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; a second filter circuit board (33) on which a constant mode choke (53), a common mode choke (55) and the like are mounted; and a bus bar member (35) having a bus bar (351) for electrically connecting the first filter circuit board (31) and the second filter circuit board (33), and a resin holding part (352) for holding the bus bar (351). The first filter circuit board (31) and the second filter circuit board (33) are housed in the inverter housing part (7) in a state of overlapping each other with the bus bar member (35) therebetween.

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 driven by the rotation of the rotating shaft; an inverter housing integrally provided with the housing and having 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; a second filter circuit substrate on which at least one second filter component is mounted; and a busbar member comprising a busbar that electrically connects the first filter circuit substrate to the second filter circuit substrate and a resin retaining portion that retains the busbar. Furthermore, the first filter circuit substrate, the second filter circuit substrate, and the busbar member are housed in the inverter housing with the first filter circuit substrate and the second filter circuit substrate overlapping with the busbar 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 perspective view of the filter circuit section that constitutes the inverter. Figure 4 This is an exploded perspective view of the filter circuit section. Figure 5 It is a partially enlarged cross-sectional view of the busbar component. Figure 6 It is a perspective view showing a modified example of the busbar member. Figure 7 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] Although not shown in the figures, the housing 5 is formed with an inlet for allowing refrigerant to flow into the housing 5 and an outlet for allowing refrigerant to flow out of the housing 5. In this embodiment, the inlet is configured to allow refrigerant to flow into the space between the partition wall 77 in the housing 5 and the motor 3. The refrigerant flowing into the housing 5 through the inlet 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 of the outlet.

[0016] The refrigerant flowing into the housing 5 from the inlet is a low-temperature gas refrigerant after passing through the expansion valve and evaporator in the refrigerant circuit of the vehicle air conditioner. Therefore, the partition wall 77 and the motor 3 can be cooled by the refrigerant flowing into the housing 5 from the inlet.

[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 perspective view of the filter circuit unit 30, Figure 4 It is an exploded perspective view of the filter circuit unit 30 .

[0022] In this embodiment, the filter circuit unit 30 includes a first filter circuit substrate 31 , a second filter circuit substrate 33 , and a bus bar member 35 .

[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 and Figure 4 It is the upper surface in the middle and is the surface facing the cover member 8 side 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 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 and Figure 4 It 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 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] The busbar member 35 is formed as a whole into a plate shape, having an outer shape that generally corresponds to the outer shape of the first filter circuit board 31 and the outer shape of the second filter circuit board 33. The busbar member 35 includes a pair of metal busbars 351, 351 for electrically connecting the first filter circuit board 31 and the second filter circuit board 33, and a resin retaining portion 352 that retains the pair of busbars 351, 351. Although not particularly limited, in this embodiment, the busbar member 35 is formed as a plate-shaped resin molded body into which the pair of busbars 351, 351 are inserted.

[0029] In this embodiment, the retaining portion 352 is formed into a plate-like shape having a substantially H-shaped cross-section, with a peripheral portion 352a having a predetermined width and bulging toward both sides in the thickness direction relative to an inner portion 352b other than the peripheral portion 352a. Specifically, both surfaces of the retaining portion 352 are formed such that the inner portion 352b is recessed relative to the peripheral portion 352a. Furthermore, both surfaces of the busbar member 35 are formed such that the inner portion 352b is recessed relative to the peripheral portion 352a.

[0030] The pair of bus bars 351, 351 are arranged at a predetermined interval on the peripheral edge portion 352a of the holding portion 352. The pair of bus bars 351, 351 each have a side ( Figure 1 and Figure 4 The first protrusion 351a protruding from the peripheral edge 352a of the holding portion 352 to the other side in the thickness direction ( Figure 1 and Figure 4 A second protrusion 351b protruding from the lower side of the panel.

[0031] Figure 5This is a partially enlarged cross-sectional view of the busbar component 35, showing the busbar 351 and its surroundings. The busbar 351 is formed in a cross shape. The busbar 351 includes: a conductive portion 3511, which is used to electrically connect the first filter circuit substrate 31 and the second filter circuit substrate 33 and extends through the peripheral edge 352a of the retaining portion 352 in the thickness direction; and a retained portion 3513, which extends across the conductive portion 3511 and is retained by the retaining portion 352. Alternatively, the retained portion 3513 can be referred to as an insertion portion. Furthermore, one end of the conductive portion 3511 forms a first protrusion 351a, and the other end of the conductive portion 3511 forms a second protrusion 351b.

[0032] More specifically, in this embodiment, a through-hole 353 is formed in the peripheral edge 352a of the retaining portion 352, extending through the through-hole in the thickness direction. The busbar 351 is disposed in this through-hole 353. Furthermore, the conductive portion 3511 of the busbar 351 extends axially within the through-hole 353, with one end protruding from one side of the through-hole 353 as a first protrusion 351a, and the other end protruding from the other side of the through-hole 353 as a second protrusion 351b. A retained portion 3513 extends in a direction perpendicular to the axial direction of the through-hole 353, with both ends embedded in the retaining portion 352, which is the peripheral wall of the through-hole 353. Consequently, the retained portion 3513 is retained by the retaining portion 352, and the busbar 351 is retained by the retaining portion 352.

[0033] That is, in this embodiment, the busbar 351 is disposed in the through-hole 353 formed in the holding portion 352, with only the two ends of the holding portion 3513 embedded in the holding portion 352 (i.e., the resin portion), and the rest of the portion is exposed from the holding portion 352. In particular, the conductive portion 3511 of the busbar 351 does not contact the peripheral wall of the through-hole 353, that is, does not contact the holding portion 352.

[0034] In this embodiment, the first filter circuit substrate 31, the second filter circuit substrate 33, and the busbar member 35 are housed in the inverter housing 7 in a state in which the first filter circuit substrate 31 and the second filter circuit substrate 33 overlap, with the busbar member 35 interposed therebetween. Specifically, the first filter circuit substrate 31, the second filter circuit substrate 33, and the busbar member 35 are housed in the inverter housing 7 in a state in which 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, the common mode choke coil 55, etc.) are opposed to each other, with the busbar member 35 interposed therebetween. This will be described in detail below.

[0035] First, the first filter circuit substrate 31 is placed on one surface of the busbar member 35 with the other surface on which the plurality of electrolytic capacitors 51 are not mounted. Figure 1 and Figure 4Specifically, the first filter circuit substrate 31 is mounted on one surface (the upper surface in the middle) of the holding portion 352 of the busbar member 35 with the other surface on which the plurality of electrolytic capacitors 51 are not mounted being supported. Figure 1 and Figure 4 The busbar member 35 is installed in a state on the peripheral edge portion 352a on the upper surface of the busbar member 35.

[0036] Here, the busbar member 35 is provided with multiple (here, four) resin-made first pins 355 protruding from the one surface. Specifically, the multiple (four) first pins 355 are arranged upright, spaced apart from each other along the circumferential direction, on the peripheral edge 352a of the retaining portion 352 of the busbar member 35 on the one surface side. Furthermore, near the peripheral edge of the first filter circuit substrate 31, multiple (the same number as the multiple first pins 355, i.e., four) first pin insertion holes 311 are formed to correspond to the multiple first pins 355 of the busbar member 35. When the first filter circuit substrate 31 is attached to the busbar member 35, the multiple first pins 355 of the busbar member 35 are inserted through the corresponding first pin insertion holes 311 of the first filter circuit substrate 31, and the tips of the multiple first pins 355 of the busbar member 35 are thermally caulked. Thereby, the first filter circuit substrate 31 and the bus bar member 35 are aligned with each other, and the first filter circuit substrate 31 is fixed to the one surface of the bus bar member 35 .

[0037] 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 busbar member 35. When the first filter circuit substrate 31 is mounted on the busbar member 35, the first protrusions 351a of the pair of busbars 351, 351 of the busbar 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 busbar member 35 are soldered to the first filter circuit substrate 31. This electrically connects the pair of busbars 351, 351 of the busbar member 35 to the first filter circuit substrate 31.

[0038] 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 retaining portion 352 (resin portion). Furthermore, only the two ends of the retained portion 3513 of the busbar 351, located away from the first protrusion 351a, are embedded in the retaining portion 352. This suppresses heat diffusion during soldering of the first protrusion 351a to the first filter circuit substrate 31, stabilizing solder quality. Furthermore, the retaining portion 352 is prevented from melting or deforming due to the heat of soldering the first protrusion 351a to the first filter circuit substrate 31.

[0039] The aforementioned small electronic component mounted on the other surface of the first filter circuit substrate 31 is accommodated in the inner portion 352 b on the one surface side of the holding portion 352 of the bus bar member 35 .

[0040] Next, the second filter circuit substrate 33 is placed on the other surface of the busbar member 35 ( Figure 1 and Figure 4 Specifically, the second filter circuit substrate 33 is mounted on the other surface (the lower surface in the middle) of the holding portion 352 of the busbar 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 and Figure 4 The busbar member 35 is mounted in a state on the peripheral edge portion 352a on the lower surface of the busbar member 35.

[0041] Here, similarly to the one surface of the busbar member 35, the other surface of the busbar member 35 is provided with a plurality (four in this case) of second pin portions 356 made of resin protruding from the other surface (however, Figure 4Only 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 retaining portion 352 of the busbar member 35. Furthermore, multiple (the same number as the multiple second pins 356, i.e., four) 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 busbar member 35. When the second filter circuit substrate 33 is attached to the busbar member 35, the multiple second pins 356 of the busbar member 35 are inserted through the corresponding second pin insertion holes 331 of the second filter circuit substrate 33, and the top ends of the multiple second pins 356 of the busbar member 35 are thermally caulked. This aligns the second filter circuit substrate 33 with the busbar member 35 and secures the second filter circuit substrate 33 to the other surface of the busbar member 35.

[0042] 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 busbar member 35. When the second filter circuit substrate 33 is mounted on the busbar member 35, the second protrusions 351b of the pair of busbars 351, 351 of the busbar 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 busbar 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 busbar member 35.

[0043] 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 retaining portion 352 (resin portion). Furthermore, only the two ends of the retained portion 3513 of the busbar 351, located away from the second protrusion 351b, are embedded in the retaining portion 352. This suppresses heat diffusion during soldering of the second protrusion 351b to the second filter circuit substrate 33, stabilizing solder quality. Furthermore, the retaining portion 352 is prevented from melting or deforming due to the heat of soldering the second protrusion 351b to the second filter circuit substrate 33.

[0044] The aforementioned small electronic components mounted on the other surface of the second filter circuit substrate 33 are housed in the inner portion 352 b on the other surface side of the holding portion 352 of the bus bar member 35 .

[0045] As described above, the first filter circuit substrate 31 and the second filter circuit substrate 33 are integrated via the bus bar member 35 , and the first filter circuit substrate 31 and the second filter circuit substrate 33 are electrically connected.

[0046] In this embodiment, the filter circuit unit 30 further includes a first case member 37 and a second case member 39 .

[0047] 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 .

[0048] In the present embodiment, the first case member 37 is attached to the one surface of the first filter circuit substrate 31 as follows.

[0049] 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.

[0050] 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.

[0051] 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 .

[0052] 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.

[0053] In this manner, in addition to integrating the first filter circuit substrate 31, the second filter circuit substrate 33, and the busbar member 35, the first case member 37 and the second case member 39 are also integrated. That is, in this embodiment, the filter circuit unit 30 includes the first filter circuit substrate 31, the second filter circuit substrate 33, the busbar member 35, the first case member 37, and the second case member 39, which are integrated to form the filter circuit unit 30.

[0054] By multiple bolts 16 ( Figure 1 (Only one of them is shown) Such a filter circuit unit 30 is mounted on the filter mounting portion 17 provided in the inverter housing portion 7.

[0055] Specifically, in this embodiment, multiple (here, four) corresponding mounting holes are formed in the first filter circuit substrate 31, the second filter circuit substrate 33, the busbar 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 busbar 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. Alternatively, the third mounting holes 357, the fourth mounting holes 371, and the fifth mounting holes 393 can be formed by metal cylindrical sleeves inserted during molding.

[0056] The filter circuit unit 30 is housed in the inverter housing 7 with the second housing member 39 facing the bottom of the inverter housing 7. Furthermore, bolts 16, which pass through the fourth mounting hole 371 of the first housing member 37, the first mounting hole 317 of the first filter circuit substrate 31, the third mounting hole 357 of the busbar member 35, the second mounting hole 337 of the second filter circuit substrate 33, and the fifth mounting hole 393 of the second housing 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 busbar member 35, the first housing member 37, and the second housing member 39 within the inverter housing 7.

[0057] 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 .

[0058] 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.

[0059] According to the electric compressor 1 of the embodiment, for example, the following effects can be obtained.

[0060] In the electric compressor 1 of the embodiment, the filter circuit unit 30 for reducing electromagnetic noise 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; 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; and a busbar member 35 having a pair of busbars 351, 351 and a resin retaining portion 352 for retaining the pair of busbars 351, 351. The first filter circuit substrate 31, the second filter circuit substrate 33, and the busbar member 35 are housed in the inverter housing 7 in a state where the first filter circuit substrate 31 and the second filter circuit substrate 33 overlap with the busbar member 35 interposed therebetween.

[0061] 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 boards (first filter circuit board 31 and second filter circuit board 33). These two circuit boards (first filter circuit board 31 and second filter circuit board 33) can be arranged, for example, one above the other, with the busbar member 35 interposed between them within the inverter housing 7. Therefore, even when the size of the filter components increases and the number of filter components increases, the projected area of ​​the filter circuit boards constituting the filter circuit unit 30, and consequently, the projected area of ​​the inverter housing 7, can be suppressed. Consequently, restrictions on the installation location of the electric compressor 1 and an increase in noise caused by vibration of the cover member 8 can be suppressed. Furthermore, since the electrolytic capacitors 51, normal-mode choke coils 53, and common-mode choke coils 55, which generate a large amount of heat, are mounted on separate circuit boards, thermal interference between them can be suppressed.

[0062] 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, common-mode choke coil 55, and other components are mounted on the one surface of the second filter circuit substrate 33. Furthermore, the busbar member 35 is formed as a plate-shaped resin molded body into which a pair of busbars 351, 351 are inserted. Furthermore, the first filter circuit substrate 31, the second filter circuit substrate 33, and the busbar member 35 are housed in the inverter housing 7 with the other surface of the first filter circuit substrate 31 and the other surface of the second filter circuit substrate 33 facing each other, with the busbar member 35 interposed therebetween. Consequently, the first and second filter circuit substrates 31, 33 are reinforced by the busbar member 35, improving the vibration resistance of the filter circuit substrates and, consequently, the filter circuit unit 30. Furthermore, (the retaining portion 352 of) the busbar member 35 functions as an insulating barrier between the first and second filter circuit substrates 31, 33, thereby ensuring an insulation distance between the first and second filter circuit substrates 31, 33.

[0063] Furthermore, the first filter circuit substrate 31 is fixed to the one surface of the busbar member 35 by thermal caulking, and the second filter circuit substrate 33 is fixed to the other surface of the busbar member 35 by thermal caulking. Therefore, the first filter circuit substrate 31, the second filter circuit substrate 33, and the busbar member 35 can be integrated (modularized) without the use of additional components such as bolts, thereby minimizing the degradation of the filter circuit unit 30's assemblability and ease of assembly of the filter circuit unit 30 into the inverter housing 7 that would result from the separate mounting of filter components onto two circuit substrates.

[0064] Furthermore, the filter circuit unit 30 includes a first case member 37, which is disposed on one surface of the first filter circuit substrate 31 and houses a plurality of electrolytic capacitors 51; and a second case member 39, which is disposed on one surface of the second filter circuit substrate 33 and houses 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. In particular, in this embodiment, the gaps within the first case member 37 and the gaps within the second case member 39 are filled with resin. This further enhances the vibration resistance of the filter circuit unit 30. Furthermore, in addition to the first filter circuit substrate 31, the second filter circuit substrate 33, and the busbar member 35, the first case member 37 and the second case member 39 can also be integrated (modularized), improving the ease of assembly of the filter circuit unit 30 into the inverter housing 7.

[0065] Furthermore, bolt holes (317, 337, 357, 371, and 393) are formed in the first filter circuit substrate 31, the second filter circuit substrate 33, the busbar member 35, the first case member 37, and the second case member 39, respectively, for the bolts that secure these components integrally to the inverter housing 7. This allows the filter circuit unit 30 to be easily and securely secured within the inverter housing 7, achieving high vibration resistance.

[0066] Furthermore, the filter circuit unit 30 is held between the bottom of the inverter housing portion 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 portion 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 more securely fixed within the inverter housing portion 7, achieving higher vibration resistance.

[0067] Furthermore, both surfaces of the busbar member 35 are formed with the inner portion 352b recessed relative to the peripheral portion 352a. Electronic components smaller than the multiple electrolytic capacitors 51 are mounted on the other surface of the first filter circuit substrate 31, and electronic components smaller than the normal-mode choke coil 53 and the common-mode choke coil 55, etc., are mounted on the other surface of the second filter circuit substrate 33. This effectively reduces the projected area of ​​the filter circuit substrates that comprise the filter circuit unit 30, and consequently, reduces 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] 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.

[0069] 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, common-mode choke coils 55, and the like 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 distributed and mounted on the first and second filter circuit substrates 31, 33. Furthermore, contrary to the above embodiment, the normal-mode choke coils 53, common-mode choke coils 55, and the like 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.

[0070] 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.

[0071] In addition, the busbar member 35 may further include a metal shielding plate 41 disposed inside the holding portion 352. The shielding plate 41 shields electromagnetic noise, for example, Figure 6 As indicated by the dotted line in the figure, the busbar member 35 is formed to have an outer shape that roughly corresponds to the inner portion 352b of the retaining portion 352. Furthermore, the shielding plate 41 is inserted along with the pair of busbars 351, 351 during the molding of the busbar member 35. In other words, the busbar member 35 can be formed as a plate-shaped resin molded body into which the pair of busbars 351, 351 and the shielding plate 41 are inserted. This effectively prevents malfunctions caused by interference from radiated noise between the first filter circuit board 31 and the second filter circuit board 33.

[0072] Furthermore, if Figure 7As shown, a sheet-like second heat sink member 43 may be disposed between the first filter circuit substrate 31 and the busbar member 35, and a sheet-like third heat sink member 45 may be disposed between the second filter circuit substrate 33 and the busbar member 35. In this case, the second heat sink member 43 is preferably disposed on the inner portion 352b of the one surface side of the retaining portion 352 of the busbar member 35 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 other surface side of the retaining portion 352 of the busbar member 35 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.

[0073] 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

[0074] 1 Electric compressor, 2 Rotating shaft, 3 Motor, 4 Compression mechanism, 5 Housing, 6 Inverter, 7 Inverter housing, 8 Cover member, 18 First vibration isolation member, 19 Second vibration isolation member, 20 Inverter circuit portion, 21 Power switching element, 23 Control circuit, 25 Inverter control board, 30 Filter circuit portion, 31 First filter circuit board, 33 Second filter circuit board, 35 Busbar member, 37 First case member, 39 Second case member, 51 Electrolytic capacitor, 53 Normal mode choke coil, 55 Common mode choke coil, 317 First mounting hole, 337 Second mounting hole, 351 Busbar, 352 Holding portion, 352a Peripheral edge portion, 352b Inner side portion, 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; a second filter circuit substrate on which at least one second filter component is mounted; and a busbar member having a busbar electrically connecting the first filter circuit substrate and the second filter circuit substrate and a resin holding portion for holding the busbar. The first filter circuit substrate, the second filter circuit substrate, and the bus bar member are housed in the inverter housing portion in a state where the first filter circuit substrate and the second filter circuit substrate overlap with each other via the bus bar member.

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, the at least one second filter component is mounted on one surface of the second filter circuit substrate, and the busbar member is formed as a plate-shaped resin molded body into which the busbar is inserted. The first filter circuit substrate, the second filter circuit substrate, and the bus bar member are housed in the inverter housing portion with the other surface of the first filter circuit substrate and the other surface of the second filter circuit substrate facing each other with the bus bar member interposed therebetween.

3. The electric compressor according to claim 2, wherein: The first filter circuit substrate is fixed to one surface of the bus bar member by thermal staking, and the second filter circuit substrate is fixed to the other surface of the bus bar member by thermal staking.

4. 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.

5. The electric compressor according to claim 4, wherein The gap in the first case member and the gap in the second case member are filled with resin.

6. The electric compressor according to claim 4, wherein Bolt through holes for passing bolts for integrally fixing the first filter circuit substrate, the second filter circuit substrate, the bus bar member, the first case member, and the second case member are respectively formed.

7. The electric compressor according to claim 4, wherein The filter circuit unit is sandwiched between the bottom of the inverter housing portion and the cover member with a vibration-isolating member interposed between at least one of the second case member and the bottom of the inverter housing portion and between the first case member and the cover member.

8. The electric compressor according to claim 2, wherein: The two sides of the busbar member are formed so that the inner side is recessed relative to the peripheral edge. 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.

9. The electric compressor according to any one of claims 1 to 8, 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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