Electric compressor

Abstract

The present invention relates to an electric compressor that can prevent excessive pressure rise in a connector housing by covering the lead wire with a cylindrical component and can also implement effective leakage countermeasures for minor damage to the lead wire in the cylindrical component. The motor mechanism has a lead wire (47), a connector (50), an inner cylindrical component (61) covering the lead wire (47), and an outer cylindrical component (63) covering the inner cylindrical component (61). The connector (50) has a connector housing (51) that forms an insertion port (51b) for inserting the lead wire (47) and a terminal storage chamber (51a). The inner cylindrical component (61) is filled with an insulating resin (49) at one end to form a gap between it and the lead wire (47). The outer cylindrical component (63) is inserted into the insertion port (51b) without a gap and covers the other end of the inner cylindrical component (61). The resin (49) covers the lead wire (47) and the coil end (45) extending from the inner cylinder component (61), and the terminal storage chamber (51a) and the motor storage chamber (3a) are connected only through the interior of the outer cylinder component (63).

Description

Technical Field

[0001] The present invention relates to an electric compressor. Background Art

[0002] An electric compressor generally comprises a compression mechanism for compressing refrigerant, a motor mechanism for driving the compression mechanism, a metal housing having a motor housing chamber for housing the motor mechanism, and an inverter circuit for driving the motor mechanism. The motor mechanism comprises a cylindrical stator core fixed to the housing, coil ends protruding from the end faces of the stator core, leads extending from the coil ends, and a connector for electrically connecting the leads to the inverter circuit. The coil ends are formed by winding an insulating conductive wire around the stator core. The connector comprises a terminal electrically connected to the top end of the lead, and a connector housing made of an insulating material. The connector housing is provided with a terminal housing chamber for housing the terminal, and an insertion port for inserting the lead.

[0003] In such electric compressors, when operation stops, the refrigerant gas remaining in the housing cools and liquefies, sometimes leaving the motor housing in the housing. In this case, if the liquid refrigerant enters the connector housing through the insertion port, the conductive parts inside the connector housing, such as leads and terminals, and the motor housing become electrically conductive through the liquid refrigerant, effectively breaking the insulation between the conductive parts inside the connector housing and the motor housing. If the electric compressor is restarted in this state, there's a risk that current supplied to the conductive parts inside the connector housing could leak into the motor housing through the liquid refrigerant.

[0004] To prevent liquid refrigerant from contacting the conductive parts within the connector housing, sealing the connector housing by sealing the insertion opening with rubber or resin is effective. However, in this case, if the air within the connector housing thermally expands due to a rise in temperature within the connector housing, the pressure within the connector housing may increase excessively, potentially making the connector housing unable to withstand high pressures.

[0005] Therefore, Patent Document 1 discloses an electric compressor that improves the insulation resistance between the motor housing chamber and the conductive part in the connector housing without sealing the connector housing. In this electric compressor, a tube component composed of an insulating tube is used to cover the lead wire electrically connected to the terminal. One end of the tube component extends in a cylindrical shape on the stator core side and covers the lead wire with a gap formed between it and the lead wire, and the other end is engaged with the insertion port of the connector housing without a gap. In this way, the inside and outside of the connector housing are connected through the gap in the tube component, preventing liquid refrigerant from invading the connector housing from outside the gap in the tube component. As a result, the leakage path between the conductive part in the connector housing and the motor housing chamber can be lengthened by the length of the tube component, which can improve the insulation resistance between the conductive part in the connector housing and the motor housing chamber.

[0006] Prior art literature

[0007] Patent Literature

[0008] Patent Document 1: Japanese Patent Application Laid-Open No. 2011-58388 Summary of the Invention

[0009] Problems to be solved by the invention

[0010] However, the lead wire consists of a conductive wire with an insulating coating covering a conductive core. If such a lead wire has a minor damage, liquid refrigerant that has entered the barrel will come into contact with the conductive core at the site of the minor damage. This creates electrical continuity between the conductive core at the site of the minor damage and the motor housing via the liquid refrigerant. This shortens the leakage path between the site of the minor damage and the conductive portion inside the connector housing compared to a situation without the minor damage. This lengthens the leakage path due to the barrel, potentially leading to insufficient insulation.

[0011] In particular, in electric compressors using refrigeration oil that is easily conductive, measures are required to counteract leakage caused by minor damage to lead wires.

[0012] Here, thickening the insulation coating of the conductors that make up the leads is effective for preventing leakage currents due to minor damage to the leads. However, if the leads become too thick due to the thickening of the insulation coating, it becomes difficult to insert the leads into the barrel, resulting in reduced productivity. In addition, due to the size limitations of the terminals that are joined to the leads by crimping, etc., the connector housing that houses the terminals, and the difficulty of applying the insulation coating, there are limits to how thick the insulation coating can be. Therefore, implementing a leakage countermeasure against minor damage to the leads by thickening the insulation coating is not effective.

[0013] The present invention has been completed in view of the above-mentioned previous reality, and the problem it aims to solve is: in an electric compressor, it is possible to prevent excessive pressure increase in the connector housing by covering the lead wire with a cylindrical component, and to implement effective leakage countermeasures for minor damage to the lead wire in the cylindrical component.

[0014] Means for solving problems

[0015] The electric compressor of the present invention has:

[0016] a compression mechanism for compressing the refrigerant;

[0017] a motor mechanism for driving the compression mechanism;

[0018] a metal housing having a motor housing chamber therein for housing the motor mechanism; and

[0019] an inverter circuit for driving the motor mechanism;

[0020] The motor mechanism includes a cylindrical stator core fixed to the housing, coil ends formed by winding a conductive wire having an insulation coating around the stator core and protruding from an end surface of the stator core, lead wires formed by the conductive wires extending from the coil ends, and a connector electrically connecting the lead wires to the inverter circuit.

[0021] The connector has a terminal electrically connected to the top end of the lead wire, and a connector housing made of an insulating material, wherein the connector housing is formed with a terminal receiving chamber for receiving the terminal and an insertion port for inserting the lead wire;

[0022] It is characterized by:

[0023] The motor mechanism includes a first insulating member having a cylindrical shape and having the lead wire inserted therein, and a second insulating member having a gap therein inserted into the first insulating member;

[0024] The first insulating member is sealed between the lead wire and the first insulating member by insulating resin at one end;

[0025] The second insulating member covers the other end of the first insulating member;

[0026] The second insulating member is connected to the insertion port in a sealed state;

[0027] The resin covers the lead wire and the coil end extending from the first insulating member;

[0028] The terminal accommodating chamber and the motor accommodating chamber communicate with each other via the gap.

[0029] In the electric compressor of the above invention, the cylindrical member covering the lead is further covered by another cylindrical member. According to the configuration in which the cylindrical member forms a double structure inside and outside, in the case where the lead in the first insulating member has a slight damage, the length of the leakage path from the slight damage to the opening at one end of the second insulating member through the liquid refrigerant becomes the sum of the distance from the slight damage to the opening at the other end of the first insulating member and the distance from the opening at the other end of the first insulating member to the opening at one end of the second insulating member. Therefore, even in the case where the lead in the first insulating member has a slight damage, the length of the leakage path from the slight damage to the opening at one end of the second insulating member can be effectively ensured. Thus, even if the lead in the first insulating member has a slight damage, an effective leakage countermeasure can be implemented.

[0030] On the other hand, in this electric compressor, the interior of the connector housing communicates with the motor housing chamber via the gap between the first and second insulating members. Therefore, air within the connector housing can escape into the motor housing chamber via the gap between the first and second insulating members. Therefore, even if the temperature inside the connector housing reaches a high temperature, the pressure inside the connector housing does not rise excessively.

[0031] Therefore, according to this electric compressor, while preventing an excessive pressure increase in the connector housing by covering the lead wires with the cylindrical member, effective measures can be taken to counteract even minor damage to the lead wires in the cylindrical member.

[0032] In the above electric compressor, the second insulating member and the connector housing may be formed integrally. In this electric compressor, since the second insulating member and the connector housing are formed integrally, the number of parts and the number of assembly steps can be reduced.

[0033] In the above-mentioned electric compressor, it is preferred that the gap between the first insulating component and the second insulating component is smaller than the gap between the lead wire and the first insulating component. In the case where the gap between the first insulating component and the second insulating component is smaller than the gap between the lead wire and the first insulating component, the leakage path of the former is thinner than the leakage path of the latter. In leakage countermeasures, a thin leakage path is more advantageous. Here, the length L of the leakage path from the minute damage on the lead wire in the first insulating component to the opening at one end of the second insulating component becomes the sum of the length L1 of the gap from the minute damage to the opening at the other end of the first insulating component and the length L2 of the gap from the opening at the other end of the first insulating component to the opening at one end of the second insulating component. The length L1 becomes longer or shorter depending on the position of the minute damage on the lead wire. On the other hand, the length L2 is equal to the overlapping length of the first insulating component and the second insulating component. Therefore, by setting the repetition length to be greater than a predetermined value, the length L2 of the gap between the first insulating component and the second insulating component, in which the leakage path is thin and effective in the leakage countermeasure, can be set to be greater than a predetermined value, and the effect of the above-mentioned leakage countermeasure greater than a predetermined value can be exerted regardless of the location of the micro-damage caused by the lead wire in the first insulating component.

[0034] Effects of the Invention

[0035] According to the electric compressor of the present invention, the lead wires are covered by the cylindrical member, thereby preventing an excessive pressure increase in the connector housing and effectively preventing leakage even from minor damage to the lead wires in the cylindrical member. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Figure 1 This is a longitudinal sectional view of the electric compressor of Example 1.

[0037] Figure 2The electric compressor according to the first embodiment is a cross-sectional view schematically showing the relationship among a coil end, a lead wire, a cylindrical member, and a connector.

[0038] Figure 3 The electric compressor according to Example 1 is a cross-sectional view schematically showing the relationship between the length of the inner cylinder member and the length of the outer cylinder member.

[0039] Figure 4 The electric compressor according to the second embodiment is a cross-sectional view schematically showing the relationship among the coil end, the lead wire, the cylindrical member, and the connector.

[0040] Figure 5 The electric compressor according to the third embodiment is a cross-sectional view schematically showing the relationship among the coil end, the lead wire, the cylindrical member, and the connector.

[0041] Figure 6 The electric compressor according to Modification 1 is a cross-sectional view schematically showing the relationship among the coil end, the lead wire, the cylindrical member, and the connector.

[0042] Figure 7 The electric compressor according to Modification 2 is a cross-sectional view schematically showing the relationship among the coil end, the lead wire, the cylindrical member, and the connector.

[0043] Figure 8 The electric compressor according to Modification 3 is a cross-sectional view schematically showing the relationship among the coil end, the lead wire, the cylindrical member, and the connector.

[0044] Label Description

[0045] 10…Compression mechanism

[0046] 12…Motor mechanism

[0047] 3a…Motor storage room

[0048] 14…housing

[0049] 16…Converter circuit

[0050] 41… stator core

[0051] 45…Coil end

[0052] 47…lead

[0053] 50…connector

[0054] 61c…1st gap

[0055] 61…Inner cylinder parts

[0056] 57…Terminal

[0057] 51a…Terminal storage compartment

[0058] 51b…Insert port

[0059] 51…Connector housing

[0060] 63c…2nd gap

[0061] 63…Outer cylinder parts

[0062] 61a ... opening at one end of the inner cylinder

[0063] 61b ... opening at the other end of the inner cylinder

[0064] 63a ... opening at one end of the outer cylinder member

[0065] 63b ... opening at the other end of the outer cylinder member

[0066] Ld…The overlapping length of the inner and outer cylinder parts

[0067] Li…Length of the inner cylinder only

[0068] Lo…Length of outer tube only

[0069] 65…Outer cylinder part

[0070] 65a…Opening at one end of the outer tube

[0071] 65b…Opening at the other end of the outer tube

[0072] G1…Size of the first gap

[0073] G2…Size of the second gap DETAILED DESCRIPTION

[0074] Hereinafter, Examples 1 to 3 which embody the present invention will be described with reference to the drawings.

[0075] (Example 1)

[0076] like Figure 1 As shown, the electric compressor of Example 1 includes a compression mechanism 10 for compressing refrigerant, a motor mechanism 12 for driving the compression mechanism 10, a housing 14, and an inverter circuit 16 for driving the motor mechanism 12. The housing 14 is made of metal, such as an aluminum alloy. The housing 14 includes a front housing 1 and a motor housing 3. The compression mechanism 10 and the motor mechanism 12 are housed within the motor housing 3.

[0077] In the following description, Figure 1 The direction of arrow Y1 shown is the front-back direction. Figure 1 The front housing 1 side on the left side of the paper is defined as the front side of the electric compressor, and the side on the opposite side is defined as the front side of the electric compressor. Figure 1The right side of the paper is defined as the rear side of the electric compressor. The front-to-back direction in the embodiment is merely an example. The front-to-back direction of the electric compressor may be appropriately changed depending on the vehicle on which it is mounted. In this specification, the terms "radial direction" and "axial direction" refer to the radial direction and axial direction of the cylinder member described later.

[0078] The motor housing 3 is in the shape of a bottomed cylinder with an opening on the front side, and has a motor peripheral wall 31 extending cylindrically in the front and rear, and a motor bottom wall 33 in the shape of a disc at the rear end of the motor peripheral wall 31. A front housing 1 is fixed to the front end of the motor housing 3, and the opening on the front side of the motor housing 3 is blocked by the front housing 1. A shaft support component 5 fixed to the motor peripheral wall 31 is accommodated in the motor housing 3. In addition, a fixed scroll 7 fixed to the motor peripheral wall 31 is accommodated in front of the shaft support component 5 in the motor housing 3. The discharge chamber 10a of the compression mechanism 10 is divided between the front housing 1 and the fixed scroll 7. A discharge port 10b is formed in the front end wall of the front housing 1 and passes through the front end wall. A suction port 10c is formed in the motor peripheral wall 31 and passes through the motor peripheral wall 31. The suction port 10c and the discharge port 10b are connected to an external refrigerant circuit not shown.

[0079] The motor housing 3 houses a movable scroll 9 that is arranged to face the fixed scroll 7 in the front-to-rear direction. The fixed scroll 7 and the movable scroll 9 mesh with each other, thereby dividing a compression chamber 10d of the compression mechanism 10 therebetween. The compression chamber 10d is connected to the motor housing chamber 3a via the suction passage 5a formed in the shaft support member 5. In addition, the compression chamber 10d is connected to the discharge chamber 10a via the discharge passage 7a formed in the fixed scroll 7. The motor housing 3 houses a rotating shaft 21 that is rotatably supported by the shaft support member 5 and the motor bottom wall 33. The movable scroll 9 is connected to the front end of the rotating shaft 21 via a bushing 23 and the like.

[0080] A motor housing chamber 3a is defined in the motor housing 3 at the rear of the shaft support member 5. The motor housing chamber 3a also serves as a suction chamber of the compression mechanism 10. The motor mechanism 12 is housed in the motor housing chamber 3a.

[0081] The motor mechanism 12 includes a cylindrical stator core 41, a cylindrical rotor 43, and coil ends 45. The stator core 41 is fixed to the motor peripheral wall 31. The rotor 43 is fixed to the rotating shaft 21 and disposed inside the stator core 41. The coil ends 45 are formed by winding a conductive wire around the stator core 41 and protrude from the end surface of the stator core 41. The conductive wire is composed of a conductive core material and an insulating coating that covers the conductive core material.

[0082] like Figure 2As shown, the motor mechanism 12 has a plurality of (three in this embodiment) motor-side leads 47 made of conductive wires and a connector 50. Each motor-side lead 47 is led out from the coil end 45 of the U-phase coil, V-phase coil, and W-phase coil of the motor mechanism 12. Figure 2 In FIG. 4 , for convenience of explanation, the motor-side lead wires 47 are shown extending linearly from the coil end 45 . However, in reality, each motor-side lead wire 47 extends in the circumferential direction along the rear end surface of the stator core 41 .

[0083] The connector 50 electrically connects the motor-side leads 47 and the inverter circuit 16. The connector 50 includes a connector housing 51 made of an insulating resin. The connector housing 51 has a box-shaped main body 53 with one side open and a cover 55 that blocks the opening of the main body 53. The main body 53 and the cover 55 are airtightly joined by a resin (not shown), forming multiple terminal storage chambers 51a within the connector housing 51. Each terminal storage chamber 51a houses a terminal 57. The cover 55 has multiple insertion openings 51b through which the motor-side leads 47 are inserted. The tip of each motor-side lead 47 is electrically connected to the terminal 57 through the insertion openings 51b. Each terminal 57 is electrically connected to a rod-shaped conductive portion 59. Each rod-shaped conductive portion 59 extends outside the connector housing 51 through an insertion opening (not shown) formed in the main body 53. The insertion openings through which the rod-shaped conductive portion 59 is inserted are sealed with an insulator (not shown). Each rod-shaped conductive portion 59 is electrically connected to the inverter circuit 16 via the inverter-side lead 17 .

[0084] like Figure 1 As shown, a box-shaped inverter cover 18 with an open front surface is fixed to the rear surface of the motor bottom wall 33. The inverter cover 18 is made of metal, such as an aluminum alloy. An inverter storage chamber 18a is defined between the motor bottom wall 33 and the inverter cover 18. The inverter circuit 16 is mounted on the rear surface of the motor bottom wall 33 and is stored in the inverter storage chamber 18a. The inverter circuit 16 includes electrical components (not shown), such as a circuit board, switching elements, and coils. The inverter circuit 16 is connected to an external power supply via an insertion port (not shown) formed in the inverter cover 18.

[0085] A communication port 33a that connects the motor housing chamber 3a and the inverter housing chamber 18a is formed in the motor bottom wall 33. A plurality of rod-shaped conductive portions 59 inserted through the communication port 33a are held in the communication port 33a via an insulator 35.

[0086] like Figure 2As shown, the motor mechanism 12 includes multiple cylindrical members 60 that each cover the motor-side leads 47. Each cylindrical member 60 is made of an insulating material and includes an inner cylindrical member 61 formed of an insulating tube and an outer cylindrical member 63 formed of an insulating tube. The inner cylindrical member 61 corresponds to the first insulating member in the present invention, and the outer cylindrical member 63 corresponds to the second insulating member in the present invention. Each inner cylindrical member 61 covers the motor-side leads 47 inserted therethrough, forming a first gap 61c therebetween. Each outer cylindrical member 63 covers the inner cylindrical member 61, forming a second gap 63c therebetween.

[0087] exist Figure 2 In the figure, for the sake of convenience, the inner cylinder member 61 and the outer cylinder member 63 are shown as extending in a straight line, but in fact, the inner cylinder member 61 and the outer cylinder member 63 extend in the circumferential direction along the rear end surface of the stator core 41 in the same manner as the motor-side lead wire 47. Figure 3 As shown, the size G2 of the second gap 63c is smaller than the size G1 of the first gap 61c. The value of G1 is determined by the radial length between the outer circumference of the motor-side lead 47 and the inner circumference of the inner cylindrical member 61. The value of G2 is determined by the radial length between the outer circumference of the inner cylindrical member 61 and the inner circumference of the outer cylindrical member 63.

[0088] The opening 61a at one end of each inner cylindrical member 61 is sealed with insulating resin 49. Specifically, resin 49 intrudes into opening 61a, blocking it and integrally covering the lead wires 47 and coil end 45 extending from opening 61a. The resin 49 seals the space between the one end of the inner cylindrical member 61 and the lead wires 47. This creates an airtight bond between the one end of the inner cylindrical member 61 and the coil end 45 via resin 49. Meanwhile, the other end of each inner cylindrical member 61 extends to the vicinity of the insertion port 51b, that is, to the end surface 51c of the connector housing 51. The opening 61b at the other end opens into the outer cylindrical member 63. This connects the interior of the inner cylindrical member 61 with the interior of the outer cylindrical member 63.

[0089] One end of each outer tube member 63 extends near the coil end 45, and an opening 63a at one end opens into the motor housing chamber 3a. Thus, the opening 63a connects the interior of the outer tube member 63 with the motor housing chamber 3a. Meanwhile, the other end of each outer tube member 63 extends into the terminal housing chamber 51a, and an opening 63b at the other end opens into the terminal housing chamber 51a. In other words, the outer tube member 63 is inserted into the insertion opening 51b. Thus, the opening 63b connects the interior of the outer tube member 63 with the terminal housing chamber 51a. The outer circumferential surface near the other end of the outer tube member 63 is seamlessly bonded to the insertion opening 51b via resin (not shown). In other words, the outer tube member 63 is sealed to the insertion opening 51b. Furthermore, the other end of the outer tube member 63 is crimped and joined to the terminal 57, and the outer circumferential surface of the other end is seamlessly bonded to the terminal 57 via resin (not shown).

[0090] like Figure 3 As shown, within the motor housing 3, the overlapping length Ld of the inner and outer cylindrical members 61 and 63 is longer than the length Li of the inner cylindrical member 61 alone and longer than the length Lo of the outer cylindrical member 63 alone. The overlapping length Ld is defined by the axial length between the opening 61b at the other end of the inner cylindrical member 61 and the opening 63a at one end of the outer cylindrical member 63. The length Li of the inner cylindrical member alone is defined by the axial length between the opening 61a at one end of the inner cylindrical member 61 and the opening 63a at one end of the outer cylindrical member 63. The length Lo of the outer cylindrical member alone is defined by the axial length between the opening 61b at the other end of the inner cylindrical member and the end surface 51c of the connector housing 51.

[0091] In the electric compressor structured as described above, when power is supplied to the stator core 41 from an external power source, the rotating shaft 21 rotates together with the rotor 43. The rotation of the rotating shaft 21 causes the movable scroll 9 connected to the rotating shaft 21 to orbit, reducing the volume of the compression chamber 10d between the movable scroll 9 and the fixed scroll 7. Refrigerant from the external refrigerant circuit is drawn into the motor housing 3 through the suction port 10c. The refrigerant drawn into the motor housing 3 is drawn into the compression chamber 10d through the suction passage 5a and compressed there. The refrigerant compressed in the compression chamber 10d is discharged from the discharge passage 7a into the discharge chamber 10a. The refrigerant in the discharge chamber 10a flows out of the external refrigerant circuit through the discharge port 10b. The refrigerant flowing out of the external refrigerant circuit then passes through the external refrigerant circuit's heat exchanger and expansion valve, returning to the motor housing 3 through the suction port 10c. The electric compressor and the external refrigerant circuit constitute a vehicle air conditioning system.

[0092] In this electric compressor, the motor-side lead 47 is covered by an inner cylindrical member 61, which is further covered by an outer cylindrical member 63. An opening 61a at one end of the inner cylindrical member 61 is closed by the coil end 45. Meanwhile, an opening 61b at the other end of the inner cylindrical member 61 opens into the outer cylindrical member 63, connecting the interior of the inner cylindrical member 61 with the interior of the outer cylindrical member 63. Furthermore, an opening 63a at one end of the outer cylindrical member 63 opens into the motor housing chamber 3a, connecting the interior of the outer cylindrical member 63 with the motor housing chamber 3a. Meanwhile, an opening 63b at the other end of the outer cylindrical member 63 opens into the terminal housing chamber 51a, connecting the interior of the outer cylindrical member 63 with the terminal housing chamber 51a.

[0093] By forming the double structure of the cylindrical member 60, it is possible to implement effective leakage countermeasures against the micro damage MS of the motor side lead 47 in the inner cylindrical member 61. Figure 3 As shown, if the motor-side lead 47 within the inner cylindrical member 61 has a micro-scratch MS, the length of the leakage path through the liquid refrigerant from the micro-scratch MS to the opening 63a at one end of the outer cylindrical member 63 is the sum of the length L1 from the micro-scratch MS to the opening 61b at the other end of the inner cylindrical member 61 and the length L2 from the opening 61b at the other end of the inner cylindrical member 61 to the opening 63a at one end of the outer cylindrical member 63. Therefore, even if the motor-side lead 47 within the inner cylindrical member 61 has a micro-scratch MS, the length of the leakage path from the micro-scratch MS to the opening 63a at one end of the outer cylindrical member 63 can be effectively ensured. This allows for effective leakage countermeasures even against micro-scratch MS on the motor-side lead 47 within the inner cylindrical member 61.

[0094] On the other hand, in this electric compressor, the terminal housing chamber 51a of the connector housing 51 communicates with the motor housing chamber 3a via the second gap 63c. Therefore, air within the connector housing 51 can escape into the motor housing chamber 3a via the second gap 63c. Consequently, even if the temperature inside the connector housing 51 reaches a high temperature, the pressure inside the connector housing 51 does not rise excessively.

[0095] Therefore, according to this electric compressor, excessive pressure increase in the connector housing 51 can be prevented by covering the motor-side lead 47 with the cylindrical member 60 , and effective leakage countermeasures can be implemented against minor damage MS to the motor-side lead 47 in the cylindrical member 60 .

[0096] In this electric compressor, the overlapping length Ld of the inner and outer cylindrical members 61, 63 within the motor housing chamber 3a is longer than the length Li of the inner cylindrical member 61 alone, and longer than the length Lo of the outer cylindrical member 63 alone. Therefore, the dual structure of the cylindrical member 60, with both inside and outside components, further effectively counteracts leakage. Furthermore, the distance Lf between the end surface 51c of the connector housing 51, i.e., the insertion opening 51b, and the coil end 45 is defined as the sum of the length Li of the inner cylindrical member 61 alone, the overlapping length Ld, and the length Lo of the outer cylindrical member 63 alone.

[0097] In this electric compressor, the size G2 of the second gap 63c is smaller than the size G1 of the first gap 61c. The length of the leakage path from the micro-scratch MS on the motor-side lead 47 inside the inner cylindrical member 61 to the opening 63a at one end of the outer cylindrical member 63 is the sum of the length L1 of the first gap 61c from the micro-scratch MS to the opening 61b at the other end of the inner cylindrical member 61 and the length L2 of the second gap 63c from the opening 61b at the other end of the inner cylindrical member 61 to the opening 63a at one end of the outer cylindrical member 63. The length L1 of the first gap 61c can be shortened or lengthened depending on the location of the micro-scratch MS on the motor-side lead 47. On the other hand, the length L2 of the second gap 63c is equal to the overlap length Ld between the inner cylindrical member 61 and the outer cylindrical member 63. A narrower leakage path is more advantageous in countermeasures, and the second gap 63c is narrower than the first gap 61c. Therefore, by setting the overlapping length Ld of the inner cylinder component 61 and the outer cylinder component 63 to be greater than a predetermined value, the length L2 of the second gap 63c, which is a thin leakage path effective in the leakage countermeasure, can be set to be greater than a predetermined value, and the effect of the above-mentioned leakage countermeasure greater than a predetermined value can be exerted regardless of the position of the micro-damage MS on the motor-side lead 47 in the inner cylinder component 61.

[0098] In this electric compressor, the opening 61a at one end of the inner cylindrical member 61 is blocked by resin 49, and the resin 49 also joins the one end of the inner cylindrical member 61 to the coil end 45. Therefore, the opening 61a can be easily and reliably blocked. Alternatively, the one end of the inner cylindrical member 61 can be integrally and airtightly joined to the coil end 45 by resin molding. In this case, the opening 61a of the inner cylindrical member 61 can also be easily and reliably blocked. Alternatively, the resin 49 that blocks the opening 61a at one end of the inner cylindrical member 61 and the resin 49 that covers the coil end 45 can be made of different materials, so that they bond to each other during curing.

[0099] (Example 2)

[0100] The electric compressor of the second embodiment has the same structure as the electric compressor of the first embodiment except that the structure of the cylinder member 60 and the connector 50 in the electric compressor of the first embodiment is changed. Figure 4 As shown in FIG. 1 , the connector housing 51 having the terminal receiving chamber 51 a and the insertion port 51 b integrally includes a plurality of outer cylindrical portions 65 made of an insulating material. The outer cylindrical portion 65 corresponds to a second insulating member.

[0101] Each outer tube portion 65 extends continuously in a cylindrical shape from the insertion port 51b of the connector housing 51. That is, the outer tube portion 65 is connected to the insertion port 51b in a sealed state. In addition, each outer tube portion 65 covers the inner tube portion 61 to form a second gap 65c between the inner tube portion 61. One end of the outer tube portion 65 extends to the vicinity of the coil end 45, and the opening 65a at one end is open in the motor storage chamber 3a. Thus, the opening 65a connects the interior of the outer tube portion 65 and the motor storage chamber 3a. On the other hand, the opening 65b at the other end of the outer tube portion 65 is connected to the insertion port 51b. Thus, the opening 65b connects the interior of the outer tube portion 65 and the terminal storage chamber 51a via the insertion port 51b.

[0102] In the motor housing 3, the overlapping length Ld of the inner cylinder member 61 and the outer cylinder portion 65 is longer than the length Li of the inner cylinder member 61 alone and longer than the length Lo of the outer cylinder portion 65 alone. Furthermore, the size G2 of the second gap 65c is smaller than the size G1 of the first gap 61c.

[0103] In the electric compressor of Example 2, the outer cylinder portion 65 functions in the same manner as the outer cylinder component 63 of the electric compressor of Example 1. Therefore, it is possible to prevent excessive pressure rise in the connector housing 51 by covering the motor side lead 47 with the cylinder component 60, and to implement effective leakage countermeasures for minor damage MS to the motor side lead 47 in the cylinder component 60.

[0104] In this electric compressor, the outer cylinder 65 is integrated with the connector housing 51, thereby reducing the number of parts and the number of assembly steps. The other functions of this electric compressor are the same as those of the electric compressor of the first embodiment.

[0105] (Example 3)

[0106] The electric compressor of embodiment 3 has the same structure as the electric compressor of embodiment 1 except that the inner cylinder member 61 in the electric compressor of embodiment 1 is lengthened. Figure 5 As shown, the other end of the inner cylindrical member 61 is located within the terminal receiving chamber 51a. Specifically, the other end of the inner cylindrical member 61 extends into the terminal receiving chamber 51a, and the opening 61b at the other end opens into the outer cylindrical member 63 at a position extending into the terminal receiving chamber 51a. Thus, the opening 61b near the other end of the outer cylindrical member 63 connects the interior of the inner cylindrical member 61 with the interior of the outer cylindrical member 63.

[0107] In this electric compressor, the overlap length Ld between the inner cylindrical member 61 and the outer cylindrical member 63 is longer than the overlap length Ld of the electric compressor of Example 1 by the length of the inner cylindrical member 61. Therefore, the length of the leakage path from the micro-scratch MS on the motor-side lead 47 within the inner cylindrical member 61 to the opening 63a at one end of the outer cylindrical member 63 is also longer than that of the electric compressor of Example 1, thereby making leakage countermeasures against micro-scratch MS more effective. The remaining functions of this electric compressor are the same as those of the electric compressor of Example 1.

[0108] (Variation 1)

[0109] The electric compressor of the modification example 1 has the same structure as the electric compressor of the embodiment 1 except that the opening 61b of the other end of the inner cylinder member 61 in the electric compressor of the embodiment 1 is closed. Figure 6 As shown, the opening 61b at the other end of the inner cylinder member 61 is sealed with an insulating resin 67. That is, the resin 67 penetrates into the opening 61b to block the opening 61b, thereby sealing the opening 61b at the other end of the inner cylinder member 61 with respect to the motor-side lead 47.

[0110] In this electric compressor, the openings 61a and 61b at both ends of the inner cylindrical member 61 are sealed against the motor-side lead 47. Therefore, even if the motor-side lead 47 within the inner cylindrical member 61 has a micro-scratch MS, liquid refrigerant will not contact the micro-scratch MS. This ensures reliable leakage protection against micro-scratch MS on the motor-side lead 47 within the inner cylindrical member 61.

[0111] On the other hand, similar to the electric compressor of Example 1, the air in the connector housing 51 can escape into the motor housing chamber 3a through the second gap 63c between the inner tube member 61 and the outer tube member 63, so even if the temperature inside the connector housing 51 becomes high, the pressure inside the connector housing 51 will not rise excessively.

[0112] (Variation 2)

[0113] The electric compressor of the modified example 2 has the same structure as the electric compressor of the embodiment 2 except that the opening 61b of the other end of the inner cylinder member 61 in the electric compressor of the embodiment 2 is closed. Figure 7 As shown, the opening 61 b at the other end of the inner cylindrical member 61 is sealed with an insulating resin 67 similarly to the electric compressor of the first modification.

[0114] In this electric compressor, similar to the electric compressor of variant example 1, the openings 61a and 61b at both ends of the inner cylinder component 61 are sealed relative to the motor-side lead 47, so that effective leakage countermeasures can be implemented for the minor damage MS of the motor-side lead 47 in the inner cylinder component 61.

[0115] In the electric compressors of Modifications 1 and 2, the openings 61 a and 61 b at both ends of the inner cylindrical member 61 are closed, so there is no need to specifically provide the first gap 61 c.

[0116] (Variation 3)

[0117] The electric compressor of the modified example 3 has the same structure as the electric compressor of the embodiment 1 except that the entire interior of the inner cylinder member 61 of the electric compressor of the embodiment 1 is filled with resin 49. Figure 8 As shown, the entire interior of the inner cylinder member 61 is filled with resin 49 up to the opening 61b at the other end. In other words, the resin 49 intrudes into the opening 61b to block the opening 61b, thereby sealing the opening 61b at the other end of the inner cylinder member 61 from the motor-side lead 47.

[0118] In this electric compressor, resin 49 covers the entire interior of inner cylindrical member 61, covering lead wire 47. Therefore, even if microscopic scratches MS are present on motor-side lead wire 47 within inner cylindrical member 61, liquid refrigerant will not contact these scratches MS. This ensures reliable leakage protection against microscopic scratches MS on motor-side lead wire 47 within inner cylindrical member 61.

[0119] On the other hand, similar to the electric compressor of Example 1, the air in the connector housing 51 can escape into the motor housing chamber 3a through the second gap 63c between the inner tube member 61 and the outer tube member 63, so even if the temperature inside the connector housing 51 becomes high, the pressure inside the connector housing 51 will not rise excessively.

[0120] As mentioned above, the present invention has been described based on Embodiments 1 to 3. However, the present invention is not limited to the above-mentioned Embodiments 1 to 3, and can be applied with appropriate modifications within the scope of the present invention.

[0121] For example, in the above-described first to third embodiments, the compression mechanism 10 is a scroll type. However, in the electric compressor of the present invention, a compression mechanism of another type, such as a swash plate type or a vane type, may be adopted.

[0122] Furthermore, an electric compressor may be formed by appropriately combining the configurations of Embodiments 1 to 3.

[0123] Industrial applicability

[0124] The present invention can be utilized in an air conditioning device for a vehicle or the like.

Claims

1. An electric compressor comprising: a compression mechanism for compressing the refrigerant; a motor mechanism for driving the compression mechanism; a metal housing having a motor housing chamber therein for housing the motor mechanism; as well as an inverter circuit for driving the motor mechanism; The motor mechanism has: a cylindrical stator core fixed to the housing; a coil end formed by winding a conductive wire having an insulation coating around the stator core and protruding from an end surface of the stator core; a lead wire formed by the conductive wire extending from an end of the coil; and a connector electrically connecting the lead and the converter circuit; The connector has a terminal electrically connected to the top end of the lead wire, and a connector housing made of an insulating material, wherein the connector housing is formed with a terminal receiving chamber for receiving the terminal and an insertion port for inserting the lead wire; It is characterized by: The motor mechanism includes a first insulating member having a cylindrical shape and having the lead wire inserted therein, and a second insulating member having a gap therein inserted into the first insulating member. The first insulating member seals the space between the first insulating member and the lead wire with an insulating resin at one end; The second insulating member covers the other end of the first insulating member and is connected to the insertion port in a sealed state; The resin covers the lead wire and the coil end extending from the first insulating member; The terminal accommodating chamber and the motor accommodating chamber communicate with each other via the gap.

2. The electric compressor according to claim 1, wherein The second insulating member and the connector housing are formed integrally.

3. The electric compressor according to claim 1 or 2, wherein: A gap between the first insulating member and the second insulating member is smaller than a gap between the lead wire and the first insulating member.

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