U.S. patent application number 11/601851 was filed with the patent office on 2007-06-07 for washing machine.
Invention is credited to Soung Bong Choi, Young Soo Kim.
Application Number | 20070125135 11/601851 |
Document ID | / |
Family ID | 38117379 |
Filed Date | 2007-06-07 |
United States Patent
Application |
20070125135 |
Kind Code |
A1 |
Kim; Young Soo ; et
al. |
June 7, 2007 |
Washing machine
Abstract
A washing machine, more particularly, an improvement in the
structure of a drive unit included in a drum type washing machine
is disclosed. The washing machine includes a tub for receiving wash
water therein, a drum rotatably disposed in the tub and adapted to
wash laundry received therein, a shaft penetrated through the tub
to thereby be connected to the drum, the shaft being adapted to
transmit a drive force of a motor to the drum, a stator coupled
fixedly to a rear wall portion of the tub, and a rotor including at
least one magnet, a back yoke defining a magnetic path, and a rotor
frame rotatably disposed at the outside of the stator, the rotor
frame being connected to the shaft so as to transmit a rotating
force of the rotor to the shaft. The rotor frame includes a side
wall portion and a rear wall portion, and is made of an aluminum
material.
Inventors: |
Kim; Young Soo;
(Changwon-si, KR) ; Choi; Soung Bong;
(Changwon-si, KR) |
Correspondence
Address: |
KED & ASSOCIATES, LLP
P.O. Box 221200
Chantilly
VA
20153-1200
US
|
Family ID: |
38117379 |
Appl. No.: |
11/601851 |
Filed: |
November 20, 2006 |
Current U.S.
Class: |
68/140 |
Current CPC
Class: |
D06F 37/304
20130101 |
Class at
Publication: |
068/140 |
International
Class: |
D06F 23/00 20060101
D06F023/00 |
Foreign Application Data
Date |
Code |
Application Number |
Nov 21, 2005 |
KR |
10-2005-011504 |
Nov 21, 2005 |
KR |
10-2005-011505 |
Nov 21, 2005 |
KR |
10-2005-011506 |
Nov 21, 2005 |
KR |
10-2005-011507 |
Claims
1. A washing machine comprising: a tub for receiving wash water
therein; a drum rotatably disposed in the tub and adapted to wash
laundry received therein; a shaft penetrated through the tub to
thereby be connected to the drum, the shaft being adapted to
transmit a drive force of a motor to the drum; a stator coupled
fixedly to a rear wall portion of the tub; and a rotor including at
least one magnet, a back yoke defining a magnetic path, and a rotor
frame rotatably disposed at the outside of the stator, the rotor
frame being connected to the shaft so as to transmit a rotating
force of the rotor to the shaft, wherein the rotor frame comprises
a side wall portion and a rear wall portion, and is made of an
aluminum material.
2. The washing machine according to claim 1, wherein the rotor
frame is formed by die casting, and the side wall portion and the
rear wall portion of the rotor frame are integrally formed with
each other.
3. The washing machine according to claim 2, wherein the rear wall
portion of the rotor frame is provided, at a center position
thereof, with a connector, which is serration-coupled onto an outer
circumference of the shaft and adapted to transmit the rotating
force of the rotor to the shaft.
4. The washing machine according to claim 3, wherein the connector
is made of an insulating material and integrally formed with the
rotor frame by insert molding.
5. The washing machine according to claim 2, further comprising: a
bearing housing provided between the rear wall portion of the tub
and the stator and coupled fixedly to both the tub and the stator,
the bearing housing receiving at least one bearing therein to
rotatably support the shaft.
6. The washing machine according to claim 5, wherein the bearing
housing is made of a metallic material.
7. The washing machine according to claim 2, wherein the side wall
portion of the rotor frame is extended forward from an edge of the
rear wall portion, and the side wall portion of the rotor frame is
formed, in a circumferential direction thereof, with a ledge having
a seating plane for supporting the magnet thereon.
8. The washing machine according to claim 2, wherein the stator
comprises: a stator core including a winding portion around which a
coil is wound and an annular body portion defining the magnetic
path; and an insulator for insulating the stator core from the
coil.
9. The washing machine according to claim 2, wherein the stator has
thirty six poles, and the rotor has forty eight poles.
10. The washing machine according to claim 2, wherein the back yoke
is attached to an inner surface of the side wall portion of the
rotor frame in a circumferential direction by use of an adhesive,
and the magnet is attached to an inner surface of the back yoke in
a circumferential direction by use of an adhesive.
Description
[0001] This application claims the benefit of the Korean Patent
Application Nos. 10-2005-0111504, 10-2005-0111505, 10-2005-0111506
and 10-2005-0111507 filed on Nov. 21, 2005 which are hereby
incorporated by reference as if fully set forth herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a washing machine, and more
particularly, to an improvement in the structure of a drive unit
included in a drum type washing machine.
[0004] 2. Discussion of the Related Art
[0005] Generally, drum type washing machines are designed to
perform a washing operation by use of a frictional force between a
drum and laundry as the drum is rotated by a drive force of a motor
transmitted thereto in a state wherein the laundry is received in
the drum together with wash water and detergent. The above
described washing operation manner has several effects of causing
damage to laundry as little as possible while preventing entangling
of laundry and also providing excellent washing effects by pounding
and rubbing.
[0006] Now, the configuration of a conventional drum type washing
machine will be described in brief with reference to FIG. 1.
[0007] Referring to FIG. 1 illustrating the configuration of the
conventional drum type washing machine in longitudinal sectional
view, the conventional washing machine comprises a tub 2 installed
in a cabinet 1 and a drum 3 rotatably installed in the center of
the tub 2.
[0008] The tub 2 is mounted, at a lower side thereof, with a motor
5a and in turn, the motor 5a is connected to a motor pulley 18 by
means of a shaft.
[0009] The drum 3 is mounted, at a rear side thereof, with a drum
shaft, and a drum pulley 19 is mounted on the drum shaft.
[0010] The drum pulley 19 mounted on the drum shaft and the motor
pulley 18 connected to the motor 5a are connected to each other by
means of a belt 20 as a power transmission element.
[0011] The cabinet 1 is provided, at a front side thereof, with a
door 21, and a gasket 22 is provided between the door 21 and the
tub 2.
[0012] A hanging spring 23 is mounted between an inner ceiling
surface of the cabinet 1 and an outer upper surface of the tub 2
and adapted to support the tub 2. Also, a friction damper 24 is
mounted between an inner bottom surface of the cabinet 1 and an
outer lower surface of the tub 2 and adapted to alleviate vibration
of the tub 2 caused during a dehydrating operation.
[0013] In the above described conventional washing machine, a drive
force of the motor 5a is transmitted to the drum 3 by way of the
motor pulley 18, the drum pulley 19, and the belt 20 connecting the
motor pulley 18 and the drum pulley 19 to each other. Such an
indirect power transmission manner, however, has the following
problems.
[0014] Firstly, since the drive force of the motor 5a is
transmitted to the drum 3 through the belt 20 wound on both the
motor pulley 18 and the drum pulley 19 rather than being directly
transmitted to the drum 3, there is a high potential loss of energy
in the transmission course of the drive force.
[0015] Secondly, in the course of transmitting the drive force of
the motor 5a to the drum 3 through the above described several
elements, such as the motor pulley 18, the drum pulley 19, and the
belt 20, and the like, there inevitably exists a problem of severe
noise as compared to the case where the drive force is directly
transmitted to the drum 3.
[0016] Thirdly, a necessity for a great number of elements for
transmitting the drive force of the motor 5a to the drum 3, such as
the motor pulley 18, the drum pulley 19, the belt 20, and the like,
consequently, causes a complicated product assembling
operation.
[0017] Fourthly, the above described great number of elements for
transmitting the drive force of the motor 5a to the drum 3 may
result in a proportional increase in the number of potential
failure areas, and this has a problem of increasing the generation
frequency of failures.
[0018] In conclusion, due to the above described power transmission
manner in which the drive force of the motor 5a is indirectly
transmitted to the drum 3 only by way of the motor pulley 18, the
belt 20, and the drum pulley 19, the conventional drum type washing
machine has problems of a high potentiality of failures and noise
generation as well as excessive consumption of energy and
seriously, may result in deterioration in washing performance
thereof, etc.
[0019] To solve the above described problems, the applicant of the
present invention has proposed to use a direct connection type
motor in a drive unit of a drum type washing machine, as disclosed
in Korean Patent Laid-open Publication No. 10-2001-0037607.
[0020] In the above published patent invention, there is provided a
rotor frame, which is formed by pressing an iron plate and
installed to transmit a rotating force of a rotor to a drum
directly while performing itself the function of a back yoke having
a magnetic path. It could be found that the disclosed rotor frame
has a capability of solving the above described problems of the
indirect power transmission manner while achieving a simplified
structure.
[0021] However, forming the rotor frame by pressing the iron plate
has a difficulty, due to characteristics of a press operation, to
obtain a required accuracy, more particularly, concentricity, when
the thickness of the iron plate exceeds a predetermined value. On
the other hand, when the rotor frame is formed by use of an iron
plate having a thickness less than the predetermined value, there
is a problem in that the rotor frame cannot obtain a required
strength and may fluctuate during rotation.
[0022] Furthermore, to provide a passage of magnetic flux, that is
to say, a magnetic path for the flow of magnetic flux generated by
electric current flowing through coils of a stator, it is essential
to provide a back yoke, which is made of a magnetic material and
has an appropriate thickness, behind a magnet. Here, it is noted
that the thinner the thickness of the back yoke, the lower a
saturation point of the magnetic flux. Accordingly, when the rotor
frame serving as the back yoke has a small thickness, there is a
limit to increase the output of a motor even if the amount of
current is increased to obtain a strong output.
[0023] Consequently, the attempt to form the rotor frame having the
function of the back yoke by use of the iron plate in views of
diversification of products reaches a limit due to the above
described thickness problem of the rotor frame.
[0024] Also, due to characteristics of the iron plate, there is a
risk in that the rotor frame tends to gather rust on its surface
easily. The rust may cause deterioration in the strength of the
rotor frame and in the worst case, there is a risk in that rust
powder that falls from the rotor frame is attached in an air gap
between the magnet and the stator, thereby acting to restrict
rotation of the rotor.
[0025] In addition, the rotor frame, made of the iron plate, has a
difficulty in the implementation of any subsequent process for
improving accuracy and other processes.
SUMMARY OF THE INVENTION
[0026] Accordingly, the present invention is directed to a washing
machine that substantially obviates one or more 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 in which a drive unit, more particularly, a rotor
frame that is adapted to transmit a rotating force of a rotor to a
shaft directly, has an improved structure suitable to transmit a
drive force of a motor to a drum directly, thereby achieving the
effects of reducing the generation potential of noise and failure
as well as excessive consumption of energy and of increasing the
durability and stability of the washing machine.
[0028] Additional advantages, objects, and features of the
invention will be set forth in part in the description which
follows and in part will become 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 may be realized and attained by the
structure particularly pointed out in the written description and
claims hereof as well as the appended drawings.
[0029] To achieve these objects and other advantages and in
accordance with the purpose of the invention, as embodied and
broadly described herein, a washing machine comprising: a tub for
receiving wash water therein; a drum rotatably disposed in the tub
and adapted to wash laundry received therein; a shaft penetrated
through the tub to thereby be connected to the drum, the shaft
being adapted to transmit a drive force of a motor to the drum; a
stator coupled fixedly to a rear wall portion of the tub; and a
rotor including at least one magnet, a back yoke defining a
magnetic path, and a rotor frame rotatably disposed at the outside
of the stator, the rotor frame being connected to the shaft so as
to transmit a rotating force of the rotor to the shaft, wherein the
rotor frame comprises a side wall portion and a rear wall portion,
and is made of an aluminum material.
[0030] The coupling structure between the tub and the stator may be
altered in various manners and thus, the detailed configuration and
method for accomplishing the above coupling structure also may be
altered in various manners.
[0031] Preferably, the rotor frame is formed by die casting, and
the side wall portion and the rear wall portion of the rotor frame
are integrally formed with each other.
[0032] The rear wall portion of the rotor frame may be provided, at
a center position thereof, with a connector, which is
serration-coupled onto an outer circumference of the shaft and
adapted to transmit the rotating force of the rotor to the shaft.
Here, the connector may be made of an insulating material and
integrally formed with the rotor frame by insert molding.
[0033] The washing machine may further comprise: a bearing housing
provided between the rear wall portion of the tub and the stator
and coupled fixedly to both the tub and the stator, the bearing
housing receiving at least one bearing therein to rotatably support
the shaft. Preferably, the bearing housing is made of a metallic
material.
[0034] Preferably, the side wall portion of the rotor frame is
extended forward from an edge of the rear wall portion, and the
side wall portion of the rotor frame is formed, in a
circumferential direction thereof, with a ledge having a seating
plane for supporting the magnet thereon. With this configuration,
the magnet can be more stably secured to the rotor frame.
[0035] Preferably, the stator comprises: a stator core including at
least one winding portion around which a coil is wound and an
annular body portion defining the magnetic path; and an insulator
for insulating the stator core from the coil. The stator may have
thirty six poles, and the rotor may have forty eight poles.
[0036] The back yoke may be attached to an inner surface of the
side wall portion of the rotor frame in a circumferential direction
by use of an adhesive, and the magnet may be attached to an inner
surface of the back yoke in a circumferential direction by use of
an adhesive. The back yoke is made of a magnetic material to define
the magnetic path. Here, the back yoke may be fabricated to have an
optical thickness in views of the performance of the motor.
[0037] The above described drum type washing machine according to
the present invention has the following effects.
[0038] Firstly, the washing machine of the present invention has a
direct connection motor and thus, has the effect of significantly
reducing the generation of noise and failure as well as the loss of
power. Also, with the use of the metallic bearing housing, the
washing machine of the present invention is applicable to products
having a high-temperature drying function, without the risk of
thermal deformation.
[0039] Secondly, in the washing machine of the present invention,
the rotor frame is made of an aluminum material and thus, has no
risk of gathering rust thereon. This results in an increase in the
durability of the motor.
[0040] Thirdly, the rotor frame of the present invention has a
magnet seating plane for achieving a highly efficient mounting
operation of the magnet. Also, with the provision of vent holes
having the function of moisture discharge and ventilation, it is
possible to prevent overheating of the motor while protecting the
motor from invasion of moisture. This consequently has the effect
of increasing the reliability of the motor and extending the
lifespan of the motor.
[0041] Fourthly, according to the present invention, the rotor
frame is formed by die casting an aluminum material. Accordingly,
the rotor frame can be manufactured with a simplified manner while
guaranteeing an improved processability required for any subsequent
process. Also, forming the rotor frame by use of a light-weight
material is efficient to minimize the power loss of the motor due
to the inertia force of the rotor frame.
[0042] Fifthly, the aluminum rotor frame provides a flexibility to
ensure freely change in the thickness of the back yoke in views of
diversification of products. This enables an increase in the
overall thickness of the rotor frame and consequently, the rotor
frame is free from unwanted fluctuation during rotation thereof,
thus resulting in reduced noise and vibration. In addition, the
change possibility of the thickness is advantageously applicable
for the sake of reinforcing the strength of the rotor frame.
[0043] It is to be understood that both the foregoing general
description and the following detailed description of the present
invention are exemplary and explanatory and are intended to provide
further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0044] 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:
[0045] FIG. 1 is a longitudinal sectional view illustrating the
configuration of a drive unit included in a conventional drum type
washing machine;
[0046] FIG. 2 is a longitudinal sectional view illustrating
important parts of a drum type washing machine according to a first
embodiment of the present invention;
[0047] FIG. 3 is a right side view of FIG. 2, in which the
illustration of a motor is omitted;
[0048] FIG. 4 is a partially cut-away perspective view illustrating
a rotor shown in FIG. 2;
[0049] FIG. 5 is a perspective view illustrating a stator shown in
FIG. 2;
[0050] FIG. 6 is a perspective view illustrating a connector shown
in FIG. 2;
[0051] FIG. 7 is a bottom perspective view of FIG. 6;
[0052] FIG. 8 is a longitudinal sectional view schematically
illustrating the configuration of a drum type washing machine using
a direct connection motor according to a second embodiment of the
present invention;
[0053] FIG. 9 is an enlarged longitudinal section view of the
portion "A" of FIG. 8, illustrating the configuration of a drive
unit included in the drum type washing machine according to the
second embodiment of the present invention;
[0054] FIG. 10 is a partially cut-away perspective view
illustrating the configuration of a rear wall portion of a tub
shown in FIG. 9;
[0055] FIG. 11 is a perspective view illustrating a bearing housing
shown in FIG. 9;
[0056] FIG. 12 is a bottom perspective view of FIG. 11;
[0057] FIG. 13 is a sectional view taken along the line I-I of FIG.
11;
[0058] FIG. 14 is a longitudinal sectional view illustrating the
configuration of a drum type washing machine using a direct
connection motor according to a third embodiment of the present
invention; and
[0059] FIG. 15 is a longitudinal sectional view illustrating the
configuration of a drum type washing machine using a direct
connection motor according to a fourth embodiment of the present
invention.
DETAILED DESCRIPTION OF THE INVENTION
[0060] Reference will now be made in detail to the preferred
embodiments of the present invention, examples of which are
illustrated in the accompanying drawings. Wherever possible, the
same reference numbers will be used throughout the drawings to
refer to the same or like parts.
[0061] In the present invention, a motor, more particularly, a
stator is coupled fixedly to a rear wall portion of a tub. A method
for coupling the stator to the tub may be changed according to
respective preferred embodiments of the present invention.
[0062] Now, a first embodiment of the present invention will be
described in detail with reference to FIGS. 2 to 7.
[0063] FIG. 2 is a longitudinal sectional view illustrating
important parts of a drum type washing machine according to a first
embodiment of the present invention, and FIG. 3 is a right side
view of FIG. 2, in which the illustration of a motor is
omitted.
[0064] FIG. 4 is a partially cut-away perspective view illustrating
a rotor shown in FIG. 2, FIG. 5 is a perspective view illustrating
a stator shown in FIG. 2, FIG. 6 is a perspective view illustrating
a connector shown in FIG. 2, and FIG. 7 is a bottom perspective
view of FIG. 6.
[0065] The drum type washing machine according to the present
embodiment comprises a tub 2 installed in a cabinet (not shown) and
used to receive wash water therein, a drum 3 rotatably provided in
the tub 2 and adapted to wash laundry received therein as it is
rotated, a shaft 4 penetrated through the tub 2 and connected to
the drum 3, the shaft 4 being adapted to transmit a drive force of
a motor 5 to the drum 3, and a stator 14 having winding portions
around which coils are wound, the stator 14 being coupled fixedly
to a rear wall portion of the tub 2.
[0066] In the present embodiment, the washing machine further
comprises a rotor 13, which includes magnets 13c, a back yoke 300
having a magnetic path, and a rotor frame rotatably disposed around
the stator 14. Here, the rotor frame is connected to the shaft 4,
to transmit a rotating force of the rotor 13 to the shaft 4.
[0067] The rotor frame has a side wall portion 13b and a rear wall
portion 13a, and is made of an aluminum material.
[0068] In the present embodiment, the washing machine may further
comprise a front bearing 6a and a rear bearing 6b installed,
respectively, on an outer circumference of either end of the shaft
4, and a bearing housing 7 provided on a rear wall surface 200 of
the tub 2 for supporting the front and rear bearings 6a and 6b.
[0069] In the present embodiment, a connector 16 may be provided in
such a manner that it is serration-coupled onto an outer
circumference of the shaft 4, in particular, at a position behind
the rear bearing 6b and also, coupled to the rotor 13, thereby
serving to transmit the rotating force of the rotor 13 to the shaft
4.
[0070] Here, the bearing housing 7 is provided between the rear
wall surface 200 of the tub 2 and the stator 4 so that it is
coupled fixedly to both the tub 2 and the stator 4. Also, the
bearing housing 7 is adapted to rotatably support the shaft 4 by
means of the front bearing 6a and the rear bearing 6b.
[0071] In this case, the bearing housing 7 is made of a metallic
material, preferably, made of an aluminum alloy. Also, preferably,
the connector 16 is made of an insulating material and integrally
formed with the rotor frame via insert molding.
[0072] The metallic bearing housing 7 is integrally formed, at a
center portion thereof, with a hub 700. The front and rear bearings
6a and 6b are located in the hub 700. Around the hub 700 are formed
a plurality of coupling bosses 701 in such a manner that the
coupling bosses 701 are spaced apart from another by a regular
distance in a circumferential direction of the hub 700. The
coupling bosses 701 are used to secure the stator 14 to the bearing
housing 7 by use of coupling members 15d. The above described
configuration of the bearing housing 7 is clearly shown in FIG.
3.
[0073] The hub 700, which is located at the center portion of the
metallic bearing housing 7, is formed, at different positions of an
inner circumference thereof, with short-stepped portions 8a and 8b.
The short-stepped portions 8a and 8b serve to support the front and
rear bearings 6a and 6b, respectively, so as to prevent the
respective bearings 6a and 6b from being separated from the bearing
housing 7.
[0074] Of the short-stepped portions 8a and 8b formed along the
inner circumference of the bearing housing 7, the short-stepped
portion 8a, which is formed at a front position, has an "L"-shaped
form suitable to support a rear end of the front bearing 6a that is
installed on the outer circumference of a front end of the shaft 4.
On the other hand, the short-stepped portion 8b, which is formed at
a rear position, has an "L"-shaped form suitable to support a front
end of the rear bearing 6b that is installed on the outer
circumference of a rear end of the shaft 4.
[0075] The shaft 4, which is located in the bearing housing 7 and
adapted to transmit the drive force of the motor 5 to the drum 3,
is formed, at front and rear locations on the outer circumference
thereof, with positioning short-stepped portions 9a and 9b for
determining the installation positions of the front and rear
bearings 6a and 6b on the shaft 4.
[0076] The front end of the shaft 4 is coupled to a spider 10 that
is provided at a rear wall portion of the drum 3. Also, to prevent
the shaft 4 from gathering rust thereon, a brass bushing 11 is
press fitted around a portion of the shaft 4 extended between the
spider 10 and the front bearing 6a. Here, the bushing 11 is
provided, around an outer circumference thereof, with a sealing
member 12 for preventing permeation of moisture into the bearings
6a and 6b.
[0077] The rotor 13, which constitutes a part of a direct
connection motor 5, is coaxially coupled to the rear end of the
shaft 4. The stator 14 is located inside the rotor 13 so as to
constitute the direct connection motor 5 along with the rotor 13.
Here, the stator 14 is coupled fixedly to the coupling bosses 701
of the bearing housing 7. Of course, it will be appreciated that
the coupling bosses 701 may be formed at the stator 14.
[0078] The rotor 13 includes the aluminum rotor frame.
[0079] As shown in FIG. 4, preferably, the rotor frame has the side
wall portion 13b and the rear wall portion 13a, which are
integrally formed with each other, and is formed by die casting an
aluminum material.
[0080] Specifically, the side wall portion 13b of the rotor frame
is extended forward from an edge of the rear wall portion 13a in a
direction perpendicular to the rear wall portion 13a. The side wall
portion 13b is formed, in a circumferential direction thereof, with
a ledge having a seating plane 130 for supporting the magnets 13c
that are attached to an inner surface of the side wall portion 13b
in a front portion of the inner surface. The rear wall portion 13a
of the rotor frame is centrally formed with a hub 132. Here, the
hub 132 is coupled to the connector 16, to allow the rotating force
of the rotor 13 to be transmitted to the shaft 4 through the
connector 16.
[0081] Around the hub 132 of the rotor frame are radially formed a
plurality of cooling fins 133. The cooling fins 133 serve to blow
air toward the stator 14 during rotation of the rotor 13, so as to
remove heat generated in the stator 14. In this case, each of the
cooling fins 133 is formed to have a predetermined length in a
radial direction of the rotor frame.
[0082] Preferably, the cooling fins 133 are integrally formed with
the rotor frame and extend radially from the hub 132 to the ledge
to have a height difference between the hub 132 and the ledge. On
the basis of the height difference, the cooling fins 133 can be
linearly formed or curved convexly or concavely. With this
configuration, the cooling fins 133 can act to blow air
concentratively to specific portions of the stator 14 having the
highest cooling requirement.
[0083] Although FIG. 4 illustrates the cooling fins 133 that are
configured to have the highest height at the side of the hub 132,
it will be appreciated that, conversely, the cooling fins 133 have
the highest height at the side of the ledge.
[0084] In the present invention, the rear wall portion 13a of the
rotor frame has a plurality of vent holes 134 perforated between
the respective adjacent cooling fins 133. The vent holes 134 have
the roles of moisture discharge and ventilation.
[0085] With the provision of the cooling fins 133 and the hub 132,
the rotor frame of the present invention can achieve a reinforced
rigidity of the rear wall portion 13b. Also, the cooling fins 133
and the hub 132 can be formed simultaneously via a single
fabrication process and therefore, achieve a reduction in
manufacturing costs.
[0086] The hub 132 of the rotor 13 has a center through-hole 131, a
plurality of coupling holes 137 equidistantly formed around the
center through-hole 131, and a plurality of positioning holes 138
equidistantly formed around the center through-hole 131 between the
respective adjacent coupling holes 137. The coupling holes 137 are
used to couple the connector 16 to the rotor 13. Here, the
connector 16 is serration-coupled onto the outer circumference of
the rear end of the shaft 4 at a position behind the rear bearing
6b. The positioning holes 138 are used to determine the assembling
position of the connector 16. Here, a coupling member 15a is
coupled into the shaft 4 by passing through the through-hole 131.
With the use of the coupling member 15a, there is no risk in that
the shaft 4 is unintentionally separated from the connector 16.
[0087] The connector 16 is made of a resin material having a
different vibration mode from that of the aluminum rotor 13.
Preferably, the connector 16 is made of an insulating material and
integrally formed with the rotor frame via insert molding.
[0088] The connector 16, as shown in FIGS. 2, 6, and 7, has
coupling holes 162 perforated in an edge region thereof along a
circumferential direction, to correspond to the coupling holes 137
formed in the hub 132 of the rotor 13. The connector 16 also has
positioning protrusions 160 integrally formed at positions between
the respective adjacent coupling holes 162. As the positioning
protrusions 160 are inserted into the positioning holes 138 of the
rotor 13, the coupling holes 137 of the rotor 13 are automatically
aligned with the coupling holes 162 of the connector 16.
[0089] In addition, the connector 16 has a center hub 163, a
serration 164 formed at an inner circumference of the hub 163 to be
engaged with a serration 400 formed on the rear end of the shaft 4,
and reinforcing ribs 161 formed at an outer circumference of the
hub 163 for reinforcing the strength of the hub 163.
[0090] As shown in FIGS. 2 and 5, the stator 14, which constitutes
the motor 5 along with the rotor 13, includes a ring-shaped
insulator 140, and coils 142 wound on winding portions 141 arranged
at the outside of the insulator 140. In addition, coupling ribs 143
are integrally formed with the insulator 140 inside the insulator
140, to secure the stator 14 to the bearing housing 7.
[0091] The stator further includes a stator core, which consists of
the winding portions 141 around which the coils 142 are wound, and
an annular body portion having a magnetic path. The insulator 140
serves to insulate the stator core and the coils 142 from each
other.
[0092] The stator core may be an annular spiral core having a
multilayered structure, which is obtained by spirally winding an
iron plate, consisting of the winding portions 141 and the body
portion, from the lowermost layer to the uppermost layer.
[0093] Alternatively, the stator core may take the form of an
annular sectional core, which is obtained by coupling a plurality
of arched stator core sections, each consisting of a plurality of
arched stator core pieces stacked one above another in multiple
layers, with one another.
[0094] A tub bracket 17 is coupled onto an outer circumference of
the tub 2 and adapted to secure the bearing housing 7 at the rear
side of the tub 2. In this case, a method for coupling the tub
bracket 17 to the tub 2 may be changed according to the material of
the tub 2. For example, if the tub 2 is made of stainless steel,
preferably, tub bracket 17 may be coupled to the tub 2 by
welding.
[0095] Here, the tub bracket 17 has extensions, which are extended
rearward beyond the rear wall surface 200 of the tub 2. Each
extension of the tub bracket 17 is perforated with a coupling hole
170 so that an associated one of the coupling members 15d is
penetrated through the coupling hole 170, to thereby be coupled
into an associated coupling recess 702 of the bearing housing
7.
[0096] The bearing housing 7 has a plurality of extensions radially
extended from the center thereof. As the extensions are coupled to
the tub bracket 17, the bearing housing 7 is secured to the tub 2.
If the bearing housing 7 has three extensions, it can be called
"trivet type".
[0097] The bearing housing 7 has a self-aligning rib 703 formed in
a circumferential direction thereof at the outside of the coupling
bosses 701, the self-aligning rib 703 having a ramp 703a at a side
thereof. To correspond to the self-aligning rib 703, the insulator
140 of the stator 14, which is coupled to the coupling bosses 701
of the bearing housing 7, has a self-aligning rib 144 formed at an
inner circumference thereof in a circumferential direction.
Similarly, the self-aligning rib 144 has a ramp 144a at a side
thereof, so as to be engaged with the ramp 703a of the
self-aligning rib 703 of the bearing housing 7.
[0098] Now, the operation of the drive unit having the above
described configuration, which is included in the drum type washing
machine according to the first embodiment of the present invention,
will be described.
[0099] If the rotor 13 is rotated as electric current is
sequentially applied to the respective coils 142 of the stator 14
under the control of a motor driving controller (not shown)
attached to a control panel, the shaft 4, which is
serration-coupled to the connector 16 coupled to the rotor 13, is
rotated. Thereby, power is transmitted to the drum 3 through the
shaft 4, thus enabling rotation of the drum 3.
[0100] Meanwhile, in the present embodiment, preferably, the stator
14 has thirty six poles and the rotor has forty eight poles. The
greater the number of the poles, the easier the positional
detection and control of the stator and the rotor can be
accomplished.
[0101] Here, the forty eight poles of the rotor alternately define
a north pole and a south pole in such a manner that twelve
permanent magnets, each having a total of four poles, are coupled
inside the rotor frame. The permanent magnets may be coupled by use
of an adhesive.
[0102] Of course, the back yoke also may be coupled inside the
rotor frame by use of an adhesive. Here, the back yoke has to be
made of a magnetic material because it must have a magnetic
path.
[0103] Hereinafter, the assembling procedure and effects of the
drive unit included in the drum type washing machine according to
the first embodiment of the present invention will be
described.
[0104] First, the bearing housing 7 of the present invention is
coupled to the tub bracket 17 by use of the coupling members 15d as
the coupling members 15d are penetrated through the coupling holes
170 of the tub bracket 17. Here, the tub bracket 17 was previously
welded to the outer circumference of the tub 2. Thereby, the
bearing housing 7 is secured to the rear side of the tub 2.
[0105] That is to say, in a state wherein the tub bracket 17 is
welded fixedly to the outer circumference of the tub 2, the bearing
housing 7 is coupled to the tub bracket 17 to thereby be mounted
onto the rear side of the tub 2.
[0106] The assembled bearing housing 7 is made of a metallic
material, such as an aluminum alloy and the like, and therefore,
has no thermal deformation even under a high temperature condition.
Accordingly, the bearing housing 7 is applicable to a drum type
washing machine having a high-temperature drying cycle.
[0107] In the present invention, the bearing housing 7 is formed,
at the front and rear positions of the inner circumference thereof,
with the "L"-shaped short-stepped portions 8a and 8b. Accordingly,
once the front and rear bearings 6a and 6b are mounted on the outer
circumference of both the ends of the shaft 4, the rear end of the
front bearing 6a and the front end of the rear bearing 6b can be
supported by the short-stepped portions 8a and 8b,
respectively.
[0108] That is to say, the metallic bearing housing 7 is able to
support both the bearings 6a and 6b without the risk of
unintentional separation by use of the short-stepped portions 8a
and 8b formed at opposite positions of the inner circumference
thereof.
[0109] Also, the shaft 4, which is located inside the bearing
housing 7 and adapted to transmit the drive force of the motor 5 to
the drum 3, is formed, at the front and rear locations on the outer
circumference thereof, with the positioning short-stepped portions
9a and 9b, whereby the assembling positions of the front bearing 6a
and the rear bearing 6b on the shaft 4 can be easily
determined.
[0110] As described above, the front end of the shaft 4 is coupled
to the spider 10 that is provided at the rear wall portion of the
drum 3, and the brass bushing 11 is forcibly press fitted around
the portion of the shaft 4 between the spider 10 and the front
bearing 6a to prevent the shaft 4 from gathering rust thereon.
[0111] Also, the sealing member 12 is installed around the outer
circumference of the bushing 11 to prevent invasion of moisture
into the bearings 6a and 6b.
[0112] Meanwhile, the bearing housing 7 has the coupling bosses 701
equidistantly formed in a circumference thereof at the outside of
the hub 700. Thereby, as the coupling members 15d, having
penetrated through the stator 14, are coupled to the coupling
bosses 701, the stator 14 can be strongly secured to the bearing
housing 7.
[0113] Here, since the rotor frame is formed by die casting an
aluminum material, it can be fabricated with a simplified process
without the risk of rust. In addition, the rotor frame has a light
weight due to characteristics of the aluminum material, and this is
efficient to reduce the inertia loss of the rotor frame while
achieving an improvement in processability. In conclusion, by
integrally forming the rotor frame with the rotor by use of the
aluminum material, more particularly, an aluminum alloy, etc., the
manufacture of the rotor can be simplified considerably. Also, when
it is desired to perform an additional process on the rotor frame
for the sake of a more accurate structure, the processing of the
rotor can be accomplished easily by virtue of its improved
processability.
[0114] Meanwhile, by the coupling holes 137 for the coupling of the
connector 16 and the positioning holes 138 for the determination of
the assembling position of the connector 16, which are formed
around the through-hole 131 in the hub 132 of the rotor frame, the
connector 16, which will be serration-coupled to the outer
circumference of the rear end of the shaft 4 at a position behind
the rear bearing 6b, can be easily assembled to the rotor 13.
[0115] Specifically, once the positioning protrusions 160 of the
connector 16 are inserted into and engaged in the positioning holes
138 of the rotor 13, the coupling holes 137 of the rotor 13 are
automatically aligned with the coupling holes 162 of the connector
16, thus allowing the coupling members 15b to be coupled through
the coupling holes 137 and 162 of the rotor 13 and the connector
16. As a result, the connector 16 can be easily assembled with the
rotor 13.
[0116] In this case, the connector 16 is injection molded by use of
a resin material and has a different vibration mode from the
aluminum rotor 13. Accordingly, the connector 16 serves to allow
the vibration of the rotor 13 to be transmitted to the shaft 4 in
an alleviated state. Here, it is noted that the connector 16 may be
integrally formed with the rotor frame via insert molding.
[0117] The connector 16 is formed with the serration 164 at the
inner circumference of the hub 163. Accordingly, as the serration
164 are engaged with the serration 400 formed at the rear end of
the shaft 4, the rotating force of the rotor 13 can be directly
transmitted to the shaft 4 through the connector 16.
[0118] The connector 16 is also formed at the outer circumference
of the hub 163 with the reinforcing ribs 601 to reinforce the
strength of the hub 163.
[0119] Hereinafter, a drum type washing machine according to a
second embodiment of the present invention will be described in
detail with reference to FIGS. 8 to 13. The present embodiment has
approximately the same configuration as that of the above described
first embodiment except for a structure for coupling fixedly the
motor to the rear wall portion of the tub. Accordingly, the
description of the same configuration as the above described
embodiment will be omitted.
[0120] FIG. 8 is a longitudinal sectional view schematically
illustrating the configuration of a drum type washing machine using
a direct connection motor according to the present embodiment, and
FIG. 9 is an enlarged longitudinal sectional view of the portion
"A" of FIG. 8, illustrating the configuration of a drive unit
included in the drum type washing machine according to the second
embodiment of the present invention.
[0121] FIG. 10 is a perspective view illustrating the rear wall
portion of the tub shown in FIG. 9, FIG. 11 is a top perspective
view of the bearing housing shown in FIG. 9, FIG. 12 is a rear
perspective view of the bearing housing, and FIG. 13 is a sectional
view taken along the line I-I of FIG. 11.
[0122] The present embodiment has a feature in that a bearing
housing 7' is integrally formed with the tub 2, which is made of a
plastic material, at the center of the rear wall portion of the tub
2. The bearing housing 7' of the present embodiment can rotatably
support the shaft 4 while allowing a stator 6 to be coupled fixedly
to the rear wall portion of the tub 2 therethrough.
[0123] Here, the bearing housing 7' is made of an aluminum alloy,
etc. In the present embodiment, the bearing housing 7' is inserted
into the rear wall portion of the tub 2 while the plastic tub 2 is
injection molded, so as to be integrally formed with the rear wall
portion of the tub 2.
[0124] Referring to FIG. 9, the bearing housing 7' includes a
bearing supporting portion 7a for supporting bearings, the bearing
supporting portion 7a having a sleeve form, and a stator coupling
portion 7b integrally formed with the bearing supporting portion 7a
to be extended radially from a rear end of the bearing supporting
portion 7a. The stator coupling portion 7b is inserted into the
rear wall portion of the tub 2 so that only stator coupling holes
700b formed in the stator coupling portion 7b are exposed to the
outside.
[0125] Referring to FIGS. 11 and 12, the stator coupling portion 7b
of the bearing housing 7' is extended radially and outwardly from
the bearing supporting portion 7a in the form of a sleeve, and has
stepped regions 70b-1, each of the stepped portions 70b-1 being
stepped at least one time in a radial outward direction
thereof.
[0126] The stator coupling portion 7b of the bearing housing 7'
further has plane regions 70b-2 defined between the respective
adjacent stepped regions 70b-1.
[0127] The bearing housing 7' of the present embodiment has a
feature in that the stepped regions 70b-1 and the plane regions
70b-2 of the stator coupling portion 7b are continuously arranged
to be connected to each other.
[0128] That is to say, the stator coupling portion 7b of the
bearing housing 7' consists of the stepped regions 70b-1 configured
to be stepped in a radial outward direction thereof and the plane
regions 70b-2 configured to define planes between the respective
adjacent stepped regions 70b-1. Here, of the regions of the stator
coupling portion 7b, the regions 70b-1 are extended in a radial
outward direction from the upper end of the bearing supporting
portion 7a so that they are stepped downward per a predetermined
distance in the radial outward direction. Also, of the regions of
the stator coupling portion 7b, the regions 70b-2 are connected to
a front end of the bearing housing 7' and have a plane
structure.
[0129] The bearing housing 7' is formed, around a rear end thereof,
with a resin filling groove 750a, for the sake of improving a
coupling force with the tub 2 during insert injection molding.
[0130] Referring to FIGS. 10 and 11, the stator coupling portion 7b
has positioning recesses 710b formed near some of the stator
coupling holes 700b at positions corresponding to positioning
protrusions formed at the stator 6.
[0131] As shown in FIG. 10, the rear wall portion of the tub 2 is
formed with a plurality of protruding bosses 210 at positions
corresponding to specific positions near the stator coupling holes
700b of the stator coupling portion 7b included in the bearing
housing 7'. The protruding bosses 210 serve to prevent the stator 6
from coming into direct contact with the stator coupling portion
7b, in order to prevent an insulator of the stator 6 from being
damaged by a coupling force applied in the course of coupling the
stator 6.
[0132] Preferably, the stator coupling portion 7b is formed with a
rib 720b in a circumferential direction at a position spaced apart
from the center of the bearing supporting portion 7a by a
predetermined distance, for the sake of increasing a coupling force
with a resin material upon injection molding of the tub 2. Although
it is preferable that coupling bosses 70b, each having the stator
coupling hole 700b, are arranged along the rib 720b, it is not
essential to form the coupling holes 700b along the rib 720b.
[0133] In addition, the rear wall portion of the tub 2 is formed
with circumferential and radial reinforcing ribs 201 except for a
region corresponding to the stepped regions of the bearing housing
7', for the sake of reinforcing the strength of the rear wall
portion of the tub 2.
[0134] Alternatively, differently from the above described
configuration of the stator coupling portion 7b of the bearing
housing 7', although the stator coupling portion 7b of the bearing
housing 7' is extended in a radial outward direction from the
bearing supporting portion 7a in the form of a sleeve, it is
branched into a plurality of portions spaced apart from one another
by a regular distance in a circumferential direction, to obtain a
radially distributed structure.
[0135] In the present embodiment, as a result of providing the
bearing housing 7' with the coupling bosses 70b having the stator
coupling holes 700b, it is unnecessary to perforate coupling holes
in the tub 2.
[0136] Specifically, according to the above described configuration
of the present embodiment, the stator 6 is secured to the rear wall
portion of the tub 2 as it is bolted to the stator coupling holes
700b of the coupling bosses 70b provided at the stator coupling
portion 7b of the bearing housing 7' that was previously embedded
in the rear wall portion of the tub 2.
[0137] Near some of the coupling holes 700b of the stator coupling
portion 7b are formed the positioning recesses 710b corresponding
to the positioning protrusions formed at the insulator of the
stator 6. With the provision of the positioning means, the stator 6
can be coupled to the rear wall portion of the tub 2 with an
improved workability.
[0138] Preferably, the positioning recesses 710b, which are formed
at the stator coupling portion 7b of the bearing housing 7', is
configured so that it is exposed to the outside rather than being
covered with a resin material. Conversely, if the positioning
recesses are formed at the insulator of the stator 6, the stator
coupling portion 7b of the bearing housing 7' may be formed with
the positioning protrusions.
[0139] Hereinafter, a drum type washing machine according to a
third embodiment of the present invention will be described in
detail. Similarly, the description of the same configuration as
that of the above described first and second embodiments will be
omitted.
[0140] FIG. 14 is a sectional view illustrating a drive unit of a
drum type washing machine according to the present embodiment.
[0141] The present embodiment has a feature in that a supporter is
interposed between the rear wall portion of the tub and the stator.
Here, the supporter serves not only to reinforce the rigidity of
the rear wall portion of the tub, but also to allow the stator to
be more strongly secured to the rear wall portion of the tub.
[0142] Accordingly, the washing machine according to the present
embodiment comprises the tub 2 installed in the cabinet (not shown)
and used to receive wash water therein, the drum 3 rotatably
provided in the tub 2 and adapted to wash laundry received therein
as it is rotated, the shaft 4 penetrated through the tub 2 and
connected to the drum 3, the shaft 4 being adapted to transmit the
drive force of the motor 5 to the drum 3, the stator 14 having the
winding portions around which the coils are wound, the stator 14
being coupled fixedly to the rear wall portion of the tub 2, and
the supporter interposed between the rear wall portion of the tub 2
and the stator 14 and adapted to increase the coupling strength
between the tub 2 and the stator 14.
[0143] In the present embodiment, the metallic bearing housing 8
may be integrally formed with the rear wall surface 200 of the tub
2 via insert molding, simultaneously with the injection molding of
the plastic tub 2.
[0144] Now, the supporter 27 of the present embodiment will be
described in more detail.
[0145] The supporter 27 is interposed between the rear wall portion
of the tub 2 and the stator 14, more particularly, between the rear
wall surface 200 of the tub 2 and the stator 14. The supporter 27
has approximately the same outer contour as that of the rear wall
surface 200 of the tub 2 and is secured to the rear wall surface
200 of the tub 2 when the stator 14 is coupled to the tub 2.
Thereby, the supporter 27 serves to support the stator 14 while
maintaining the stator 14 coaxially with the tub 2.
[0146] The supporter 27 has a front end coming into close contact
with an inner surface of a rib 203 that is provided at a side of
the rear wall surface 200 of the tub 2. A rear end of the supporter
27 is configured to come into close contact with an outer
circumference of the rear end of the bearing housing 7', which is
exposed to the outside without being surrounded by the hub 132 of
the rotor frame provided at the center of the rear wall surface 200
of the tub 2.
[0147] Now, a drum type washing machine according to a fourth
embodiment of the present invention will be described in detail
with reference to FIG. 15.
[0148] The present embodiment has a feature in that a distance
regulation washer is provided in addition to the configuration of
the above described fourth embodiment. The distance regulation
washer is interposed between the supporter and the stator and
adapted to regulate a distance between the tub and the stator.
[0149] More specifically, in the present embodiment, the distance
regulation washer 500 may be interposed between the supporter 27
and the stator 14 coupled to the supporter 27 and adapted to
regulate a distance between the tub 2 and the stator 14.
Preferably, the distance regulation washer 500 has an annular form
suitable to stably separate the stator 14 from the tub 2. The
distance regulation washer 500 may be formed, in a circumferential
direction thereof, with a plurality of coupling holes. Accordingly,
the distance regulation washer 500 performs the function of
allowing the stator 14 to be coupled to the tub 2 with a
predetermined distance therebetween.
[0150] Generally, the size of the tub and consequently, the
capacity of the motor may be changed according to diversified
capacities of washing machines. Also, the capacity of the motor is
mainly determined by the magnitude of current applied to the motor.
Accordingly, it can be said that the stator is the most important
factor of determining the capacity of the motor. Although it is
preferable to standardize the size of the rotor in views of price
saving for the sake of mass production, this has an essential
necessity for guaranteeing the flexible coupling of the motor even
if the size of the stator is changed.
[0151] For this reason, if a small size stator is used, the
distance regulation washer 500 has to be used to prevent the rotor
from coming into contact with the rear wall portion of the tub when
the stator is coupled with the rotor.
[0152] It will be apparent to those skilled in the art that various
modifications and variations, related to the size, shape, and
material of the constituent elements, 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 covers
the modifications and variations of this invention provided they
come within the scope of the appended claims and their
equivalents.
* * * * *