Linear compressor

Abstract

A linear compressor includes: a shell including an intake pipe configured to suction a refrigerant, a piston including a piston body, an intake muffler including a first muffler that includes a first muffler body defining a main flow passage and a first muffler flange extending in a radial direction from the first muffler body, and at least one auxiliary flow passage disposed between an outer peripheral surface of the first muffler body and an inner peripheral surface of the piston body and configured to guide the refrigerant remaining between the first muffler body and the piston body to an outside of the piston. A cross-sectional area of the at least one auxiliary flow passage is less than a cross-sectional area of an inlet hole provided at a rear end of the main flow passage and greater than or equal to 10% of the cross-sectional area of the inlet hole.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to and the benefit of Korean Patent Application No. 10-2020-0188286 filed in the Korean Intellectual Property Office on Dec. 30, 2020.

TECHNICAL FIELD

The present disclosure relates to a compressor. More specifically, the present disclosure relates to a linear compressor for compressing a refrigerant by a linear reciprocating motion of a piston.

BACKGROUND

A compressor refers to a device that is configured to receive power from a power generator such as a motor or a turbine and compress a working fluid such as air or refrigerant, and is widely used in the whole industry and home appliances.

The compressors may be classified into a reciprocating compressor, a rotary compressor, and a scroll compressor according to a method of compressing the refrigerant.

The reciprocating compressor uses a method in which a compression chamber is formed between a piston and a cylinder to suck or discharge a working gas, and the piston linearly reciprocates in the cylinder to compress a refrigerant.

The rotary compressor uses a method in which a compression chamber is formed between a roller that eccentrically rotates and a cylinder to suck or discharge a working gas, and the roller eccentrically rotates along an inner wall of the cylinder to compress a refrigerant.

The scroll compressor uses a method in which a compression chamber is formed between an orbiting scroll and a fixed scroll to suck or discharge a working gas, and the orbiting scroll rotates along the fixed scroll to compress a refrigerant.

Recently, among the reciprocating compressors, the use of linear compressors is gradually increasing since these linear compressors can improve compression efficiency without a mechanical loss due to motion switch by directly connecting a piston to a drive motor linearly reciprocating and have a simple structure.

The linear compressor is configured such that a piston in a casing forming a sealed space sucks and compresses a refrigerant and then discharges the refrigerant while linearly reciprocating along an axial direction (or axially) in a cylinder by a linear motor.

Here, “axial direction” refers to a direction in which the piston reciprocates.

Thus, a noise occurs in a process in which the piston continues to suck, compress, and discharge the refrigerant while reciprocating in the cylinder along the axial direction.

In order to reduce the noise generated thus, a technology for installing an intake muffler in a piston body is disclosed.

With reference to FIGS. 1 and 2, an intake muffler included in a related art linear compressor is described below.

FIG. 1 is a cross-sectional view illustrating configuration of an intake muffler included in a related art linear compressor. FIG. 2 is a conceptual diagram illustrating that an internal pressure of a piston increases in a refrigerant intake process in an intake muffler included in a related art linear compressor, and hence a reverse flow occurs.

An intake muffler 2000 included in a related art linear compressor includes a first muffler 2100 disposed in a piston body (not shown), a second muffler 2300 disposed behind the first muffler 2100, and a third muffler 2500 accommodating at least a portion of the first muffler 2100 and the second muffler 2300.

The first muffler 2100 includes a first muffler body 2110 that forms a refrigerant flow passage and extends along the axial direction, a first muffler flange 2120 extending along a radial direction (or radially) around a rear end of the first muffler body 2110, and a first flange extension 2130 extending rearward in the axial direction from a flange connection portion 2140 of the first muffler flange 2120.

The rear end of the first muffler body 2110 extends axially further rearward than the first muffler flange 2120. The rear end of the first muffler body 2110 is opened to form an inlet hole 2110a, and a front end of the first muffler body 2110 is opened to form a discharge hole 2110b.

A first extension 2210 and a second extension 2230 are positioned around the front end of the first muffler body 2110 and protrude radially at a predetermined distance to form an intake guide portion 2200. The first muffler 2100 is coupled to the third muffler 2500 by the first flange extension 2130 being press-fitted to the third muffler 2500.

A cross-sectional area of a flow passage formed inside the first flange extension 2130 may be formed to be greater than a cross-sectional area of a flow passage of the first muffler body 2110.

The second muffler 2300 includes a second muffler body 2310 that is configured such that a cross-sectional area of a flow passage of a refrigerant varies as it goes from the upstream to the downstream of the refrigerant flow based on a flow direction of the refrigerant.

The second muffler body 2310 includes a first part 2310a having a predetermined inner diameter and a second part 2310b that extends forward from the first part 2310a and has an inner diameter less than the inner diameter of the first part 2310a.

A rear end of the second muffler body 2310 of the second muffler 2300, more specifically, a rear end of the first part 2310a is opened, and the open rear end of the first part 2310a forms an inlet hole 2320a through which the refrigerant introduced through a through hole 2520 of the third muffler 2500 is introduced.

A front end of the second muffler body 2310, more specifically, a front end of the second part 2310b is opened, and the open front end of the second part 2310b forms a discharge hole 2320b discharging the refrigerant passing through the second part 2310b.

According to the configuration described above, the refrigerant introduced into the second muffler 2300 through the inlet hole 2320a of the second muffler 2300 passes through a flow passage that has a reduced cross-sectional area in a process of flowing from the first part 2310a to the second part 2310b.

The second muffler 2300 further includes a second muffler flange 2330 extending in the radial direction around the front end of the second part 2310b and a second flange extension 2340 extending forward from the second muffler flange 2330.

Thus, the front end of the second part 2310b further extends forward from the second muffler flange 2330 in the axial direction. The second flange extension 2340 may be press-fitted to an inner peripheral surface of the third muffler 2500.

A cross-sectional area of a flow passage formed inside the second flange extension 2340 may be formed to be greater than a cross-sectional area of a flow passage of the second part 2310b.

Thus, the refrigerant discharged from the second muffler body 2310 may diffuse while flowing in the second flange extension 2340. Since a flow rate of the refrigerant is reduced by the diffusion of the refrigerant, a noise reduction effect can be obtained.

The third muffler 2500 includes a third muffler body 2510 having a cylindrical shape with an empty interior, and the third muffler body 2510 extends forward and rearward.

The through hole 2520, into which an inflow guide portion (not shown) is inserted, is formed at a rear surface of the third muffler 2500, and the inflow guide portion (not shown) allows the refrigerant sucked through a refrigerant intake pipe to flow into the third muffler 2500.

The through hole 2520 may be defined as an “inlet hole” guiding the inflow of the refrigerant into the intake muffler 2000.

The third muffler 2500 further includes a protrusion 2530 extending forward from the rear surface of the third muffler 2500. The protrusion 2530 extends axially forward from an outer peripheral portion of the through hole 2520, and the inflow guide portion (not shown) may be inserted into the inside of the protrusion 2530.

The first and second mufflers 2100 and 2300 may be coupled to each other inside the third muffler 2500. For example, the first and second mufflers 2100 and 2300 may be press-fitted and coupled to the inner peripheral surface of the third muffler 2500.

In the intake muffler 2000 having the above-described configuration, when an intake valve coupled to a front end of the piston opens, the refrigerant filled in the piston is discharged to a compression chamber through an intake port formed at the front end of the piston. In this instance, there occurs an intake flow of refrigerant through the intake muffler.

In the refrigerant intake process, when a pressure of the compression chamber and an inner pressure of the piston are equal to each other, the intake valve is closed, and the inner pressure of the piston gradually increases while the refrigerants flowing into the piston are filled in the piston.

When the inner pressure of the piston greatly increases, a reverse flow of the refrigerant occurs in the opposite direction of a refrigerant flow direction, and a flow loss blocking the refrigerant intake occurs. The reverse flow of the refrigerant continues until the intake valve opens.

Accordingly, there is a need to develop the intake muffler capable of reducing the flow loss due to the reverse flow phenomenon occurring in the refrigerant intake process.

SUMMARY

An object of the present disclosure is to provide a linear compressor capable of reducing a flow loss due to a reverse flow phenomenon occurring in a refrigerant intake process by flowing a refrigerant remaining inside a piston to the outside of the piston in the refrigerant intake process.

Another object of the present disclosure is to provide a linear compressor capable of increasing a pressure at an outlet end of an intake muffler in a refrigerant intake process.

Another object of the present disclosure is to provide a linear compressor including an intake muffler capable of reducing a noise.

To achieve the above-described and other objects, a linear compressor according to one aspect of the present disclosure comprises an intake muffler. At least one auxiliary flow passage is formed between an outer peripheral surface of a first muffler body of the intake muffler and an inner peripheral surface of a piston body to which the first muffler body is coupled. A cross-sectional area of the auxiliary flow passage is less than a cross-sectional area of an inlet hole formed at a rear end of a main flow passage and is greater than or equal to 10% of the cross-sectional area of the inlet hole of the main flow passage.

For example, the auxiliary flow passage may be formed by a communication pipe that is positioned at the outer peripheral surface of the first muffler body and extends in the axial direction. The auxiliary flow passage of the communication pipe may communicate with a communication hole positioned in a first muffler flange.

For another example, the linear compressor may further comprise a pipe that is positioned between the outer peripheral surface of the first muffler body and the inner peripheral surface of the piston body and surrounds the outer peripheral surface of the first muffler body. In this case, the auxiliary flow passage may be formed between an outer peripheral surface of the pipe and the inner peripheral surface of the piston body and may communicate with a communication hole positioned at a first flange extension extending rearward in the axial direction from the first muffler flange.

The linear compressor according to an embodiment of the present disclosure can maintain a pressure of the refrigerant in a high state from the beginning where the piston moves from top dead center to bottom dead center by discharging the refrigerant remaining in the piston to the outside of the piston through the auxiliary flow passage when the piston sucks the refrigerant while moving from top dead center to bottom dead center.

Accordingly, when the refrigerant intake is achieved as the intake valve is opened, an amount of refrigerant sucked to the intake port through the piston can increase. That is, since a time at which the intake valve is opened is the same as a time at which a pressure of the sucked refrigerant increases, an intake performance of the compressor can be improved.

In addition, embodiments of the present disclosure provide a linear compressor including an intake muffler capable of reducing a noise

The second muffler can serve as a resonator by properly adjusting a volume of the expansion chamber formed by the first and second mufflers through changes in a design of the second muffler positioned at the rear of the first muffler.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a further understanding of the present disclosure and constitute a part of the detailed description, illustrate embodiments of the present disclosure and serve to explain technical features of the present disclosure together with the description.

FIG. 1 is a cross-sectional view illustrating configuration of an intake muffler according to a related art.

FIG. 2 is a conceptual diagram illustrating that an internal pressure of a piston increases in a refrigerant intake process in an intake muffler included in a related art linear compressor, and hence a reverse flow occurs.

FIG. 3 is an appearance perspective view illustrating configuration of a linear compressor according to an embodiment of the present disclosure.

FIG. 4 is an exploded perspective view of a shell and a shell cover of a linear compressor according to an embodiment of the present disclosure.

FIG. 5 is a cross-sectional view taken along line III-III′ of FIG. 3.

FIG. 6 is an exploded perspective view illustrating configuration of a piston assembly according to an embodiment of the present disclosure.

FIG. 7 is a cross-sectional view of an intake muffler according to a first embodiment of the present disclosure.

FIG. 8 is a cross-sectional view of an intake muffler according to a second embodiment of the present disclosure.

FIG. 9 is a cross-sectional view of an intake muffler according to a third embodiment of the present disclosure.

FIG. 10 is a cross-sectional view of an intake muffler according to a fourth embodiment of the present disclosure.

FIG. 11 is a graph illustrating energy efficiency depending on a ratio of a cross-sectional area of an auxiliary flow passage to a cross-sectional area of a main flow passage in an intake muffler according to a second embodiment of the present disclosure.

FIG. 12 is a graph comparing a pressure of a linear compressor including an intake muffler according to a related art with a pressure of a linear compressor including an intake muffler according to a second embodiment of the present disclosure.

FIG. 13 is a graph comparing a transmission loss (TL) in a low frequency region of a linear compressor including an intake muffler according to a related art with a transmission loss in a low frequency region of a linear compressor including an intake muffler according to a second embodiment of the present disclosure.

FIG. 14 is a graph comparing an insertion loss (IL) in a low frequency region of a linear compressor including an intake muffler according to a related art with an insertion loss in a low frequency region of a linear compressor including an intake muffler according to a second embodiment of the present disclosure.

DETAILED DESCRIPTION

Reference will now be made in detail to embodiments of the present disclosure, 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.

It should be understood that when a component is described as being “connected to” or “coupled to” other component, it may be directly connected or coupled to the other component or intervening component(s) may be present.

It will be noted that a detailed description of known arts will be omitted if it is determined that the detailed description of the known arts can obscure embodiments of the present disclosure. The accompanying drawings are used to help easily understand various technical features and it should be understood that embodiments presented herein are not limited by the accompanying drawings. As such, the present disclosure should be understood to extend to any alterations, equivalents and substitutes in addition to those which are particularly set out in the accompanying drawings.

In addition, a term of “disclosure” may be replaced by document, specification, description, etc.

FIG. 3 is an appearance perspective view illustrating configuration of a linear compressor according to an embodiment of the present disclosure. FIG. 4 is an exploded perspective view of a shell and a shell cover of a linear compressor according to an embodiment of the present disclosure. FIG. 5 is a cross-sectional view taken along line III-III′ of FIG. 3.

Referring to the figures, a linear compressor 10 according to an embodiment of the present disclosure includes a shell 101 and shell covers 102 and 103 coupled to the shell 101. In a broad sense, the first shell cover 102 and the second shell cover 103 can be understood as one configuration of the shell 101.

Legs 50 may be coupled to a lower side of the shell 101. The legs 50 may be coupled to a base of a product in which the linear compressor 10 is installed. Examples of the product may include a refrigerator, and the base may include a machine room base of the refrigerator. As another example, the product may include an outdoor unit of an air conditioner, and the base may include a base of the outdoor unit.

The shell 101 may have a substantially cylindrical shape and may be disposed in a transverse direction or a horizontal direction or an axial direction. FIG. 3 illustrates that the shell 101 is extended in the horizontal direction and has a slightly low height in a radial direction, by way of example.

That is, since the linear compressor 10 can have a low height, there is an advantage in that a height of the machine room can decrease when the linear compressor 10 is installed in the machine room base of the refrigerator.

A terminal 108 may be installed on an outer surface of the shell 101. The terminal 108 is understood as configuration to transmit external electric power to a motor assembly of the linear compressor 10. The terminal 108 may be connected to a lead line of a coil 141c (see FIG. 5).

A bracket 109 is installed on the outside of the terminal 108. The bracket 109 may include a plurality of brackets surrounding the terminal 108. The bracket 109 can perform a function of protecting the terminal 108 from an external impact, etc.

Both sides of the shell 101 are configured to be opened. The shell covers 102 and 103 may be coupled to both sides of the opened shell 101.

The shell covers 102 and 103 include the first shell cover 102 coupled to one opened side of the shell 101 and the second shell cover 103 coupled to the other opened side of the shell 101. An inner space of the shell 101 may be sealed by the shell covers 102 and 103.

FIG. 3 illustrates that the first shell cover 102 is positioned on the right side of the linear compressor 10, and the second shell cover 103 is positioned on the left side of the linear compressor 10, by way of example. Thus, the first and second shell covers 102 and 103 may be disposed to face each other.

The linear compressor 10 further includes a plurality of pipes 104, 105, and 106 that are included in the shell 101 or the shell covers 102 and 103 and may suck, discharge, or inject the refrigerant.

The plurality of pipes 104, 105, and 106 include an intake pipe 104 that allows the refrigerant to be sucked into the linear compressor 10, a discharge pipe 105 that allows the compressed refrigerant to be discharged from the linear compressor 10, and a process pipe 106 for supplementing the refrigerant in the linear compressor 10.

For example, the intake pipe 104 may be coupled to the first shell cover 102. The refrigerant may be sucked into the linear compressor 10 along the axial direction through the intake pipe 104.

The discharge pipe 105 may be coupled to an outer peripheral surface of the shell 101. The refrigerant sucked through the intake pipe 104 may be compressed while flowing in the axial direction. The compressed refrigerant may be discharged through the discharge pipe 105. The discharge pipe 105 may be disposed closer to the second shell cover 103 than to the first shell cover 102.

The process pipe 106 may be coupled to the outer peripheral surface of the shell 101. A worker may inject the refrigerant into the linear compressor 10 through the process pipe 106.

The process pipe 106 may be coupled to the shell 101 at a different height from the discharge pipe 105 in order to prevent interference with the discharge pipe 105. Herein, the “height” may be understood as a distance measured from the leg 50 in a vertical direction (or a radial direction).

On an inner peripheral surface of the shell 101 corresponding to a location at which the process pipe 106 is coupled, at least a portion of the second shell cover 103 may be positioned adjacently. In other words, at least a portion of the second shell cover 103 may act as a resistance of the refrigerant injected through the process pipe 106.

Thus, with respect to a flow passage of the refrigerant, a size of the flow passage of the refrigerant introduced through the process pipe 106 may be configured to decrease while the refrigerant enters into the inner space of the shell 101.

In this process, a pressure of the refrigerant may be reduced to vaporize the refrigerant, and an oil contained in the refrigerant may be separated. Thus, while the refrigerant, from which the oil is separated, is introduced into a piston 130, a compression performance of the refrigerant can be improved. The oil may be understood as a working oil present in a cooling system.

A cover support portion 102a is provided at the inner surface of the first shell cover 102. A second support device 185 to be described later may be coupled to the cover support portion 102a. The cover support portion 102a and the second support device 185 may be understood as devices for supporting the main body of the linear compressor 10.

Here, the main body of the compressor refers to a component provided inside the shell 101, and may include, for example, a driver that reciprocates forward and rearward and a support portion supporting the driver.

The driver may include a piston 130, a magnet frame 138, a permanent magnet 146, a supporter 137, an intake muffler 200, and the like. The support portion may include resonance springs 176a and 176b, a rear cover 170, a stator cover 149, a first support device 165, and a second support device 185, and the like.

A stopper 102b may be provided at the inner surface of the first shell cover 102. The stopper 102b is understood as configuration to prevent the main body of the compressor 10, in particular, a motor assembly (not shown) from being damaged by colliding with the shell 101 due to a vibration or an impact, etc. generated during transportation of the linear compressor 10.

The stopper 102b is positioned adjacent to the rear cover 170 to be described later. The stopper 102b can prevent an impact from being transferred to the motor assembly (not shown) since the rear cover 170 interferes with the stopper 102b when shaking occurs in the linear compressor 10.

A spring fastening portion 101a may be provided on the inner peripheral surface of the shell 101. The spring fastening portion 101a may be disposed adjacent to the second shell cover 103. The spring fastening portion 101a may be coupled to a first support spring 166 of a first support device 165 to be described later. As the spring fastening portion 101a and the first support device 165 are coupled, the main body of the compressor may be stably supported inside the shell 101.

FIG. 5 is a cross-sectional view taken along line III-III′ of FIG. 3. FIG. 6 is an exploded perspective view illustrating configuration of a piston assembly according to an embodiment of the present disclosure.

Referring to FIGS. 5 and 6, the linear compressor 10 according to an embodiment of the present disclosure includes a cylinder 120 provided in the shell 101, a piston 130 that linearly reciprocates in the cylinder 120, and a motor assembly (not shown) including a linear motor that gives a driving force to the piston 130.

When the motor assembly (not shown) drives, the piston 130 may reciprocate in the axial direction.

The linear compressor 10 further includes an intake muffler 200 coupled to the piston 130. The intake muffler 200 can reduce a noise generated from a refrigerant sucked through an intake pipe 104.

The refrigerant sucked through the intake pipe 104 passes through the intake muffler 200 and flows into the piston 130. For example, in a process in which the refrigerant passes through the intake muffler 200, the flow noise of the refrigerant can be reduced.

The intake muffler 200 includes a plurality of mufflers 210, 230, and 250. The plurality of mufflers 210, 230, and 250 include a first muffler 210, a second muffler 230, and a third muffler 250 that are coupled to each other.

The first muffler 210 is positioned in the piston 130, and the second muffler 230 is coupled to the rear of the first muffler 210. The third muffler 250 may accommodate the second muffler 230 therein and may extend to the rear of the first muffler 210.

From a perspective of the flow direction of the refrigerant, the refrigerant sucked through the intake pipe 104 may sequentially pass through the third muffler 250, the second muffler 230, and the first muffler 210. In this process, the flow noise of the refrigerant can be reduced.

The intake muffler 200 further includes a muffler filter 280. The muffler filter 280 may be positioned at an interface where the first muffler 210 and the second muffler 230 are coupled. For example, the muffler filter 280 may have a circular shape, and an outer peripheral portion of the muffler filter 280 may be supported between the first and second mufflers 210 and 230.

In the present disclosure, “axial direction (or axially)” may be understood as a direction in which the piston 130 reciprocates, i.e., a longitudinal direction in FIG. 5. In the “axial direction”, a direction directed from the intake pipe 104 to a compression chamber P, i.e., a direction in which the refrigerant flows may be understood as “front”, and the opposite direction thereof may be understood as “rear”.

On the other hand, “radial direction (or radially)” may be understood as a direction perpendicular to the direction in which the piston 130 reciprocates, i.e., a transverse direction in FIG. 5.

The piston 130 includes a piston body 131 having a substantially cylindrical shape and a piston flange 132 extending radially from the piston body 131.

The piston body 131 may reciprocate axially inside the cylinder 120, and the piston flange 132 may reciprocate axially outside the cylinder 120.

The cylinder 120 is configured to accommodate at least a portion of the first muffler 210 and at least a portion of the piston body 131.

The compression chamber P in which the refrigerant is compressed by the piston 130 is formed in the cylinder 120. An intake port 133 that introduces the refrigerant into the compression chamber P is formed at a front surface of the piston body 131, and an intake valve 135 that selectively opens the intake port 133 is provided at the front of the intake port 133. A second fastening hole 135a to which a valve fastening member 134 is coupled is formed at approximately the center of the intake valve 135.

The valve fastening member 134 may be understood as configuration to couple the intake valve 135 to a first fastening hole 131b of the piston 130. The first fastening hole 131b is formed at approximately the center of a front end surface of the piston 130. The valve fastening member 134 may pass through the second fastening hole 135a of the intake valve 135 and may be coupled to the first fastening hole 131b.

The piston 130 includes the piston body 131 that has a substantially cylindrical shape and extends forward and rearward, and the piston flange 132 extending radially outwardly from the piston body 131.

A body front portion 131a in which the first fastening hole 131b is formed is provided at the front of the piston body 131. The intake port 133 selectively shielded by the intake valve 135 is formed at the body front portion 131a. The intake port 133 includes a plurality of intake ports, and the plurality of intake ports 133 are formed outside the first fastening hole 131b.

The plurality of intake ports 133 may be disposed to surround the first fastening hole 131b. For example, the eight intake ports 133 may be provided.

A rear portion of the piston body 131 is opened so that the intake of the refrigerant is achieved. At least a portion of the intake muffler 200, i.e., the first muffler 210 may be inserted into the piston body 131 through the opened rear portion of the piston body 131.

The piston flange 132 includes a flange body 132a extending radially outwardly from the rear portion of the piston body 131, and a piston fastening portion 132b further extending radially outwardly from the flange body 132a.

The piston fastening portion 132b includes a piston fastening hole 132c to which a predetermined fastening member is coupled. The fastening member may pass through the piston fastening hole 132c and may be coupled to a magnet frame 138 and a supporter 137. The piston fastening portion 132b may include a plurality of piston fastening portions 132b, and the plurality of piston fastening portions 132b may be spaced apart from each other and disposed at an outer peripheral surface of the flange body 132a.

At the front of the compression chamber P, a discharge cover 160 forming a discharge space 160a of the refrigerant discharged from the compression chamber P, and discharge valve assemblies 161 and 163 that are coupled to the discharge cover 160 and selectively discharge the refrigerant compressed in the compression chamber P are provided. The discharge space 160a includes a plurality of spaces partitioned by an inner wall of the discharge cover 160. The plurality of spaces may be disposed forward and rearward and may communicate with each other.

The discharge valve assemblies 161 and 163 include a discharge valve 161 that is opened when a pressure of the compression chamber P is greater than or equal to a discharge pressure, and introduces the refrigerant into the discharge space 160a of the discharge cover 160, and a spring assembly 163 that is provided between the discharge valve 161 and the discharge cover 160 and provides axially an elastic force.

The spring assembly 163 may include a valve spring (not shown) and a spring support portion (not shown) for supporting the valve spring (not shown) to the discharge cover 160.

For example, the valve spring (not shown) may be formed as a leaf spring. The spring support portion (not shown) may be integrally injection-molded with the valve spring (not shown) by an injection process.

The discharge valve 161 is coupled to the valve spring (not shown), and a rear portion or a rear surface of the discharge valve 161 is positioned so that it is supportable to the front surface of the cylinder 120.

When the discharge valve 161 is supported to the front surface of the cylinder 120, the compression chamber P may maintain a sealed state. When the discharge valve 161 is spaced apart from the front surface of the cylinder 120, the compression chamber P may be opened, and the compressed refrigerant inside the compression chamber P may be discharged.

The compression chamber P may be defined as a space between the intake valve 135 and the discharge valve 161.

The intake valve 135 may be formed on one side of the compression chamber P, and the discharge valve 161 may be provided on other side of the compression chamber P, that is, on the opposite side of the intake valve 135.

In the process in which the piston 130 reciprocates linearly in the axial direction inside the cylinder 120, when the pressure of the compression chamber P is lower than the discharge pressure and is less than or equal to an intake pressure, the discharge valve 161 is closed and the intake valve 135 is opened. Hence, the refrigerant is sucked into the compression chamber P.

On the other hand, when the pressure of the compression chamber P is greater than or equal to the intake pressure, the refrigerant in the compression chamber P is compressed in the closed state of the intake valve 135.

When the pressure of the compression chamber P is greater than or equal to the intake pressure, the valve spring (not shown) is deformed forward to open the discharge valve 161, and the refrigerant is discharged from the compression chamber P and is discharged into the discharge space 160a of the discharge cover 160.

When the discharge of the refrigerant is completed, the valve spring (not shown) provides a restoring force to the discharge valve 161, and thus the discharge valve 161 is closed.

The linear compressor 10 further includes a cover pipe 162a that is coupled to the discharge cover 160 and discharges the refrigerant flowing in the discharge space 160a of the discharge cover 160. For example, the cover pipe 162a may be made of a metal material.

The linear compressor 10 further includes a loop pipe 162b that is coupled to the cover pipe 162a and transfers the refrigerant flowing through the cover pipe 162a to the discharge pipe 105. One side of the loop pipe 162b may be coupled to the cover pipe 162a, and other side may be coupled to the discharge pipe 105.

The loop pipe 162b may be made of a flexible material. The loop pipe 162b may roundly extend from the cover pipe 162a along the inner peripheral surface of the shell 101 and may be coupled to the discharge pipe 105. For example, the loop pipe 162b may have a wound shape.

The linear compressor 10 further includes a frame 110 fixing the cylinder 120. For example, the cylinder 120 may be press-fitted to the inside of the frame 110. The cylinder 120 and the frame 110 may be made of aluminum or an aluminum alloy material.

The frame 110 is disposed to surround the cylinder 120. That is, the cylinder 120 may be positioned to be accommodated inside the frame 110. The discharge cover 160 may be coupled to a front surface of the frame 110 by a fastening member.

The motor assembly (not shown) includes an outer stator 141 that is fixed to the frame 110 and is disposed to surround the cylinder 120, an inner stator 148 that is disposed to be spaced apart from the inside of the outer stator 141, and a permanent magnet 146 positioned in a space between the outer stator 141 and the inner stator 148.

The permanent magnet 146 may reciprocate linearly by a mutual electromagnetic force between the permanent magnet 146 and the outer stator 141 and the inner stator 148. The permanent magnet 146 may be composed of a single magnet having one pole, or may be configured by combining a plurality of magnets having three poles.

The permanent magnet 146 may be installed in the magnet frame 138. The magnet frame 138 has a substantially cylindrical shape and may be inserted into a space between the outer stator 141 and the inner stator 148.

Based on the cross-sectional view of FIG. 5, the magnet frame 138 may be coupled to the piston flange 132, extended outward in the radial direction, and bent forward. The permanent magnet 146 may be installed in a front portion of the magnet frame 138.

When the permanent magnet 146 reciprocates, the piston 130 may reciprocate axially along with the permanent magnet 146.

The outer stator 141 includes coil winding bodies 141b, 141c, and 141d and a stator core 141a. The coil winding bodies 141b, 141c, and 141d include a bobbin 141b and a coil 141c wound in a circumferential direction of the bobbin 141b.

The coil winding bodies 141b, 141c, and 141d further include a terminal portion 141d for guiding a power supply line connected to the coil 141c to be withdrawn or exposed to the outside of the outer stator 141. The terminal portion 141d may be disposed to be inserted into a terminal insertion portion of the frame 110.

The stator core 141a includes a plurality of core blocks that is configured such that a plurality of laminations is stacked in a circumferential direction. The plurality of core blocks may be disposed to surround at least a portion of the coil winding bodies 141b and 141c.

The stator cover 149 is provided on one side of the outer stator 141. That is, one side of the outer stator 141 may be supported by the frame 110, and other side may be supported by the stator cover 149.

The linear compressor 10 further includes a cover fastening member (not shown) for fastening the stator cover 149 to the frame 110. The cover fastening member (not shown) may pass through the stator cover 149, extend forward toward the frame 110, and may be coupled to a first fastening hole of the frame 110.

The inner stator 148 is fixed to the outer periphery of the frame 110. Further, the inner stator 148 is configured such that a plurality of laminations is stacked in a circumferential direction from the outside of the frame 110.

The linear compressor 10 further includes a supporter 137 supporting the piston 130. The supporter 137 is coupled to the rear side of the piston 130, and the intake muffler 200 may be disposed inside the supporter 137 to pass therethrough.

The piston flange 132, the magnet frame 138, and the supporter 137 may be fastened by a fastening member.

A balance weight (not shown) may be coupled to the supporter 137. A weight of the balance weight (not shown) may be determined based on an operating frequency range of the compressor body.

The linear compressor 10 further includes a rear cover 170 that is coupled to the stator cover 149, extends rearward, and is supported by the second support device 185.

The rear cover 170 includes three support legs, and the three support legs may be coupled to the rear surface of the stator cover 149. A spacer (not shown) may be interposed between the three support legs and the rear surface of the stator cover 149.

A distance from the stator cover 149 to a rear end of the rear cover 170 may be determined by adjusting a thickness of the spacer (not shown). The rear cover 170 may be elastically supported by the supporter 137.

The linear compressor 10 further includes an inflow guide portion 156 that is coupled to the rear cover 170 and guides the inflow of the refrigerant into the intake muffler 200. At least a portion of the inflow guide portion 156 may be inserted into the inside of the intake muffler 200.

The linear compressor 10 further includes a plurality of resonance springs 176a and 176b in which each natural frequency is adjusted so that the piston 130 can perform a resonant motion.

The plurality of resonance springs 176a and 176b include a first resonance spring 176a supported between the supporter 137 and the stator cover 149 and a second resonance spring 176b supported between the supporter 137 and the rear cover 170.

By the action of the plurality of resonance springs 176a and 176b, a stable movement of the driver reciprocating in the linear compressor 10 can be performed, and generation of vibration or noise caused by the movement of the driver can be reduced.

The supporter 137 includes a first spring support portion (not shown) coupled to the first resonance spring 176a.

The linear compressor 10 further includes a first support device 165 that is coupled to the discharge cover 160 and supports one side of the main body of the compressor 10. The first support device 165 may be disposed adjacent to the second shell cover 103 to elastically support the main body of the compressor 10.

The first support device 165 includes a first support spring 166. The first support spring 166 may be coupled to the spring fastening portion 101a.

The linear compressor 10 further includes a second support device 185 that is coupled to the rear cover 170 and supports other side of the main body of the compressor 10. The second support device 185 may be coupled to the first shell cover 102 to elastically support the main body of the compressor 10.

The second support device 185 includes a second support spring 186.

The second support spring 186 may be coupled to the cover support portion 102a.

FIG. 7 is a cross-sectional view of an intake muffler according to a first embodiment of the present disclosure.

Referring to FIG. 7, an intake muffler 200 according to an embodiment of the present disclosure includes a plurality of mufflers 210, 230, and 250. The plurality of mufflers 210, 230, and 250 may be press-fitted and coupled to each other.

The plurality of mufflers 210, 230, and 250 may be made of a plastic material and easily press-fitted and coupled to each other. Hence, and a heat loss through the plurality of mufflers 210, 230, and 250 in the flow process of the refrigerant can be reduced.

The intake muffler 200 includes a first muffler 210, a second muffler 230 coupled to the rear of the first muffler 210, a muffler filter 280 supported by the first muffler 210 and the second muffler 230, and a third muffler 250 that is coupled to the first and second mufflers 210 and 230 and into which the inflow guide portion 156 is inserted. The third muffler 250 extends to the rear of the second muffler 230.

The third muffler 250 includes a third muffler body 251 having a cylindrical shape with an empty interior. The third muffler body 251 extends forward and rearward. A through hole 252, into which the inflow guide portion 156 is inserted, is formed at a rear surface of the third muffler 250. The through hole 252 may be defined as an “inlet hole” guiding the inflow of the refrigerant into the intake muffler 200.

The third muffler 250 further includes a protrusion 253 extending forward from the rear surface of the third muffler 250. The protrusion 253 extends forward from an outer peripheral portion of the through hole 252, and the inflow guide portion 156 may be inserted into the inside of the protrusion 253.

The first and second mufflers 210 and 230 may be coupled to each other inside the third muffler 250. For example, the first and second mufflers 210 and 230 may be press-fitted and coupled to an inner peripheral surface of the third muffler 250. A stepped portion 254, to which the second muffler 230 is coupled, is formed at the inner peripheral surface of the third muffler 250.

When the second muffler 230 moves into the third muffler 250 and is press-fitted to the third muffler 250, the second muffler 230 may be caught in the stepped portion 254. Thus, the stepped portion 254 may be understood as a stopper for limiting the rearward movement of the second muffler 230.

The first muffler 210 is coupled to a front end of the second muffler 230 and is press-fitted to the inner peripheral surface of the third muffler 250. The muffler filter 280 may be interposed at a boundary where the first and second mufflers 210 and 230 are coupled.

The second muffler 230 includes a second muffler body 231 that is configured such that a cross-sectional area of a flow passage of the refrigerant changes as it goes from the upstream to the downstream of the refrigerant flow based on a flow direction of the refrigerant. An inlet hole 232a, through which the refrigerant discharged from the inflow guide portion 156 is introduced, is formed at a rear end of the second muffler body 231.

The second muffler body 231 includes a first part 231a that extends from the inlet hole 232a toward the front to have a predetermined inner diameter, and a second part 231b that extends from the first part 231a to the front and has an inner diameter less than the inner diameter of the first part 231a. The inlet hole 232a of the second muffler 230 is formed at a rear end of the first part 231a.

According to the configuration described above, the refrigerant introduced into the second muffler 230 through the inlet hole 232a of the second muffler 230 passes through a flow passage that has a reduced cross-sectional area in a process of flowing from the first part 231a to the second part 231b.

A discharge hole 232b discharging the refrigerant passing through the second part 231b is formed at a front end of the second muffler body 231. The discharge hole 232b of the second muffler 230 may be formed at a front end of the second part 231b.

The second muffler 230 includes a second muffler flange 233, that extends radially from an outer peripheral surface of a front portion of the second muffler body 231, more specifically, an outer peripheral surface of the second part 231b, and a second flange extension 234 extending forward from the second muffler flange 233. The second muffler flange 233 may be radially formed at the outer peripheral surface of the second part 231b, and the second flange extension 234 may be press-fitted to the inner peripheral surface of the third muffler 250.

A boundary between the second muffler flange 233 and the second flange extension 234 of the second muffler 230, that is, a portion bent from the radial direction to the axial direction may form a “locking jaw” that allows the second muffler 230 to be caught in the stepped portion 254 of the third muffler 250.

A cross-sectional area of a flow passage formed inside the second flange extension 234 may be formed to be greater than a cross-sectional area of a flow passage of the second part 231b.

The first muffler 210 includes a first muffler body 211 positioned in front of the muffler filter 280, that is, positioned on the downstream side of the refrigerant flow. The first muffler body 211 of the first muffler 210 has a cylindrical shape with an empty interior and may extend forward. An inner space of the first muffler body 211 forms a main flow passage PA1 through which the refrigerant flows.

The first muffler 210 includes a first muffler flange 212 radially formed on an outer peripheral surface of the first muffler body 211, and a first flange extension 213 extending axially rearward from the first muffler flange 212.

The first flange extension 213 may have a substantially cylindrical shape. The first flange extension 213 may be press-fitted in the inner peripheral surface of the third muffler 250. The first muffler flange 212 includes a flange connection portion 214 to which the first flange extension 213 is connected.

The first flange extension 213 may support a front portion of the muffler filter 280. In other words, the muffler filter 280 may be interposed between the first flange extension 213 of the first muffler 210 and the second flange extension 234 of the second muffler 230.

The first muffler body 211 may be configured such that a cross-sectional area of the main flow passage PA1 increases as it goes from the upstream to the downstream based on the flow direction of the refrigerant.

The intake muffler according to an embodiment of the present disclosure further includes at least one auxiliary flow passage PA2 that is positioned between the outer peripheral surface of the first muffler body 211 and an inner peripheral surface of the piston body 131 and allows the refrigerant remaining between the first muffler body 211 and the piston body 131 to flow into the outside of the piston.

In an embodiment, the auxiliary flow passage PA2 is formed by a communication pipe P1 that is positioned at the outer peripheral surface of the first muffler body 211 and extends in the axial direction, and the auxiliary flow passage PA2 of the communication pipe P1 communicates with a communication hole 215 positioned in the first muffler flange 212.

The auxiliary flow passage PA2 and the communication hole 215 may be understood as a configuration for guiding a refrigerant pressure of an intake space 260 (see FIG. 5) to rapidly increase in the refrigerant intake process.

To explain this, when the refrigerant compressed in the compression chamber P is discharged to the discharge cover 160, the piston 130 moves from top dead center to bottom dead center, and the refrigerant sucked by the compressor 10 in this process flows into the piston 130 through the intake muffler 200.

In this instance, as a refrigerant pressure in the intake space 260 is high and this state continues for a long time, the intake valve 135 opens faster and remains open for a long time, and thus a large amount of refrigerant can be introduced into the compression chamber P.

However, when the pressure in the intake space 260 is relatively low at a time at which the intake valve 135 is opened, an amount of refrigerant introduced into the compression chamber P through the opened intake valve 135 is reduced. Thus, it is necessary to rapidly increase the pressure in the intake space 260 according to the time at which the intake valve 135 is opened.

After the refrigerant is discharged from the compression chamber P, when the piston 130 moves rearward, that is, toward the bottom dead center, a phenomenon in which the refrigerant is not rapidly introduced into the first muffler 210 may occur by a volume of the refrigerant remaining between the piston 130 and the first muffler 210. Accordingly, the auxiliary flow passage PA2 and the communication hole 215 are understood as a configuration for guiding the remaining refrigerant to flow rearward and be discharged from the piston 130.

The plurality of auxiliary flow passages PA2 and the plurality of communication holes 215 may be provided.

If the auxiliary flow passage PA2 and the communication hole 215 are disposed to be biased at a specific position of the main flow passage PA1, it may not be easy to discharge the refrigerant. Therefore, by evenly distributing the auxiliary flow passage PA2 and the communication hole 215 in the up and down direction, or the left and right direction, or the up and down direction and the left and right direction with respect to the main flow passage PA1, the remaining refrigerant can be easily discharged to the rear. The number of auxiliary flow passages PA2 and the number of communication holes 215 are not limited thereto.

The refrigerant discharged in the axial direction rearward through the auxiliary flow passage PA2 and the communication hole 215 may flow into an expansion chamber 270 formed between the first muffler flange 212 and a second muffler flange 233, and then may be introduced into the first muffler body 211 through an inlet hole 211a of the first muffler 210 together with the refrigerant sucked into the intake muffler 200.

FIG. 7 illustrates that a front end of the communication pipe P1 is positioned rearward in the axial direction compared to a front end of the first muffler body 211, by way of example. However, the front end of the communication pipe P1 may be positioned forward in the axial direction compared to the front end of the first muffler body 211, or positioned on the same line in the axial direction as the front end of the first muffler body 211.

An intake guide portion 220 may be formed around a discharge hole 211b of the first muffler 210 at the first muffler body 211 and may guide the refrigerant discharged from the discharge hole 211b to the intake port 133.

The intake guide portion 220 is configured to surround at least a portion of the first muffler body 211. The intake guide portion 220 may include a first extension 221 extending outward in the radial direction from a position on the outer peripheral surface of the first muffler body 211 and a second extension 223 that is forward spaced apart from the first extension 221.

FIG. 7 illustrates that both the first and second extensions 221 and 223 are formed at the outer peripheral surface of the first muffler body 211, by way of example. However, when a length of the communication pipe P1 extends further forward in the axial direction than FIG. 7, the first extension 221 may overlap the communication pipe P1, or both the first and second extensions 221 and 223 may overlap the communication pipe PT.

The inlet hole 211a into which the refrigerant passing through the muffler filter 280 is introduced is formed at the rear end of the first muffler body 211. The discharge hole 211b through which the refrigerant passing through the first muffler body 211 is discharged is formed at the front end of the first muffler body 211.

The first muffler flange 212 may be coupled to the piston flange 132 of the piston 130.

A radially outer portion of the first muffler flange 212 includes a piston coupling portion 212a coupled to a coupling groove (not shown) of the piston 130. The fastening groove (not shown) may be formed in a piston flange portion (not shown).

The third muffler 250 includes a piston coupling portion 251a coupled to the piston coupling portion 212a.

The piston coupling portion 251a of the third muffler 250 may be configured to extend outward in the radial direction from the front portion of the third muffler body 251.

The piston coupling portions 212a and 251a may be interposed between the supporter 137 and the piston flange portion (not shown). The piston coupling portion 251a may extend to be inclined outward in the radial direction with respect to the third muffler body 251. An angle θ between the third muffler body 251 and the piston coupling portion 251a may be greater than 60° and less than 90°. The piston coupling portion 251a may be configured to be elastically deformable.

According to the above-described configuration, the piston coupling portions 212a and 251a can be stably supported between the supporter 137 and the piston flange portion (not shown). In the process of moving forward or rearward the intake muffler 200, the piston coupling portions 212a and 251a can move to be close to each other or spaced apart from each other by an inertial force, and hence, an excessive load can be prevented from being applied to the intake muffler 200.

The main flow passage PA1 of the first muffler body 211 may be configured such that a cross-sectional area of the flow passage of the refrigerant increases as it goes from the upstream to the downstream based on the flow direction of the refrigerant.

A size of a noise chamber formed between the first muffler body 211 and the piston body 131 is less than that in the related art due to the communication pipe P1 for forming the auxiliary flow passage PA2.

Accordingly, it is advantageous to remove the low-frequency noise when the size of the auxiliary flow passage PA2 and/or the size of the communication pipe P1 are set to have a volume of 90% or more compared to a volume of a noise chamber of the related art intake muffler.

An operation of the linear compressor according to an embodiment of the present disclosure is described below.

The refrigerant sucked into the compressor 10 flows into the intake muffler 200 through the through hole 252 of the third muffler 250.

The refrigerant may pass through the second muffler 230 and may be introduced into the first muffler body 211 of the first muffler 210 through the inlet hole 211a of the first muffler 210.

The refrigerant in the first muffler body 211 may flow into the intake space 260, and may be sucked into the compression chamber P through the intake port 133 of the piston 130 when the intake valve 135 is opened. Here, the intake space 260 may be understood as a space between the body front portion 131a of the piston 130 and the front end of the intake muffler 200, i.e., the front end of the first muffler 210.

When a pressure of the compression chamber P is higher than a pressure of the intake space 260, the intake valve 135 is closed, and a volume of the compression chamber P decreases while the piston 130 moves forward. Hence, the compression of the refrigerant is achieved.

When the pressure of the compression chamber P increases and is higher than a pressure of the discharge space 160a, the discharge of the refrigerant is achieved while the discharge valve 161 is opened.

When the discharge of the refrigerant is achieved, the piston 130 and the intake muffler 200 move to the rear, and the refrigerant is sucked into the intake muffler 200.

When the pressure of the compression chamber P and an internal pressure of the piston 130 are the same, the intake valve 135 is closed, and the internal pressure of the piston 130 gradually increases while the refrigerant flowing into the piston 130 fills the inside of the piston 130.

In the refrigerant intake process, since the refrigerant remaining in the piston 130 flows into the expansion chamber 270 through the auxiliary flow passage PA2 and the communication hole 215, a flow loss occurring in the refrigerant intake process is reduced.

With reference to FIGS. 8 to 10, other embodiments of the present disclosure are described below.

In the following embodiments, the same reference numerals are given to the same components as the first embodiment described above, and a detailed description thereof is omitted.

In a second embodiment with reference to FIG. 8, an intake muffler 200A according to the second embodiment is configured such that a second muffler 230A can perform a resonator function by changing a design of the second muffler 230A.

More specifically, a second muffler body 231A of the second muffler 230A according to the second embodiment includes a first part 231a-1 that extends forward from an inlet hole 232a to have a predetermined inner diameter, and a second part 231b-1 that extends forward from the first part 231a-1 and has an inner diameter less than the inner diameter of the first part 231a-1.

A second muffler flange 233A extending in the radial direction is formed at an outer peripheral surface of a rear portion of the second muffler body 231A, more specifically, at an outer peripheral surface of the first part 231a-1. A second flange extension 234A extending forward in the axial direction is formed at the second muffler flange 233A.

However, in the intake muffler 200A according to the second embodiment, the second muffler 230A has a longer axial length than that of the second muffler 230 according to the first embodiment described above, and the second muffler 230A occupies most of an inner space of a third muffler 250.

Accordingly, since a volume of an expansion chamber 270A formed by a first muffler flange 212 and the second muffler flange 233A is larger than the volume of the expansion chamber 270 of the first embodiment described above, the second muffler 230A may serve as a resonator.

FIG. 11 is a graph illustrating energy efficiency depending on a ratio of a cross-sectional area of an auxiliary flow passage to a cross-sectional area of a main flow passage in an intake muffler according to a second embodiment of the present disclosure. FIG. 12 is a graph comparing a pressure of a linear compressor including an intake muffler according to a related art with a pressure of a linear compressor including an intake muffler according to a second embodiment of the present disclosure.

FIG. 13 is a graph comparing a transmission loss (TL) in a low frequency region of a linear compressor including an intake muffler according to a related art with a transmission loss in a low frequency region of a linear compressor including an intake muffler according to a second embodiment of the present disclosure. FIG. 14 is a graph comparing an insertion loss (IL) in a low frequency region of a linear compressor including an intake muffler according to a related art with an insertion loss in a low frequency region of a linear compressor including an intake muffler according to a second embodiment of the present disclosure.

Referring to FIG. 11, in order to obtain an increase in a visible energy efficiency ratio (EER), a sum (A) of cross-sectional areas of the auxiliary flow passages PA2 has to be less than a cross-sectional area (Am) of the inlet hole 211a formed at the rear end of the main flow passage PA1. In this instance, when the sum (A) of the cross-sectional areas of the auxiliary flow passages PA2 is greater than or equal to 10% of the cross-sectional area (Am) of the inlet hole 211a, the EER can increase.

Referring to FIG. 12, the linear compressor including the intake muffler according to the second embodiment of the present disclosure can improve compression efficiency of the linear compressor by forming a higher pressure than a linear compressor including an intake muffler according to a related art during an intake valve open.

Referring to FIGS. 13 and 14, the linear compressor including the intake muffler according to the second embodiment of the present disclosure can further improve a transmission loss (TL) and an insertion loss (IL) in a low frequency region compared to the linear compressor including the intake muffler according to the related art.

An intake muffler according to a third embodiment of the present disclosure is described below with reference to FIG. 9.

As illustrated in FIG. 9, an auxiliary flow passage PA2-1 included in an intake muffler 200B may be formed to surround a main flow passage PA1. To this end, a communication pipe P1-1 for forming the auxiliary flow passage PA2-1 is formed to surround a first muffler body 211.

A communication hole 215B is formed at a first muffler flange 212 and communicates with the auxiliary flow passage PA2-1, and an intake guide portion 220 is formed at an outer peripheral surface of the first muffler body 211.

An intake muffler according to a fourth embodiment of the present disclosure is described below with reference to FIG. 10.

In the fourth embodiment, an intake muffler 200C further includes a pipe P2 that is disposed between an outer peripheral surface of a first muffler body 211C of a first muffler 210C and an inner peripheral surface of a piston body 131 and surrounds the outer peripheral surface of the first muffler body 211C. An auxiliary flow passage PA2-2 is formed between an outer peripheral surface of the pipe P2 and the inner peripheral surface of the piston body 131.

A communication hole 215C is formed at a first flange extension 213C extending rearward in the axial direction from a first muffler flange 212C and communicates with the auxiliary flow passage PA2-2.

Claims

1. A linear compressor comprising: a shell including an intake pipe that is configured to suction a refrigerant;a cylinder provided inside the shell;a piston that is configured to reciprocate in an axial direction inside the cylinder and that includes a piston body and a piston flange;an intake muffler including a first muffler that includes (i) a first muffler body disposed inside the piston body and defining a main flow passage and (ii) a first muffler flange extending in a radial direction from the first muffler body; andat least one auxiliary flow passage that is disposed at an area between an outer peripheral surface of the first muffler body and an inner peripheral surface of the piston body and that is configured to guide refrigerant remaining in the area to an outside of the piston,wherein the intake muffler further includes a second muffler disposed at a rear side of the first muffler,wherein the at least one auxiliary flow passage is in fluid communication with the area and an expansion chamber defined between the first muffler and the second muffler, andwherein a cross-sectional area of the at least one auxiliary flow passage is (i) less than a cross-sectional area of an inlet hole provided at a rear end of the main flow passage and (ii) greater than or equal to 10% of the cross-sectional area of the inlet hole.

2. The linear compressor of claim 1, wherein the at least one auxiliary flow passage is defined at a communication pipe that is positioned at the outer peripheral surface of the first muffler body and that extends in the axial direction, and wherein the at least one auxiliary flow passage of the communication pipe is in fluid communication with a communication hole defined at the first muffler flange.

3. The linear compressor of claim 2, wherein the at least one auxiliary flow passage is positioned at an upper side of the main flow passage in the axial direction.

4. The linear compressor of claim 2, wherein the at least one auxiliary flow passage surrounds the main flow passage in the axial direction.

5. The linear compressor of claim 2, wherein a front end of the communication pipe is (i) positioned forward or rearward in the axial direction compared to a front end of the first muffler body or (i) positioned on the same line in the axial direction as the front end of the first muffler body.

6. The linear compressor of claim 2, wherein the second muffler includes (i) a second muffler body that is disposed at the rear side of the first muffler and that is in fluid communication with the first muffler and (ii) a second muffler flange that extends in the radial direction from the second muffler body,wherein the linear compressor further comprises: a third muffler configured to accommodate a part of the first muffler body and the second muffler body.

7. The linear compressor of claim 6, wherein the expansion chamber is defined between the first muffler flange and the second muffler flange, and wherein the at least one auxiliary flow passage is in fluid communication with the expansion chamber through a communication hole defined at the second muffler flange.

8. The linear compressor of claim 7, wherein the second muffler body includes a first part having a first inner diameter and a second part having a second inner diameter less than the first inner diameter, and wherein the second muffler flange is defined at an outer peripheral surface of the first part in the radial direction.

9. The linear compressor of claim 7, wherein the second muffler body includes a first part having a first inner diameter and a second part having a second inner diameter less than the first inner diameter, and wherein the second muffler flange is defined at an outer peripheral surface of the second part in the radial direction.

10. The linear compressor of claim 7, wherein a part of the first muffler and a part of the second muffler are press-fitted and coupled to an inner peripheral surface of the third muffler.

11. The linear compressor of claim 7, further comprising: a muffler filter disposed between the first muffler and the second muffler.

12. The linear compressor of claim 7, further comprising: an intake guide portion configured to guide refrigerant discharged from a discharge hole of the first muffler body to an intake port of the piston.

13. The linear compressor of claim 12, wherein the intake guide portion is provided on at least one of the outer peripheral surface of the first muffler body or an outer peripheral surface of the communication pipe.

14. The linear compressor of claim 1, further comprising: a pipe that is disposed between the outer peripheral surface of the first muffler body and the inner peripheral surface of the piston body and that surrounds the outer peripheral surface of the first muffler body,wherein the at least one auxiliary flow passage is (i) defined between an outer peripheral surface of the pipe and the inner peripheral surface of the piston body and (ii) in fluid communication with a communication hole defined at a first flange extension that extends rearward in the axial direction from the first muffler flange.

15. The linear compressor of claim 14, wherein the at least one auxiliary flow passage is configured to surround the main flow passage in the axial direction.

16. The linear compressor of claim 14, wherein a front end of the pipe is (i) positioned forward or rearward in the axial direction compared to a front end of the first muffler body or (ii) positioned on the same line in the axial direction as the front end of the first muffler body.

17. The linear compressor of claim 14, further comprising: the second muffler includes (i) a second muffler body that is disposed at the rear side of the first muffler and that is in fluid communication with the first muffler and (ii) a second muffler flange extending in the radial direction from the second muffler body; and a third muffler configured to accommodate a part of the first muffler body and the second muffler body.

18. The linear compressor of claim 14, further comprising: an intake guide portion configured to guide the refrigerant discharged from a discharge hole of the first muffler body to an intake port of the piston.

19. The linear compressor of claim 18, wherein the intake guide portion is provided at the outer peripheral surface of the first muffler body.

20. The linear compressor of claim 14, wherein the first flange extension has a cylindrical shape.