Electric compressor

Abstract

The invention provides an electric compressor capable of suppressing an increase in the projected area of an inverter housing part even when a filter member for electromagnetic noise countermeasures is large in size and the number of filter members is increased. In an electric compressor (1), a filter circuit unit (30) includes a first filter circuit board (31) on which a plurality of electrolytic capacitors (51) are mounted, and a second filter circuit board (33) on which a constant mode choke (53), a common mode choke (55) and the like are mounted, and the first filter circuit board (31) and the second filter circuit board (33) are electrically connected to each other. The inverter housing section (7) has a plate-shaped resin member (35) therebetween and is housed in an overlapping state.

Description

Technical Field

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

[0002] Patent Document 1 describes an example of an electric compressor. The electric compressor described in Patent Document 1 is an inverter-integrated electric compressor for use in vehicle air conditioning systems. The electric compressor described in Patent Document 1 includes a housing with a built-in motor, an inverter for driving the motor, an inverter housing provided in the housing, and a cover for sealing the inverter housing. The inverter includes six power switching elements for converting direct current into three-phase alternating current, an inverter control substrate on which a control circuit for controlling the six power switching elements is mounted, and a filter circuit substrate on which coils and capacitors, etc., serving as filter components, are mounted, all of which are housed in the inverter housing.

[0003] Patent Document 1: Japanese Patent Application Laid-Open No. 2020-143594

[0004] In recent years, as electronic control units have become more advanced along with the electrification of automobiles, further electromagnetic noise countermeasures have been required in electric compressors used in vehicle air conditioning systems. As one of such electromagnetic noise countermeasures, for example, it is considered to adopt a coil with a larger inductance value than before. However, the component size of a coil with a large inductance value is larger. Therefore, if a coil with a large inductance value is simply adopted, it may lead to an increase in the projected area of ​​the filter circuit substrate, and further lead to an increase in the projected area of ​​the inverter housing that accommodates the filter circuit substrate. If the projected area of ​​the inverter housing is expanded, there is a risk that the installation location of the electric compressor will be limited, the cover that closes the inverter housing will become more susceptible to vibration, and the noise caused by the vibration of the cover will increase, so it is not preferred. Summary of the Invention

[0005] Therefore, an object of the present invention is to provide an electric compressor capable of suppressing an increase in the projected area of ​​an inverter housing even when a filter component for counteracting electromagnetic noise is enlarged and the number of filter components increases.

[0006] According to one aspect of the present invention, an electric compressor is provided. The provided electric compressor comprises: a housing that houses a motor that rotates a rotating shaft and a compression mechanism that is driven by the rotation of the rotating shaft; an inverter housing that is integrally provided with the housing and has an opening that houses an inverter that drives the motor; and a cover member that closes the opening of the inverter housing. The inverter comprises an inverter circuit that supplies power to the motor and a filter circuit that reduces electromagnetic noise. The filter circuit comprises a first filter circuit substrate on which at least one first filter component is mounted, and a second filter circuit substrate on which at least one second filter component is mounted. The first filter circuit substrate and the second filter circuit substrate are electrically connected to each other and are housed in the inverter housing in an overlapping state with a plate-shaped resin member interposed therebetween.

[0007] According to the present invention, it is possible to provide an electric compressor capable of suppressing an increase in the projected area of ​​an inverter housing portion even when a filter component for counteracting electromagnetic noise is enlarged and the number of filter components increases. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 It is a schematic longitudinal sectional view of the electric compressor according to the embodiment. Figure 2 This is a schematic perspective view showing an inverter and an inverter housing portion. Figure 3 This is a cross-sectional view of the filter circuit section. Figure 4 This is an exploded perspective view of the filter circuit section. Figure 5 This is a perspective view of a resin component. Figure 6 This is a partially enlarged cross-sectional view of a resin component. Figure 7 It is a perspective view showing a modified example of the filter circuit portion. Figure 8 It is a perspective view showing a modified example of the filter circuit portion. DETAILED DESCRIPTION

[0009] The following describes an embodiment of the present invention with reference to the accompanying drawings. In addition, the terms "first," "second," ..., etc. below are used only to distinguish similar elements and do not limit the elements to which they are added.

[0010] Figure 1This is a schematic longitudinal cross-sectional view of an electric compressor 1 according to one embodiment of the present invention. The electric compressor 1 according to this embodiment is an inverter-integrated electric compressor that integrally includes an inverter. The electric compressor 1 is used in a vehicle air conditioner. Specifically, the electric compressor 1 is mounted on a vehicle and constitutes part of the refrigerant circuit of the vehicle air conditioner, configured to compress and discharge refrigerant.

[0011] The electric compressor 1 includes a rotating shaft 2 , a motor 3 , a compression mechanism 4 , a housing 5 , an inverter 6 , an inverter housing 7 , and a cover member 8 .

[0012] The rotating shaft 2 is rotatably supported in the housing 5 by bearings (not shown). The motor 3 is a three-phase synchronous motor (brushless DC motor) and is driven by power to rotate the rotating shaft 2. The compression mechanism 4 is, for example, a scroll compression mechanism and is driven by the rotation of the rotating shaft 2. The housing 5 has a cylindrical cross-section and accommodates the rotating shaft 2, the motor 3, and the compression mechanism 4. Within the housing 5, the motor 3 and the compression mechanism 4 are arranged in series in the axial direction of the rotating shaft 2.

[0013] The inverter 6 supplies power to the motor 3, driving it. The inverter 6 includes an inverter circuit unit 20, which supplies power to the motor 3, and a filter circuit unit 30, which reduces electromagnetic noise. The inverter housing 7 is integrally provided with the housing 5 and houses the inverter 6. Specifically, the inverter housing 7 is provided at the end of the housing 5 facing the motor 3. In this embodiment, the inverter housing 7 has a projected area larger than the projected area of ​​the housing 5. The inverter housing 7 is formed by a bottom wall 71 and a peripheral wall 73 rising from the periphery of the bottom wall 71. The inverter housing 7 has an opening 75 facing the bottom wall 71. Furthermore, the inverter circuit unit 20 and the filter circuit unit 30 that constitute the inverter 6 are housed in the inverter housing 7. The opening 75 of the inverter housing 7 is sealed by a cover member 8. The cover member 8 is secured to the peripheral wall of the inverter housing 7 (also part of the housing 5) by bolts (not shown).

[0014] An HV connector (high voltage connector) 9 is attached to the bottom wall 71 of the inverter housing 7. This connector supplies DC power from an onboard battery (not shown) to the inverter 6 (inverter circuit unit 20). Furthermore, a portion of the bottom wall 71 of the inverter housing 7 forms a partition 77 separating the interior of the housing 5 from the interior of the inverter housing 7.

[0015] The housing 5 is formed with an inlet 5a for allowing refrigerant to flow into the housing 5 and an outlet 5b for allowing refrigerant to flow out of the housing 5. The inlet 5a is configured to allow refrigerant to flow between the partition wall 77 in the housing 5 and the motor 3. The refrigerant flowing into the housing 5 through the inlet 5a passes through the motor 3 and reaches the compression mechanism 4, where it is compressed. The refrigerant compressed by the compression mechanism 4 then flows out through the outlet 5b.

[0016] The refrigerant flowing into the housing 5 from the inlet 5a is a low-temperature gas refrigerant after passing through the expansion valve and evaporator in the refrigerant circuit of the vehicle air conditioner.

[0017] Reference Figure 1 and Figure 2 The inverter 6 will be further described. Figure 2 1 is a schematic perspective view showing the inverter 6 and the inverter housing 7. As described above, in this embodiment, the inverter 6 includes the inverter circuit unit 20 for supplying power to the motor 3 and the filter circuit unit 30 for reducing electromagnetic noise.

[0018] The inverter circuit unit 20 is configured to convert the DC power supplied from the vehicle battery via the HV connector 9 into three-phase AC power and supply it to the motor 3 (the stator coil 3a thereof) via the power supply line 10 extending through the partition wall 77. The inverter circuit unit 20 includes six power switching elements 21 and an inverter control board 25 on which a control circuit 23 for controlling the six power switching elements 21 is mounted.

[0019] In this embodiment, the six power switching elements 21 are supported on the sheet-like first heat dissipation member 11, which is provided on the surface of the partition wall 77 on the inverter housing portion 7 side. In addition, the six power switching elements 21 are fixed in a state of being pressed against the first heat dissipation member 11 by the arm member 12 (see FIG. Figure 1 The arm member 12 is mounted to an arm mounting portion 14 provided in the inverter housing portion 7 by means of bolts 13 .

[0020] The inverter control board 25 has a plurality of (seven in this case) mounting holes 25a. The inverter control board 25 is mounted to the board mounting portion 15 provided in the inverter housing portion 7 by a plurality of bolts (not shown). In this embodiment, the inverter control board 25 is arranged near the cover member 8, that is, separated from the six power switching elements 21 (see FIG. 1 ). Figure 1 Therefore, each of the six power switching elements 21 has a lead extending toward the inverter control board 25. Specifically, each of the six power switching elements 21 has a lead extending through the inverter control board 25. Furthermore, by soldering these leads to the inverter control board 25, the six power switching elements 21 are electrically connected to the inverter control board 25.

[0021] The filter circuit unit 30 is arranged between the inverter circuit unit 20 and the HV connector 9 . Figure 3 is a cross-sectional view of the filter circuit portion 30, Figure 4 It is an exploded perspective view of the filter circuit unit 30 .

[0022] Reference Figure 1 、 Figure 3 and Figure 4 In this embodiment, the filter circuit unit 30 includes a first filter circuit substrate 31 and a second filter circuit substrate 33 .

[0023] At least one filter component (hereinafter referred to as "first filter component") for electromagnetic noise countermeasures is mounted on one surface of the first filter circuit substrate 31. The at least one first filter component mounted on the one surface of the first filter circuit substrate 31 is a relatively large filter component. The at least one first filter component may include a plurality of filter components of the same type or different types. Although not particularly limited, in this embodiment, a plurality of (here, nine) electrolytic capacitors 51 are mounted on the one surface of the first filter circuit substrate as the at least one first filter component. In addition, the one surface of the first filter circuit substrate 31 is Figure 1 、 Figure 3 and Figure 4 It is the upper surface in the middle and is the surface facing the cover member 8 when housed in the inverter housing portion 7.

[0024] Although not shown in the figure, a plurality of electronic components smaller than the at least one first filter component (here, the electrolytic capacitor 51) are mounted on the first filter circuit substrate 31. At least some of these small electronic components are mounted on the other surface (the surface of the first filter circuit substrate 31) of the first filter circuit substrate 31. Figure 1 、 Figure 3 and Figure 4 , and is a surface facing the bottom side of the inverter housing portion 7 when housed in the inverter housing portion 7), further, it is installed at a position in the other surface of the first filter circuit substrate 31 that avoids the lower range of the multiple electrolytic capacitors 51.

[0025] At least one filter component (hereinafter referred to as "second filter component") for electromagnetic noise countermeasures is mounted on one surface of the second filter circuit substrate 33. The at least one second filter component mounted on the one surface of the second filter circuit substrate 33 is a relatively large filter component, similar to the at least one first filter component, and may include multiple filter components of the same type or different types. Although not particularly limited, in this embodiment, the normal mode choke 53, the common mode choke 55, the X capacitor and the Y capacitor are mounted on the one surface of the second filter circuit substrate 33 as the at least one second filter component. However, the X capacitor and the Y capacitor are not shown in the figure. In addition, the one surface of the second filter circuit substrate 33 is Figure 1 、 Figure 3 and Figure 4It is the lower surface in the inverter housing portion 7 and is the surface facing the bottom side of the inverter housing portion 7 when housed in the inverter housing portion 7.

[0026] Although not shown in the figure, a plurality of electronic components smaller than the at least one second filter component (here, the normal mode choke coil 53, the common mode choke coil 55, the X capacitor, and the Y capacitor) are mounted on the second filter circuit substrate 33. At least some of these small electronic components are mounted on the other surface (the Figure 1 、 Figure 3 and Figure 4 , and is the upper surface in the middle, and is the surface facing the cover member 8 when housed in the inverter housing portion 7). Furthermore, it is mounted on the other surface of the second filter circuit substrate 33 at a position avoiding the lower range of the normal mode choke coil 53, the common mode choke coil 55, the X capacitors, and the Y capacitors.

[0027] In addition, the normal mode choke coil 53 , the common mode choke coil 55 , the X capacitors, and the Y capacitors serving as the at least one second filter component are hereinafter simply referred to as “normal mode choke coil 53 , common mode choke coil 55 , etc.”

[0028] In this embodiment, the first filter circuit substrate 31 and the second filter circuit substrate 33 are electrically connected to each other and housed in the inverter housing 7 in a state where they overlap with each other via a plate-shaped resin member 35. Specifically, the first filter circuit substrate 31 and the second filter circuit substrate 33 are electrically connected to each other and housed in the inverter housing 7 in a state where the other surface of the first filter circuit substrate 31 (the surface not mounted with the electrolytic capacitor 51) and the other surface of the second filter circuit substrate 33 (the surface not mounted with the normal mode choke coil 53 and the common mode choke coil 55, etc.) are opposed to each other via the plate-shaped resin member 35. This will be explained in detail below.

[0029] First, the resin member 35 will be described. Figure 5This is a perspective view of the resin member 35. In this embodiment, the resin member 35 includes a pair of metal busbars 351, 351 for electrically connecting the first filter circuit substrate 31 to the second filter circuit substrate 33; a resin main body 352 that holds the pair of busbars 351, 351; and a metal shielding plate 41 disposed within the main body 352 to shield electromagnetic noise. In other words, the resin member 35 includes the pair of busbars 351, 351 and incorporates the shielding plate 41. Specifically, in this embodiment, the resin member 35 is formed as a plate-shaped resin molded body into which the pair of busbars 351, 351 and the shielding plate 41 are inserted. Furthermore, in this embodiment, the resin member 35 is formed to have an outer shape corresponding to (substantially identical to) the outer shape of the first filter circuit substrate 31.

[0030] The main body 352 of the resin member 35 is formed into a plate-like shape with a substantially H-shaped cross section, with a peripheral edge portion 352a having a predetermined width and bulging toward both sides in the thickness direction relative to an inner side portion 352b other than the peripheral edge portion 352a. Specifically, both surfaces of the main body 352, i.e., both surfaces of the resin member 35, are formed so that the inner side portion 352b is recessed relative to the peripheral edge portion 352a.

[0031] A pair of busbars 351, 351 are arranged at a predetermined interval on the peripheral portion 352a of the main body 352. The pair of busbars 351, 351 respectively penetrate the peripheral portion 352a of the main body 352 in the thickness direction and have a side ( Figure 1 、 Figures 3 to 5 The first protrusion 351a protruding from the peripheral edge 352a of the main body 352 to the other side in the thickness direction ( Figure 1 、 Figures 3 to 5 A second protrusion 351b protruding from the lower side of the panel.

[0032] Figure 6 FIG is a partially enlarged cross-sectional view of the resin member 35, showing the busbar 351 and its surroundings. Figure 6 As shown, in this embodiment, the busbar 351 is formed as a cross-shaped terminal. The busbar 351 includes a conductive portion 3511, which electrically connects the first filter circuit substrate 31 and the second filter circuit substrate 33 and extends through the peripheral edge 352a of the main body 352 in the thickness direction; and a retained portion 3513, which extends across the conductive portion 3511 and is retained by the main body 352. One end of the conductive portion 3511 forms a first protrusion 351a, while the other end forms a second protrusion 351b.

[0033] More specifically, in this embodiment, a through hole 353 is formed in the peripheral portion 352a of the main body portion 352, which passes through in the thickness direction. The bus bar 351 is arranged in the through hole 353. The conductive portion 3511 of the bus bar 351 extends axially within the through hole 353, and one end thereof protrudes from one side (ie, the through hole 353) of the through hole 353 as a first protrusion 351a. Figure 6 The other end portion protrudes from the other side of the through hole 353 ( Figure 6 The held portion 3513 extends in a direction perpendicular to the axial direction of the through-hole 353, and both ends are embedded in the peripheral wall of the through-hole 353, i.e., the main body 352. As a result, the held portion 3513 is held by the main body 352, and the busbar 351 is thereby held by the main body 352.

[0034] That is, in this embodiment, only the two ends of the busbar 351 are embedded in the main body 352 (i.e., the resin portion) by the retaining portion 3513, and the remaining portion is exposed from the main body 352. Furthermore, in this embodiment, the conductive portion 3511 of the busbar 351 does not contact the peripheral wall of the through-hole 353, i.e., the main body 352.

[0035] In addition, although not particularly limited, in this embodiment, Figure 4 、 Figure 5 As indicated by the dotted line in the figure, the shielding plate 41 is formed to have an outer shape substantially corresponding to the inner side portion 352 b of the main body portion 352 .

[0036] The first filter circuit substrate 31 is placed on one surface of the resin member 35 with the other surface on which the plurality of electrolytic capacitors 51 are not mounted. Figure 1 、 Figures 3 to 5 More specifically, the first filter circuit substrate 31 is mounted on one surface (the upper surface in the middle) of the main body 352 of the resin member 35 with the other surface on which the plurality of electrolytic capacitors 51 are not mounted being supported. Figure 1 、 Figures 3 to 5 It is mounted on the resin member 35 in a state of being on the peripheral edge portion 352a on the upper surface) side.

[0037] Here, the resin member 35 is provided with a plurality (here, four) of first pin portions 355 protruding from the one surface. Specifically, the plurality (four) of first pin portions 355 are arranged upright, spaced apart from each other, along the circumferential direction on the peripheral edge portion 352a of the main body 352 of the resin member 35. Furthermore, a plurality (the same number as the plurality of first pin portions 355, i.e., four) of first pin insertion holes 311 are formed near the peripheral edge of the first filter circuit substrate 31, corresponding to the plurality of first pin portions 355 of the resin member 35. When the first filter circuit substrate 31 is mounted on the resin member 35, the plurality of first pin portions 355 of the resin member 35 are inserted through the corresponding first pin insertion holes 311 of the first filter circuit substrate 31. Thereafter, the tips of the plurality of first pin portions 355 of the resin member 35 are thermally caulked. Thereby, the first filter circuit substrate 31 and the resin member 35 are aligned with each other, and the first filter circuit substrate 31 is fixed to the one surface of the resin member 35 .

[0038] Furthermore, the first filter circuit substrate 31 is formed with a pair of first busbar through-holes 313, 313 corresponding to the pair of busbars 351, 351 of the resin member 35. When the first filter circuit substrate 31 is mounted on the resin member 35, the first protrusions 351a of the pair of busbars 351, 351 of the resin member 35 are inserted through the pair of first busbar through-holes 313, 313 of the first filter circuit substrate 31, and the first protrusions 351a of the pair of busbars 351, 351 of the resin member 35 are soldered to the first filter circuit substrate 31. This electrically connects the pair of busbars 351, 351 of the resin member 35 to the first filter circuit substrate 31.

[0039] As described above, the first protrusion 351a of the busbar 351 is part of the conductive portion 3511 of the busbar 351. Most of the conductive portion 3511 of the busbar 351 is located within the through-hole 353, and the conductive portion 3511 of the busbar 351 does not contact the main body 352 (resin portion). Furthermore, in the busbar 351, only the two ends of the retained portion 3513, located away from the first protrusion 351a, are embedded in the main body 352. This suppresses heat diffusion during soldering of the first protrusion 351a to the first filter circuit substrate 31, stabilizing solder quality. Furthermore, the main body 352 is prevented from melting or deforming due to the heat of soldering the first protrusion 351a to the first filter circuit substrate 31.

[0040] The small electronic component mounted on the other surface of the first filter circuit substrate 31 is housed in the inner portion 352b on the one surface side of the main body 352 of the resin member 35. Therefore, the inner portion 352b on the one surface side of (the main body 352 of) the resin member 35 corresponds to the "first recess" of the present invention.

[0041] The second filter circuit substrate 33 is placed on the other surface ( Figure 1 、 Figures 3 to 5 Specifically, the second filter circuit substrate 33 is mounted on the other surface (the lower surface in the middle) of the main body 352 of the resin member 35 with the other surface on which the normal mode choke coil 53 and the common mode choke coil 55 are not mounted. Figure 1 、 Figures 3 to 5 It is mounted on the resin member 35 in a state of being on the peripheral edge portion 352a on the lower surface) side.

[0042] Here, similarly to the one surface of the resin member 35, a plurality of (four in this case) resin-made second pins 356 are provided on the other surface of the resin member 35 so as to protrude from the other surface. Figure 5 Only two are shown. Specifically, multiple (four) second pins 356 are arranged upright, spaced apart from each other, along the circumferential direction on the peripheral edge 352a of the main body 352 of the resin member 35. Furthermore, multiple (four, the same number as the multiple second pins 356) second pin insertion holes 331 are formed near the peripheral edge of the second filter circuit substrate 33, corresponding to the multiple second pins 356 of the resin member 35. When the second filter circuit substrate 33 is mounted on the resin member 35, the multiple second pins 356 of the resin member 35 are inserted through the corresponding second pin insertion holes 331 of the second filter circuit substrate 33. Thereafter, the top ends of the multiple second pins 356 of the resin member 35 are thermally caulked. This aligns the second filter circuit substrate 33 with the resin member 35 and secures the second filter circuit substrate 33 to the other surface of the resin member 35.

[0043] Furthermore, the second filter circuit substrate 33 is formed with a pair of second busbar through-holes 333, 333 corresponding to the pair of busbars 351, 351 of the resin member 35. When the second filter circuit substrate 33 is mounted on the resin member 35, the second protrusions 351b of the pair of busbars 351, 351 of the resin member 35 are inserted through the pair of second busbar through-holes 333, 333 of the second filter circuit substrate 33, and the second protrusions 351b of the pair of busbars 351, 351 are soldered to the second filter circuit substrate 33. This electrically connects the pair of busbars 351, 351 of the resin member 35 to the second filter circuit substrate 33. Furthermore, the first filter circuit substrate 31 and the second filter circuit substrate 33 are electrically connected via (the pair of busbars 351, 351 of) the resin member 35.

[0044] As described above, the second protrusion 351b of the busbar 351 is part of the conductive portion 3511 of the busbar 351. Most of the conductive portion 3511 of the busbar 351 is located within the through-hole 353, and the conductive portion 3511 of the busbar 351 does not contact the main body 352 (resin portion). Furthermore, in the busbar 351, only the two ends of the retained portion 3513, located away from the second protrusion 351b, are embedded in the main body 352. This suppresses heat diffusion during soldering of the second protrusion 351b to the second filter circuit substrate 33, stabilizing solder quality. Furthermore, the main body 352 is prevented from melting or deforming due to the heat of soldering the second protrusion 351b to the second filter circuit substrate 33.

[0045] The aforementioned small electronic component mounted on the other surface of the second filter circuit substrate 33 is housed in the inner portion 352b of the other surface of the main body 352 of the resin member 35. Therefore, the inner portion 352b of the other surface of the main body 352 of the resin member 35 corresponds to the "second recess" of the present invention.

[0046] As described above, the first filter circuit substrate 31 and the second filter circuit substrate 33 are integrated with each other via the resin member 35 , and the first filter circuit substrate 31 and the second filter circuit substrate 33 are electrically connected.

[0047] In this embodiment, the filter circuit unit 30 further includes a first case member 37 and a second case member 39 .

[0048] The first case member 37 is formed of, for example, a hard resin and is mounted on the one surface of the first filter circuit substrate 31 to accommodate the plurality of electrolytic capacitors 51 mounted on the one surface of the first filter circuit substrate 31 .

[0049] In the present embodiment, the first case member 37 is attached to the one surface of the first filter circuit substrate 31 as follows.

[0050] First, a predetermined amount of softened or molten resin R is filled into the first case member 37. Next, the first filter circuit substrate 31 and the first case member 37 are aligned, and the first case member 37 is attached to the one surface of the first filter circuit substrate 31. The first filter circuit substrate 31 and the first case member 37 are aligned by inserting two third pins (not shown) provided in the first case member 37 through third pin insertion holes 315a and first pin insertion slots 315b formed in the first filter circuit substrate 31. The resin R filled into the first case member 37 is then cured. This secures the first case member 37 to the one surface of the first filter circuit substrate 31. Furthermore, the resin R fills the gaps within the first case member 37, namely the gaps between the electrolytic capacitors 51 and the gaps between the electrolytic capacitors 51 and the first case member 37. A heat-resistant thermoplastic resin or thermosetting resin is preferably used as the resin R.

[0051] The second case member 39 is formed of, for example, a hard resin, similarly to the first case member 37. The second case member 39 is mounted on the one surface of the second filter circuit board 33 and is configured to accommodate the normal mode choke coil 53 and the like mounted on the one surface of the second filter circuit board 33.

[0052] In the present embodiment, the second case member 39 is attached to the one surface of the second filter circuit substrate 33 in the following manner, similar to the first case member 37 .

[0053] First, a predetermined amount of softened or molten resin R is filled into the second case member 39. Next, the second filter circuit substrate 33 and the second case member 39 are aligned, and the second case member 39 is attached to the one surface of the second filter circuit substrate 33. The second filter circuit substrate 33 and the second case member 39 are aligned by inserting two fourth pins 391 provided in the second case member 39 through the fourth pin insertion holes 335a and the second pin insertion slots 335b formed in the second filter circuit substrate 33. The filled resin R is then cured. This secures the second case member 39 to the one surface of the second filter circuit substrate 33. Furthermore, the resin R fills the gaps within the second case member 39, namely, the gaps between components such as the normal mode choke coil 53, and the gaps between the normal mode choke coil 53 and the second case member 39.

[0054] In this manner, in addition to integrating the first filter circuit substrate 31 and the second filter circuit substrate 33 via the resin member 35, the first case member 37 and the second case member 39 are also integrated. Specifically, in this embodiment, the filter circuit unit 30 includes the first filter circuit substrate 31, the second filter circuit substrate 33, the resin member 35, the first case member 37, and the second case member 39, which are integrated to form the filter circuit unit 30.

[0055] By multiple bolts 16 ( Figure 1 (Only one of them is shown) Such a filter circuit unit 30 is mounted and fixed to the filter mounting portion 17 provided in the inverter housing portion 7.

[0056] Specifically, in this embodiment, a plurality (here, four) of corresponding mounting holes are formed in the first filter circuit substrate 31, the second filter circuit substrate 33, the resin member 35, the first case member 37, and the second case member 39. Specifically, four first mounting holes 317 are formed in the first filter circuit substrate 31, and four second mounting holes 337 are formed in the second filter circuit substrate 33. Furthermore, four third mounting holes 357 are formed in the resin member 35, four fourth mounting holes 371 are formed in the first case member 37, and four fifth mounting holes 393 are formed in the second case member 39. The third mounting holes 357, fourth mounting holes 371, and fifth mounting holes 393 can also be formed by metal cylindrical sleeves inserted during molding.

[0057] The filter circuit unit 30 is housed in the inverter housing 7 with the second case member 39 facing the bottom of the inverter housing 7. Furthermore, bolts 16, which pass through the fourth mounting hole 371 of the first case member 37, the first mounting hole 317 of the first filter circuit substrate 31, the third mounting hole 357 of the resin member 35, the second mounting hole 337 of the second filter circuit substrate 33, and the fifth mounting hole 393 of the second case member 39, are screwed into threaded holes formed in the filter mounting portion 17. This integrally secures the first filter circuit substrate 31, the second filter circuit substrate 33, the resin member 35, the first case member 37, and the second case member 39 within the inverter housing 7.

[0058] When the inverter circuit unit 20 and the filter circuit unit 30 are completely installed in the inverter housing portion 7 , the cover member 8 is fixed to the peripheral wall 73 of the inverter housing portion 7 .

[0059] In this embodiment, when the filter circuit unit 30 is housed in the inverter housing unit 7, a sheet-like first vibration isolation member 18 is placed on the bottom of the inverter housing unit 7, or the first vibration isolation member 18 is attached to the outer surface of the second case member 39. Furthermore, when the filter circuit unit 30 is housed in the inverter housing unit 7, a sheet-like second vibration isolation member 19 is attached to the outer surface of the first case member 37, or when the cover member 8 is secured to the peripheral wall of the inverter housing unit 7, the second vibration isolation member 19 is attached to the outer surface of the first case member 37 or the inner surface of the cover member 8. In this manner, in addition to the filter circuit unit 30 being mounted and secured to the filter mounting unit 17 by bolts 16, the filter circuit unit 30 is sandwiched between the bottom of the inverter housing unit 7 and the cover member 8, with the first vibration isolation member 18 interposed between the second case member 39 and the bottom of the inverter housing unit 7 and the second vibration isolation member 19 interposed between the first case member 37 and the cover member 8.

[0060] According to the electric compressor 1 of the embodiment, for example, the following effects can be obtained.

[0061] In the electric compressor 1 of the embodiment, the filter circuit unit 30 includes a first filter circuit substrate 31 on which a plurality of electrolytic capacitors 51 are mounted as the at least one first filter component; and a second filter circuit substrate 33 on which a normal-mode choke coil 53 and a common-mode choke coil 55 are mounted as the at least one second filter component. The first filter circuit substrate 31 and the second filter circuit substrate 33 are electrically connected to each other and housed in the inverter housing 7 in an overlapping state with a plate-shaped resin member 35 interposed therebetween.

[0062] Specifically, in this embodiment, multiple filter components (e.g., electrolytic capacitors 51, normal-mode choke coils 53, and common-mode choke coils 55) for electromagnetic noise suppression are distributed and mounted on two circuit substrates (first filter circuit substrate 31 and second filter circuit substrate 33). These two circuit substrates (first filter circuit substrate 31 and second filter circuit substrate 33) can be arranged, for example, one above the other, within inverter housing 7, with resin member 35 interposed between them. Therefore, even when the size of the filter components increases and the number of filter components increases, the projected area of ​​the filter circuit substrates constituting filter circuit unit 30, and consequently, the projected area of ​​inverter housing 7, can be suppressed. Consequently, the installation location of the electric compressor 1 can be restricted, and noise increases caused by vibration of cover member 8 can be suppressed. Furthermore, since the electrolytic capacitors 51, normal-mode choke coils 53, and common-mode choke coils 55 are mounted on separate circuit substrates, thermal interference between them can be suppressed.

[0063] In particular, in this embodiment, multiple electrolytic capacitors 51 are mounted on the one surface of the first filter circuit substrate 31, while the normal-mode choke coil 53, the common-mode choke coil 55, and the like are mounted on the one surface of the second filter circuit substrate 33. Furthermore, the other surface of the first filter circuit substrate 31 and the other surface of the second filter circuit substrate 33 are housed in the inverter housing 7, facing each other with the resin member 35 interposed therebetween. Consequently, the first filter circuit substrate 31 and the second filter circuit substrate 33 are each reinforced by the plate-shaped resin member 35, improving the vibration resistance of the filter circuit substrates and, consequently, the filter circuit unit 30.

[0064] Furthermore, the resin member 35 includes a pair of metal busbars 351, 351 that electrically connect the first filter circuit board 31 and the second filter circuit board 33, and incorporates a shielding plate 41 for shielding electromagnetic noise. This eliminates the need for separate components for electrically connecting the first filter circuit board 31 and the second filter circuit board 33, enabling a compact and stable connection structure between the first and second filter circuit boards 31, 33. This also prevents malfunctions caused by interference from radiated noise between the first and second filter circuit boards 31, 33.

[0065] Furthermore, the resin member 35 has an outer shape corresponding to the outer shape of the first filter circuit substrate 31. Therefore, the resin member 35 functions as an insulating wall between the first filter circuit substrate 31 and the second filter circuit substrate 33, thereby ensuring an insulating distance between the first filter circuit substrate 31 and the second filter circuit substrate 33.

[0066] Furthermore, the first filter circuit substrate 31 is fixed to the one surface of the resin member 35 by thermal caulking, and the second filter circuit substrate 33 is fixed to the other surface of the resin member 35 by thermal caulking. Thus, the first filter circuit substrate 31 and the second filter circuit substrate 33 can be integrated (modularized), thereby suppressing any degradation in the assembly of the filter circuit unit 30 into the inverter housing 7 caused by the separate mounting of filter components on two circuit substrates.

[0067] Furthermore, small electronic components mounted on the other surface of the first filter circuit substrate 31 are housed in the recessed inner portion 352b on the one surface side of the main body 352 of the resin member 35. Small electronic components mounted on the other surface of the second filter circuit substrate 33 are housed in the recessed inner portion 352b on the other surface side of the main body 352 of the resin member 35. In other words, recesses for housing small electronic components are formed on each of the one and other surfaces of the resin member 35. This effectively reduces the projected area of ​​the filter circuit substrates that comprise the filter circuit unit 30, and consequently, the projected area of ​​the inverter housing 7. Furthermore, interference with small electronic components such as the multiple electrolytic capacitors 51, the normal mode choke coil 53, and the common mode choke coil 55 can be reduced.

[0068] Furthermore, the filter circuit unit 30 includes a first case member 37 disposed on one surface of the first filter circuit substrate 31 and housing a plurality of electrolytic capacitors 51; and a second case member 39 disposed on one surface of the second filter circuit substrate 33 and housing a normal-mode choke coil 53, a common-mode choke coil 55, and the like. Specifically, the first case member 37 protects the plurality of electrolytic capacitors 51 from vibration, while the second case member 39 protects the normal-mode choke coil 53, the common-mode choke coil 55, and the like from vibration. This improves the vibration resistance of the filter circuit unit 30.

[0069] Furthermore, the gaps within the first case member 37 and the gaps within the second case member 39 are filled with resin. This further improves the vibration resistance of the filter circuit unit 30 . Furthermore, in addition to the first filter circuit substrate 31 and the second filter circuit substrate 33 , the first case member 37 and the second case member 39 can also be integrated (modularized), thereby improving the ease of assembly of the filter circuit unit 30 into the inverter housing 7 .

[0070] Furthermore, the filter circuit unit 30 is secured by bolts 16 and is held between the bottom of the inverter housing unit 7 and the cover member 8, with the first vibration-isolating member 18 interposed between the second housing member 39 and the bottom of the inverter housing unit 7, and the second vibration-isolating member 19 interposed between the first housing member 37 and the cover member 8. Consequently, the filter circuit unit 30 can be securely fixed within the inverter housing unit 7, achieving high vibration resistance.

[0071] In the above embodiment, the housing 5 and the inverter housing 7 are integrally formed. However, this is not limiting. The inverter housing 7 only needs to be integrally provided with the housing 5. For example, the housing 5 and the inverter housing 7 may be formed as separate bodies and then combined into an integrated body.

[0072] Furthermore, in the above embodiment, multiple electrolytic capacitors 51 are mounted on the one surface of the first filter circuit substrate 31, and normal-mode choke coils 53 and common-mode choke coils 55 are mounted on the one surface of the second filter circuit substrate 33. However, this is not limiting. Multiple filter components for electromagnetic noise suppression can be mounted dispersedly on the first filter circuit substrate 31 and the second filter circuit substrate 33. Therefore, for example, in contrast to the above embodiment, the normal-mode choke coils 53 and common-mode choke coils 55 can be mounted on the one surface of the first filter circuit substrate 31, while the multiple electrolytic capacitors 51 are mounted on the one surface of the second filter circuit substrate 33.

[0073] In addition, in the above-mentioned embodiment, the resin member 35 has a pair of metal busbars 351, 351 that electrically connect the first filter circuit substrate 31 and the second filter circuit substrate 33, and has a metal shielding plate 41 built in to shield electromagnetic noise. However, this is not limited to this. The pair of busbars 351, 351 and / or the shielding plate 41 can also be omitted. This is because the first filter circuit substrate 31 and the second filter circuit substrate 33 can be electrically connected by components other than the pair of busbars 351, 351, and there may be cases where the shielding plate 41 is not required due to a low level of electromagnetic noise. That is, in addition to the above-mentioned embodiment, the resin member 35 can also be implemented in any of the following ways: (1) a first way with a pair of busbars 351, 351 but without a built-in shielding plate 41, (2) a second way with a built-in shielding plate 41 but without a pair of busbars 351, 351, and (3) a third way without a pair of busbars 351, 351 and without a built-in shielding plate 41.

[0074] Furthermore, in the above-described embodiment, the resin member 35 is formed to have an outer shape corresponding to the outer shape of the first filter circuit substrate 31. However, this is not limiting. The resin member 35 may be formed to have an outer shape corresponding to (substantially identical to) at least one of the outer shape of the first filter circuit substrate 31 and the outer shape of the second filter circuit substrate 33. It is preferred that the first filter circuit substrate 31, the second filter circuit substrate 33, and the resin member 35 be formed so that their outer shapes are substantially identical.

[0075] Furthermore, in the above-described embodiment, the filter circuit unit 30 is sandwiched between the bottom of the inverter housing portion 7 and the cover member 8, with vibration isolation members present between the second housing member 39 and the bottom of the inverter housing portion 7, and between the first housing member 37 and the cover member 8. However, this is not limiting. The filter circuit unit 30 may also be sandwiched between the bottom of the inverter housing portion 7 and the cover member 8, with vibration isolation members present between at least one of the second housing member 39 and the bottom of the inverter housing portion 7 and between the first housing member 37 and the cover member 8.

[0076] Furthermore, if Figure 7 、 Figure 8 As shown, in the filter circuit unit 30, a sheet-shaped second heat sink member 43 may be disposed between the first filter circuit substrate 31 and the resin member 35, and a sheet-shaped third heat sink member 45 may be disposed between the second filter circuit substrate 33 and the resin member 35. In this case, the second heat sink member 43 is preferably disposed on the inner portion 352b of the main body 352 of the resin member 35 on one surface side so as to be located below the multiple electrolytic capacitors 51, while the third heat sink member 45 is preferably disposed on the inner portion 352b of the main body 352 of the resin member 35 on the other surface side so as to be located below the normal mode choke coil 53, the common mode choke coil 55, and the like. This allows efficient heat dissipation of heat generated by the electrolytic capacitors 51, the normal mode choke coil 53, the common mode choke coil 55, and the like.

[0077] The embodiments of the present invention and its modified examples have been described above, but the present invention is not limited to the above-described embodiments and modified examples, and further modifications are possible based on the technical concept of the present invention. Description of Reference Numerals

[0078] 1 Electric compressor, 2 Rotating shaft, 3 Motor, 4 Compression mechanism, 5 Housing, 6 Inverter, 7 Inverter housing, 8 Cover member, 11 First heat sink, 18 First vibration isolation member, 19 Second vibration isolation member, 20 Inverter circuit, 21 Power switching element, 23 Control circuit, 25 Inverter control board, 30 Filter circuit, 31 First filter circuit board, 33 Second filter circuit board, 35 Resin member, 37 First case member, 39 Second case member, 41 Shielding plate, 43 Second heat sink, 45 Third heat sink, 51 Electrolytic capacitor, 53 Normal mode choke, 55 Common mode choke, 317 First mounting hole, 337 Second mounting hole, 351 Bus bar, 352 Main body, 352a Peripheral edge, 352b Inner side, 357 Third mounting hole, 371 Fourth mounting hole, 393 Fifth mounting hole, R Resin.

Claims

1. An electric compressor comprising: a housing accommodating a motor for rotating a rotary shaft and a compression mechanism driven by the rotation of the rotary shaft; an inverter housing, integrally provided with the housing, having an opening and housing an inverter for driving the motor; and a cover member for closing the opening of the inverter housing portion, wherein The inverter includes an inverter circuit portion for supplying power to the motor and a filter circuit portion for reducing electromagnetic noise. The filter circuit unit includes a first filter circuit substrate on which at least one first filter component is mounted, and a second filter circuit substrate on which at least one second filter component is mounted. The first filter circuit substrate and the second filter circuit substrate are electrically connected to each other and are housed in the inverter housing portion in a stacked state with a plate-shaped resin member interposed therebetween.

2. The electric compressor according to claim 1, wherein The at least one first filter component is mounted on one surface of the first filter circuit substrate, and the at least one second filter component is mounted on one surface of the second filter circuit substrate. The other surface of the first filter circuit substrate and the other surface of the second filter circuit substrate are housed in the inverter housing portion in a state in which they are arranged to face each other with the resin member interposed therebetween.

3. The electric compressor according to claim 1, wherein The resin member includes a bus bar that electrically connects the first filter circuit substrate and the second filter circuit substrate.

4. The electric compressor according to claim 1, wherein The resin member includes a bus bar for electrically connecting the first filter circuit substrate and the second filter circuit substrate, and has a built-in shielding plate for shielding electromagnetic noise.

5. The electric compressor according to claim 1, wherein The resin member has an outer shape corresponding to at least one of an outer shape of the first filter circuit substrate and an outer shape of the second filter circuit substrate.

6. The electric compressor according to claim 1, wherein The first filter circuit substrate is fixed to one surface of the resin member by thermal caulking, and the second filter circuit substrate is fixed to the other surface of the resin member by thermal caulking.

7. The electric compressor according to claim 2, wherein: An electronic component smaller than the at least one first filter component is mounted on the other surface of the first filter circuit substrate, and an electronic component smaller than the at least one second filter component is mounted on the other surface of the second filter circuit substrate. A first recess for accommodating an electronic component smaller than the at least one first filter component is formed on one surface of the resin member, and a second recess for accommodating an electronic component smaller than the at least one second filter component is formed on the other surface of the resin member.

8. The electric compressor according to claim 2, wherein: Heat dissipation members are disposed between the other surface of the first filter circuit substrate and the resin member, and between the other surface of the second filter circuit substrate and the resin member.

9. The electric compressor according to claim 2, wherein: The filter circuit portion further includes: a first housing member disposed on the one surface of the first filter circuit substrate and accommodating the at least one first filter component; and a second housing member disposed on the one surface of the second filter circuit substrate and accommodating the at least one second filter component.

10. The electric compressor according to claim 9, wherein The gap in the first case member and the gap in the second case member are filled with resin.

11. The electric compressor according to claim 9, wherein The filter circuit unit is fixed in the inverter housing portion by bolts and is clamped by the bottom of the inverter housing portion and the cover member in a state where a vibration-proof member is present between the second housing member and the bottom of the inverter housing portion and between the first housing member and the cover member.

12. The electric compressor according to any one of claims 1 to 11, wherein One of the at least one first filter component and the at least one second filter component includes a plurality of electrolytic capacitors, and the other of the at least one first filter component and the at least one second filter component includes a normal mode choke coil and a common mode choke coil.

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