Motor compressor

Abstract

To provide an inverter type motor compressor for preventing damage to a circuit board when fixing the circuit board to a resin member while positioning it.SOLUTION: A resin member 35 receiving a first filter circuit board 31 on which a first filter component is mounted for reducing electromagnetic noise, is integrated with a plurality of first engagement members 355 that are elastically deformable and engage with a plurality of first engagement holes 311 formed on the first filter circuit board 31 with snap fit. The first engagement member 355 includes a plurality of engagement claws 355a arranged in axial symmetry while extending vertically to the plate surface of the resin member 35. The outer peripheral face of a front end TE1 of each engagement claw 355a is formed into a shape copying the inner face of a first engagement hole 311 of the first filter circuit board 31.SELECTED DRAWING: Figure 6

Description

[Technical field]

[0001] The present invention relates to an electric compressor that compresses a refrigerant. [Background technology]

[0002] Regarding an inverter-integrated electric compressor, as described in JP 2021-105363 A (Patent Document 1), an electric compressor is known that has a circuit board on which electronic components are mounted and a resin member on which the circuit board is placed and supported. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2021-105363 A Summary of the Invention [Problem to be solved by the invention]

[0004] In order to position and fix the circuit board relative to the resin member, it is possible to insert a plurality of pins provided in the resin member into pin insertion holes in the circuit board and thermally crimp the tips of the pins protruding from the circuit board. However, if the tips of the pins protruding from the circuit board are thermally crimped using, for example, a thermal crimping device, heat is transferred from the thermal crimping device to the circuit board, which may damage the circuit board.

[0005] SUMMARY OF THE PRESENT DISCLOSURE An object of the present invention is to provide an electric compressor with an integrated inverter in which the circuit board is not damaged when the circuit board is positioned and fixed to the resin member. [Means for solving the problem]

[0006] According to one aspect of the present invention, an electric compressor includes an electric motor, a rotating shaft rotated by the electric motor, a compression mechanism driven by the rotating shaft, and an inverter including an inverter circuit section that drives the electric motor and a noise filter circuit section that reduces electromagnetic noise. The noise filter circuit section includes a circuit board on which filter components are mounted, and a resin member that supports the circuit board. The resin member is integrated with a plurality of elastically deformable engaging members that engage with a plurality of engaging holes formed in the circuit board by snap-fitting. The engaging members include a plurality of engaging claws that are arranged axially symmetrically while extending perpendicularly to the plate surface of the resin member. The outer peripheral surfaces of the tips of the engaging claws are formed into a shape that follows the inner surfaces of the engaging holes in the circuit board.

[0007] According to another aspect of the present invention, an electric compressor includes an electric motor, a rotating shaft rotated by the electric motor, a compression mechanism driven by the rotating shaft, and an inverter including an inverter circuit section that drives the electric motor and a noise filter circuit section that reduces electromagnetic noise. The noise filter circuit section includes a first circuit board on which a first filter component is mounted, a second circuit board on which a second filter component is mounted, and a resin member arranged between the first circuit board and the second circuit board with the first filter component and the second filter component facing in opposite directions. The resin member is integrated with a plurality of elastically deformable first engagement members that engage with a plurality of first engagement holes formed in the first circuit board by snap-fitting, and a plurality of elastically deformable second engagement members that engage with a plurality of second engagement holes formed in the second circuit board by snap-fitting. Each of the first engagement member and the second engagement member includes a plurality of engagement claws that extend perpendicularly to the plate surface of the resin member and are arranged axially symmetrically. The outer circumferential surface of the tip of the engagement claw is formed into a shape that matches the inner surface of the first engagement hole of the first circuit board or the second engagement hole of the second circuit board. Effect of the Invention

[0008] According to the present invention, in an electric compressor with an integral inverter, it is possible to prevent the circuit board from being damaged when the circuit board is positioned and fixed to a resin member. [Brief description of the drawings]

[0009] [Figure 1] FIG. 1 is a vertical cross-sectional view showing an example of an inverter-integrated electric compressor. [Diagram 2] 2 is a perspective view showing an example of an inverter and an inverter accommodating portion; FIG. [Diagram 3] FIG. 2 is an exploded perspective view showing an example of a noise filter circuit section. [Figure 4] FIG. 2 is a perspective view illustrating an example of a resin member. [Diagram 5] 4 is an enlarged cross-sectional view of the periphery of a bus bar of a resin member. FIG. [Figure 6] FIG. 4 is a perspective view showing an example of an engagement member. [Figure 7] FIG. 4 is a vertical cross-sectional view showing an example of an engagement member. [Figure 8] FIG. 11 is a perspective view showing another example of the engaging member. [Figure 9] FIG. 11 is a vertical cross-sectional view showing another example of the engaging member. [Figure 10] FIG. 4 is an explanatory diagram of a mold for integrally molding an engaging member. [Figure 11] FIG. 2 is a plan view showing an example of a layout of a plurality of electrolytic capacitors. [Figure 12] FIG. 4 is a perspective view showing an example of a noise filter circuit unit and a heat dissipation sheet. [Figure 13] FIG. 11 is a plan view showing a first modified example of the layout of a plurality of electrolytic capacitors. [Figure 14] FIG. 13 is a plan view showing a second modified example of the layout of a plurality of electrolytic capacitors. [Figure 15] FIG. 11 is a cross-sectional view showing a modified example of the noise filter circuit portion. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Hereinafter, with reference to the attached drawings, an embodiment for carrying out the present invention will be described in detail. Note that the terms "first", "second", etc. used in the following description are merely used to distinguish similar elements, and do not limit the elements to which they are attached. In addition, the embodiment described below is merely an example, and should not be construed as being limited to the configuration.

[0011] 1 shows an example of an inverter-integrated electric compressor 1 to which the present invention can be applied. The electric compressor 1 is incorporated in a refrigerant circuit (not shown) of an air conditioner mounted on a vehicle, for example, and configured to compress and discharge a refrigerant.

[0012] The electric compressor 1 has an electric motor 2, a rotating shaft 3 rotated by the electric motor 2, a compression mechanism 4 driven by the rotating shaft 3, a housing 5 that accommodates the electric motor 2, the rotating shaft 3, and the compression mechanism 4, an inverter 6 that drives and controls the electric motor 2, an inverter accommodating section 7, and a cover member 8.

[0013] The electric motor 2 is, for example, a three-phase synchronous motor such as a brushless DC motor, and is driven by power supplied from an inverter 6. The rotating shaft 3 is rotatably supported in a housing 5 by bearings (not shown), and is rotated by the electric motor 2. The housing 5 has a cylindrical cross section, and accommodates the electric motor 2, the rotating shaft 3, and the compression mechanism 4. The electric motor 2, the rotating shaft 3, and the compression mechanism 4 are arranged concentrically inside the housing 5.

[0014] The inverter 6 has an inverter circuit section 20 that drives the electric motor 2 and a noise filter circuit section 30 that reduces electromagnetic noise. The inverter accommodating section 7 is provided integrally with the housing 5 and accommodates the inverter 6 therein. Specifically, the inverter accommodating section 7 is provided on the electric motor 2 side of the housing 5. 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 that rises from the periphery of the bottom wall 71, and has an opening 75 that faces the bottom wall 71. When the inverter circuit section 20 and the noise filter circuit section 30 that constitute the inverter 6 are accommodated in the inverter accommodating section 7, 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 a part of the housing 5) by bolts not shown.

[0015] An HV connector (high voltage connector) 9 for supplying DC power from an on-board battery (not shown) to the inverter circuit section 20 of the inverter 6 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 7 forms a partition wall 77 that separates the interior of the housing 5 from the interior of the inverter accommodating section 7.

[0016] 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 inside the housing 5 and the electric motor 2. The refrigerant that flows into the housing 5 from the inlet 5a passes through the electric motor 2 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.

[0017] 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 a refrigerant circuit of an air conditioner mounted on a vehicle. Therefore, the partition wall 77 and the electric motor 2 can be cooled by the refrigerant flowing into the housing 5 from the inlet 5a.

[0018] The inverter 6 will be further described with reference to Figures 1 and 2. Figure 2 is a perspective view showing the inverter 6 and the inverter accommodating section 7. As described above, the inverter 6 includes the inverter circuit section 20 that drives the electric motor 2, and the noise filter circuit section 30 that reduces electromagnetic noise.

[0019] 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 the power to the stator coil 2a of the electric motor 2 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.

[0020] 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 that faces 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 inside the inverter accommodating section 7.

[0021] The inverter control board 25 has a plurality of (seven in this example) mounting holes 25a. The inverter control board 25 is attached to a plurality of board mounting portions 15 provided inside the inverter accommodating portion 7 by a plurality of bolts (not shown). 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). For this reason, 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, thereby electrically connecting the six power switching elements 21 and the inverter control board 25.

[0022] The noise filter circuit section 30 is disposed between the inverter circuit section 20 and the HV connector 9. FIG.

[0023] 1 and 3, the noise filter circuit section 30 includes a first filter circuit board 31 and a second filter circuit board 33. The first filter circuit board 31 and the second filter circuit board 33 are given as an example of a circuit board, a first circuit board, or a second circuit board.

[0024] For electromagnetic noise countermeasures, a plurality of (here, nine) relatively large, cylindrical electrolytic capacitors 51 are mounted in an upright state on one surface of the first filter circuit board 31. Note that one surface of the first filter circuit board 31 is the top surface in Figs. 1 and 3, which faces the cover member 8 when the first filter circuit board 31 is accommodated in the inverter accommodating section 7. Here, the electrolytic capacitors 51 are given as an example of a filter component, a first filter component, or a second filter component.

[0025] Although not clearly shown in the drawings, the first filter circuit board 31 also has a plurality of electronic components mounted thereon that are smaller than the plurality of electrolytic capacitors 51. At least some of these small electronic components are mounted on the other surface of the first filter circuit board 31, more specifically, on the other surface of the first filter circuit board 31 at positions that avoid the area below the plurality of electrolytic capacitors 51. The other surface of the first filter circuit board 31 is the lower surface in FIGS. 1 and 3, and is the surface that faces the bottom of the inverter accommodating section 7 when the first filter circuit board 31 is accommodated in the inverter accommodating section 7.

[0026] For electromagnetic noise countermeasures, a relatively large normal mode choke coil 53, a common mode choke coil 55, an X capacitor, and a Y capacitor (not shown) are mounted on one surface of the second filter circuit board 33. Note that one surface of the second filter circuit board 33 is the lower surface in Figs. 1 and 3, which faces the bottom of the inverter accommodating section 7 when the second filter circuit board 33 is accommodated in the inverter accommodating section 7. Here, the normal mode choke coil 53 and the common mode choke coil 55 are given as an example of a filter component, a first filter component, or a second filter component.

[0027] Although not clearly shown in the figures, a plurality of electronic components smaller than the normal mode choke coil 53, the 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 of the second filter circuit board 33, more specifically, on the other surface of the second filter circuit board 33 at positions that avoid the area below the normal mode choke coil 53, the common mode choke coil 55, the X capacitor, and the Y capacitor. The other surface of the second filter circuit board 33 is the top surface in Figures 1 and 3, and is the surface that faces the cover member 8 when the second filter circuit board 33 is accommodated in the inverter accommodating section 7.

[0028] In the following, for simplicity of explanation, the normal mode choke coil 53, the common mode choke coil 55, the X capacitor, and the Y capacitor are simply abbreviated as "the normal mode choke coil 53 and the common mode choke coil 55."

[0029] The first filter circuit board 31 and the second filter circuit board 33 are electrically connected to each other and 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 plate-shaped resin member 35 sandwiched between them. Specifically, the first filter circuit board 31 and the second filter circuit board 33 are electrically connected to each other and are accommodated in the inverter accommodating section 7 in a state in which the other surface of the first filter circuit board 31 and the other surface of the second filter circuit board 33 are arranged back-to-back with the plate-shaped resin member 35 interposed between them. This will be described in detail below.

[0030] First, an example of the resin member 35 will be described with reference to Fig. 4. The resin member 35 includes a pair of bus bars 351 that electrically connect the first filter circuit board 31 and the second filter circuit board 33, a resin body 352 that holds the pair of bus bars 351, and a metal shielding plate 41 that is disposed inside the body 352 and blocks electromagnetic noise. In other words, the resin member 35 has the pair of bus bars 351 and incorporates the shielding plate 41. Specifically, the resin member 35 is formed as a plate-shaped resin molded body into which the pair of bus bars 351 and the shielding plate 41 are inserted. In addition, the resin member 35 is formed in a shape that follows the outer shape of the first filter circuit board 31 (an outer shape that is substantially the same as the outer shape).

[0031] The main body 352 of the resin member 35 is formed in a shape 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. In other words, both sides of the main body 352, i.e., both sides of the resin member 35, are formed in a shape in which the inner portions 352b are recessed relative to the peripheral portion 352a.

[0032] The pair of bus bars 351 are arranged at a predetermined interval on the peripheral portion 352a of the main body portion 352. Each of the pair of bus bars 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, and 4) 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, and 4).

[0033] 5 is a partially enlarged cross-sectional view of the resin member 35, showing the bus bar 351 and its surroundings. The bus bar 351 is formed as a cross-shaped terminal. 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, the conductive portion 3511 extending through the peripheral portion 352a of the main body portion 352 in the thickness direction, and a held portion 3513 extending intersecting the conductive portion 3511 and 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.

[0034] Specifically, a through hole 353 penetrating in the thickness direction is formed in a 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 within the through hole 353, with one end protruding from one side of the through hole 353 (upper side in FIG. 5) as a first protruding portion 351a, and the other end protruding from the other side of the through hole 353 (lower side in FIG. 5) as a second protruding portion 351b. The held portion 3513 extends in a direction perpendicular to the axial direction of the through hole 353, with both ends embedded in the peripheral wall of the through hole 353, i.e., in the main body portion 352, whereby the held portion 3513, and therefore the bus bar 351, are held by the main body portion 352.

[0035] That is, only both ends of held portion 3513 of busbar 351 are embedded in main body portion 352 (i.e., resin portion), and the other portion is exposed from main body portion 352. Furthermore, conductive portion 3511 of busbar 351 is not in contact with the peripheral wall of through hole 353, i.e., main body portion 352.

[0036] Although not particularly limited, the shielding plate 41 is formed in a shape generally following the shape of the inner portion 352b of the main body portion 352, as indicated by the dashed lines in FIGS.

[0037] The first filter circuit board 31 is attached to the resin member 35 in a state where the other surface on which the multiple electrolytic capacitors 51 are not mounted is placed and received on one surface (the upper surface in FIGS. 1, 3, and 4) of the resin member 35. Specifically, the first filter circuit board 31 is attached to the resin member 35 in a state where the other surface on which the multiple electrolytic capacitors 51 are not mounted is placed on a peripheral portion 352a on one surface side of the main body portion 352 of the resin member 35.

[0038] A plurality of elastically deformable first engagement members 355 are integrated with one surface of the resin member 35, protruding perpendicularly from the surface toward the first filter circuit board 31 and engaging by snap-fit ​​with a plurality (four in this case) of first engagement holes 311 (details of which will be described later) formed in the first filter circuit board 31. Specifically, the plurality of first engagement members 355 are erected on one surface of the main body portion 352 of the resin member 35 at intervals from one another in the circumferential direction of the peripheral edge portion 352a. The first engagement holes 311 are one example of an engagement hole or a first engagement hole.

[0039] Further, a plurality of first engagement holes 311 are formed in the vicinity of the peripheral edge of first filter circuit board 31 at locations corresponding to the plurality of first engagement members 355 of resin member 35 so as to receive these first engagement members 355. Then, each of first engagement members 355 of resin member 35 is inserted into and engaged with first engagement holes 311 of first filter circuit board 31, so that first filter circuit board 31 is fixed to resin member 35. Details of first engagement members 355 will be described later.

[0040] The first filter circuit board 31 is formed with a pair of first busbar insertion holes 313 that receive the pair of busbars 351 of the resin member 35. Then, first protruding portions 351a of the pair of busbars 351 of the resin member 35 are inserted into the pair of first busbar insertion holes 313 of the first filter circuit board 31, and the first protruding portions 351a of the busbars 351 protruding from the first busbar insertion holes 313 are solder-joined to the first filter circuit board 31. This electrically connects the pair of busbars 351 of the resin member 35 and the first filter circuit board 31. The first busbar insertion holes 313 are an example of a busbar insertion hole.

[0041] As described above, the first protrusion 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. In the busbar 351, only both ends of the held portion 3513 located away from the first protrusion 351a are embedded in the main body portion 352. This suppresses the diffusion of heat generated when the first protrusion 351a is soldered to the first filter circuit board 31, resulting in stable solder quality. In addition, for example, the main body portion 352 is suppressed from being melted or deformed due to the heat generated when the first protrusion 351a is soldered to the first filter circuit board 31.

[0042] Note that a pair of bus bars 351 of resin member 35 may be provided with spring members (not shown) so as to be electrically connected by press-fitting into first bus bar insertion holes 313 of first filter circuit board 31. In this way, soldering for establishing electrical connection between bus bars 351 and first filter circuit board 31 can be eliminated.

[0043] 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 and the common mode choke coil 55 are not mounted is placed on and received by the other surface (the lower surface in FIGS. 1, 3, and 4) 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 and the common mode choke coil 55 are not mounted is placed on the peripheral portion 352a on the other surface side of the main body 352 of the resin member 35.

[0044] On the other surface of the resin member 35, similarly to the one surface of the resin member 35, a plurality of elastically deformable second engagement members 356 are integrally formed, which protrude vertically from the one surface of the resin member 35 toward the second filter circuit board 33 and engage with a plurality (four in this case) of second engagement holes 331 (details of which will be described later) formed in the second filter circuit board 33 by snap-fitting. However, only two of them are shown in FIG. 4. Specifically, the plurality of second engagement members 356 are erected on the other surface of the main body portion 352 of the resin member 35 at intervals from each other in the circumferential direction of the peripheral edge portion 352a. Here, the second engagement member 356 is disposed coaxially with the first engagement member 355 with respect to the plate surface of the main body portion 352 of the resin member 35. That is, the first engagement member 355 and the second engagement member 356 are disposed coaxially with respect to the plate surface of the main body portion 352 of the resin member 35.

[0045] Further, a plurality of second engagement holes 331 are formed in the vicinity of the peripheral edge of second filter circuit board 33 at locations corresponding to the plurality of second engagement members 356 of resin member 35 so as to receive these members. Then, each of second engagement members 356 of resin member 35 is inserted into and engaged with second engagement holes 331 of second filter circuit board 33, so that second filter circuit board 33 is fixed to resin member 35. Details of second engagement members 356 will be described later.

[0046] The second filter circuit board 33 is formed with a pair of second busbar insertion holes 333 that receive the pair of busbars 351 of the resin member 35. The second protruding portions 351b of the pair of busbars 351 of the resin member 35 are inserted into the pair of second busbar insertion holes 333 of the second filter circuit board 33, and the second protruding portions 351b of the busbars 351 protruding from the second busbar insertion holes 333 are solder-joined to the second filter circuit board 33. This electrically connects the pair of busbars 351 of the resin member 35 and the second filter circuit board 33. The second busbar insertion holes 333 are an example of a busbar insertion hole.

[0047] Here, as described above, the second protrusion 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. In the busbar 351, only both ends of the held portion 3513 located away from the second protrusion 351b are embedded in the main body portion 352. This suppresses the diffusion of heat when the second protrusion 351b is soldered to the second filter circuit board 33, resulting in stable solder quality. In addition, for example, the main body portion 352 is suppressed from melting or deforming due to the heat when the second protrusion 351b is soldered to the second filter circuit board 33.

[0048] 6 and 7, the first engagement member 355 has two engagement claws 355a arranged axially symmetrically while extending perpendicularly to the plate surface of the main body 352 of the resin member 35. Each of the two engagement claws 355a has a rectangular cross-sectional portion that rises perpendicularly from the plate surface of the main body 352 of the resin member 35 and a triangular tip portion TE1 that bulges outward from the rectangular cross-sectional portion. In a free state, the outer circumferential surfaces of the tip portions TE1 of the two engagement claws 355a are formed in a shape that conforms to the inner surface of the first engagement hole 311 of the first filter circuit board 31, that is, in a circular arc shape that conforms to the inner surface of the first engagement hole 311. Here, the free state refers to a state in which no external force other than gravity is acting on the first engagement member 355.

[0049] Therefore, in the process of the first engagement member 355 engaging with the first engagement hole 311, the entire surfaces of the tip portions TE1 of the two engagement claws 355a come into contact with the inner surface of the first engagement hole 311, and the tip portions TE1 of the two engagement claws 355a are elastically deformed so as to approach each other by the force of pushing the first engagement member 355 into the first engagement hole 311. Therefore, the force of pushing the first engagement member 355 into the first engagement hole 311 can be efficiently used to easily and effortlessly engage the first engagement member 355 with the first engagement hole 311 of the first filter circuit board 31. Note that, in a state in which the first engagement member 355 is completely engaged with the first engagement hole 311, the tip portions TE1 of the two engagement claws 355a penetrate the first engagement hole 311, and the two engagement claws 355a return to their natural state by elasticity, so that the engagement state between the two is not easily released. Here, when releasing the engagement of the first engagement member 355 with the first engagement hole 311 of the first filter circuit board 31, for example, an external force may be used to deform the tip ends TE1 of the two engagement claws 355a so that they approach each other, and in that state, the first engagement member 355 may be pulled out of the first engagement hole 311.

[0050] Furthermore, a base end portion of the first engagement member 355 is integrated with a seat 355b for receiving the first filter circuit board 31. The shape of the seat 355b is not limited to a cylindrical shape as shown in Fig. 6, and may be any shape, such as a triangular prism or a square prism.

[0051] The second engagement member 356, like the first engagement member 355, has two engagement claws 356a arranged axially symmetrically while extending perpendicularly to the plate surface of the main body 352 of the resin member 35. Each of the two engagement claws 356a has a rectangular cross-sectional portion that rises perpendicularly from the plate surface of the main body 352 of the resin member 35 and a triangular tip portion TE2 that bulges outward from the rectangular cross-sectional portion. The outer peripheral surface of the tip portion TE2 of the two engagement claws 356a is formed in a shape following the inner surface of the second engagement hole 331 of the second filter circuit board 33 in a free state, that is, in a circular arc shape following the inner surface of the second engagement hole 331. In addition, a base end portion of the second engagement member 356 is integrated with a seat 356b that receives the second filter circuit board 33. The seat 356b is not limited to a cylindrical shape as shown in FIG. 6, and can be any shape, such as a triangular prism shape or a square prism shape. The action and effect of the second engagement member 356 are similar to those of the first engagement member 355, and therefore detailed description thereof will be omitted. Please refer to the action and effect of the first engagement member 355 if necessary.

[0052] The two engagement claws 355a of the first engagement member 355 and the two engagement claws 356a of the second engagement member 356 are arranged with a phase difference of 90° around an axis perpendicular to the plate surface of the main body 352 of the resin member 35. Therefore, when the first engagement member 355 engages with the first engagement hole 311 of the first filter circuit board 31 and the second engagement member 356 engages with the second engagement hole 331 of the second filter circuit board 33, the resin member 35 is positioned with respect to the first filter circuit board 31 and the second filter circuit board 33.

[0053] In addition, when the first engaging member 355 and the second engaging member 356 are not arranged coaxially or the noise filter circuit section 30 includes only one circuit board, the first engaging member 355 (or the second engaging member 356) may be configured as follows. That is, as shown in FIG. 8, the first engaging member 355 includes four engaging claws 355a arranged axially symmetrically while extending perpendicularly to the plate surface of the main body 352 of the resin member 35. Other configurations of the first engaging member 355 are similar to those described above, and detailed description thereof will be omitted. Here, the number of engaging claws 355a of the first engaging member 355 is not limited to four, and may be three or five or more. In this way, when the first engaging member 355 engages with the first engaging hole 311 of the first filter circuit board 31 by snap-fitting, the first filter circuit board 31 and the resin member 35 can be positioned by the three or more engaging claws 355a of the first engaging member 355. In addition, since the second engagement member 356 has a similar configuration to the first engagement member 355, a detailed description thereof will be omitted.

[0054] In the first engaging member 355 (similarly to the second engaging member 356) as shown in FIG. 8, since no other engaging members are arranged coaxially sandwiching the resin member 35, a die-cut hole 355c may be formed in the base 355b at a portion overlapping the tip TE1 of the engaging claw 355a when viewed from the perpendicular direction of the plate surface of the main body 352 of the resin member 35. The die-cut hole 355c penetrates from one surface to the other surface of the main body 352 of the resin member 35, as shown in FIG. 9. In this way, when the first engaging member 355 is integrally molded using the separable first mold MLD1 and second mold MLD2, as shown in FIG. 10, the first mold MLD1 and the second mold MLD2 can be demolded in one direction in the direction in which the engaging claw 355a of the first engaging member 355 extends. This eliminates the need for a slide mold that complicates the mold, and reduces the cost of the mold.

[0055] In this manner, the first filter circuit board 31 and the second filter circuit board 33 are integrated by the resin member 35, and the first filter circuit board 31 and the second filter circuit board 33 are electrically connected. Therefore, when the first filter circuit board 31 and the second filter circuit board 33 are attached to the resin member 35, thermal caulking is not required, and thus the thermal influence on the first filter circuit board 31 and the second filter circuit board 33 can be avoided. In addition, as described above, by devising the shapes of the tip portions of the first engagement member 355 and the second engagement member 356, the engagement with the first engagement hole 311 of the first filter circuit board 31 and the second engagement hole 331 of the second filter circuit board 33 can be easily and effortlessly performed. For this reason, when the first filter circuit board 31 and the second filter circuit board 33 are positioned and fixed to the resin member 35, they can be prevented from being damaged.

[0056] The noise filter circuit section 30 further includes a first case member 37 and a second case member 39.

[0057] The first case member 37 is formed of, for example, hard resin. The first case member 37 is attached to one surface of the first filter circuit board 31, and is configured to accommodate and cover the nine electrolytic capacitors 51 mounted on one surface of the first filter circuit board 31. The first case member 37 is attached to the one surface of the first filter circuit board 31 in the following manner.

[0058] First, a predetermined amount of resin R in a softened or molten state is filled inside the first case member 37. Next, while the first filter circuit board 31 and the first case member 37 are aligned, the first case member 37 is pressed against 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 pins (not shown) provided on the first case member 37 into the pin insertion hole 315a and the pin insertion long hole 315b formed in the first filter circuit board 31. Thereafter, the resin R filled inside the first case member 37 is hardened. In this manner, the first case member 37 is fixed to one surface of the first filter circuit board 31. Also, the gaps inside the first case member 37, that is, the gaps between the multiple electrolytic capacitors 51 and the gaps between the electrolytic capacitors 51 and the first case member 37, are filled with the resin R. It is preferable that the resin R be a heat-resistant thermoplastic resin or a thermosetting resin.

[0059] Here, the upper surface of the first case member 37, i.e., the surface located distal to the first filter circuit board 31, is formed into a shape corresponding to the layout of the nine electrolytic capacitors 51 mounted on one surface of the first filter circuit board 31. As shown in Fig. 11, the nine electrolytic capacitors 51 are divided into three rows of groups of three, and the groups on both sides of the middle row are arranged at positions offset from the middle group by half the arrangement interval between two adjacent electrolytic capacitors 51 in the middle group. In this case, one surface of the first case member 37 seen from the mounting direction of the multiple electrolytic capacitors 51 on the first filter circuit board 31 is formed into a pentagon in which the outlines of the multiple electrolytic capacitors 51 are connected by straight lines.

[0060] In short, the layout of the nine electrolytic capacitors 51 may be devised so that one surface of the first case member 37 viewed from the mounting direction of the multiple electrolytic capacitors 51 on the first filter circuit board 31 is formed into a pentagon with straight lines connecting the contours of the multiple electrolytic capacitors 51. The same applies to other layouts of the nine electrolytic capacitors 51 (details of which will be described later).

[0061] The second case member 39 is formed of, for example, hard resin, similar to the first case member 37. The second case member 39 is configured to be attached to the other surface of the second filter circuit board 33, thereby housing and covering the normal mode choke coil 53 and the common mode choke coil 55 mounted on one surface of the second filter circuit board 33. Similarly to the first case member 37, the second case member 39 is attached to one surface of the second filter circuit board 33 in the following manner.

[0062] First, a predetermined amount of resin R in a softened or molten state is filled inside the second case member 39. Next, while the second filter circuit board 33 and the second case member 39 are aligned, the second case member 39 is pressed against 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 pin parts 391 provided on the second case member 39 into the pin insertion hole 335a and the pin insertion long hole 335b formed in the second filter circuit board 33. Thereafter, the resin R filled inside the second case member 39 is hardened. In this manner, the second case member 39 is fixed to one surface of the second filter circuit board 33. Also, the gaps inside the second case member 39, that is, the gaps between the components such as the normal mode choke coil 53 and the common mode choke coil 55 and the gaps between these components and the second case member 39, are filled with the resin R.

[0063] 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, the noise 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 these are integrated to form a module.

[0064] Such a noise filter circuit section 30 is fixed to a filter attachment section 17 provided inside the inverter accommodating section 7 by a plurality of bolts 16 (only one of which is shown in FIG. 1).

[0065] Specifically, 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 example) corresponding mounting holes formed therein. That is, the first filter circuit board 31 has four first mounting holes 317 formed therein, and the second filter circuit board 33 has four second mounting holes 337 formed therein. Furthermore, the resin member 35 has four third mounting holes 357 formed therein, the first case member 37 has four fourth mounting holes 371 formed therein, and the second case member 39 has four fifth mounting holes 393 formed therein. Here, the third mounting holes 357, the fourth mounting holes 371, and the fifth mounting holes 393 may be formed by metallic cylindrical sleeves inserted during molding.

[0066] The noise filter circuit section 30 is accommodated in the inverter accommodating section 7 with the second case member 39 facing the bottom 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 inside the inverter accommodating section 7.

[0067] Then, when the installation of the inverter circuit section 20 and the noise filter circuit section 30 in the inverter accommodating section 7 is completed, the cover member 8 is attached to the peripheral wall 73 of the inverter accommodating section 7 .

[0068] Here, as shown in FIG. 12, a first heat dissipation sheet 18 is attached to one surface of the first case member 37 of the noise filter circuit section 30 to increase the amount of heat transferred from the noise filter circuit section 30 to the cover member 8 and improve heat dissipation. When one surface of the first case member 37 is formed in a pentagon as shown in FIG. 11, the first heat dissipation sheet 18 attached thereto can also be formed in a pentagon. That is, the first heat dissipation sheet 18 can be formed in a shape following the shape of one surface of the first case member 37. In this way, the first heat dissipation sheet 18 has a simple shape, so that when cutting out a plurality of first heat dissipation sheets 18 from a large heat dissipation sheet, the portion to be discarded can be reduced. In addition, since the two corners of the pentagon have an angle of 90°, the reference for the attachment position of the first heat dissipation sheet 18 to the first case member 37 becomes clear, making it easier for an operator to attach the sheet, and also enabling automation of the attachment work by a robot or the like.

[0069] A second heat dissipation sheet 19 is attached to one surface of the second case member 39 of the noise filter circuit section 30, that is, the surface facing the bottom of the inverter accommodating section 7, to improve heat dissipation by increasing the amount of heat transferred from the noise filter circuit section 30 to the bottom of the inverter accommodating section 7. The second heat dissipation sheet 19 can be shaped to match the shape of one surface of the second case member 39.

[0070] In this manner, the noise filter circuit section 30 is sandwiched between the bottom of the inverter accommodating section 7 and the cover member 8, with the first heat dissipation sheet 18 being interposed between the first case member 37 and the cover member 8, and the second heat dissipation sheet 19 being interposed between the second case member 39 and the bottom of the inverter accommodating section 7. Therefore, the heat generated in the noise filter circuit section 30 is efficiently transferred to the cover member 8 and the bottom of the inverter accommodating section 7 through the first heat dissipation sheet 18 and the second heat dissipation sheet 19, and dissipated from the outer surface, thereby improving the heat dissipation performance of the noise filter circuit section 30. At this time, the bottom wall 71 is cooled by the refrigerant flowing into the housing 5 from the inlet 5a, thereby further improving the heat dissipation performance of the noise filter circuit section 30.

[0071] One surface of the first case member 37 of the noise filter circuit section 30 is not limited to a pentagon, and may be a polygon as shown in Fig. 13 and Fig. 14. In short, the layout of the nine electrolytic capacitors 51 may be devised so that one surface of the first case member 37 viewed from the mounting direction of the multiple electrolytic capacitors 51 on the first filter circuit board 31 is formed into a polygon in which the outlines of the multiple electrolytic capacitors 51 are connected by straight lines.

[0072] 13, if the nine electrolytic capacitors 51 mounted on one surface of the first filter circuit board 31 are arranged within the range of a trapezoid, one surface of the first case member 37 can be made into a trapezoid following this. Also, as shown in FIG. 14, if the nine electrolytic capacitors 51 arranged on one surface of the first filter circuit board 31 are arranged within the range of an approximate parallelogram, one surface of the first case member 37 can be made into an approximate parallelogram following this. However, in the case of an approximate parallelogram as shown in FIG. 14, it is desirable that, for example, two acute corners have 90° in order to clarify the standard for attaching the first heat dissipation sheet 18 to the first case member 37. Although not shown, if the nine electrolytic capacitors 51 mounted on one surface of the first filter circuit board 31 are arranged within the range of a square, one surface of the first case member 37 can be made into a square following this.

[0073] In short, by devising a layout of the multiple electrolytic capacitors 51, one surface of the first case member 37 can be made into a polygon having at least two corners at 90°. When one surface of the first case member 37 is formed into a polygon having at least two corners at 90°, the first heat dissipation sheet 18 attached thereto can be formed into a shape following that polygon.

[0074] In addition to the effects described above, the electric compressor 1 according to this embodiment can achieve the following effects.

[0075] In the electric compressor 1, the noise filter circuit section 30 includes a first filter circuit board 31 on which a plurality of electrolytic capacitors 51 are mounted, and a second filter circuit board 33 on which a normal mode choke coil 53 and a common mode choke coil 55 are mounted. The first filter circuit board 31 and the second filter circuit board 33 are electrically connected to each other and are housed in the inverter accommodating section 7 in a back-to-back state with a plate-shaped resin member 35 sandwiched therebetween.

[0076] That is, a plurality of electrolytic capacitors 51, a normal mode choke coil 53, and a common mode choke coil 55 for electromagnetic noise countermeasures are distributed and mounted on the first filter circuit board 31 and the second filter circuit board 33, and the first filter circuit board 31 and the second filter circuit board 33 are arranged above and below with the resin member 35 sandwiched therebetween. Therefore, even if the noise filter circuit section 30 is enlarged or the number of parts is increased, the projected area of ​​the filter circuit board constituting the noise filter circuit section 30, in other words, the projected area of ​​the inverter accommodating section 7 is prevented from increasing. Therefore, the installation location of the electric compressor 1 is restricted, and the noise caused by the vibration of the cover member 8 is prevented from increasing. In addition, since the plurality of electrolytic capacitors 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.

[0077] In particular, a plurality of electrolytic capacitors 51 are mounted on one surface of the first filter circuit board 31, and a normal mode choke coil 53 and a common mode choke coil 55 are mounted on one surface of the second filter circuit board 33. The other surface of the first filter circuit board 31 and the other surface of the second filter circuit board 33 are accommodated in the inverter accommodating section 7 in a state in which they are arranged to face each other with the resin member 35 in between. Therefore, the first filter circuit board 31 and the second filter circuit board 33 are each reinforced by the plate-shaped resin member 35, thereby improving the earthquake resistance of the filter circuit boards, in other words, the noise filter circuit section 30.

[0078] Moreover, the resin member 35 has a pair of metallic bus bars 351 that electrically connect the first filter circuit board 31 and the second filter circuit board 33, and also has a built-in shielding plate 41 that blocks electromagnetic noise. Therefore, there is no need to separately prepare a part that electrically connects the first filter circuit board 31 and the second filter circuit board 33, and a compact and stable connection between the first filter circuit board 31 and the second filter circuit board 33 can be realized. As a result, malfunctions caused by interference due to radiation noise between the first filter circuit board 31 and the second filter circuit board 33 can be prevented.

[0079] Furthermore, resin member 35 has a shape following 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.

[0080] The first filter circuit board 31 is fixed to one surface of the resin member 35 by a first engagement member 355, and the second filter circuit board 33 is fixed to the other surface of the resin member 35 by a second engagement member 356. Therefore, the first filter circuit board 31 and the second filter circuit board 33 can be integrated into a module, and deterioration in the ease of mounting the noise filter circuit section 30 to the inverter accommodating section 7 caused by distributing and mounting a plurality of filter components on two circuit boards is suppressed.

[0081] Furthermore, a mounting space for small electronic components mounted on the other surface of the first filter circuit board 31 is secured by receiving the first filter circuit board 31 on the seat 355b of the first engagement member 355. A mounting space for small electronic components mounted on the other surface of the second filter circuit board 33 is secured by receiving the second filter circuit board 33 on the seat 356b of the second engagement member 356. Therefore, by appropriately setting the height of the seat 355b of the first engagement member 355 and the height of the seat 356b of the second engagement member 356 in accordance with the small electronic components, the noise filter circuit section 30 is miniaturized while securing the mounting space for the small electronic components.

[0082] 15, in the noise filter circuit section 30, a third heat dissipation sheet 43 may be disposed between the first filter circuit board 31 and the resin member 35, and a fourth heat dissipation sheet 45 may be further disposed between the second filter circuit board 33 and the resin member 35. In this case, the third heat dissipation sheet 43 and the fourth heat dissipation sheet 45 may each be shaped to cover at least the range of the heat-generating electronic components. In this way, heat generated in the multiple electrolytic capacitors 51, the normal mode choke coil 53, and the common mode choke coil 55 can be efficiently dissipated.

[0083] In the above embodiment, the housing 5 and the inverter accommodating portion 7 are integrally molded, but it is sufficient that the inverter accommodating portion 7 is provided integrally with the housing 5. For example, the housing 5 and the inverter accommodating portion 7 may be formed separately and then combined into an integrated body.

[0084] In the above embodiment, the plurality of electrolytic capacitors 51 are mounted on one surface of the first filter circuit board 31, and the normal mode choke coil 53 and the common mode choke coil 55 are mounted on one surface of the second filter circuit board 33. However, the present invention is not limited to this configuration, and the normal mode choke coil 53 and the common mode choke coil 55 may be mounted on one surface of the first filter circuit board 31, and the plurality of electrolytic capacitors 51 may be implemented on one surface of the second filter circuit board 33. However, when adopting such a configuration, in the noise filter circuit section 30, the other surface of the second case member 39, i.e., the surface facing the bottom of the inverter accommodating section 7, needs to be formed into a polygonal shape according to the arrangement of the plurality of electrolytic capacitors 51. In addition, the first heat dissipation sheet 18 is disposed between the first case member 37 and the bottom of the inverter accommodating section 7, and the second heat dissipation sheet 19 is disposed between the second case member 39 and the cover member 8.

[0085] Furthermore, in the above embodiment, the resin member 35 has a pair of metallic bus bars 351 that electrically connect the first filter circuit board 31 and the second filter circuit board 33, and also has a metallic shielding plate 41 built-in that blocks electromagnetic noise. However, the present invention is not limited to this configuration, and the first filter circuit board 31 and the second filter circuit board 33 may be electrically connected by a component other than the bus bars 351, and the shielding plate 41 may be omitted when the level of electromagnetic noise is relatively low.

[0086] Furthermore, in the above embodiment, the resin member 35 is formed into a shape following the outer shape of the first filter circuit board 31. However, this is not limited to the configuration, and the resin member 35 may be formed into a shape following the outer shape of at least one of the first filter circuit board 31 and the second filter circuit board 33. Desirably, 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 approximately the same.

[0087] Additionally, in the above embodiment, nine electrolytic capacitors 51 are mounted on the first filter circuit board 31 of the noise filter circuit section 30, but the number of electrolytic capacitors 51 is not limited to nine and may be any multiple. However, the multiple electrolytic capacitors 51 need to be accommodated within a polygon whose outline is connected by straight lines, specifically, a polygon with at least two corners having 90° angles.

[0088] Furthermore, a person skilled in the art will easily understand that new embodiments can be created by omitting parts of the technical ideas of the various above-mentioned embodiments, combining parts of them appropriately, or replacing parts of them with well-known technology. [Explanation of symbols]

[0089] REFERENCE SIGNS LIST 1...electric compressor, 2...electric motor, 3...rotating shaft, 4...compression mechanism, 6...inverter, 20...inverter circuit section, 30...noise filter circuit section, 31...first filter circuit board (circuit board, first circuit board, second circuit board), 33...second filter circuit board (circuit board, first circuit board, second circuit board), 35...resin member, 51...electrolytic capacitor (filter component, first filter component, second filter component), 53...normal mode choke coil (filter component, first filter component, second filter component), 55...common mode choke Coil (filter component, first filter component, second filter component), 311...first engagement hole (engagement hole, first engagement hole), 313...first bus bar insertion hole (bus bar insertion hole), 333...second bus bar insertion hole (bus bar insertion hole), 351...bus bar, 355...first engagement member (engagement member, first engagement member), 355a...engagement claw, 355b...base, 355c...punch hole, 331...second engagement hole (engagement hole, second engagement hole), 356...second engagement member (engagement member, second engagement member), 356a...engagement claw, 356b...base, TE1...tip portion, TE2...tip portion

Claims

1. An electric motor; A rotating shaft rotated by the electric motor; a compression mechanism driven by the rotating shaft; an inverter including an inverter circuit unit that drives the electric motor and a noise filter circuit unit that reduces electromagnetic noise; An electric compressor having the noise filter circuit section includes a circuit board on which a filter component is mounted, and a resin member that supports the circuit board, the resin member is integrated with a plurality of elastically deformable engaging members that are engaged by snap-fitting with a plurality of engaging holes formed in the circuit board; the engaging member includes a plurality of engaging claws that are arranged axially symmetrically and extend perpendicularly to a plate surface of the resin member, The outer peripheral surface of the tip of the engagement claw is formed into a shape conforming to the inner surface of the engagement hole of the circuit board. Electric compressor.

2. A base for receiving the circuit board is integrated into the base end of the engagement member. The electric compressor according to claim 1 .

3. A die-cut hole is formed in the base at a portion overlapping the tip of the engagement claw when viewed from a direction perpendicular to the plate surface of the resin member. The electric compressor according to claim 2.

4. An electric motor; A rotating shaft rotated by the electric motor; a compression mechanism driven by the rotating shaft; an inverter including an inverter circuit unit that drives the electric motor and a noise filter circuit unit that reduces electromagnetic noise; An electric compressor having the noise filter circuit section includes a first circuit board on which a first filter component is mounted, a second circuit board on which a second filter component is mounted, and a resin member disposed between the first circuit board and the second circuit board with the first filter component and the second filter component facing in opposite directions, the resin member is integrated with a plurality of elastically deformable first engagement members which are engaged by snap-fitting with a plurality of first engagement holes formed in the first circuit board, and a plurality of elastically deformable second engagement members which are engaged by snap-fitting with a plurality of second engagement holes formed in the second circuit board, each of the first engaging member and the second engaging member includes a plurality of engaging claws that are arranged axially symmetrically and extend perpendicularly to a plate surface of the resin member; The outer peripheral surface of the tip of the engagement claw is formed into a shape following the inner surface of the first engagement hole of the first circuit board or the second engagement hole of the second circuit board. Electric compressor.

5. a base end portion of the first engaging member and a base end portion of the second engaging member are integrated with a base for receiving the first circuit board and the second circuit board, respectively; The electric compressor according to claim 4.

6. The engagement claws of the first engagement member and the engagement claws of the second engagement member are disposed at a relative angle of 90° around an axis perpendicular to a plate surface of the resin member. The electric compressor according to claim 4.

7. The first engaging member and the second engaging member are arranged coaxially with respect to a plate surface of the resin member. The electric compressor according to claim 4.

8. the first circuit board and the second circuit board are electrically connected to each other by press-fitting a spring member attached to a bus bar provided on the resin member into a bus bar insertion hole of the first circuit board or a bus bar insertion hole of the second circuit board. The electric compressor according to claim 4.

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