Housing unit for electronic components of an electric refrigerant compressor

Abstract

The invention relates to a housing unit (1) for electronic components, in particular for an inverter of an electric refrigerant compressor, wherein the housing unit (1) comprises a first housing element (2) and a second housing element (3), which can be connected to a housing part (5) of the refrigerant compressor, in particular to a motor housing (5) of the refrigerant compressor, and in the process form a cavity which accommodates the electronic components, in particular the inverter.

Description

TECHNICAL FIELD

[0001] The present invention relates to a housing unit for electronic components, in particular for an inverter of an electric refrigerant compressor. The housing unit is provided for assembly with a housing part, in particular a motor housing part of an electric refrigerant compressor. BACKGROUND

[0002] Refrigerant compressors are used for compressing gaseous refrigerant in a circuit of an air conditioning system. In electric refrigerant compressors, a compressor unit, in the case of a scroll compressor for example comprising a stationary scroll and a movable scroll, is driven by a drive unit having an electric motor. The electric drive unit comprises an electronic control unit, a so-called inverter, which is provided for controlling the electric motor. For connecting the inverter area, in which the housing device accommodating the inverter is located, various housing configurations are known. Typically, the inverter is accommodated in a support which allows a thermal connection for removing heat from the electronic components of the inverter. The support is either an integral part of the motor housing of the electric refrigerant compressor or is flange-connected to the motor housing as a separate housing structure. The separate housing structure comprises a support and a cover which are mounted together on the motor housing. In the assembled state, the support and the cover form a closed housing for the electronic components of the inverter. The cover is connected to the support by means of a separate sealing element for preventing the ingress of moisture, dust and dirt and is fastened by screws.

[0003] The inverter is in electrical contact with the vehicle system via one or more plug-in connectors. Typically, the plug-in connector housing and the plug-in connector with the electrical conductor contacts are inserted into an opening provided in the housing and fastened by screws. A seal is provided between the plug-in connector and the housing wall to prevent the penetration of dust and moisture into the inverter or between the plug-in connector and the housing. The seal in particular helps to prevent corrosion of the housing part.

[0004] Another important aspect for the operation of an electric refrigerant compressor is electromagnetic compatibility (EMC), which is achieved by a suitable electromagnetic shielding of the electronic components of the electric refrigerant compressor. As is known, this is achieved by using a housing or housing part of metal, typically aluminum. SUMMARY

[0005] TECHNICAL PROBLEM

[0006] A disadvantage of known housing designs is the need for a large number of individual components which have to be assembled together in a time-consuming manner during assembly. For example, a plurality of screws and separate sealing elements are required for mounting the plug-in connector. These elaborate structures of the plug-in connector housing are difficult to handle and require an increased assembly effort. Likewise, a plurality of screws and separately inserted sealing elements are used for mounting the cover. Furthermore, the machining of the openings, the plug-in connector seats and the sealing surfaces requires a considerable manufacturing effort. In order to ensure adequate corrosion protection, a high-quality aluminum alloy is necessary. The sealing has to be designed in such a way that no liquid can penetrate into the gap. The aluminum cover, which is currently in the form of a cast component, has the additional disadvantage of the weight.

[0007] Technical solution

[0008] It is an object of the present application to propose a housing unit for electronic components, in particular for an inverter of an electric refrigerant compressor, which meets the requirements of good electromagnetic compatibility, has a low weight and can be assembled with a small effort.

[0009] This object is achieved by a housing unit according to the present application. Improved solutions and advantageous embodiments of the housing unit are specified in the present application.

[0010] A housing unit for electronic components, in particular for an inverter of an electric refrigerant compressor, is proposed. The housing unit comprises a first housing element and a second housing element, which can be connected to a housing part of the refrigerant compressor, in particular to a motor housing of the refrigerant compressor, and in the process form a cavity which accommodates the electronic components, in particular the inverter.

[0011] The cavity is formed by the housing elements when the housing unit is in the assembled state. Thus, the housing unit has a cavity inside when in the assembled state. To this end, one or more moldings can be formed on the first housing element and / or the second housing element, which form the cavity. The moldings forming the cavity are designed to accommodate the electronic components, so that the electronic components are surrounded by the housing unit in a completely enclosed manner when the housing unit is in the assembled state. Furthermore, the housing unit has at least one plug-in connector housing which is integrally molded on an outer side of the housing unit, said plug-in connector housing having electrical contact elements for electrically contacting the electronic components accommodated in the cavity. In this case, the plug-in connector housing is formed as an integral structure of the housing unit, preferably from the material of the housing unit.

[0012] In the meaning of the present application, electronic components in particular mean an inverter for controlling a motor of an electric refrigerant compressor. However, other electronic components of an electric refrigerant compressor can also be accommodated in the housing unit according to the present application.

[0013] The housing elements of the housing unit are preferably made of plastic.

[0014] To ensure dust prevention and a tight fluid seal, sealing elements or sealing materials are arranged between the housing elements and the housing portion of the refrigerant compressor. These sealing elements or sealing materials are arranged between the housing elements and between the housing portion of the refrigerant compressor and the housing elements of the housing unit according to the invention facing the refrigerant compressor. Therefore, sealing elements or sealing materials are arranged between all housing elements of the assemblable housing unit.

[0015] Another structure of the housing unit according to the invention is an electromagnetic shield for housing electronic components within the cavity of the housing unit. The electromagnetic shield, having conductive elements, ensures good electromagnetic compatibility.

[0016] The advantage of this invention is that no separate support is needed to house the electronic components, especially the inverter, since the electronic components are housed within a cavity formed by the housing elements. The molded part with the cavity meets all requirements to ensure precise fitting and housing of the electronic components. Another advantage is that the integrally molded insert connector housing has electrical contact elements for electrically contacting the electronic components housed internally, i.e., within the cavity formed by the housing elements. Because the insert connector housing is integrally formed from the material of the housing unit, the time-consuming assembly of separate insert connector housings and electrical contact elements is eliminated. For the integrally molded insert connector housing, it is advantageously unnecessary to have separate seals, since at least one insert connector housing is molded as a single piece from the material of the housing unit, i.e., molded as a single piece from the material of the first housing element and / or molded as a single piece from the material of the second housing element. The electrical contact elements and electrical conductor contacts for electrically contacting the electronic components can already be configured as inserts during the manufacture of the housing elements, particularly in the case of using injection molding to manufacture the housing elements, where the inserts are then enclosed by the material of the housing unit or housing element and are bonded in the process. Such electrical connectors can be formed on each housing element of the housing unit. The at least one plug-in connector housing is designed to accommodate an electrically plug-in connector for electrical contact with electronic components housed in the cavity of the housing unit.

[0017] According to an advantageous embodiment of the housing unit of the invention, the at least two housing elements can be formed of conductive plastic, wherein the housing element comprising the conductive plastic is formed with an electromagnetic shielding element for electronic components housed within the housing unit. In this embodiment, the electromagnetic shielding element is advantageously integrated into the housing element.

[0018] Electromagnetic shielding for electronic components housed within the cavity of the housing unit can also be configured using overmolded, preferably aluminum-containing metal inserts, or arranged as planar or grid-like elements around the electronic components. Advantageously, the metal inserts are integrated into the housing element and therefore do not need to be installed separately. Electrical contacts are formed between the housing elements to allow for electrical contact between the metal inserts of the housing elements.

[0019] Electromagnetic shielding for electronic components housed within cavities inside the housing unit can also be applied to the housing element alternatively or additionally as a conductive surface coating in the form of vapor-deposited metal or as a paint.

[0020] According to an advantageous improvement of the housing unit of the invention, a hole can be provided on the side of the housing portion of the housing unit facing the refrigerant compressor. This hole allows contact between the electronic components housed in the cavity of the housing unit and the housing portion of the refrigerant compressor. Due to the hole in the housing unit, contact between the electronic components and the motor housing of the electric refrigerant compressor, which is typically made of metal, is advantageously ensured, and thus electrical switching elements, such as MOSFETs, on printed circuit boards that must be cooled can be positioned on the motor housing. The motor housing can therefore be used as a heat sink for heat dissipation. In the region of the hole in the housing unit, the motor housing can have a flat area where electronic components can be arranged to utilize the large contact area for heat dissipation. The hole can be formed in a first housing element or a second housing element, depending on which housing element faces the housing portion of the refrigerant compressor in the preferred arrangement. Due to the refrigerant mass flow during compressor operation, the flat area is cooled from the inside, and the inverter or electrical switching elements are cooled via the housing wall of the motor housing. It is also conceivable that the motor housing has a deeper molded section in the cut-out area of ​​the housing unit, allowing the electrical switching elements to be positioned within this molded section with a larger contact area for heat transfer. This advantageously improves the efficiency of heat transfer.

[0021] The housing components can be fastened with screws, connected by latches, or welded together and / or connected to the housing portion of the electric refrigerant compressor.

[0022] Rubber, plastic, or foam can be used as sealing materials. Sealing materials can be firmly attached to housing elements by adhesive bonding or injection molding. Advantageously, sealing materials can form an integral structure on the housing element. This simplifies the assembly of the housing unit because the sealing material does not need to be positioned separately.

[0023] The sealing material can also be a two-component plastic with an elastic plastic component. This two-component plastic can be applied using an injection molding method, wherein the elastic component forming the seal is injection molded onto the housing element. The first and second housing elements can thus have injection-molded seals.

[0024] In another embodiment of the housing unit according to the invention, the sealing material between the housing elements can be configured as a melt formed from the housing element material during welding of the contact surfaces of the housing elements. This embodiment proves suitable if at least one of the housing elements is formed of plastic. The sealing material to be melted can be introduced between the first housing element and the second housing element, and between the first housing element facing the housing portion of the electric refrigerant compressor and the housing portion of the electric refrigerant compressor. Furthermore, the first housing element and the second housing element themselves can be formed of a weldable material, and when the first housing element and the second housing element are joined, the melt forms as a sealing material for sealing the housing elements.

[0025] Advantageously, the housing unit can be designed such that the cavity is formed by a molded part formed on the first housing element, wherein the second housing element forms a cover that at least covers the molded part of the first housing element in which electronic components are housed. The first housing element and / or the second housing element can be formed of plastic or metal. The second housing element can be a cast part or a stamped metal part.

[0026] At least one insert connector housing having electrical contact elements for electrical contacting electronic components housed in a cavity can be molded in a first housing element and / or a second housing element. The at least one insert connector housing is molded as a single piece from the material of the housing unit, i.e., the material of the first housing element and / or the material of the second housing element.

[0027] The housing unit according to the invention reduces the number of components that need to be installed separately and incorporates electromagnetic shielding. The inverter area is configured as a separate housing unit, and its flange is connected to the motor housing of the electric refrigerant compressor. Attached Figure Description

[0028] Further details, features, and advantages of embodiments of the present invention can be found in the following description of exemplary embodiments with reference to the accompanying drawings. In the drawings:

[0029] Figure 1 a / b: Schematic diagrams illustrating an exemplary embodiment of the housing unit according to the present invention are shown, a) in an assembled state, and b) an exploded view.

[0030] Figure 2A schematic diagram of an exemplary embodiment of a housing element of a housing unit according to the present invention is shown in the form of a supporting housing element.

[0031] Figure 3 A schematic diagram of another embodiment of the housing unit according to the present invention is shown, and

[0032] Figure 4 The diagram shows a schematic representation of yet another exemplary embodiment of a housing unit according to the present invention, the housing unit having an integral electromagnetic shield and an integral sealing element. Detailed Implementation

[0033] Figure 1 A schematic diagram of an exemplary embodiment of the housing unit according to the present invention is shown, with Figure a) in an assembled state and Figure b) being an exploded view. The housing unit 1 has two housing elements 2 and 3 formed of plastic. The first housing element 2 has a molded part 4 for accommodating an inverter (not shown). The first housing element 2 may be referred to as a support housing element. The second housing element 3 is formed as a cover corresponding to the first housing element 2, such that the inverter housed in the molded part 4 is fully accommodated when the housing unit 1 is in the assembled state (see [reference]). Figure 1 a) Therefore, the molded part 4 formed on the first housing element 2, together with the second housing element 3, forms the cavity of the housing unit 1, in which the inverter is housed. Housing parts 2 and 3 can be connected to the motor housing 5 of a refrigerant compressor (not shown). Furthermore, the housing unit 1 has integrally molded plug-in connector housings 6 and 7 on the first housing element 2. The plug-in connector housings 6 and 7 are molded from the material of the first housing element 2 and are used to house plug-in connectors (not shown). The plug-in connector housings 6 and 7 have internal electrical contact elements through which the inverter housed in the cavity can make electrical contact when the corresponding plug-in connector is inserted into the plug-in connector housings 6 and 7. Electrical conductors thus extend into the interior of the cavity formed by the first housing element 2 and the second housing element 3. Accordingly, the electrical contact elements have electrically conductive connections for electrical contact with the inverter housed in the cavity. The plug-in connector housing 6 is in the form of a high-voltage terminal, while the plug-in connector housing 7 is a low-voltage terminal.

[0034] Individual sealing elements 8 are arranged between the first housing element 2 and the second housing element 3, and between the motor housing 5 and the first housing element 2, for dustproof sealing and fluid tight sealing.

[0035] Furthermore, housing unit 1 has an electromagnetic shield for housing the inverter within a cavity inside housing unit 1. The electromagnetic shield includes aluminum-containing metal inserts 9 and 10, designed such that they are received by housing elements 2 and 3 and enclose the inverter when housing elements 2 and 3 are connected to each other. Metal insert 10 is formed in two parts for reception in a second housing element 3. Metal insert 9, corresponding to and received by the inner surface of the first housing element 2, is arranged opposite to it. When housing unit 1 is in the assembled state, metal inserts 9 and 10 form a practically enclosed shell surrounding the inverter, thereby forming the electromagnetic shield. Metal inserts 9 and 10 are thus arranged between the inverter and housing elements 2 and 3.

[0036] Housing elements 2 and 3 are fastened to motor housing 5 by means of screws (not shown), which are screwed into the threads (not shown) of motor housing 5 through holes 11 formed in the second housing element 3 and corresponding holes 12 formed in the first housing element 2.

[0037] Figure 2 A schematic diagram of an exemplary embodiment of a separate first housing element 2 of the housing unit 1 according to the invention is shown in the form of a supporting housing element. The figure shows a perspective view of a plug-in connector housing 6 in the form of high-voltage terminals and a plug-in connector housing 7 in the form of low-voltage terminals toward a molded part 4 for receiving an inverter. The plug-in connector housings 6 and 7 are molded outwardly from the material of the first housing element 2. Reference numeral 12 indicates holes through which screws pass and are screwed into the threads of the motor housing 5 to secure the housing unit 1 to the motor housing 5. Electrical contact elements for electrically contacting the inverter are not shown here.

[0038] Figure 3 A schematic diagram of another exemplary embodiment of the housing unit 1 according to the present invention is shown, the housing unit 1 having an integrated EMF filter. Figure 3 The embodiment of the housing unit 1 shown is the same as Figure 1 The housing unit 1 shown in b is basically the same, except that the electromagnetic shielding is not in the form of a metal insert. Figure 3 In the illustrated embodiment, the electromagnetic shielding element is in the form of a metallic coating deposited on the first housing element 2 and the second housing element 3. The coating can be formed on the inner and / or outer sides. The coating can be applied using a vacuum coating method. Alternatively, a conductive coating for electromagnetic shielding can be applied to housing elements 2 and 3 in the form of a paint. Because the electromagnetic shielding element is already integrated into housing elements 2 and 3, assembly work can be reduced and assembly time can be shortened.

[0039] Figure 4A schematic diagram of yet another exemplary embodiment of the housing unit 1 according to the present invention is shown, the housing unit 1 having an integral electromagnetic shield and an integral sealing element. Figure 4 The embodiment of the housing unit 1 shown is the same as Figure 3 The housing unit 1 shown is substantially the same, except that the sealing elements for sealing housing elements 2 and 3, and the sealing element for sealing the entire housing unit 1 against the motor housing 5, are fixedly integrated into housing elements 2 and 3. In the example shown, an elastic sealing material 13 in the form of plastic is fastened to the end face 14 of the second housing element 3. When housing elements 2 and 3 are supported against each other in the assembled state, the sealing material 13 seals the second housing element 3 against the first housing element 2.

[0040] The first housing element 2 has an end face 15 facing the motor housing 5. An elastic sealing material 16 in the form of plastic is also fastened to this end face 15 so as to seal the housing unit 1 against the motor housing 5 in the assembled state. Because the sealing materials 13 and 16 are fixedly formed on housing elements 2 and 3, assembly time can be further reduced, as the time-consuming positioning of individual sealing elements is no longer required. Advantageously, housing elements 2 and 3 only need to be placed together for assembly.

[0041] List of reference numerals

[0042] 1 housing unit

[0043] 2 First housing element

[0044] 3 Second housing element

[0045] 4-mold parts

[0046] 5. Refrigerant compressor housing and motor housing

[0047] 6-prong plug connector housing

[0048] 7. Insert-type connector housing

[0049] 8 sealing elements

[0050] 9 metal inserts

[0051] 10 metal inserts

[0052] 11 holes

[0053] 12 holes

[0054] 13 Sealing materials

[0055] 14 end faces

[0056] 15 end face

[0057] 16 Sealing Material

Claims

1. A housing unit (1) for an inverter of an electric refrigerant compressor, wherein, The housing unit (1) includes a first housing element (2) and a second housing element (3), the first housing element (1) and the second housing element (2) being connectable to the housing portion (5) of the refrigerant compressor, and in doing so forming a cavity for accommodating the inverter, wherein the housing unit (1) further comprises: At least one plug-in connector housing (6, 7), at least one of the plug-in connector housings (6, 7) being integrally molded on the outer side of the housing unit (1), the plug-in connector housing having electrical contact elements for electrical contact with the inverter housed in the cavity, A sealing element (8) or sealing material (13, 16) is arranged between the first housing element (2) and the second housing element (3) and between the first housing element (2) and the housing portion (5) of the refrigerant compressor for dust prevention and fluid tight sealing. An electromagnetic shielding element is provided for housing the inverter within the cavity inside the housing unit (1). The electromagnetic shielding component includes metal inserts (9, 10), which are respectively housed in the first housing element (2) and the second housing element (3). When the first housing element (2) and the second housing element (3) are connected to each other, the metal inserts (9, 10) enclose the inverter and form a closed shell around the inverter.

2. The housing unit (1) according to claim 1, characterized in that, The first housing element (2) and the second housing element (3) are formed of conductive plastic, wherein the first housing element (2) and the second housing element (3) containing conductive plastic are formed with the electromagnetic shield of the inverter housed in the cavity of the housing unit (1).

3. The housing unit (1) according to claim 1, characterized in that, The electromagnetic shielding of the inverter housed in the cavity of the housing unit (1) is applied to the first housing element (2) and the second housing element (3) as a conductive surface coating in the form of vapor-deposited metal or as a paint.

4. The housing unit (1) according to claim 1, characterized in that, A hole is formed on the side of the housing portion (5) of the first housing element (2) facing the refrigerant compressor, the hole allowing contact between the inverter housed in the cavity of the housing unit (1) and the housing portion (5) of the refrigerant compressor.

5. The housing unit (1) according to claim 1, characterized in that, The first housing element (2) and the second housing element (3) are fastened to each other by screws, by latching, or by welding and / or connected to the housing portion (5) of the electric refrigerant compressor.

6. The housing unit (1) according to claim 1, characterized in that, The sealing materials (13, 16) are rubber, plastic or foam plastic, and the sealing materials (13, 16) are fixedly attached to the first housing element (2) and the second housing element (3) by adhesive bonding or by injection molding.

7. The housing unit (1) according to claim 1, characterized in that, The sealing materials (13, 16) are two-component plastics with elastic plastic components.

8. The housing unit (1) according to claim 1, characterized in that, The sealing material (13) between the first housing element (2) and the second housing element (3) is a melt formed from the materials of the first housing element (2) and the second housing element (3) during the welding of the contact surfaces of the first housing element (2) and the second housing element (3).

9. The housing unit (1) according to claim 1, characterized in that, The cavity is formed by a molding (4) formed on the first housing element (2), wherein the second housing element (3) forms a cover that at least covers the molding (4) of the first housing element (2), and the inverter is housed in the molding (4).

10. The housing unit (1) according to claim 1, characterized in that, The first housing element (2) and / or the second housing element (3) are formed of plastic or metal.

11. The housing unit (1) according to claim 8, characterized in that, The second housing element (3) is a cast part or a stamped metal part.

12. The housing unit (1) according to claim 7, characterized in that, At least one of the plug-in connector housings (6, 7) having electrical contact elements for electrical contact with the inverter housed in the cavity is molded on the second housing element (3) and / or the first housing element (2).

13. The housing unit (1) according to claim 1, characterized in that, At least one of the plug-in connector housings (6, 7) is molded from the material of the housing unit (1) into a single piece.

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