even if the BLDC motor with a net stator weight over
1.5 kg, and a rotation speed varied in a range of 0.about.2000 RPM,
or over is mounted on the tub wall directly, the tub rear wall can
support the stator, securely.
* * * * *