FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
[See section 10, Rule 13]
OUTDOOR UNIT AND AIR CONDITIONER;
MITSUBISHI ELECTRIC CORPORATION, A CORPORATION ORGANISED AND
EXISTING UNDER THE LAWS OF JAPAN, WHOSE ADDRESS IS 7-3,
MARUNOUCHI 2-CHOME, CHIYODA-KU, TOKYO 100-8310, JAPAN
THE FOLLOWING SPECIFICATION PARTICULARLY DESCRIBES THE INVENTION
AND THE MANNER IN WHICH IT IS TO BE PERFORMED
2
5 DESCRIPTION
TECHNICAL FIELD
[0001]
The present disclosure relates to an outdoor unit and an
10 air conditioner.
BACKGROUND ART
[0002]
An outdoor unit has a fan and a unit housing in which the
fan is housed. The fan has a rotating blade and a motor to
15 rotate the rotating blade. Some motors have a consequent pole
rotor that includes a magnet magnetic pole formed by a
permanent magnet and a virtual magnetic pole formed by a rotor
core (see, for example, Patent Reference 1).
PRIOR ART REFERENCE
20 PATENT REFERENCE
[0003]
Patent Reference 1: International Publication WO2018/
179025 (see FIGS. 1 and 2)
SUMMARY OF THE INVENTION
25 PROBLEM TO BE SOLVED BY THE INVENTION
[0004]
In the consequent pole rotor, since the virtual magnetic
pole has no permanent magnet, part of the magnetic flux exiting
from the magnet magnetic pole is likely to flow to the shaft.
30 The magnetic flux flowing to the shaft may further flow to a
unit housing via a support body supporting the fan, and may
leak to the outside of the outdoor unit.
[0005]
The leakage of the magnetic flux to the outside of the
35 outdoor unit may affect peripheral components of the outdoor
unit. In addition, in order to meet the International Air
Transport Association (IATA) standards, it is required to
suppress magnetic flux leakage to the outside of the outdoor
3
5 unit.
[0006]
The present disclosure is intended to solve the abovedescribed problem, and an object of the present disclosure is
to suppress magnetic flux leakage to the outside of an outdoor
10 unit.
MEANS OF SOLVING THE PROBLEM
[0007]
An outdoor unit of the present disclosure includes a
motor. The motor includes a rotor having a rotor core and a
15 permanent magnet attached to the rotor core, the permanent
magnet forming a magnet magnetic pole, a part of the rotor core
forming a virtual magnetic pole, and a stator surrounding the
rotor. The outdoor unit further includes a frame holding the
motor, a support body supporting the frame, a unit housing in
20 which the frame and the support body are housed, and a
nonmagnetic body disposed between the support body and the unit
housing.
EFFECTS OF THE INVENTION
[0008]
25 According to the present disclosure, magnetic flux
leakage to the outside of the outdoor unit can be suppressed
because the nonmagnetic body is disposed between the support
body and the unit housing.
BRIEF DESCRIPTION OF THE DRAWINGS
30 [0009]
FIG. 1 is a longitudinal-sectional view illustrating an
outdoor unit of a first embodiment.
FIG. 2 is a cross-sectional view illustrating the outdoor
unit of the first embodiment.
35 FIG. 3 is a longitudinal-sectional view illustrating a
fan of the first embodiment.
FIG. 4 is a cross-sectional view illustrating a motor of
the first embodiment.
4
5 FIG. 5 is a cross-sectional view illustrating a rotor of
the first embodiment.
FIG. 6 is a graph illustrating the magnetic flux
distribution on the surface of the rotor of the first
embodiment.
10 FIG. 7 is a schematic diagram illustrating the flow of
leakage magnetic flux in the outdoor unit of the first
embodiment.
FIG. 8 is a schematic diagram illustrating the flow of
leakage magnetic flux in the outdoor unit of the first
15 embodiment.
FIG. 9 is an enlarged sectional view illustrating an
upper part of the outdoor unit of the first embodiment.
FIG. 10 is a longitudinal-sectional view illustrating an
outdoor unit of a second embodiment.
20 FIG. 11 is a cross-sectional view illustrating the
outdoor unit of the second embodiment.
FIG. 12 is a diagram illustrating an air conditioner to
which the outdoor unit of each embodiment is applicable.
MODE FOR CARRYING OUT THE INVENTION
25 [0010]
FIRST EMBODIMENT
(Configuration of Outdoor Unit)
An outdoor unit 100 of a first embodiment will be
described. FIG. 1 is a longitudinal-sectional view
30 illustrating the outdoor unit 100 of the first embodiment. The
outdoor unit 100 constitutes a part of an air conditioner such
as a room air conditioner.
[0011]
As illustrated in FIG. 1, the outdoor unit 100 has a unit
35 housing 110 which is an outer frame, a fan 5 disposed inside
the unit housing 110, a support body 130 that supports the fan
5, a front panel 120 disposed at the front side of the unit
housing 110, and a heat exchanger 140 disposed at the back side
5
5 of the unit housing 110.
[0012]
The direction of an axis C1, which is a rotation center
axis of a motor 3 (to be described later) of the fan 5, is
referred to as an "axial direction". The circumferential
10 direction about the axis C1 is referred to as a
"circumferential direction" and indicated by the arrow R1 in
FIG. 4 and other figures. The radial direction about the axis
C1 is referred to as a "radial direction". A sectional view in
a plane parallel to the axial direction is referred to as a
15 "longitudinal-sectional view". A sectional view in a plane
orthogonal to the axial direction is referred to as a "crosssectional view".
[0013]
The outdoor unit 100 is placed on a horizontal plane in
20 this example. The horizontal plane is an XY plane, and the
vertical direction is a Z direction. A Y direction is parallel
to the axial direction and is the front-back direction of the
outdoor unit 100.
[0014]
25 FIG. 2 is a cross-sectional view of the outdoor unit 100
taken along the line 2-2 illustrated in FIG. 1. As illustrated
in FIG. 2, the unit housing 110 has a bottom plate 111, a top
plate 112, and side plates 113 and 114. Each of the bottom
plate 111, the top plate 112, and the side plates 113 and 114
30 is formed of, for example, a metal sheet. The material for the
metal sheet is, for example, iron, stainless steel, or the like.
[0015]
The fan 5 and other components are disposed in an area
enclosed by the bottom plate 111, the top plate 112, and the
35 side plates 113 and 114. The top plate 112 covers an upper
part of the area in which the fan 5 and the other components
are disposed, while the side plates 113 and 114 cover both
sides in the X direction, i.e., both left and right sides, of
6
5 the area.
[0016]
The front panel 120 (FIG. 1) is formed of, for example, a
metal sheet, and fixed to the bottom plate 111 by screws. An
opening 121 is formed in the front panel 120, and a not-shown
10 grille is fitted to the opening 121. The grille is composed of
a plurality of iron wires which are combined in a grid pattern.
The opening 121 is a part through which an airflow generated by
the fan 5 passes.
[0017]
15 The support body 130 has a pillar 131 extending in the Z
direction, a pedestal portion 132 formed at a lower end of the
pillar 131, and an arm portion 133 extending back and forth
from an upper end of the pillar 131. The support body 130 is
formed of, for example, a metal sheet. The pedestal portion
20 132 is fixed to the bottom plate 111 by screws.
[0018]
The pillar 131 has a pair of columnar portions disposed
with a space therebetween in the X direction. A mounting plate
135 (FIG. 2) is formed at the center of the pair of columnar
25 portions in the Z direction. A frame 41 of the fan 5 is fixed
to the mounting plate 135, as described below.
[0019]
As illustrated in FIG. 1, the arm portion 133 supports
the top plate 112 from below via nonmagnetic bodies 71, 72, and
30 73 described below. A front end of the arm portion 133 has a
fixing portion 136 formed to be bent downward, and an upper end
of the front panel 120 is fixed to the fixing portion 136 by
screws. A back end of the arm portion 133 has a fixing portion
137 formed to be bent downward, and an upper end of the heat
35 exchanger 140 is fixed to the fixing portion 137 by screws.
That is, the arm portion 133 holds the upper ends of the front
panel 120 and the heat exchanger 140.
[0020]
7
5 The back side of the unit housing 110 is open, and the
heat exchanger 140 is disposed at the back side of the unit
housing 110. The heat exchanger 140 has a plurality of fins
which are elongated in the Z direction and arranged in the X
direction, and heat transfer pipes each of which passes through
10 the plurality of fins. A gap is formed between fins adjacent
to each other in the X direction. The fin is formed of, for
example, aluminum, and the heat transfer pipe is formed of, for
example, copper.
[0021]
15 The heat exchanger 140 extends in the X direction along
the back side of the unit housing 110 and further extends in
the Y direction along the side plate 113. That is, the heat
exchanger 140 has an L shape as viewed from the above.
[0022]
20 Heat exchange is carried out between a refrigerant
flowing in the heat exchanger 140 and air passing through the
heat exchanger 140. In this regard, the width of the abovedescribed support body 130 in the X direction is set narrower
than the width of the heat exchanger 140 in the X direction so
25 as not to obstruct the airflow passing through the heat
exchanger 140.
[0023]
As illustrated in FIG. 2, a compressor 101 is further
disposed in the unit housing 110. The compressor 101 is
30 disposed adjacent to the fan 5 in the X direction, i.e., on the
right side of the fan 5 in FIG. 2. The compressor 101 is fixed
to the bottom plate 111 by screws. The compressor 101, the
heat exchanger 140, a heat exchanger 205 (FIG. 12) of an indoor
unit 201, and the like constitute a refrigerant circuit.
35 [0024]
A partition plate 115 as a partition member is formed
between the fan 5 and the compressor 101. The partition plate
115 is parallel to the side plates 113 and 114 and is fixed to
8
5 the bottom plate 111. The fan 5 is disposed between the
partition plate 115 and the side plate 113, and the compressor
101 is disposed between the partition plate 115 and the side
wall 114.
[0025]
10 The back side of the unit housing 110 is open, while a
back plate 122 is disposed on the back side of an area in which
the compressor 101 is disposed. A control board 102 for
controlling the outdoor unit 100 is disposed between the
partition plate 115 and the side plate 114.
15 [0026]
(Configuration to Suppress Magnetic Flux Leakage)
Next, the configuration to suppress magnetic flux leakage
to the outside of the outdoor unit 100 will be described. As
illustrated in FIG. 1, the nonmagnetic bodies 71, 72, and 73
20 are disposed between the arm portion 133 of the support body
130 and the top plate 112.
[0027]
The nonmagnetic body 71 is disposed to straddle the front
end of the arm portion 133 and the upper end of the front panel
25 120. The nonmagnetic body 73 is disposed at the back end of
the arm portion 133. The nonmagnetic body 72 is disposed on
the arm portion 133 at a position above the pillar 131 in the
vertical direction.
[0028]
30 In other words, the support body 130 supports the top
plate 112 via the nonmagnetic bodies 71, 72, and 73. In this
example, each of the nonmagnetic bodies 71, 72, and 73 is
formed of, for example, a resin, more specifically urethane
resin. Each of the nonmagnetic bodies 71, 72, and 73 may be in
35 the form of a sponge.
[0029]
The nonmagnetic bodies 71, 72, and 73 have the effect of
suppressing magnetic flux leakage to the top plate 112. It is
9
5 sufficient that each of the nonmagnetic bodies 71, 72, and 73
has a thickness enough to exhibit the effect of suppressing
magnetic flux leakage.
[0030]
In this example, the width of each of the nonmagnetic
10 bodies 71, 72, and 73 in the X direction is the same as the
width of the support body 130 in the X direction. In this
regard, the width of each of the nonmagnetic bodies 71, 72, and
73 in the X direction may be wider or narrower than the width
of the support body 130 in the X direction.
15 [0031]
As illustrated in FIG. 2, a nonmagnetic body 74 is
disposed between an upper end of the side plate 113 and the top
plate 112. It is sufficient that the nonmagnetic body 74 is
disposed at least at one location in the Y direction along the
20 upper end of the side plate 113.
[0032]
Similarly, a nonmagnetic body 75 is disposed between an
upper end of the side plate 114 and the top plate 112. It is
sufficient that the nonmagnetic body 75 is disposed at least at
25 one location in the Y direction along the upper end of the side
plate 114.
[0033]
A nonmagnetic body 76 is disposed between an upper end of
the partition plate 115 and the top plate 112. It is
30 sufficient that the nonmagnetic body 76 is disposed at least at
one location in the Y direction along the upper end of the
partition plate 115.
[0034]
That is, the side plates 113 and 114 and the partition
35 plate 115 support the top plate 112 via the nonmagnetic bodies
74, 75, and 76. Each of the nonmagnetic bodies 74, 75, and 76
is formed of a nonmagnetic material, as is the case with the
nonmagnetic bodies 71, 72, and 73. Examples of the nonmagnetic
10
5 material are as described above.
[0035]
(Configuration of Fan)
FIG. 3 is a longitudinal-sectional view illustrating the
fan 5. The fan 5 includes the motor 3, a motor housing 4 in
10 which the motor 3 is housed, and a rotating blade 6 fixed to a
shaft 18 of the motor 3. The motor 3 includes a rotor 1 having
the shaft 18 and a stator 2 surrounding the rotor 1 from
outside in the radial direction. The center axis of the shaft
18 is the axis C1 described above. In the direction of the
15 axis C1, the side on which the rotating blade 6 is provided is
the front side.
[0036]
The motor housing 4 has a bottomed cylindrical frame 41
having an opening at its front and a bearing support plate 42
20 fixed to the opening of the frame 41. The stator 2 is housed
inside the frame 41.
[0037]
The frame 41 has a cylindrical portion 41a that surrounds
the stator 2 from outside in the radial direction and a wall
25 portion 41b formed at a back end of the cylindrical portion 41a.
The wall portion 41b is a disk-shaped portion that extends in a
plane orthogonal to the axial direction. A holding portion 41c
is formed at the center of the wall portion 41b in the radial
direction so as to hold a bearing 32. The holding portion 41c
30 has an end surface portion 41d that is in contact with an end
surface of the bearing 32 in the axial direction.
[0038]
Leg portions 43 extend outward in the radial direction
from a back end of the frame 41. In this example, a plurality
35 of leg portions 43 are provided in the circumferential
direction. The four leg portions 43 are arranged at equal
intervals in the circumferential direction in this example, but
the number and arrangement of the leg portions 43 are not
11
5 limited. The frame 41 is fixed to the mounting plate 135 of
the support body 130 (FIG. 2) at the leg portions 43 by screws
(indicated by dashed-dotted lines 43a in FIG. 3).
[0039]
The bearing support plate 42 faces the wall portion 41b
10 of the frame 41 in the axial direction. The bearing support
plate 42 is a disk-shaped member that extends in a plane
orthogonal to the axial direction. The bearing support plate
42 is fixed to the opening of the frame 41, for example, by
press fit.
15 [0040]
An annular holding portion 42a that holds a bearing 31 is
formed at the center of the bearing support plate 42 in the
radial direction. The holding portion 42a has an end surface
portion 42b that is in contact with an end surface of the
20 bearing 31 in the axial direction.
[0041]
The frame 41 may be formed of a magnetic material, but is
desirably formed of a nonmagnetic material. When the frame 41
is formed of a nonmagnetic material, it is desirable to use a
25 thermosetting resin such as a bulk molding compound (BMC). The
bearing support plate 42 is formed of a magnetic material such
as iron.
[0042]
The shaft 18 of the rotor 1 is made of iron or stainless
30 steel. The shaft 18 is rotatably supported by the bearing 31
held by the bearing support plate 42 and the bearing 32 held by
the wall portion 41b of the frame 41.
[0043]
The shaft 18 passes through the bearing support plate 42
35 in the axial direction and protrudes therefrom frontward. The
rotating blade 6 is fixed to the tip end of the shaft 18.
[0044]
The rotating blade 6 has a hub 61 fixed to the shaft 18
12
5 and a plurality of blades 62 fixed to the hub 61. The hub 61
is cylindrical, and the inner circumferential surface of the
hub 61 is fixed to the shaft 18.
[0045]
On the outer circumferential surface of the hub 61, the
10 plurality of blades 62 are arranged at equal intervals in the
circumferential direction. The number of blades 62 is, for
example, three (see FIG. 2), but only needs to be two or more.
When the rotating blade 6 rotates together with the shaft 18,
the blades 62 generate an airflow in the axial direction.
15 [0046]
The rotating blade 6 is desirably formed of a nonmagnetic
material. The rotating blade 6 is desirably formed of a resin,
more specifically polypropylene (PP) to which glass fiber and
mica are added.
20 [0047]
(Configuration of Motor)
FIG. 4 is a cross-sectional view illustrating the motor 3.
The motor 3 has the rotor 1 and the annular stator 2
surrounding the rotor 1 as described above. The motor 3 is a
25 permanent-magnet embedded motor in which permanent magnets 16
are embedded in the rotor 1. An air gap G of, for example, 0.4
mm, is provided between the stator 2 and the rotor 1.
[0048]
The stator 2 has a stator core 20 and coils 25 wound on
30 the stator core 20. The stator core 20 is composed of a
plurality of electromagnetic steel sheets which are stacked in
the axial direction and fastened together by crimping or the
like. The sheet thickness of each electromagnetic steel sheet
is, for example, 0.2 mm to 0.5 mm.
35 [0049]
The stator core 20 has a yoke 21 having an annular shape
about the axis C1 and a plurality of teeth 22 extending inward
in the radial direction from the yoke 21. The teeth 22 are
13
5 arranged at equal intervals in the circumferential direction.
The number of teeth 22 is 12 in this example, but is not
limited to 12. A slot, which is a space to house the coil 25,
is formed between adjacent teeth 22.
[0050]
10 A tip end 22a of the tooth 22 on its inner side in the
radial direction has a greater width in the circumferential
direction than other portions of the tooth 22. The tip end 22a
of the tooth 22 faces the outer circumference of the rotor 1
via the air gap G described above.
15 [0051]
An insulating portion made of polybutylene terephthalate
(PBT) or the like is fixed to the stator core 20. The coil 25
is wound around the tooth 22 via the insulating portion. The
coil 25 is made of copper or aluminum.
20 [0052]
The rotor 1 has the shaft 18, a rotor core 10 fixed to
the shaft 18, and the plurality of permanent magnets 16
embedded in the rotor core 10.
[0053]
25 FIG. 5 is a diagram illustrating the rotor core 10 and
the permanent magnets 16 of the rotor 1. The rotor core 10 is
a member having an annular shape about the axis C1. The rotor
core 10 has an outer circumference 10a and an inner
circumference 10b, both of which are annular. The rotor core
30 10 is composed of a plurality of electromagnetic steel sheets
which are stacked in the axial direction and fastened together
by crimping or the like. The sheet thickness of each
electromagnetic steel sheet is, for example, 0.2 mm to 0.5 mm.
[0054]
35 The rotor core 10 has a plurality of magnet insertion
holes 11. The magnet insertion holes 11 are arranged at equal
intervals in the circumferential direction and also at the same
distance from the axis C1. The number of magnet insertion
14
5 holes 11 is five in this example.
[0055]
Each magnet insertion hole 11 extends linearly in a
direction orthogonal to a straight line (referred to as a
magnetic pole center line) in the radial direction that passes
10 through a pole center, i.e., a center of the magnetic insertion
hole 11 in the circumferential direction. The shape of the
magnet insertion hole 11 is not limited to such a shape, but
may be a V shape, for example.
[0056]
15 A flux barrier 12, which is a hole, is formed at each end
of the magnet insertion hole 11 in the circumferential
direction. A thin wall portion is formed between the flux
barrier 12 and the outer circumference 10a of the rotor core 10.
In order to suppress the leakage magnetic flux between adjacent
20 magnetic poles, it is desirable that the thickness of the thin
wall portion is the same as the sheet thickness of each
electromagnetic steel sheet of the rotor core 10.
[0057]
The permanent magnet 16 is inserted in each magnet
25 insertion hole 11. The permanent magnet 16 has a flat plate
shape, and has a rectangular cross-sectional shape in a plane
orthogonal to the axial direction. The permanent magnet 16 is
composed of a rare earth magnet. More specifically, the
permanent magnet 16 is composed of a neodymium sintered magnet
30 containing Nd (neodymium), Fe (iron), and B (boron).
[0058]
The permanent magnets 16 are arranged so that the same
magnetic poles (for example, the N poles) face the outer
circumference 10a side of the rotor core 10. In the rotor core
35 10, a magnetic pole (for example, the S pole) opposite to the
permanent magnets is formed in a region between the permanent
magnets adjacent in the circumferential direction.
[0059]
15
5 Thus, five magnet magnetic poles P1 constituted by the
permanent magnets 16 and five virtual magnetic poles P2
constituted by the rotor core 10 are formed in the rotor 1.
This configuration is referred to as a consequent pole type.
Hereinafter, when the term "magnetic pole" is simply used, it
10 refers to either the magnet magnetic pole P1 and the virtual
magnetic pole P2. The rotor 1 has 10 magnetic poles.
[0060]
In the consequent pole rotor 1, the number of permanent
magnets 16 can be halved as compared with a non-consequent pole
15 rotor having the same number of poles. Since the number of the
permanent magnets 16 which are expensive is small, the
manufacturing cost of the rotor 1 is reduced.
[0061]
Although the number of poles of the rotor 1 is 10 in this
20 example, the number of poles only needs to be an even number of
four or more. Although one permanent magnet 16 is disposed in
each magnet insertion hole 11 in this example, two or more
permanent magnets 16 may be disposed in each magnet insertion
hole 11. The magnet magnetic pole P1 may be the S pole, while
25 the virtual magnetic pole P2 may be the N pole.
[0062]
The rotor core 10 has at least one slit 13 elongated in
the radial direction in the virtual magnetic pole P2. The slit
13 functions to rectify the flow of magnetic flux passing
30 through the virtual magnetic pole P2 so that the magnetic flux
flows in the radial direction. In this regard, it is not
necessary to form the slit 13 in the virtual magnetic pole P2.
[0063]
The rotor core 10 has cavity portions 15 on the inner
35 side of the magnet insertion holes 11 in the radial direction.
Each cavity portion 15 is provided to uniformize the flow of
magnetic flux in the circumferential direction, on the inner
side of the magnet insertion hole 11 in the radial direction.
16
5 The cavity portion 15 has a slit shape elongated in the radial
direction. In this regard, the shape of the cavity portion 15
is not limited to a slit shape, but may be a circular shape or
other shapes.
[0064]
10 The shaft 18 is fitted into the inner circumference 10b
of the rotor core 10. In this regard, a resin portion may be
provided between the inner circumference 10b of the rotor core
10 and the shaft 18.
[0065]
15 A width W2 of the virtual magnetic pole P2 in the
circumferential direction is narrower than a width W1 of the
permanent magnet 16 in the circumferential direction. The
magnetic flux density at the virtual magnetic pole P2 increases
because much magnetic flux exiting from the permanent magnets
20 16 passes through the narrow virtual magnetic poles P2. That
is, a reduction in the magnetic flux density due to absence of
the permanent magnet in the virtual magnetic pole P2 can be
compensated for by narrowing the width W2 of the virtual
magnetic pole P2.
25 [0066]
(Operation)
Next, the operation of the first embodiment will be
described. FIG. 6 is a graph illustrating the magnetic flux
density distribution on the outer circumference of the rotor 1,
30 obtained by actual measurement of the magnetic flux density.
The vertical axis indicates the magnetic flux density [mT],
while the horizontal axis indicates the position in the
circumferential direction, i.e., an angle [degrees] about the
axis C1. In FIG. 6, the positions of the pole center of the
35 magnet magnetic pole P1 and the position of the pole center of
the virtual magnetic pole P2 are indicated by reference
characters P1 and P2, respectively.
[0067]
17
5 As illustrated in FIG. 6, the magnetic flux density
reaches a positive peak at the magnet magnetic pole P1 and a
negative peak at the virtual magnetic pole P2. In this regard,
the reason why the magnetic flux density decreases at the pole
center of the magnet magnetic pole P1 while the magnetic flux
10 density increases at the pole center of the virtual magnetic
pole P2 is that the magnetic flux flows symmetrically with
respect to the corresponding pole center.
[0068]
An absolute value of the magnetic flux density at the
15 virtual magnetic pole P2 is smaller than an absolute value of
the magnetic flux density at the magnet magnetic pole P1. This
is because the virtual magnetic pole P2 has no permanent magnet
16.
[0069]
20 In the consequent pole rotor 1, since the virtual
magnetic pole P2 has no permanent magnet 16, the magnetic flux
is more likely to flow toward the center of the rotor core 10.
The magnetic flux flowing toward the center of the rotor core
10 further flows into the shaft 18, i.e., a leakage magnetic
25 flux occurs.
[0070]
FIG. 7 is a diagram illustrating the flow of leakage
magnetic flux in the outdoor unit 100 of the first embodiment.
The magnetic flux flowing to the shaft 18 further flows through
30 the pillars 131 of the support body 130 upward and downward and
then proceeds toward the top plate 112 and the bottom plate 111.
[0071]
The top plate 112 is exposed to the outside of the
outdoor unit 100 and has a large area. Thus, if the magnetic
35 flux flows to the top plate 112, it may affect peripheral
components of the outdoor unit 100. Thus, it is desirable to
suppress the magnetic flux from flowing to the top plate 112.
Further, in order to meet the IATA standards, it is required
18
5 that the magnetic flux does not flow to the top plate 112
having a large area.
[0072]
For this reason, in the first embodiment, the nonmagnetic
bodies 71, 72, and 73 are disposed between the support body 130
10 and the top plate 112. Since the nonmagnetic bodies 71, 72,
and 73 are disposed in this way, the contact area between the
support body 130 and the top plate 112 can be reduced. This
makes it possible to suppress the flow of magnetic flux from
the support body 130 to the top plate 112.
15 [0073]
The nonmagnetic body 71 is also located between the upper
end of the front panel 120 and the top plate 112, and thus the
flow of magnetic flux from the front panel 120 to the top plate
112 can be suppressed.
20 [0074]
It is most desirable that the support body 130 is not in
contact with the top plate 112, but the support body 130 is not
limited to such a configuration. In other words, by reducing
the contact area between the support body 130 and the top plate
25 112, the effect of reducing the flow of magnetic flux from the
support body 130 to the top plate 112 can be achieved.
[0075]
It is not necessary to provide all of the nonmagnetic
bodies 71, 72, and 73. When at least one nonmagnetic body is
30 provided between the top plate 112 and the support body 130,
the effect of reducing the flow of magnetic flux to the top
plate 112 can be achieved.
[0076]
As illustrated in FIG. 8, the magnetic flux flowing from
35 the support body 130 to the bottom plate 111 further flows to
the side plates 113 and 114 and the partition plate 115. The
magnetic flux flowing to the side plates 113 and 114 and the
partition plate 115 further flows toward the top plate 112.
19
5 [0077]
For this reason, in the first embodiment, the nonmagnetic
body 74 is disposed between the side plate 113 and the top
plate 112, the nonmagnetic body 75 is disposed between the side
plate 114 and the top plate 112, and the nonmagnetic body 76 is
10 disposed between the partition plate 115 and the top plate 112.
[0078]
The arrangement of the nonmagnetic bodies 74, 75, and 76
in this way makes it possible to suppress the flow of magnetic
flux from the side plates 113 and 114 and the partition plate
15 115 to the top plate 112. That is, the effect of suppressing
magnetic flux leakage to the top plate 112 can be enhanced.
[0079]
In this regard, it is not necessary to provide all of the
nonmagnetic bodies 74, 75, and 76. The effect of reducing the
20 flow of magnetic flux to the top plate 112 can be achieved as
long as the nonmagnetic body is disposed at least one of
between the side plate 113 and the top plate 112, between the
side plate 114 and the top plate 112, and between the partition
plate 115 and the top plate 112.
25 [0080]
FIG. 9 is a cross-sectional view illustrating the upper
part of the outdoor unit 100. The arm portion 133 of the
support body 130 has a bent portion 138 as a displacement
portion that is displaced in a direction away from the top
30 plate 112. The bent portion 138 is formed, for example, by
bending the metal sheet, which constitutes the arm portion 133,
in the direction away from the top plate 112.
[0081]
The bent portion 138 of the arm portion 133 is located at
35 a greater distance from the top plate 112. This makes it
possible to prevent contact between the top plate 112 and the
arm portion 133 even when the top plate 112 is deformed
downward, or even when the arm portion 133 is deformed upward.
20
5 Thus, the magnetic flux leakage to the top plate 112 due to the
contact between the top plate 112 and the arm portion 133 can
be suppressed.
[0082]
The bent portion 138 is formed at a position above the
10 rotating blade 6 in this example, but may be formed at any
other positions. The bent portion 138 may be formed at two or
more locations on the arm portion 133.
[0083]
(Effects of Embodiment)
15 As described above, the outdoor unit 100 of the first
embodiment includes the motor 3 having the consequent pole
rotor 1 and the stator 2, the frame 41 holding the motor 3, the
support body 130 supporting the frame 41, and the unit housing
110 enclosing the frame 41 and the support body 130. The
20 nonmagnetic bodies 71, 72, and 73 (the first nonmagnetic
bodies) are disposed between the support body 130 and the unit
housing 110. This makes it possible to suppress the magnetic
flux leakage to the outside of the outdoor unit 100. Thus, the
influence of the magnetic flux onto the peripheral components
25 can be suppressed, and the IATA standards can be satisfied.
[0084]
In particular, the nonmagnetic bodies 71, 72, and 73 are
disposed between the support body 130 and the top plate 112, so
that the magnetic flux can be prevented from flowing to the top
30 plate 112 having a larger area. Thus, the effect of
suppressing the magnetic flux leakage can be enhanced.
[0085]
Further, the nonmagnetic bodies 74 and 75 (the second
nonmagnetic bodies) are disposed between the side plate 113 and
35 the top plate 112 and between the side plate 114 and the top
plate 112, respectively. Thus, it is possible to suppress the
magnetic flux leakage to the top plate 112 through the side
plates 113 and 114.
21
5 [0086]
In addition, the nonmagnetic body 76 (the third
nonmagnetic body) is disposed between the partition plate 115
and the top plate 112, and thus it is possible to suppress the
magnetic flux leakage to the top plate 112 through the
10 partition plate 115.
[0087]
At least a part (the bent portion 138) of the arm portion
133 serving as a top-plate facing portion of the support body
130 is displaced in the direction away from the top plate 112,
15 and thus the contact between the top plate 112 and the arm
portion 133 can be suppressed. Thus, the magnetic flux leakage
to the top plate 112 due to this contact can be suppressed.
[0088]
The magnetic flux leakage to the top plate 112 through
20 the heat exchanger 140 can be suppressed because the heat
exchanger 140 is formed of a nonmagnetic material.
[0089]
The magnetic flux leakage from the motor 3 to the support
body 130 can also be suppressed because the frame 41 holding
25 the motor 3 is formed of a nonmagnetic material. Thus, the
effect of suppressing the leakage magnetic flux to the outside
of the outdoor unit 100 can be enhanced.
[0090]
Second Embodiment
30 Next, an outdoor unit 100A of a second embodiment will be
described. FIG. 10 is a longitudinal-sectional view
illustrating the outdoor unit 100A of the second embodiment.
In the second embodiment, in addition to the nonmagnetic bodies
71, 72, and 73 described in the first embodiment, nonmagnetic
35 bodies are further disposed between the bottom plate 111 and
each of the support body 130, the side plates 113 and 114, and
the partition plate 115.
[0091]
22
5 A nonmagnetic body 82 is disposed between the pedestal
portion 132 of the support body 130 and the bottom plate 111.
The nonmagnetic body 82 desirably has the same area as a lower
surface of the pedestal portion 132, but the nonmagnetic body
82 is not limited to such a configuration. The nonmagnetic
10 body 82 may be disposed at a plurality of locations along the
lower surface of the pedestal portion 132. The nonmagnetic
body 82 suppresses the flow of magnetic flux from the support
body 130 to the bottom plate 111.
[0092]
15 A nonmagnetic body 81 is disposed between the front panel
120 and the bottom plate 111. It is sufficient that the
nonmagnetic body 81 is disposed at least at one location in the
X direction along a lower end of the front panel 120. The
nonmagnetic body 81 suppresses the flow of magnetic flux from
20 the bottom plate 111 to the front panel 120.
[0093]
A nonmagnetic body 83 is disposed between the heat
exchanger 140 and the bottom plate 111. It is sufficient that
the nonmagnetic body 83 is disposed at least at one location in
25 the X direction along a lower end of the heat exchanger 140.
The nonmagnetic body 83 suppresses the flow of magnetic flux
from the bottom plate 111 to the heat exchanger 140.
[0094]
FIG. 11 is a cross-sectional view illustrating the
30 outdoor unit 100A of the second embodiment. As illustrated in
FIG. 11, a nonmagnetic body 84 is disposed between a lower end
of the side plate 113 and the bottom plate 111. It is
sufficient that the nonmagnetic body 84 is disposed at least at
one location in the Y direction along the lower end of the side
35 plate 113. The nonmagnetic body 84 suppresses the flow of
magnetic flux from the bottom plate 111 to the side plate 113.
[0095]
Similarly, a nonmagnetic body 85 is disposed between a
23
5 lower end of the side plate 114 and the bottom plate 111. It
is sufficient that the nonmagnetic body 85 is disposed at least
at one location in the Y direction along the lower end of the
side plate 114. The nonmagnetic body 85 suppresses the flow of
magnetic flux from the bottom plate 111 to the side plate 114.
10 [0096]
A nonmagnetic body 86 is disposed between a lower end of
the partition plate 115 and the bottom plate 111. It is
sufficient that the nonmagnetic body 86 is disposed at least at
one location in the Y direction along the lower end of the
15 partition plate 115. The nonmagnetic body 86 suppresses the
flow of magnetic flux from the bottom plate 111 to the
partition plate 115.
[0097]
A nonmagnetic body 87 is disposed between the compressor
20 101 and the bottom plate 111. The nonmagnetic body 87
desirably has the same area as the bottom surface of the
compressor 101, but the nonmagnetic body 87 is not limited to
such a configuration. The nonmagnetic body 87 may be disposed
at a plurality of locations along the bottom surface of the
25 compressor 101. The nonmagnetic body 87 suppresses the flow of
magnetic flux from the bottom plate 111 to the compressor 101.
[0098]
Further, a nonmagnetic body 88 is disposed between the
upper end of the heat exchanger 140 and the arm portion 133.
30 It is sufficient that the nonmagnetic body 88 is disposed at
least at one location in the X direction along the upper end of
the heat exchanger 140. The nonmagnetic body 88 has an L shape
in the YZ plane so as to be in contact with the upper end of
the heat exchanger 140 and the fixing portion 137 (see FIG. 10).
35 The nonmagnetic body 88 suppresses the flow of magnetic flux
from the heat exchanger 140 to the arm portion 133.
[0099]
A nonmagnetic body 89 is disposed between the motor
24
5 housing 4 and the mounting plate 135 of the support body 130.
The nonmagnetic body 89 suppresses the flow of magnetic flux
generated in the rotor 1 into the support body 130 through the
motor housing 4.
[0100]
10 The nonmagnetic bodies 81 to 89 are formed of the same
material as the nonmagnetic bodies 71 to 76 described in the
first embodiment.
[0101]
In addition, the outdoor unit 100A of the second
15 embodiment has the nonmagnetic bodies 71 to 76 described in the
first embodiment. The configurations of the nonmagnetic bodies
71 to 76 are as described in the first embodiment. In this
regard, the nonmagnetic body 71 has an L shape in the XZ plane
so as to be in contact with a lower surface of the top plate
20 112 and a front end of the fixing portion 136 (see FIG. 11).
[0102]
The arrangement of the nonmagnetic bodies 81 to 89 in
this way makes it possible to suppress magnetic flux leakage to
the bottom plate 111, the top plate 112, the side plates 113
25 and 114, the front panel 120, and the heat exchanger 140. In
other words, it is possible to suppress the magnetic flux
leakage to the surface of the outdoor unit 100 exposed to the
outside, and thus the effect of suppressing the magnetic flux
leakage to the outside of the outdoor unit 100 can be enhanced.
30 [0103]
In this regard, it is not necessary to provide all the
nonmagnetic bodies 71 to 76 and 81 to 89. The effect of
reducing the magnetic flux leakage to the outside of the
outdoor unit 100 can be achieved as long as at least one of the
35 nonmagnetic bodies 81 to 89 is provided.
[0104]
The outdoor unit 100A of the second embodiment is
configured in the same manner as the outdoor unit 100 of the
25
5 first embodiment except for the provision of the nonmagnetic
bodies 81 to 89 and the shape of the nonmagnetic body 71.
[0105]
As described above, in the second embodiment, the
nonmagnetic body 82 (the fourth nonmagnetic body) is disposed
10 between the bottom plate 111 and the support body 130, and thus
the flow of magnetic flux from the support body 130 to the
bottom plate 111 can be suppressed. Therefore, the effect of
suppressing the magnetic flux leakage to the outside of the
outdoor unit 100 can be enhanced.
15 [0106]
Further, the nonmagnetic bodies 84 and 85 (the fifth
nonmagnetic bodies) are disposed between the side plate 113 and
the bottom plate 111, and between the side plate 114 and the
bottom plate 111, respectively. Thus, it is possible to
20 suppress the flow of magnetic flux from the bottom plate 111 to
the side plates 113 and 114.
[0107]
In addition, the nonmagnetic body 86 (the sixth
nonmagnetic body) is disposed between the partition plate 115
25 and the bottom plate 111, and thus it is possible to suppress
the flow of magnetic flux from the bottom plate 111 to the top
plate 112 through the partition plate 115.
[0108]
Further, the nonmagnetic body 87 (the seventh nonmagnetic
30 body) is disposed between the compressor 101 and the bottom
plate 111, and thus the magnetic flux leakage from the bottom
plate 111 to the compressor 101 can be suppressed. Therefore,
the reliability of the operation of the compressor 101 can be
enhanced.
35 [0109]
The nonmagnetic body 83 (the eighth nonmagnetic body) is
disposed between the heat exchanger 140 and the bottom plate
111, and thus the magnetic flux leakage from the bottom plate
26
5 111 to the heat exchanger 140 can be suppressed. Therefore,
the effect of suppressing the magnetic flux leakage to the
outside of the outdoor unit 100 can be enhanced.
[0110]
Further, the nonmagnetic body 81 (the ninth nonmagnetic
10 body) is disposed between the front panel 120 and the bottom
plate 111, and thus the magnetic flux leakage from the bottom
plate 111 to the front panel 120 can be suppressed. Therefore,
the effect of suppressing the magnetic flux leakage to the
outside of the outdoor unit 100 can be enhanced.
15 [0111]
In addition, the nonmagnetic body 89 (the tenth
nonmagnetic body) is disposed between the motor housing 4 and
the support body 130, and thus it is possible to suppress the
flow of magnetic flux generated in the rotor 1 into the support
20 body 130 through the motor housing 4.
[0112]
(Air Conditioner)
Next, an air conditioner to which the outdoor unit 100 or
100A of each of the embodiments is applicable will be described.
25 FIG. 12 is a diagram illustrating the configuration of an air
conditioner 200 to which the outdoor unit 100 of the first
embodiment is applied. The air conditioner 200 includes the
outdoor unit 100, the indoor unit 201, and a refrigerant pipe
207 that connects these units.
30 [0113]
The indoor unit 201 has an indoor fan 202. The indoor
fan 202 has an impeller 203, which is, for example, a cross
flow fan, a motor 204 that drives the impeller 203, the heat
exchanger 205 disposed to face the impeller 203, and a casing
35 206 in which these elements are housed.
[0114]
The compressor 101, the heat exchanger 140, and a notshown decompression device of the outdoor unit 100, and the
27
5 heat exchanger 205 of the indoor unit 201 are connected by the
refrigerant pipe 207 to constitute a refrigerant circuit.
[0115]
In the outdoor unit 100, the rotation of the motor 3 of
the fan 5 causes the rotating blade 6 to rotate, and generates
10 an airflow passing through the heat exchanger 140. During a
cooling operation, heat is released when the refrigerant
compressed by the compressor 101 is condensed in the heat
exchanger 140 (condenser). Air heated with this heat is blown
out through the opening 121 (FIG. 1) of the front panel 120 to
15 the outside of the room by the airflow of the fan 5.
[0116]
In the indoor unit 201, the rotation of the motor 204 in
the indoor fan 202 rotates the impeller 203 to blow air into
the room. During the cooling operation, air deprived of heat
20 when the refrigerant evaporates in the heat exchanger 205
(evaporator) is blown into the room by the airflow of the
indoor fan 202.
[0117]
As described in the first embodiment, the magnetic flux
25 leakage to the outside of the outdoor unit 100 can be
suppressed, and thus it is possible to suppress the influence
of the magnetic flux onto peripheral components. Further, the
IATA standards can be satisfied.
[0118]
30 Instead of the outdoor unit 100 of the first embodiment,
the outdoor unit 100A (FIGS. 10 and 11) of the second
embodiment may be used.
[0119]
Although the desirable embodiments of the present
35 disclosure have been specifically described, the present
disclosure is not limited to the above embodiments, and various
modifications or changes can be made to those embodiments
without departing from the scope of the present disclosure.
28
5 DESCRIPTION OF REFERENCE CHARACTERS
[0120]
1: rotor, 2: stator, 3: motor, 4: motor housing, 5:
fan, 6: rotating blade, 10: rotor core, 11: magnet insertion
hole, 12: flux barrier, 13: slit, 16: permanent magnet, 18:
10 shaft, 20: stator core, 21: yoke, 22: tooth, 25: coil,
31,32: bearing, 41: frame, 42: bearing support plate, 43: leg
portion, 61: hub, 62: blade, 71, 72, 73, 74, 75, 76:
nonmagnetic body, 81, 82, 83, 84, 85, 86, 87, 88, 89:
nonmagnetic body, 100, 100A: outdoor unit, 101: compressor,
15 110: unit housing, 111: bottom plate, 112: top plate, 113,
114: side plate, 115: partition plate, 120: front panel, 121:
opening, 130: support body, 131: pillar, 132: pedestal
portion, 133: arm portion, 135: mounting portion, 140: heat
exchanger, 200: air conditioner, 201: indoor unit, 202:
20 indoor fan, 206: refrigerant pipe.
29
5 WE CLAIM:
1. An outdoor unit comprising:
a motor comprising:
a rotor having a rotor core and a permanent magnet
10 attached to the rotor core, the permanent magnet forming a
magnet magnetic pole, a part of the rotor core forming a
virtual magnetic pole; and
a stator surrounding the rotor;
a frame holding the motor;
15 a support body supporting the frame;
a unit housing in which the frame and the support body
are housed; and
a nonmagnetic body disposed between the support body and
the unit housing.
20
2. The outdoor unit according to claim 1, wherein the unit
housing has a top plate located above the frame and a bottom
portion located under the frame, and
wherein the nonmagnetic body is disposed between the
25 support body and the top plate.
3. The outdoor unit according to claim 2, wherein a
nonmagnetic body is further disposed between the support body
and the bottom portion.
30
4. The outdoor unit according to claim 2 or 3, wherein the
unit housing has a side plate, and
wherein a nonmagnetic body is further disposed at least
one of between the side plate and the top plate and between the
35 side plate and the bottom portion.
5. The outdoor unit according to any one of claims 2 to 4,
further comprising:
30
5 a compressor disposed inside the unit housing; and
a partition member disposed between the support body and
the compressor,
wherein a nonmagnetic body is further disposed at least
one of between the partition member and the top plate and
10 between the partition member and the bottom portion.
6. The outdoor unit according to claim 5, wherein
nonmagnetic body is further disposed between the compressor and
the bottom portion.
15
7. The outdoor unit according to any one of claims 2 to 6,
wherein the support body has a top-plate facing portion
that faces the top plate, and
wherein at least a part of the top-plate facing portion
20 is displaced in a direction away from the top plate.
8. The outdoor unit according to any one of claims 2 to 7,
further comprising:
a heat exchanger disposed inside the unit housing,
25 wherein the heat exchanger is formed of a nonmagnetic
material.
9. The outdoor unit according to claim 8, wherein a
nonmagnetic body is further disposed at least one of between
30 the heat exchanger and the top plate and between the heat
exchanger and the bottom portion.
10. The outdoor unit according to any one of claims 2 to 9,
wherein the unit housing has a front panel, and
35 wherein a nonmagnetic body is further disposed at least
one of between the front panel and the top plate and between
the front panel and the bottom portion.
31
5 11. The outdoor unit according to claim 10, wherein a
nonmagnetic body is further disposed between the front panel
and the support body.
12. The outdoor unit according to any one of claims 1 to 11,
10 wherein a nonmagnetic body is further disposed between the
frame and the support body.
13. The outdoor unit according to any one of claims 1 to 12,
wherein the frame is formed of a nonmagnetic material.
15
14. The outdoor unit according to any one of claims 1 to 13,
wherein the rotor has a shaft,
wherein the outdoor unit further comprising a rotating
blade fixed to the shaft.
20
15. An air conditioner comprising:
the outdoor unit according to any one of claims 1 to 14;
and
an indoor unit connected to the outdoor unit via a
25 refrigerant pipe.