Description

AIR CONDITIONER

Technical Field

[1] The present invention relates to an air conditioner, and more particularly, to an air conditioner that uses a brushless direct current (BDCM) motor with a blower fan installed on the exterior of the motor.

[2]

Background Art

[3] Air conditioners are generally cooling/heating systems used for cooling or heating an indoor space.

[4] Air conditioners can largely be divided into split system air conditioners having an outdoor unit installed separately from an indoor unit, and single unit air conditioners that integrate the components of the outdoor and indoor units in one unit.

[5] Recently, in order for a household to install two or more air conditioners, or each office of a multi-office building to install an air conditioner, an effective alternative that has become commercially available is a multi room air conditioner. Such multi room air conditioners use a single outdoor unit with a plurality of indoor units, to offer the same effect as installing multiple split system air conditioners.

[6] FlG. 1 is an exemplary perspective view showing a multi room air conditioning system with one outdoor unit connected to two indoor units.

[7] Referring to FlG. 1, a standing first indoor unit 20 is installed in a living room, and a wall mounted second indoor unit 30 is installed in a master bedroom. One outdoor unit 10, for performing compression, condensation, and expansion of refrigerant, is installed on a veranda outdoors; and the above first and second indoor units 20 and 30 installed in the separate indoor spaces are respectively connected to the outdoor unit 10, and perform evaporating of the refrigerant. The air conditioning system is thus configured.

[8] FlG. 2 is a perspective view showing the inner structure of an outdoor unit according to the related art.

[9] Referring to FlG. 2, an outdoor unit 10 according to the related art includes a compressor 40 for compressing refrigerant to a high temperature and pressure, an outdoor heat exchanger 42 connected to the compressor 40 and condensing the refrigerant discharged from the compressor 40 through heat exchange with outdoor air, an outdoor blower fan 44 blowing outdoor air toward the outdoor heat exchanger 42, and an accumulator 46 for accumulating liquid refrigerant from the refrigerant discharged from the first and second indoor units 20 and 30.

[10] Also, a fan motor 50, that provides rotational force to the outdoor blower fan 44, is provided at the inner or rear portion of the outdoor blower fan 44. The fan motor 50 is supported on a motor mount 52.

[11] Although not shown, the first and second indoor units 20 and 30 each have a built- in indoor heat exchanger to generate cold air through heat exchange of refrigerant with indoor air, an indoor blower fan for blowing indoor air toward an indoor heat exchanger, etc.

[12] However, as described above, outdoor units of air conditioners according to the related art have only one outdoor blower fan 44, one compressor 40, and one outdoor heat exchanger 42, so that the performance of the entire air conditioning system is reduced.

[13] Also, the fan motor 50 used in a conventional outdoor unit 10 uses alternating current as a power source and a motor with a brush. Accordingly, after prolonged use, supply of power can be interrupted or a short can occur due to wear of the brush.

[14]

Disclosure of Invention Technical Problem

[15] Accordingly, the present invention is directed to an air conditioner that substantially obviates one or more problems due to limitations and disadvantages of the related art

[16] An object of the present invention is to provide an air conditioner that uses a BLDC motor that does not require a brush.

[17] Another object of the present invention is to provide a an air conditioner that better supplies electrical power to the stator of the motor through an improved method of coupling the blower fan and the motor.

[18] A further object of the present invention is to provide an air conditioner in which the blower fan rotates more smoothly through an improved method of coupling the blower fan and the motor.

[19]

Technical Solution

[20] To achieve these objects and other advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, there is provided an air conditioner including: a cabinet; a heat exchanger provided within the cabinet; a blower fan installed in a location near the heat exchanger, for forcefully generating a flow of air; and a motor including a rotor to which the blower fan is coupled, a stator enclosed by the rotor and generating a magnetic field through a supplied current, and a shaft fixed to the stator.

[21] In another aspect of the present invention, there is provided an air conditioner

including: a motor including a stator with a coil wound a plurality of times around the stator for generating an electromagnetic field, a left rotor provided at one side of the stator and rotating, a right rotor provided at the other side of the stator and coupled to rotate together with the left rotor, a shaft integrally coupled to the stator and providing a rotating center of the rotors, and a fixing member for connecting the shaft and the stator; a plurality of blower fans respectively coupled to the left rotor and the right rotor; and a plurality of heat exchangers respectively provided close to the blower fans. [22] In a further aspect of the present invention, there is provided an air conditioner including: a motor including a fixing shaft, a fixing member coupled at a center thereof to the fixing shaft, a stator fixed to an end of the fixing member, and a rotor enclosing the stator and rotating; a blower fan coupled to an outer surface of the rotor; and a heat exchanger for exchanging heat between air suctioned by a rotation of the blower fan, and refrigerant, wherein the fixing shaft and the stator are stationary, and the rotor and the blower fan rotate integrally. Advantageous Effects

[23] An advantage of the air conditioner according to the present invention is a BLDC motor is used, so that disruptions in the supply of power in air conditioners according to the related art can be prevented. That is, short circuits and various other electrical problems caused by wear or damage of the brush over a prolonged period of use can be prevented. Thus, product reliability is improved.

[24] A further advantage of the air conditioner according to the present invention is that the BLDC motor used in the present invention is different from a conventional BLDC motor in that the stator and the motor shaft are fixed, and the rotor rotates around the outside of the stator. Therefore, the supply of electrical power through the fixed stator is greatly improved.

[25] A still further advantage of the air conditioner according to the present invention is that the blower fan is fixed to the exterior of the rotor to rotate together with the rotor, so that the blower fan can rotate more smoothly.

[26]

Brief Description of the Drawings

[27] FlG. 1 is an exemplary perspective view showing a multi room air conditioning system with one outdoor unit connected to two indoor units.

[28] FlG. 2 is a perspective view showing the inner structure of an outdoor unit according to the related art.

[29] FlG. 3 is a perspective view showing the exterior of an outdoor unit of an air conditioner according to the present invention.

[30] FlGs. 4 and 5 are perspective views showing the inner structure of the outdoor unit

in FTG. 3.

[31] FlG. 6 is an exploded perspective view of the outdoor unit in FlG. 3.

[32] FlG. 7 is a perspective view showing the exterior of a blower according to the present invention.

[33] FlG. 8 is an exploded perspective view of the blower in FlG. 7.

[34] FlG. 9 is a perspective view showing the exterior of the blower fan according to the present invention. [35] FlGs. 10 and 11 are perspective views showing the structure of a right fan of a blower fan according to the present invention. [36] FlG. 12 is a perspective view showing the exterior of a motor included in a blower according to the present invention. [37] FlG. 13 is an exploded perspective view of a motor included in a blower according to the present invention. [38] FlG. 14 is a perspective view showing the interior structure of the rotor included in the motor in FlG. 13.

[39] FlG. 15 is a cross sectional view of the motor in FlG. 12 taken along line I-I'.

[40] FlG. 16 is a cutaway perspective view of the motor in FlG. 12 taken along line I-I'.

[41] FlG. 17 is a perspective view showing the coupling of a supporting bracket and a reinforcing member included in a blower according to the present invention. [42]

Best Mode for Carrying Out the Invention [43] 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. [44] FlG. 3 is a perspective view of an outdoor unit of an air conditioner according to the present invention, FlGs. 4 and 5 are perspective views showing the inner structure of the outdoor unit in FlG. 3, and FlG. 6 is an exploded perspective view of the outdoor unit in FlG. 3. [45] Referring to FlGs. 3 through 6, a base pan 110 forming a floor of an outdoor unit

100 of an air conditioner according to the present invention is provided at the bottom of the outdoor unit 100. Also, the a plurality of fixing portions 112 are formed to protrude outward from the left and right sides of the base pan 110. When fastening members such as screws are passed through the fixing portions 112, they can fasten the base pan 110 to a floor surface of a building. [46] A pair of heat exchangers 120 and 120' is vertically installed - one on either side of the base pan 110. The heat exchangers 120 and 120' exchange heat between refrigerant

that passes within and outdoor air, and are installed facing each other. That is, a left heat exchanger 120 is installed on the left edge of the base pan 110, and a right heat exchanger 120' is installed on the right edge of the base pan 110.

[47] The left and right heat exchangers 120 and 120' each have an intake grill 130 and

130' installed thereon. The intake grills 130 and 130' guide air flowing into the outdoor unit 100 and include a plurality of grid-shaped air passages. In further detail, a left intake grill 130 is formed on the side of the left heat exchanger 120, and a right intake grill 130' is formed on the side of the right heat exchanger 120'.

[48] Also, safety meshes 135 and 135' are respectively installed between the heat exchangers 120 and 120' and intake grills 130 and 130'. That is, a left safety mesh 135 is provided between the left heat exchanger 120 and the left intake grill 130, and a right safety mesh 135' is provided between the right heat exchanger 120' and the right intake grill 130'. Specifically, the safety meshes 135 and 135' have net shapes and filter foreign objects from air passing through the intake grills 130 and 130' while also blocking body parts such as fingers from being inserted into the outdoor unit.

[49] A pair of front frames 140 is installed at the front end of the base pan 110.

Specifically, the front frames 140 are respectively installed at the left and right of the front end of the base pan 110, and support the intake grills 130 and 130' and the safety meshes 135 and 135'.

[50] Also, a discharge safety grill 142 is installed between the pair of front frames 140.

The discharge safety grill 142 is installed vertically at the front edge of the base pan 110. The discharge safety grill 142 is formed in a net shape like the safety meshes 135 and 135', and prevents bodily parts from being inserted into a discharge port 232 of a fan housing 230 (to be described below).

[51] Rear supporting frames 144 are respectively installed at the rear end of the intake grills 130 and 130' and the safety meshes 135 and 135'. The supporting frames 144 support the rear end of the intake grills 130 and 130' and the safety meshes 135 and 135', and simultaneously support front ends of blowers 200 and 200', to be described below.

[52] Also, a cabinet 150 is installed at a rear end of the base pan 110. The cabinet 150 has a cross sectional "U" shape such that the cabinet 150 covers a part of a rear surface and left and right side surfaces of the outdoor unit 100.

[53] Meanwhile, one side of the cabinet 150 passes through an inspection opening 152.

The inspection opening 152 is used for easily gaining access to the inside of the outdoor unit 100 from the rear of the outdoor unit 100. Also, a control box 190 is located at the front of the inspection opening 152.

[54] The inspection opening 152 is sealed by an inspection plate 152'. In detail, the inspection plate 152 has a shape and a size equivalent to the inspection opening 152.

Thus, the inspection plate 152 is coupled to the cabinet 150 from the rear of the outdoor unit 100 by a coupling member such as a screw to seal the inspection opening 152.

[55] Also, a pipe through opening 154 is formed at a rear lower end of the cabinet 150, for allowing a pipe to pass through the cabinet 150 from the front to rear thereof. Also, a pipe bracket 156 is mounted on the pipe through opening 154. That is, the pipe through opening 154 is sealed by the pipe bracket 156 having a size equivalent to the pipe through opening 154. A pipe (not shown) for guiding refrigerant flowing between the inside and outside of the outdoor unit 100 passes through the pipe through opening 154.

[56] Barrier supporters 158 are respectively formed at front ends of the cabinet 150. The barrier supporters 158 are respectively formed at left and right front ends of the cabinet 150 and formed in a pair having a predetermined gap therebetween. Thus, barrier slots 158 for inserting both side ends of a barrier 160 are formed between the pair of barrier supporters 158. The barrier 160 will be described below.

[57] In detail, the barrier slot 158 is elongated in a vertical direction. Also, the inside surfaces of ends of the cabinet 150 are formed facing each other. Preferably, the barrier slot 158 has a width equivalent to a thickness of the barrier 160. In further detail, the width of the barrier slot 158 is slightly larger than the thickness of the barrier 160 to be described below. Thus, it is preferable that the barrier 160 is attachable in a sliding manner in the barrier slot 158' in the vertical direction.

[58] The barrier 160 that divides the space within the outdoor unit 100 into front and rear spaces, is installed between the rearmost portions of the heat exchangers 120 and 120'.

[59] The barrier 160, with a rectangular plate shape, is installed between the rearmost portion of the left heat exchanger 120 and the rearmost portion of the right heat exchanger 120', and divides a space in which the compressors 180 and 180 to be described below are installed from a space in which the blowers 200 and 200' are installed.

[60] In further detail, the barrier 160 is fixedly inserted into the slots at the front end of the cabinet 150. That is, both side edges of the barrier 160 are respectively inserted into the barrier slots 158 formed at the front end of the barrier 160 from the top in a downward direction to couple the barrier 160 to the cabinet 150.

[61] Also, an upper panel 170 is installed at an upper side of the cabinet 150. The upper panel 170 has a square plate shape of a size equivalent to the size of the base pan 110. Thus, the upper panel 170 forms the upper exterior of the outdoor unit 100.

[62] The blower for forcing a flow of air is installed at the front of the barrier 160. In detail, a pair of blowers 200 and 200'is arranged vertically between the pair of heat exchangers 120 and 120'.

[63] In further detail, the blowers consist of a lower blower 200 installed at the lower portion in the inner space of the base pan 110 and an upper blower 200 installed at an upper portion above the lower blower 200, and the lower blower 200 and the upper blower 200' have identical configurations.

[64] The blowers 200 and 200' are slidingly inserted into the pair of supporting frames

144 to couple the blowers 200 and 200' to the supporting frames 144. Thus, blower fixers 201 respectively extend to the left and right of the blowers, so that the extended blower fixers 201 may be inserted into blower fixing slots 144' in the supporting frames 144.

[65] Here, the thickness of the blower fixer 201 is less than the width of the blower fixing slot 144'. Therefore, the blower fixer 201 can be slid along the blower fixing slot 144' when inserted therein.

[66] Also, a housing supporter 202 is provided at the lower end of the lower blower 200.

The housing support 202 is installed on an upper surface of the base pan 110 to support the blowers 200 and 200'. An upper surface of the housing support 202 has a shape corresponding to the bottom of the lower blower 200. That is, the upper surface of the housing support 202 is curved in a corresponding shape to the lower surface of a blower housing 230 (to be described below) to completely press against the blower housing 230.

[67] The blowers 200 and 200' are shown in duplicate as an example, and may be provided singularly or in triplicate or higher. The pair of blowers 200 and 200' suction air from either side thereof and blow the air in a forward direction. A detailed description of the blowers 200 and 200' will be given below.

[68] A plurality of compressors 180 and 180' are installed behind the barrier 160. The compressors 180 and 180' are fixedly installed on the base pan 110, and compress refrigerant to a high temperature and pressure.

[69] The compressors 180 and 180' are provided in duplicate, as shown. That is, one is a constant speed compressor 180 that operates at a constant speed, and the other is an inverter compressor 180' capable of controlling its operating speed. The constant speed compressor 180 is a compressor that operates at a uniform RPM, and the inverter converter 180' is an inverter scroll compressor that adjusts its RPM according to the load it is handling.

[70] Thus, when only a few indoor units are being used so that the load is light, the inverter compressor 180' first operates, and as the load gradually increases to a point where the inverter compressor 180' cannot handle the load alone, the constant speed compressor 180 operates.

[71] An accumulator 182 and a receiver 184 are respectively installed near the compressors 180 and 180'. The accumulator 182 filters refrigerant in liquid form and

allows only gaseous refrigerant to flow into the compressors 180 and 180'. The receiver 184 stores surplus refrigerant in an adjustable amount.

[72] Also, the control box 190 is installed behind the barrier 160. Specifically, the a control box installing bracket 192 is installed at the rear of the upper part of the barrier 160, and the control box 190 is mounted on the control box installing bracket 192. The control box 190 includes a plurality of controlling components installed within, controlling the overall operation of the indoor unit 100.

[73] The supporting frame has a supporting frame 144 coupling a plurality of blower assemblies into one unit respectively installed on the left and right upper surfaces of the base pan 110. Also, the transverse member of the supporting frame 144 is formed in a "U" shape. The supporting frames 144 are formed extending vertically and symmetrically formed to face each other when installed. The blower fixing slots 144 are formed in the inner surfaces of the supporting frames 144, for inserting the blower fixer 201. The blower fixing slot 144 has a width corresponding to the thickness of the blower fixer 201. Specifically, the blower fixing slot 144 is slightly wider than the thickness of the blower fixer 201, so the blower fixer 201 is able to slide along the blower fixing slot 144' when inserted therein.

[74] FlG. 7 is a perspective view showing the exterior of a blower according to the present invention, FlG. 8 is an exploded perspective view of the blower in FlG. 7, and FlG. 9 is a perspective view showing the exterior of the blower fan according to the present invention.

[75] Referring to FlGs. 7 through 9, the blower 200 includes a blower fan 210 for generating a flow of air by rotating, a motor 220 generating the rotational force to rotate the blower fan 210, and a fan housing 230 provided around the outside of the blower fan 210, for guiding the discharging of air suctioned by the blower fan 210. Here, the motor 220 is a BLDC motor, the structure of which will be described in detail below with reference to the diagrams.

[76] The blower fans 210 are symmetrically formed to form a pair of coupled fans. As shown in FlG. 8, the blower fans 210 include a left fan 210 and a right fan 210' that are coupled together and formed symmetrically.

[77] The left fan 210 and the right fan 210' are fastened together using a screw or other fastening member, and combine to form a unitary assembly. Thus, the left fan 210 and the right fan 210' enclose the outside of the motor 220.

[78] The motor 220 is a motor that does not have a brush for transmitting electrical power. The motor is a brushless direct current (generally referred to as a BLDC) motor.

[79] The motor 220 is disposed within the blower fans 210. That is, the motor 220 is enclosed between the left fan 210 and the right fan 210'.

[80] In further detail, the left and right fans 210 and 210' are fixedly installed to the outside of the motor 220, and rotate together with the rotor 226 (in FlG. 13) of the motor 220.

[81] The blower housing 230 is formed to enclose the outside of the blower fan 210, and the left and right sides thereof are opened, as is a discharge port 232 formed at the front thereof. The discharge port 232 discharges air that is forcefully blown by the blower fan 210.

[82] The left side and the right side of the blower housing 230 have orifice frames 234 and 234 further installed thereon. In detail, the left side has a left orifice frame 234 provided thereon, and the right side has a right orifice frame 234 provided thereon. The left orifice frame 234 has a left orifice 234a formed therein, and the right orifice frame 234' has a right orifice 234'a formed therein.

[83] Furthermore, the left and right sides of the blower housing 230 have supporting brackets 240 and 240' for supporting both ends of the motor 220 respectively installed thereon. In other words, the left side of the blower housing 230 is provided with a left supporting bracket 240 to support the left end of the motor 220, and the right side of the blower housing 230 is provided with a right supporting bracket 240' to support the right end of the motor 220.

[84] The left and right supporting brackets 240 and 240' further include reinforcing members 250 and 250'. That is, the left supporting bracket 240 includes a left reinforcing member 250, and the right supporting bracket 240' includes a right reinforcing member 250'. Here, the reinforcing members 250 and 250' support both ends of the motor 220 together with the supporting brackets 240 and 240'.

[85] Although not shown, a shock absorbing member (packing) may further be provided at the central portion of the supporting brackets 240 and 240'. In detail, the shock absorbing member absorbs vibrations from the motor 220 or the blower fan 210, to prevent vibrations from the blowers 200 and 200' from being transmitted to the outside. The shock absorbing member may be formed of rubber or other elastic material.

[86] FlGs. 10 and 11 are perspective views showing the structure of a right fan of a blower fan according to the present invention.

[87] Referring to HGs. 10 and 11, the right fan 210" forming the blower fan 210 according to the present invention includes a hub 212, a plurality of blades 216 arranged around the outer perimeter of the hub at regular intervals, and a shroud 214 to which the tips of the blades 216 are mounted.

[88] In detail, the floor of the hub 212 is formed as a circular plate, and is attached to a flange portion 228 of a rotor 226 (to be described below). In other words, each side of the flange portion 228 is respectively attached to the hub floors of the left fan 210 and

the right fan 210". Also, a plurality of fan screw holes 212a are formed around the floor of the hub 212. The fan screw holes 212a are holes for inserting fan screws (not shown) through to couple the left fan 210' to the right fan 210"

[89] Motor screw fastening holes 212b are further formed in the floor of the hub 212.

The motor screw fastening holes 212b are holes that expose the heads of motor screws 228b fastened to the flange portion 228. Accordingly, the motor screw fastening holes 212b may be formed with a larger diameter than that of the fan screw holes 212a. As shown, the motor screw fastening holes 212b are formed at predetermined even intervals between the fan screw holes 212a.

[90] A motor enclosure 218 is concaved at a predetermined depth in the central portion of the hub 212. One end of the motor 220 is received in the motor enclosure 218. A shaft through hole 218a, for the fixing member 224 to pass through, is formed in the central portion of the motor enclosure 218. The shaft through hole 218a has a diameter that is larger than the outer diameter of the fixing member 224. This will be described below in further detail.

[91] The shroud 214 connects and supports the tips of the blades 216, and is formed in an annular mushrooming shape. The blades 216 directly generate the flow of air, and are provided in plurality with a regular interval therebetween.

[92] The left fan 210' is formed the same as the right fan 210" and the fans are disposed facing one another. A detailed description thereof will not be provided.

[93] FlG. 12 is a perspective view showing the exterior of a motor included in a blower according to the present invention, FlG. 13 is an exploded perspective view of a motor included in a blower according to the present invention, FlG. 14 is a perspective view showing the interior structure of the rotor included in the motor in FlG. 13, FlG. 15 is a cross sectional view of the motor in FlG. 12 taken along line I-I' and FlG. 16 is a cutaway perspective view of the motor in FlG. 12 taken along line I-I'.

[94] Referring to FlGs. 12 through 16, the motor 220 according to the present invention includes a stator 222 having a coil (C) that is wound a plurality of times for generating an electromagnetic field, a fixing member 224 for fixing the stator 222, and a rotor 226 formed to enclose the outside of the stator 222 and provided with a plurality of permanent magnets (M).

[95] In detail, the stator 222 and the fixing member 224 are connected, and the fixing member 224 passes through the center of the stator 222 to act as the rotating center of the rotor 226. In other words, the rotor 226 rotates about the fixing member 224 at the center. Thus, a bearing (B) is provided between the rotor 226 and the fixing member 224.

[96] The fixing member 224 includes a fixing disk 224 for fixing the stator 222, and a rod-shaped fixing shaft 224 passing through the center of the fixing disk 224'.

[97] In detail, the fixing shaft 224" includes a left fixing shaft 224" that is inserted through and fixed to the left central portion of the fixing disk 224' and a right fixing shaft 224" that is inserted through and fixed to the right central portion of the fixing disk 224'.

[98] The fixing disk 224' includes a round plate-shaped disk portion 224'a connected to the stator 222, and a shaft supporting portion 224'b extending with a predetermined diameter for a predetermined distance from one side at the center of the disk portion 224'a. The stator 222 is fixed to the edge of one side of the disk portion 224'a. The left fixing shaft 224"a is inserted through the center of the fixing disk 224'. The right fixing shaft 224"b is inserted through the center of the shaft supporting portion 224'b. That is, the left fixing shaft 224"a and the right fixing shaft 224"b, that are disposed facing each other at the center of the disk portion 224'a form one central shaft.

[99] Bearings B are respectively provided around the outer surfaces of the left and right fixing shafts 224"a and 224"b to facilitate a smooth rotation of the rotor 226. That is, to facilitate the rotation of a left rotor 226 and a right rotor 226' (to be described below), the bearings B are respectively installed around the outside surfaces of the left and right fixing shafts 224"a and 224"b, and are enclosed by the rotor 226.

[100] A wire through slot 224b is formed in the right fixing shaft 224"b. That is, a wire through slot 224b is recessed a predetermined depth into the left side of the right fixing shaft 224"b. The wire through slot 224b is for allowing a wire (not shown) that supplies power to the coils C of the stator 222 to pass. Of course, the same wire through slot 224b may also formed in the left fixing shaft 224"a, or in both the left and right fixing shafts 224"a and 224"b.

[101] The fixing disk 224 for supporting the stator 222 is fixed at the center of the fixing shaft 224 , and both ends of the fixing shaft 224 are fixedly installed to the supporting brackets 240 and 240 (in FlG. 17). Specifically, the end of the left fixing shaft 224"a is supported by the left supporting bracket 240, and the end of the right fixing shaft 224"b is supported by right supporting bracket 240'.

[102] A fixing edge 224a is cut into either end of the fixing shaft 224'. That is, a portion of the outer surface at either end of the fixing shaft 224" is cut away to form the fixing edge 224a. The fixing edge 224a contacts the fixing portion 246 of the supporting brackets 240 and 240' (described below), and prevents the fixing shaft 224" from rotating.

[103] The stator 222 also includes a bobbin guide 222 pressed around the outer surface of the fixing member 224' and bobbins 222 formed to protrude radially from the outer surface of the bobbin guide 222'.

[104] Also, the bobbins 222 are formed in plurality at a regular interval around the bobbin guide 222', and a coil C is wound a plurality of times around the outer surface of each

bobbin 222'. Therefore, when a current is supplied from the outside to the coils C, an electromagnetic field is formed around the bobbins 222'.

[105] The rotor 226 is formed of a left rotor 226' forming the left exterior thereof, a right rotor 226" forming a right exterior thereof, and a plurality of permanent magnets M. The left rotor 226' and the right rotor 226" are coupled using fastening members.

[106] A stator enclosure 227 is formed in the left rotor 226' The stator enclosure 227 is a space formed to enclose the stator 222 within, and is recessed a distance corresponding to the outer dimensions of the stator 222.

[107] In further detail, the inner diameter of the stator enclosure 227 corresponds in size to the outer diameter of the stator 222. Also, a plurality of holes is formed in the stator enclosure 227 for allowing air to flow through.

[108] Of course, the stator enclosure 227 may be formed in the right rotor 226" or in both the left and right rotors 226' and 226".

[109] The plurality of permanent magnets M is installed at regular intervals on the inner surface of the stator enclosure 227. That is, the plurality of permanent magnets M are attached at regular intervals on the inner surface of the stator enclosure of the rotor 226, and the number of permanent magnets M is equal to the number of bobbins 222".

[110] As such, the permanent magnets M of the rotor 226 are arranged around the bobbins

222" with a small gap therebetween. That is, when the rotor 226 is installed around the stator 222, the ends of the bobbins 222" and the permanent magnets are spaced apart by a small gap.

[Ill] Accordingly, when an electrical current flows through the coils C wound around the bobbins 222" of the stator 222, the electromagnetic field generated by the coils C and the magnetic fields generated by the permanent magnets M interact to turn the rotor 226. That is, the stator 222 and the fixing shaft 224" are stationary, while the rotor 226 rotates.

[112] Furthermore, a flange portion 228 is formed around the outer perimeter of the rotor

226. The flange portion 228 is formed to protrude radially outward from the outer perimeter of the rotor 226. Specifically, a left flange portion 228 is formed by being bent in a radial direction from the outer circumference of the left rotor 226' and a right flange portion 228 is formed correspondingly to the left flange portion 228 on the right rotor 226". Thus, the left flange portion 228' and the right flange portion 228" are coupled with screws.

[113] A blower fan 210 is installed on the flange portion 228. That is, a left fan 210 and a right fan 210' are fastened to the flange portion 228, and the left and right fans 210' and 210" are fastened together to the flange portion 228 using the same fastening members (fan screws).

[114] A plurality of fan screw through holes 228a are formed in the flange portion 228.

The fan screw through holes 228a are for fan screws (not shown) to pass through. That is, when the left and right fans 210' and 210" are connected in a contacting manner, the flange portion 228 of the motor 220 is disposed between the hubs 212 of the left fan 210 and the right fan 210" Here, the fan screws that fasten the left and right fans 210' and 210" pass through the fan screw through holes 228a.

[115] Three motor screws 228b are fastened to the flange portion 228. The motor screws

228b couple the two parts of the rotor 226. That is, the motor screws 228b are for coupling the left and right rotors 226' and 226" together, so that the left and right flange portions 228' and 228" are fastened together. Accordingly, the left flange portion 228' and the right flange portion 228" have three motor screw holes 228b' formed therethrough.

[116] FlG. 17 is a perspective view showing the coupling of a supporting bracket and a reinforcing member included in a blower according to the present invention.

[117] Referring to FlG. 17, the supporting brackets 240 and 240' are formed with a central portion 242 through which either end of the fixing member 224 passes, and a plurality of supporting portions 244 extending radially from the central portion 242.

[118] The central portion is formed in a circular plate shape, which is fixed to directly support either end of the motor shaft. Therefore, the central portion 242 has a shaft through hole 246 formed through its central portion for either end of the fixing member 224 to be inserted through.

[119] The supporting portions 244 protrude outward from the central portion 242, and are fixed at the ends thereof to the blower housing 230 by screws or other fasteners. As shown, three radial supporting portions 244 may be provided. In further detail, the supporting portions 244 that are provided in triplicate, may be evenly spaced from each other. That is, the respective angles between the supporting portions 244 may be 120°, in order to form an equilibrium.

[120] Also, the shaft through hole 246 may further include a fixing portion 246 . That is, the shaft through hole 246 is formed in a circular shape corresponding to the shape of the fixing member 224; however, a portion of the circumference of the shaft through hole 246 is formed straight, forming the fixing portion 246'. The fixing portion 246' is formed to contact a fixing surface 224 of the fixing member 224 described above. Thus, the fixing member 224 does not rotate due to the mutual holding of the fixing portion 246' and the fixing surface 224".

[121] A pair of rib fastening holes 248 is formed in the central portion 242. The rib fastening hole 248 is a portion in which the fastening rib 254 of the reinforcing members 250 and 250' is inserted, as described below.

[122] The reinforcing members 250 and 250' are fastened to the central portion 242 of the supporting brackets 240 and 240' to support either end of the fixing member 224

together with the supporting brackets 240 and 240' and also have a shaft through hole 252 formed in central portions thereof. The shaft through holes 252 have shapes and size of the shaft through holes 246 formed in the central portions 242 of the supporting brackets 240 and 240'. Therefore, a shaft fixing portion 252 formed the same as the fixing portion 246 is formed in the shaft through hole 252.

[123] The upper and lower ends of the reinforcing members 250 and 250' respectively have a bent fastening rib 254 formed thereon. The fastening ribs 254 allow the reinforcing members 250 and 250' to be fastened to the supporting brackets 240 and 240'. Accordingly, the fastening ribs 254 are inserted respectively into the rib fastening holes 248 formed in the central portions 242 of the supporting brackets 240 and 240'.

[124] Below, the applications of an outdoor unit of an air conditioner according to the above-described embodiments of the present invention will be described.

[125] First, when the air conditioner is operated (in cooling mode), refrigerant flows between an outdoor unit 100 and an indoor unit (not shown). Here, the flow of refrigerant in the outdoor unit 100 will be described.

[126] Refrigerant in a gaseous state flows from the indoor unit (not shown) into the accumulator 182. The gaseous refrigerant that leaves the accumulator 182 flows into the compressors 180 and 180'. The compressors 180 and 180' used, as described above, include only an inverter compressor 180' that operates according to a load, or a constant speed compressor 180 and an inverter compressor 180'.

[127] The refrigerant that is discharged from the compressors 180 and 180' flows into the heat exchangers 120 and 120'. The heat exchangers 120 and 120' are applied in cooling mode to exchange heat between refrigerant and outdoor air, thereby cooling the liquid refrigerant.

[128] The refrigerant that passes through the compressors 120 and 120' passes through the receiver 184 that adjusts the amount of flowing refrigerant, and then flows into the indoor unit (not shown). Although not shown, the refrigerant that enters the indoor unit exchanges heat in an indoor heat exchanger acting as an evaporator, and returns to the outdoor unit 100 from the indoor heat exchanger. Thus, a cooling cycle is completed in these steps.

[129] Next, the operation of the blowers 200 and 200' will be described.

[130] When electric power is applied to the stator 222 from an external source, an electromagnetic field is generated by current flowing through the coils (C) wound around the bobbins 222a. Thus, the electromagnetic force around the bobbins 222a interacts with the magnetic field formed by the permanent magnets (M), rotating the rotor 226. Here, the blower fan 210 installed on the flange portion 228 of the rotor 226 rotates together with the rotor 226 to generate airflow.

[131] When the blower fan 210 rotates, air is suctioned into the outdoor unit 100 through

both sides thereof. That is, air from outside the outdoor unit 100 enters the outdoor unit 100 through the left intake grill 130 and the right intake grill 130'.

[132] The air that enters the inside of the outdoor unit 100 through the left and right intake grills 130 and 130' enters the inside of the blower housing 230 through the left and right sides of the blower housing 230, or more specifically, the left orifice 234a and the right orifice 234' towards the inner portion of the blower fan 210.

[133] The air that proceeds to the inner portion of the blower fan 210 is forcibly blown in a radial direction to be discharged through the discharge port 232 at the front of the fan housing 230. The air that is discharged through the discharge port 232 passes through the discharge safety grill 142 and is discharged from the front of the outdoor unit 100.

[ 134] The installation of the blowers 200 and 200' will briefly be described.

[135] First, the rotor 226 that is provided in two parts, that is, the left rotor 226 and the right rotor 226 are coupled through the three motor screws 228b in the left flange portion 228 and the right flange portion 228'. Thus, the stator 222 is disposed inside the stator enclosure 227 of the rotor 226. Here, the permanent magnets M are disposed around the outside of the bobbins 222" with a small gap therebetween.

[136] In the above process, the blower fan 210 is coupled to the outside of the assembled motor 220.

[137] In detail, after the motor is disposed between the left fan 210' and the right fan 210" the left fan 210' and the right fan 210" are pressed together. Therefore, the motor enclosures 218 of the left and right fans 210' and 210" house the motor 220. Also, the hub 212 and the flange portion 228 of the motor 220 are fastened using screws or other fastening members.

[138] Here, fan screws (not shown) pass through the fan screw through holes 228a and fasten to the respective fan screw holes 212a in the hub 212. Therefore, the left and right fans 210' and 210" and the flange portion 228 of the motor 220 are integrally coupled through one fastening member (the fan screw). Also, the head of the motor screw 228b fastened to the flange portion 228 of the motor 220 is disposed within the motor screw fastening hole 212b of the hub 212.

[139] Next, both ends of the fixing shaft 224 are inserted through the shaft through holes formed in the central portions 242 formed in the supporting brackets 240 and 240'. Here, the fixing portion 246 of the shaft through hole 246 and the fixing edge 224a of the fixing shaft 224 contact each other. Also, the reinforcing members 250 and 250' are installed on the supporting brackets 240 and 240'.

[140] Finally, the supporting portions 244 of the supporting brackets 240 and 240' are fastened to the perimeter of the blower housing 230 using screws. The assembly of the blowers 200 and 200' is thus completed.

[141] It will be apparent to those skilled in the art that various modifications and

variations can be made in the present 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. [142]

Industrial Applicability

[143] In the air conditioner according to the present invention, a BLDC motor is used, so that disruptions in the supply of power due to worn brushes can be prevented and the supply of electrical power through the fixed stator is greatly improved; and the blower fan is fixed to the exterior of the rotor to rotate together with the rotor, so that the blower fan can rotate more smoothly, to provide an air conditioner with a high industrial applicability.

[144]