Electric compressor

Abstract

To provide an electric compressor capable of suppressing enlargement of a projection area of an inverter housing even when a filter component for an electromagnetic noise countermeasure is enlarged or the number of the filter components is increased.SOLUTION: In an electric compressor 1, a first filter circuit board 31 and a second filter circuit board 33 are disposed to face each other via a plate-like resin member 35 to which a pair of bus bars 351, 351 is inserted, and each of the bus bars 351, 351 includes a first protrusion 351a inserted into a corresponding first bus bar through hole 313 formed on the first filter circuit board 31, and a second protrusion 351b inserted into a corresponding second bus bar through hole 333 formed on the second filter circuit board 33. The first protrusion 351a is soldered to the first filter circuit board 31, and the second protrusion 351b is soldered to the second filter circuit board 33.SELECTED DRAWING: Figure 4

Description

[Technical field]

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

[0002] One example of an electric compressor is described in Patent Document 1. The electric compressor described in Patent Document 1 is an inverter-integrated electric compressor used in a vehicle air conditioner. The electric compressor described in Patent Document 1 has a housing with a built-in motor, an inverter for driving the motor, an inverter accommodating section provided in the housing, and a cover for closing the inverter accommodating section. The inverter includes six power switching elements for converting DC power into three-phase AC power, an inverter control board on which a control circuit for controlling the six power switching elements is mounted, and a filter circuit board on which filter components such as coils and capacitors are mounted, and these are accommodated in the inverter accommodating section. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2020-143594 A Summary of the Invention [Problem to be solved by the invention]

[0004] In recent years, due to the sophistication of electronic control units accompanying the electrification of automobiles, further electromagnetic noise countermeasures are required for electric compressors used in vehicle air conditioners. One of such electromagnetic noise countermeasures is, for example, the use of a coil with a larger inductance value than before. However, a coil with a larger inductance value has a large component size. Therefore, simply using a coil with a larger inductance value leads to an increase in the projected area of ​​the filter circuit board, and in turn, an increase in the projected area of ​​the inverter accommodating section that accommodates the filter circuit board. If the projected area of ​​the inverter accommodating section is increased, it is undesirable because it may limit the installation location of the electric compressor or the cover that closes the inverter accommodating section may be easily affected by vibration, increasing noise caused by the vibration of the cover.

[0005] Therefore, an object of the present invention is to provide an electric compressor that can suppress an increase in the projected area of ​​the inverter accommodating section even if the filter components for electromagnetic noise countermeasures are enlarged or the number of filter components is increased. [Means for solving the problem]

[0006] According to one aspect of the present invention, there is provided an electric compressor. The electric compressor includes a housing that accommodates a motor that rotates a rotating shaft and a compression mechanism driven by the rotation of the rotating shaft, and an inverter accommodating section that is provided integrally with the housing and accommodates an inverter that drives the motor. The inverter includes an inverter circuit section that supplies power to the motor, and a filter circuit section for reducing electromagnetic noise. The filter circuit section includes a first filter circuit board on which at least one first filter component is mounted, a second filter circuit board on which at least one second filter component is mounted, and a plate-shaped resin member into which a bus bar is inserted. The first filter circuit board, the second filter circuit board, and the resin member are accommodated in the inverter accommodating section in a state in which the other surface of the first filter circuit board and the other surface of the second filter circuit board are arranged opposite each other with the resin member sandwiched therebetween. The bus bar has a first protruding portion protruding from the resin member to one side in a thickness direction of the resin member and inserted into a first bus bar insertion hole formed in the first filter circuit board, and a second protruding portion protruding from the resin member to the other side in the thickness direction and inserted into a second bus bar insertion hole formed in the second filter circuit board, the first protruding portion being soldered to the first filter circuit board, and the second protruding portion being soldered to the second filter circuit board. Effect of the Invention

[0007] According to the present invention, it is possible to provide an electric compressor that can suppress an increase in the projected area of ​​the inverter accommodating section even if the filter components for electromagnetic noise countermeasures are enlarged or the number of filter components is increased. [Brief description of the drawings]

[0008] [Figure 1] 1 is a schematic vertical cross-sectional view of an electric compressor according to an embodiment; [Diagram 2] 2 is a schematic perspective view showing an inverter and an inverter accommodating portion; FIG. [Diagram 3] FIG. 4 is a cross-sectional view of a filter circuit portion. [Figure 4] FIG. 2 is an exploded perspective view of a filter circuit portion. [Diagram 5] FIG. [Figure 6] FIG. 4 is a partially enlarged cross-sectional view of a resin member. [Figure 7] FIG. 13 is a perspective view showing a modified example of the filter circuit section. [Figure 8] FIG. 13 is a perspective view showing a modified example of the filter circuit section. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] Hereinafter, an embodiment of the present invention will be described with reference to the accompanying drawings. Note that the terms "first", "second", ..., etc. are used simply to distinguish similar elements and are not intended to limit the elements to which they are attached.

[0010] Fig. 1 is a schematic vertical cross-sectional view of an electric compressor 1 according to an embodiment of the present invention. The electric compressor 1 according to the embodiment is an inverter-integrated electric compressor having an inverter integrated therein. The electric compressor 1 is used in an air conditioner for a vehicle. That is, the electric compressor 1 is mounted on a vehicle to form part of a refrigerant circuit of the air conditioner for a vehicle, and is configured to compress and discharge a 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 accommodating portion 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) that is driven by power supply to rotate the rotating shaft 2. The compression mechanism 4 is, for example, a scroll compression mechanism that 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 to drive the motor 3. The inverter 6 includes an inverter circuit section 20 that supplies power to the motor 3 and a filter circuit section 30 for reducing electromagnetic noise. The inverter accommodating section 7 is provided integrally with the housing 5 and accommodates the inverter 6. Specifically, the inverter accommodating section 7 is provided at the end of the housing 5 on the motor 3 side. In this embodiment, the inverter accommodating section 7 has a larger projected area than the housing 5. The inverter accommodating section 7 is formed by a bottom wall 71 and a peripheral wall 73 rising from the periphery of the bottom wall 71, and has an opening 75 facing the bottom wall 71. The inverter circuit section 20 and the filter circuit section 30 that constitute the inverter 6 are accommodated in the inverter accommodating section 7, and the opening 75 of the inverter accommodating section 7 is closed by a cover member 8. The cover member 8 is fixed to the peripheral wall of the inverter accommodating section 7 (which is also part of the housing 5) by bolts not shown.

[0014] An HV connector (high voltage connector) 9 for supplying DC power from an on-board battery (not shown) to the inverter 6 (inverter circuit section 20) is attached to a bottom wall 71 of the inverter accommodating section 7. A part of the bottom wall 71 of the inverter accommodating section forms a partition wall 77 that separates the inside of the housing 5 from the inside of the inverter accommodating section 7.

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

[0016] The refrigerant flowing into the housing 5 from the inlet 5a is a low-temperature gas refrigerant that has passed through an expansion valve and an 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 5a.

[0017] The inverter 6 will be further described with reference to Figures 1 and 2. Figure 2 is a schematic perspective view showing the inverter 6 and the inverter accommodating section 7. As described above, in this embodiment, the inverter 6 has the inverter circuit section 20 that supplies power to the motor 3, and the filter circuit section 30 for reducing electromagnetic noise.

[0018] The inverter circuit unit 20 is configured to convert DC power supplied from the on-board battery via the HV connector 9 into three-phase AC power and supply it to the motor 3 (the stator coil 3a) via a power supply line 10 extending through the partition wall 77. For this reason, 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 placed on a sheet-like first heat dissipation member 11 that is installed on the surface of the partition wall 77 facing the inverter accommodating section 7. Each of the six power switching elements 21 is fixed in a state in which it is pressed against the first heat dissipation member 11 by an arm member 12 (see FIG. 1). The arm member 12 is attached by a bolt 13 to an arm attachment portion 14 that is provided in the inverter accommodating section 7.

[0020] The inverter control board 25 has a plurality of (seven in this embodiment) mounting holes 25a. The inverter control board 25 is attached to the board mounting portion 15 provided in the inverter accommodating portion 7 by a plurality of bolts (not shown). In this embodiment, the inverter control board 25 is disposed near the cover member 8, that is, spaced apart from the six power switching elements 21 (see FIG. 1). Therefore, each of the six power switching elements 21 has a lead wire extending toward the inverter control board 25, and more specifically, a lead wire extending through the inverter control board 25. These lead wires are soldered to the inverter control board 25, so that the six power switching elements 21 and the inverter control board 25 are electrically connected to each other.

[0021] The filter circuit section 30 is disposed between the inverter circuit section 20 and the HV connector 9. Fig. 3 is a cross-sectional view of the filter circuit section 30, and Fig. 4 is an exploded perspective view of the filter circuit section 30.

[0022] 1, 3 and 4, in this embodiment, the filter circuit section 30 includes a first filter circuit board 31, a second filter circuit board 33, and a resin member .

[0023] At least one filter component (hereinafter referred to as the "first filter component") for electromagnetic noise countermeasures is mounted on one surface of the first filter circuit board 31. The at least one first filter component mounted on the one surface of the first filter circuit board 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 board 31 as the at least one first filter component. The one surface of the first filter circuit board 31 is the upper surface in Figs. 1, 3, and 4, and is the surface facing the cover member 8 when housed in the inverter housing section 7.

[0024] Although not shown in the figures, a plurality of electronic components smaller than the at least one first filter component (here, electrolytic capacitor 51) are also mounted on first filter circuit board 31. At least some of these small electronic components are mounted on the other surface (the lower surface in FIGS. 1, 3, and 4, which faces the bottom side of inverter accommodating section 7 when accommodated in inverter accommodating section 7) of first filter circuit board 31, and more specifically, at positions on the other surface of first filter circuit board 31 that avoid the area below the plurality of 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 board 33. The at least one second filter component mounted on the one surface of the second filter circuit board 33 is a relatively large filter component similar to the at least one first filter component, and may include a plurality of filter components of the same type or different types. Although not particularly limited, in this embodiment, a normal mode choke coil 53, a common mode choke coil 55, an X capacitor, and a Y capacitor are mounted on the one surface of the second filter circuit board 33 as the at least one second filter component. However, the X capacitor and the Y capacitor are not shown in the figures. The one surface of the second filter circuit board 33 is the lower surface in Figures 1, 3, and 4, and is the surface that faces the bottom side of the inverter accommodating section 7 when accommodated in the inverter accommodating section 7.

[0026] Although not shown in the figures, a plurality of electronic components smaller than the at least one second filter component (here, normal mode choke coil 53, common mode choke coil 55, the X capacitor, and the Y capacitor) are also mounted on the second filter circuit board 33. At least some of these small electronic components are mounted on the other surface (the upper surface in Figs. 1, 3, and 4, which faces the cover member 8 when housed in the inverter housing section 7) of the second filter circuit board 33, and more specifically, at positions on the other surface of the second filter circuit board 33 that avoid the areas below the normal mode choke coil 53, the common mode choke coil 55, the X capacitor, and the Y capacitor.

[0027] In the following, the normal mode choke coil 53, the common mode choke coil 55, the X capacitor, and the Y capacitor as the at least one second filter component may be simply referred to as "the normal mode choke coil 53, the common mode choke coil 55, etc."

[0028] 5 is a perspective view of the resin member 35. In this embodiment, the resin member 35 includes a pair of metal bus bars 351, 351 for electrically connecting the first filter circuit board 31 and the second filter circuit board 33, a resin body part 352 that holds the pair of bus bars 351, 351, and a metal shielding plate 41 that is disposed inside the body part 352 and shields electromagnetic noise. In other words, the resin member 35 has the pair of bus bars 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 bus bars 351, 351 and the shielding plate 41 are inserted. In addition, in this embodiment, the resin member 35 is formed to have an outer shape corresponding to (approximately the same outer shape as) the outer shape of the first filter circuit board 31.

[0029] The main body 352 of the resin member 35 is formed in a plate shape having a substantially H-shaped cross section in which a peripheral portion 352a having a predetermined width is raised on both sides in the thickness direction relative to an inner portion 352b other than the peripheral portion 352a. In other words, both sides of the main body 352, i.e., both sides of the resin member 35, are formed such that the inner portions 352b are recessed relative to the peripheral portion 352a.

[0030] The pair of bus bars 351, 351 are disposed at a predetermined interval on the peripheral portion 352a of the main body portion 352. Each of the pair of bus bars 351, 351 penetrates the peripheral portion 352a of the main body portion 352 in the thickness direction, and has a first protruding portion 351a protruding from the peripheral portion 352a to one side in the thickness direction (upper side in Figs. 1, 3 to 5) and a second protruding portion 351b protruding from the peripheral portion 352a of the main body portion 352 to the other side in the thickness direction (lower side in Figs. 1, 3 to 5). That is, each of the pair of bus bars 351, 351 has the first protruding portion 351a protruding from the resin member 35 to one side in the thickness direction of the resin member 35, and the second protruding portion 351b protruding from the resin member 35 to the other side in the thickness direction of the resin member 35.

[0031] 6 is a partially enlarged cross-sectional view of the resin member 35, showing the bus bar 351 and its surroundings. As shown in FIG. 6, the bus bar 351 has a conductive portion 3511 for electrically connecting the first filter circuit board 31 and the second filter circuit board 33, which extends through the peripheral portion 352a of the main body portion 352 in the thickness direction, and a held portion 3513 that extends intersecting the conductive portion 3511 and is held by the main body portion 352. One end of the conductive portion 3511 forms a first protruding portion 351a, and the other end of the conductive portion 3511 forms a second protruding portion 351b. In this embodiment, the bus bar 351 is formed as a cross-shaped terminal, and the conductive portion 3511 and the held portion 3513 each extend linearly.

[0032] More specifically, in this embodiment, a through hole 353 penetrating in the thickness direction is formed in the peripheral portion 352a of the main body portion 352, and the bus bar 351 is disposed in this through hole 353. The conductive portion 3511 of the bus bar 351 extends in the axial direction of the through hole 353 within the through hole 353, and one end portion protrudes from one side of the through hole 353 (upper side in FIG. 6) as a first protrusion 351a, and the other end portion protrudes from the other side of the through hole 353 (lower side in FIG. 6) as a second protrusion 351b. In other words, the one end portion of the conductive portion 3511 forms the first protrusion 351a, and the other end portion of the conductive portion 3511 forms the second protrusion 351b. 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., in the main body portion 352, thereby causing the held portion 3513, and thus the bus bar 351, to be held by the main body portion 352.

[0033] That is, in this embodiment, only both ends of held portion 3513 of bus bar 351 are embedded in main body portion 352 (i.e., resin portion), and the other portion is exposed from main body portion 352. Furthermore, in this embodiment, conductive portion 3511 of bus bar 351 is not in contact with the peripheral wall of through hole 353, i.e., main body portion 352.

[0034] Although not particularly limited, in this embodiment, the shielding plate 41 is formed to have an outer shape that generally corresponds to the inner portion 352b of the main body portion 352, as shown by the dashed lines in FIGS.

[0035] In this embodiment, the first filter circuit board 31, the second filter circuit board 33, and the resin member 35 are accommodated in the inverter accommodating section 7 in a state in which the first filter circuit board 31 and the second filter circuit board 33 are stacked with the resin member 35 sandwiched between them. Specifically, the first filter circuit board 31, the second filter circuit board 33, and the resin member 35 are accommodated in the inverter accommodating section 7 in a state in which the other surface (the surface on which the electrolytic capacitor 51 is not mounted) of the first filter circuit board 31 and the other surface (the surface on which the normal mode choke coil 53, the common mode choke coil 55, and the like are not mounted) of the second filter circuit board 33 face each other with the resin member 35 sandwiched between them. This will be described in detail below.

[0036] The first filter circuit board 31 is attached to the resin member 35 with the other surface on which the multiple electrolytic capacitors 51 are not mounted placed on one surface (the upper surface in FIGS. 1 and 3 to 5) of the resin member 35. More specifically, the first filter circuit board 31 is attached to the resin member 35 with the other surface on which the multiple electrolytic capacitors 51 are not mounted placed on a peripheral portion 352a on one surface (the upper surface in FIGS. 1 and 3 to 5) of the main body portion 352 of the resin member 35.

[0037] Here, the one surface of the resin member 35 is provided with a plurality of (four in this embodiment) first pin portions 355 protruding from the one surface. Specifically, the plurality (four) first pin portions 355 are erected at intervals from one another in the circumferential direction on a peripheral portion 352a on the one surface side of the main body portion 352 of the resin member 35. In addition, a plurality of (the same number as the plurality of first pin portions 355, i.e., four) first pin insertion holes 311 are formed in the vicinity of the peripheral portion of the first filter circuit board 31 so as to correspond to the plurality of first pin portions 355 of the resin member 35. Then, when the first filter circuit board 31 is attached to the resin member 35, each of the plurality of first pin portions 355 of the resin member 35 is inserted into the corresponding first pin insertion hole 311 of the first filter circuit board 31, and then the tip portion of each of the plurality of first pin portions 355 of the resin member 35 is thermally caulked. As a result, the first filter circuit board 31 and the resin member 35 are aligned, and the first filter circuit board 31 is fixed to the one surface of the resin member 35.

[0038] Further, the first filter circuit board 31 is formed with a pair of first busbar insertion holes 313, 313 corresponding to the pair of busbars 351, 351 of the resin member 35. When the first filter circuit board 31 is attached to the resin member 35, the first protrusions 351a of the pair of busbars 351, 351 of the resin member 35 are inserted into the pair of first busbar insertion holes 313, 313 of the first filter circuit board 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 board 31. That is, the first protrusions 351a of the pair of busbars 351, 351 inserted into the pair of first busbar insertion holes 313, 313 of the first filter circuit board 31 are soldered to the first filter circuit board 31. As a result, the pair of busbars 351, 351 of the resin member 35 and the first filter circuit board 31 are electrically connected to each other.

[0039] Here, as described above, the first protruding portion 351a of the busbar 351 is a part of the conductive portion 3511 of the busbar 351, and most of the conductive portion 3511 of the busbar 351 is located inside the through hole 353 and is not in contact with the main body portion 352 (resin portion). In addition, in the busbar 351, only both ends of the held portion 3513 located away from the first protruding portion 351a are embedded in the main body portion 352. Therefore, the diffusion of heat when the first protruding portion 351a is soldered to the first filter circuit board 31 is suppressed, and the solder quality is stabilized. In addition, the main body portion 352 is prevented from melting, deforming, or the like due to the heat when the first protruding portion 351a is soldered to the first filter circuit board 31.

[0040] The above-mentioned small electronic components mounted on the other surface of the first filter circuit board 31 are housed in an inner portion 352b on the one surface side of the main body portion 352 of the resin member 35. Therefore, the inner portion 352b on the one surface side of (the main body portion 352 of) the resin member 35 corresponds to a "first recess" of the present invention.

[0041] The second filter circuit board 33 is attached to the resin member 35 in a state where the other surface on which the normal mode choke coil 53, the common mode choke coil 55, etc. are not mounted is placed on the other surface (the lower surface in Fig. 1, and Fig. 3 to Fig. 5) of the resin member 35. Specifically, the second filter circuit board 33 is attached to the resin member 35 in a state where the other surface on which the normal mode choke coil 53, the common mode choke coil 55, etc. are not mounted is placed on the peripheral portion 352a on the other surface (the lower surface in Fig. 1, and Fig. 3 to Fig. 5) side of the main body portion 352 of the resin member 35.

[0042] Here, similarly to the one surface of the resin member 35, the other surface of the resin member 35 is provided with a plurality of (four here) resin-made second pin portions 356 protruding from the other surface. However, only two of them are shown in FIG. 5. Specifically, the plurality (four) of second pin portions 356 are erected at intervals from one another in the circumferential direction on a peripheral portion 352a on the other surface side of the main body portion 352 of the resin member 35. In addition, a plurality of (the same number as the plurality of second pin portions 356, i.e., four) second pin insertion holes 331 are formed in the vicinity of the peripheral portion of the second filter circuit board 33 so as to correspond to the plurality of second pin portions 356 of the resin member 35. When the second filter circuit board 33 is attached to the resin member 35, each of the second pin portions 356 of the resin member 35 is inserted into the corresponding second pin insertion holes 331 of the second filter circuit board 33, and then the tip portions of each of the second pin portions 356 of the resin member 35 are thermally caulked. As a result, the second filter circuit board 33 and the resin member 35 are aligned, and the second filter circuit board 33 is fixed to the other surface of the resin member 35.

[0043] Further, the second filter circuit board 33 is formed with a pair of second busbar insertion holes 333, 333 corresponding to the pair of busbars 351, 351 of the resin member 35. When the second filter circuit board 33 is attached to the resin member 35, the second protrusions 351b of the pair of busbars 351, 351 of the resin member 35 are inserted into the pair of second busbar insertion holes 333, 333 of the second filter circuit board 33, and the second protrusions 351b of the pair of busbars 351, 351 are soldered to the second filter circuit board 33. That is, the second protrusions 351b of the pair of busbars 351, 351 inserted into the pair of second busbar insertion holes 333, 333 of the second filter circuit board 33 are soldered to the second filter circuit board 33. As a result, the pair of busbars 351, 351 of the resin member 35 and the second filter circuit board 33 are electrically connected to each other. More specifically, the first filter circuit board 31 and the second filter circuit board 33 are electrically connected via the resin member 35 (the pair of bus bars 351, 351 thereof).

[0044] Here, as described above, the second protruding portion 351b of the busbar 351 is a part of the conductive portion 3511 of the busbar 351, and most of the conductive portion 3511 of the busbar 351 is located inside the through hole 353 and is not in contact with the main body portion 352 (resin portion). In addition, in the busbar 351, only both ends of the held portion 3513 located away from the second protruding portion 351b are embedded in the main body portion 352. Therefore, the diffusion of heat when the second protruding portion 351b is soldered to the second filter circuit board 33 is suppressed, and the solder quality is stabilized. In addition, the main body portion 352 is prevented from melting, deforming, or the like due to the heat when the second protruding portion 351b is soldered to the second filter circuit board 33.

[0045] The above-mentioned small electronic components mounted on the other surface of the second filter circuit board 33 are housed in an inner portion 352b on the other surface side of the main body portion 352 of the resin member 35. Therefore, the inner portion 352b on the other surface side of (the main body portion 352 of) the resin member 35 corresponds to a "second recess" of the present invention.

[0046] In this manner, first filter circuit board 31 and second filter circuit board 33 are integrated via resin member 35, and first filter circuit board 31 and second filter circuit board 33 are electrically connected.

[0047] In this embodiment, the filter circuit section 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. The first case member 37 is attached to the one surface of the first filter circuit board 31 and configured to accommodate the plurality of electrolytic capacitors 51 mounted on the one surface of the first filter circuit board 31.

[0049] In this embodiment, the first case member 37 is attached to the one surface of the first filter circuit board 31 in the following manner.

[0050] First, a predetermined amount of resin R in a softened or molten state is filled into the first case member 37. Next, the first filter circuit board 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 board 31. The first filter circuit board 31 and the first case member 37 are aligned by inserting two third pin portions (not shown in the figure) provided in the first case member 37 into the third pin insertion hole 315a and the first pin insertion long hole 315b formed in the first filter circuit board 31. Thereafter, the resin R filled into the first case member 37 is hardened. As a result, the first case member 37 is fixed onto the one surface of the first filter circuit board 31. Also, the gaps in the first case member 37, that is, the gaps between the electrolytic capacitors 51 and the gaps between the electrolytic capacitors 51 and the first case member 37, are filled with the resin R. As the resin R, it is preferable to use a heat-resistant thermoplastic resin or a thermosetting resin.

[0051] The second case member 39 is formed of, for example, a hard resin, similar to the first case member 37. The second case member 39 is attached to 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 this embodiment, like the first case member 37, the second case member 39 is attached to the one surface of the second filter circuit board 33 in the following manner.

[0053] First, a predetermined amount of resin R in a softened or molten state is filled in the second case member 39. Next, the second filter circuit board 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 board 33. The second filter circuit board 33 and the second case member 39 are aligned by inserting two fourth pin parts 391 provided in the second case member 39 into the fourth pin insertion hole 335a and the second pin insertion long hole 335b formed in the second filter circuit board 33. Then, the filled resin R is hardened. As a result, the second case member 39 is fixed on the one surface of the second filter circuit board 33. Also, the gaps in the second case member 39, that is, the gaps between the 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, are filled with the resin R.

[0054] In this manner, the first filter circuit board 31 and the second filter circuit board 33 are integrated via the resin member 35, and the first case member 37 and the second case member 39 are also integrated. That is, in this embodiment, the filter circuit section 30 includes the first filter circuit board 31, the second filter circuit board 33, the resin member 35, the first case member 37, and the second case member 39, and is formed by integrating these together.

[0055] Such a filter circuit section 30 is attached and fixed to a filter attachment section 17 provided in the inverter accommodating section 7 by a plurality of bolts 16 (only one of which is shown in FIG. 1).

[0056] Specifically, in this embodiment, the first filter circuit board 31, the second filter circuit board 33, the resin member 35, the first case member 37, and the second case member 39 each have a plurality of (four in this embodiment) mounting holes that correspond to each other. That is, the first filter circuit board 31 has four first mounting holes 317, and the second filter circuit board 33 has four second mounting holes 337. The resin member 35 has four third mounting holes 357, the first case member 37 has four fourth mounting holes 371, and the second case member 39 has four fifth mounting holes 393. Here, the third mounting holes 357, the fourth mounting holes 371, and the fifth mounting holes 393 may be formed by a metallic cylindrical sleeve inserted during molding.

[0057] The filter circuit section 30 is accommodated in the inverter accommodating section 7 with the second case member 39 facing the bottom side of the inverter accommodating section 7. Then, the bolts 16 are inserted through the fourth mounting hole 371 of the first case member 37, the first mounting hole 317 of the first filter circuit board 31, the third mounting hole 357 of the resin member 35, the second mounting hole 337 of the second filter circuit board 33, and the fifth mounting hole 393 of the second case member 39 in this order, and are screwed into the screw holes formed in the filter mounting section 17. As a result, the first filter circuit board 31, the second filter circuit board 33, the resin member 35, the first case member 37, and the second case member 39 are fixed integrally within the inverter accommodating section 7.

[0058] When the installation of the inverter circuit section 20 and the filter circuit section 30 in the inverter accommodating section 7 is completed, the cover member 8 is fixed to the peripheral wall 73 of the inverter accommodating section 7 .

[0059] Here, in this embodiment, when the filter circuit section 30 is accommodated in the inverter accommodating section 7, the sheet-like first vibration-isolating member 18 is placed on the bottom of the inverter accommodating section 7, or the first vibration-isolating member 18 is attached to the outer surface of the second case member 39. When the filter circuit section 30 is accommodated in the inverter accommodating section 7, the sheet-like second vibration-isolating member 19 is attached to the outer surface of the first case member 37, or when the cover member 8 is fixed to the peripheral wall of the inverter accommodating section 7, the second vibration-isolating member 19 is attached to the outer surface of the first case member 37 or the inner surface of the cover member 8. As a result, the filter circuit section 30 is not only attached and fixed to the filter mounting section 17 by the bolts 16, but is also sandwiched between the bottom of the inverter accommodating section 7 and the cover member 8 with the first vibration-isolating member 18 interposed between the second case member 39 and the bottom of the inverter accommodating section 7 and the second vibration-isolating member 19 interposed between the first case member 37 and the cover member 8.

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

[0061] In the electric compressor 1 according to the embodiment, the filter circuit section 30 includes a first filter circuit board 31 having a plurality of electrolytic capacitors 51 mounted on one surface as the at least one first filter component, a second filter circuit board 33 having a normal mode choke coil 53, a common mode choke coil 55, etc. mounted on one surface as the at least one second filter component, and a plate-shaped resin member 35 (resin molded body) into which a pair of bus bars 351, 351 are inserted. The first filter circuit board 31, the second filter circuit board 33, and the resin member 35 are accommodated in the inverter accommodating section 7 with the other surface of the first filter circuit board 31 and the other surface of the second filter circuit board 33 facing each other with the resin member 35 sandwiched therebetween.

[0062] That is, in this embodiment, a plurality of filter components (electrolytic capacitor 51, normal mode choke coil 53, common mode choke coil 55, etc.) for electromagnetic noise countermeasures are distributed and mounted on two circuit boards (first filter circuit board 31, second filter circuit board 33), and these two circuit boards (first filter circuit board 31, second filter circuit board 33) can be arranged, for example, one above the other with resin member 35 sandwiched between them in inverter accommodating section 7. Therefore, even if the filter components are enlarged or the number of filter components is increased, the projected area of ​​the filter circuit board constituting filter circuit section 30 is prevented from increasing, and the projected area of ​​the inverter accommodating section 7 is prevented from increasing. Therefore, the installation location of electric compressor 1 is prevented from being limited, and noise caused by vibration of cover member 8 is prevented from increasing. In addition, first filter circuit board 31 and second filter circuit board 33 are reinforced by plate-shaped resin member 35, and the vibration resistance of filter circuit board and filter circuit section 30 is improved. Furthermore, since the electrolytic capacitor 51, the normal mode choke coil 53, and the common mode choke coil 55 are mounted on separate circuit boards, thermal interference therebetween is suppressed.

[0063] Each of the pair of bus bars 351, 351 has a first protruding portion 351a protruding from the resin member 35 to one side in the thickness direction of the resin member 35 and inserted into a corresponding first bus bar insertion hole 313 formed in the first filter circuit board 31, and a second protruding portion 351b protruding from the resin member 35 to the other side in the thickness direction of the resin member 35 and inserted into a corresponding second bus bar insertion hole 333 formed in the second filter circuit board 33, the first protruding portion 351a being soldered to the first filter circuit board 31, and the second protruding portion 351b being soldered to the second filter circuit board 33. Therefore, electrical connection between the first filter circuit board 31 and the second filter circuit board 33 can be realized relatively easily and with a compact structure.

[0064] Furthermore, the resin member 35 has a through hole 353 penetrating the resin member 35 in the thickness direction, and the bus bar 351 has a conductive portion 3511 extending within the through hole 353 in the axial direction of the through hole 353, one end forming a first protrusion 351a and the other end forming a second protrusion 351b, and a held portion 3513 extending across the conductive portion 3511 and having both ends embedded in the peripheral wall of the through hole 353 and held therein.

[0065] That is, most of the conductive portion 3511 of the bus bar 351 is located in the through hole 353, but is not in contact with the resin portion, and only both ends of the held portion 3513 are in contact with (embedded in) the resin portion. The both ends of the held portion 3513 are separated from the first protruding portion 351a and the second protruding portion 351b to be soldered. Therefore, the diffusion of heat generated when the first protruding portion 351a is soldered to the first filter circuit board 31 and the heat generated when the second protruding portion 351b is soldered to the second filter circuit board 33 is suppressed, and the solder quality is stabilized, and the resin portion is prevented from melting or deforming due to the heat generated when soldering. Particularly, in this embodiment, the bus bar 351 is formed in a cross shape by the conductive portion 3511 and the held portion 3513 that extend linearly. Therefore, bus bar 351 can be made smaller, bus bar 351 can be easily formed, and bus bar 351 can be stably held by main body portion 352.

[0066] Moreover, resin member 35 has an outer shape corresponding to the outer shape of first filter circuit board 31. Therefore, resin member 35 functions as an insulating wall between first filter circuit board 31 and second filter circuit board 33, and the insulation distance between first filter circuit board 31 and second filter circuit board 33 can be ensured.

[0067] In addition to the pair of bus bars 351, 351, a shielding plate 41 for shielding electromagnetic noise is inserted into the resin member 35. The shielding plate 41 is disposed inside the main body 352, that is, the shielding plate 41 is built into the resin member 35. This prevents malfunctions and the like caused by interference of radiation noise between the first filter circuit board 31 and the second filter circuit board 33.

[0068] Moreover, the first filter circuit board 31 is fixed to the one surface of the resin member 35 by thermal caulking, and the second filter circuit board 33 is fixed to the other surface of the resin member 35 by thermal caulking. Therefore, the first filter circuit board 31 and the second filter circuit board 33 can be integrated (modularized), and deterioration in the ease of assembling the filter circuit section 30 to the inverter accommodating section 7 caused by distributing and mounting the filter components on two circuit boards is suppressed.

[0069] Particularly, in this embodiment, a plurality of first pin portions 355 are provided on the one surface of the resin member 35, and a plurality of first pin insertion holes 311 corresponding to the plurality of first pin portions 355 are formed in the first filter circuit board 31. A plurality of second pin portions 356 are provided on the other surface of the resin member 35, and a plurality of second pin insertion holes 331 corresponding to the plurality of second pin portions 356 are provided in the second filter circuit board 33. Each of the plurality of first pin portions 355 is inserted into the corresponding first pin insertion hole 311 formed in the first filter circuit board 31, and the tip portions of each of the plurality of first pin portions 355 are thermally caulked, whereby the first filter circuit board 31 is fixed to the one surface of the resin member 35. Moreover, each of the multiple second pin portions 356 is inserted into a corresponding second pin insertion hole 331 formed in the second filter circuit board 33, and the tip portion of each of the multiple second pin portions 356 is thermally caulked, whereby the second filter circuit board 33 is fixed to the other surface of the resin member 35. Therefore, after the first filter circuit board 31 and the resin member 35 are appropriately aligned and the second filter circuit board 33 and the resin member 35 are appropriately aligned, the first filter circuit board 31, the second filter circuit board 33, and the resin member 35 can be integrated together.

[0070] Further, the small electronic components mounted on the other surface of the first filter circuit board 31 are accommodated in the recessed inner portion 352b on the one surface side of the main body portion 352 of the resin member 35, and the small electronic components mounted on the other surface of the second filter circuit board 33 are accommodated in the recessed inner portion 352b on the other surface side of the main body portion 352 of the resin member 35. That is, the one surface and the other surface of the resin member 35 each have a recess for accommodating a small electronic component. Therefore, the projected area of ​​the filter circuit board constituting the filter circuit section 30 is more effectively prevented from increasing, and the projected area of ​​the inverter accommodating section 7 is more effectively prevented from increasing. Also, interference with small electronic components such as the plurality of electrolytic capacitors 51, the normal mode choke coil 53, and the common mode choke coil 55 is also suppressed.

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

[0072] In the above embodiment, a plurality of electrolytic capacitors 51 are mounted on the one surface of the first filter circuit board 31, and a normal mode choke coil 53, a common mode choke coil 55, and the like are mounted on the one surface of the second filter circuit board 33. However, this is not limited to this. It is sufficient that a plurality of filter components for electromagnetic noise countermeasures are distributed and mounted on the first filter circuit board 31 and the second filter circuit board 33. Therefore, for example, opposite to the above embodiment, a normal mode choke coil 53, a common mode choke coil 55, and the like may be mounted on the one surface of the first filter circuit board 31, and a plurality of electrolytic capacitors 51 may be mounted on the one surface of the second filter circuit board 33.

[0073] In the above embodiment, bus bar 351 is formed in a cross shape by linearly extending conductive portion 3511 and held portion 3513. However, this is not limited to this. For example, conductive portion 3511 and / or held portion 3513 constituting bus bar 351 may be formed in a crank shape.

[0074] 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 board 31. However, this is not limited to this. It is sufficient that the resin member 35 is formed to have an outer shape corresponding to (substantially matching) at least one of the outer shapes of the first filter circuit board 31 and the second filter circuit board 33. Preferably, the first filter circuit board 31, the second filter circuit board 33, and the resin member 35 are formed so that their outer shapes are substantially matching.

[0075] In the above embodiment, the pair of bus bars 351, 351 and the shielding plate 41 are inserted into the resin member 35. However, this is not limited to the above, and the shielding plate 41 may be omitted. This is because there may be cases where the shielding plate 41 is not required, such as when the level of electromagnetic noise is relatively low. In this case, only the pair of bus bars 351, 351 are inserted into the resin member 35.

[0076] 7 and 8, in the filter circuit section 30, a sheet-like second heat dissipation member 43 may be disposed between the first filter circuit board 31 and the resin member 35, and a sheet-like third heat dissipation member 45 may be disposed between the second filter circuit board 33 and the resin member 35. In this case, preferably, the second heat dissipation member 43 is disposed on the inner side 352b on the one surface side of the main body 352 of the resin member 35 so as to be located in a range below the plurality of electrolytic capacitors 51, and the third heat dissipation member 45 is disposed on the inner side 352b on the other surface side of the main body 352 of the resin member 35 so as to be located in a range below the normal mode choke coil 53, the common mode choke coil 55, etc. In this way, heat generated by the electrolytic capacitor 51 and heat generated by the normal mode choke coil 53, the common mode choke coil 55, etc. can be efficiently dissipated.

[0077] Although the embodiments and modifications of the present invention have been described above, the present invention is not limited to the above-described embodiments and modifications, and it goes without saying that further modifications are possible based on the technical concept of the present invention. [Explanation of symbols]

[0078] 1...electric compressor, 2...rotating shaft, 3...motor, 4...compression mechanism, 5...housing, 6...inverter, 7...inverter accommodating section, 8...cover member, 11...first heat dissipation member, 18...first vibration-isolating member, 19...second vibration-isolating member, 20...inverter circuit section, 21...power switching element, 23...control circuit, 25...inverter control board, 30...filter circuit section, 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 dissipation member, 45...third heat dissipation member Heating member, 51...electrolytic capacitor, 53...normal mode choke coil, 55...common mode choke coil, 311...first pin insertion hole, 313...first bus bar insertion hole, 317...first mounting hole, 331...second pin insertion hole, 333...second bus bar insertion hole, 337...second mounting hole, 351...bus bar, 351a...first protrusion, 351b...second protrusion, 352...main body, 352a...periphery, 352b...inner part, 355...first pin portion, 356...second pin portion, 357...third mounting hole, 371...fourth mounting hole, 393...fifth mounting hole, R...resin

Claims

1. An electric compressor having a housing that accommodates a motor that rotates a rotary shaft and a compression mechanism that is driven by the rotation of the rotary shaft, and an inverter accommodating section that is integral with the housing and accommodates an inverter that drives the motor, the inverter has an inverter circuit section that supplies power to the motor and a filter circuit section that reduces electromagnetic noise, the filter circuit unit includes a first filter circuit board having at least one first filter component mounted on one surface thereof, a second filter circuit board having at least one second filter component mounted on one surface thereof, and a plate-shaped resin member into which a bus bar is inserted, the first filter circuit board, the second filter circuit board, and the resin member are accommodated in the inverter accommodating portion in a state in which the other surface of the first filter circuit board and the other surface of the second filter circuit board are disposed opposite to each other with the resin member interposed therebetween, the bus bar has a first protruding portion protruding from the resin member to one side in a thickness direction of the resin member and inserted into a first bus bar insertion hole formed in the first filter circuit board, and a second protruding portion protruding from the resin member to the other side in the thickness direction of the resin member and inserted into a second bus bar insertion hole formed in the second filter circuit board, the first protruding portion being soldered to the first filter circuit board, and the second protruding portion being soldered to the second filter circuit board. Electric compressor.

2. a through hole penetrating the resin member in the thickness direction is formed in the resin member; the bus bar has a conductive portion that extends within the through hole in an axial direction of the through hole, one end of which forms the first protruding portion and the other end of which forms the second protruding portion, and a held portion that extends intersecting the conductive portion and has both ends embedded in and held by a peripheral wall of the through hole. The electric compressor according to claim 1 .

3. The electric compressor according to claim 2 , wherein the bus bar is formed in a cross shape.

4. 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 board and an outer shape of the second filter circuit board.

5. 2. The electric compressor according to claim 1, wherein the resin member further includes a shielding plate inserted therein for shielding against electromagnetic noise.

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

7. a plurality of first pin portions are provided on the one surface of the resin member, and a plurality of second pin portions are provided on the other surface of the resin member, each of the plurality of first pin portions is inserted into a corresponding first pin insertion hole formed in the first filter circuit board, and a tip portion of the first pin portion is thermally caulked, thereby fixing the first filter circuit board to the one surface of the resin member; each of the second pin portions is inserted into a corresponding second pin insertion hole formed in the second filter circuit board, and a tip portion of the second pin portion is thermally caulked, thereby fixing the second filter circuit board to the other surface of the resin member; The electric compressor according to claim 6.

8. an electronic component smaller than the at least one first filter component is mounted on the other surface of the first filter circuit board, and an electronic component smaller than the at least one second filter component is mounted on the other surface of the second filter circuit board, A first recess is formed on one surface of the resin member to accommodate an electronic component smaller than the at least one first filter component, and a second recess is formed on the other surface of the resin member to accommodate an electronic component smaller than the at least one second filter component. The electric compressor according to claim 1 .

9. 2. The electric compressor according to claim 1, wherein a heat dissipation member is disposed between the other surface of the first filter circuit board and the resin member and between the other surface of the second filter circuit board and the resin member.

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