Electric compressor and method for manufacturing the same

Abstract

To provide an electric compressor that can improve the ease of installation of busbar units. [Solution] The busbar unit 26 is provided on the motor room side and comprises a busbar that electrically connects the magnet wire coming out of the motor to the three-phase terminal 33, and the three-phase terminal 33 is molded with a resin part. The busbar unit 26 has a winding connection part 41 to which the lead portion 23A of the magnet wire is connected, and the lead portion 23A is connected to the winding connection part 41 with a predetermined margin in its length dimension. The busbar unit 26 is fixed to the partition wall 10 from the inverter room side by bolts 71 that are screwed into the busbar unit 26, and the three-phase terminal 33 passes through the through hole 51 and faces the inverter room.

Description

Technical Field

[0001] The present invention relates to an electric compressor that electrically connects a motor and an inverter by means of a three-phase terminal penetrating through a partition wall of a casing, and a method for manufacturing the same.

Background Art

[0002] Conventionally, a motor for driving a compression element of an electric compressor is composed of a stator and a rotor that rotates inside the stator. Among these, the stator is composed of a core formed by laminating electromagnetic steel sheets, a plurality of teeth protruding from the core in the inner diameter direction, and magnet wires wound around each tooth. Since the core and the magnet wires need to be insulated, an insulator made of an insulating resin is provided at the end of the core, and the magnet wires are wound around this insulator to achieve insulation between the core and the magnet wires.

[0003] Also, a busbar unit in which a metal busbar and a three-phase terminal (a terminal connected to an inverter) are resin-molded is attached to the end (lead side) of the stator, and the magnet wires emerging from each slot of the stator are electrically connected to the three-phase terminal by the busbar. In this case, the busbar unit was fixed to the motor by engaging it with the core of the stator.

[0004] On the other hand, the inside of the casing of the electric compressor is partitioned into a motor chamber and an inverter chamber by a partition wall. The motor is fixed in the motor chamber, and the inverter is attached to the inverter chamber. And the three-phase terminal of the busbar unit is inserted from the motor chamber side into a through-hole formed in the partition wall, and its tip faces the inverter chamber and is configured to be electrically connected to the inverter (for example, see Patent Document 1).

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

[0006] However, if the busbar unit is fixed to the motor in a way that prevents it from moving, as described in Patent Document 1 above, the degree of freedom of position is lost. Therefore, it is necessary to position the busbar unit on both the busbar unit side and the motor side of the casing, and when assembling it into through holes formed in the partition walls of the casing or at the connection points of the inverter, high positional accuracy and dimensional accuracy of the parts are required, which leads to problems with ease of installation.

[0007] The present invention was made to solve the aforementioned conventional technical problems, and aims to provide an electric compressor that can improve the ease of installation of a busbar unit, and a method for manufacturing the same. [Means for solving the problem]

[0008] The electric compressor of the present invention comprises a casing having a motor room containing a motor, an inverter room equipped with an inverter that supplies power to the motor, and a partition wall separating the motor room and the inverter room, and electrically connects the motor and the inverter by a three-phase terminal that penetrates the partition wall, and comprises a busbar unit arranged on the motor room side, which comprises a busbar that electrically connects the magnet wire coming out of the motor to the three-phase terminal and a three-phase terminal molded from a resin part, the busbar has a winding connection part to which the lead portion of the magnet wire is connected, this winding connection part and the three-phase terminal protrude from the resin part, the lead portion is connected to the winding connection part with a predetermined margin in its length dimension, and a through hole is formed in the partition wall, the busbar unit is fixed to the partition wall from the inverter room side by bolts screwed into the busbar unit, and in this state the three-phase terminal passes through the through hole and its tip faces the inverter room.

[0009] The electric compressor of the second invention is characterized in that the busbar unit is movable in the axial direction in the above invention.

[0010] The third invention is characterized by comprising a sealing member interposed between the partition wall and the busbar unit in each of the above inventions.

[0011] The fourth invention is a method for manufacturing an electric compressor comprising a motor room containing a motor, an inverter room equipped with an inverter that supplies power to the motor, and a casing having a partition wall separating the motor room and the inverter room, wherein the motor and inverter are electrically connected by a three-phase terminal that penetrates the partition wall, the invention comprising a busbar unit disposed on the motor room side, comprising a busbar and a three-phase terminal molded from a resin part, which electrically connect the magnet wire coming out of the motor to the three-phase terminal, and a through hole formed in the partition wall, wherein the busbar has a winding connection part to which the lead portion of the magnet wire is connected, and the winding connection part and the three-phase terminal protrude from the resin part, the lead portion is connected to the winding connection part with a predetermined slack in its length dimension, a bolt that penetrates the partition wall from the inverter room side is screwed into the busbar unit, the busbar unit is pulled towards the partition wall side and fixed to the motor room side of the partition wall, so that the three-phase terminal is inserted into the through hole and passes through the through hole so that its tip faces the inverter room.

[0012] The fifth invention is a method for manufacturing an electric compressor, characterized in that the slack portion provided in the lead portion in the above invention is set to a dimension greater than or equal to the distance by which the busbar unit is pulled towards the bulkhead by the screwing of the bolts. [Effects of the Invention]

[0013] According to the present invention and the fourth invention, the lead portion of the magnet wire is connected to the winding connection portion of the busbar unit with a predetermined slack in its length, and a bolt that penetrates the partition wall from the inverter room side is screwed into the busbar unit, pulling the busbar unit towards the partition wall and fixing it to the motor room side of the partition wall. As a result, the three-phase terminal is inserted into the through hole, passes through the through hole, and its tip faces the inverter room, so that the busbar unit and the motor can be mounted to the casing independently. Furthermore, the slack in the lead portion can absorb any misalignment between the busbar unit and the motor, thus improving the ease of installation of the busbar unit.

[0014] In this case, by making the busbar unit movable in the axial direction as in the second invention, the busbar unit can be held by the motor and pulled towards the bulkhead by screwing in bolts.

[0015] Furthermore, by interposing a sealing member between the partition wall and the busbar unit, as in the third invention, it becomes possible to ensure a seal between the motor room and the inverter room.

[0016] Furthermore, as in the fifth invention, by setting the slack portion provided to the lead section to a dimension greater than the distance by which the busbar unit is pulled towards the bulkhead by the bolt threading, the busbar unit can be fixed to the bulkhead without any problems. [Brief explanation of the drawing]

[0017] [Figure 1] This is a schematic longitudinal cross-sectional side view of an electric compressor according to one embodiment, equipped with the motor of the embodiment (Embodiment 1). [Figure 2] This is a side view of the stator and busbar unit that make up the motor in Figure 1. [Figure 3] Figure 2 is a perspective view of the motor busbar unit. [Figure 4] Figure 2 is a longitudinal cross-sectional side view of the main part of the motor. [Figure 5]It is an enlarged front view of the leg portion of the bus bar unit of the motor and the key groove portion of the inverter in FIG. 2. [Figure 6] It is a plan view of the electric compressor in FIG. 1 as viewed from the side of the inverter chamber. [Figure 7] It is a cross-sectional view taken along the line A-A in FIG. 6. [Figure 8] It is a cross-sectional view taken along the line B-B in FIG. 6. [Figure 9] It is a diagram for explaining the procedure of attaching the motor to the casing. [Figure 10] It is a cross-sectional view corresponding to FIG. 7 of the electric compressor of another embodiment (Embodiment 2). [Figure 11] It is a cross-sectional view corresponding to FIG. 8 of the electric compressor of another embodiment. [Figure 12] It is a cross-sectional view corresponding to FIG. 7 of the electric compressor of yet another embodiment (Embodiment 3). [Figure 13] It is a cross-sectional view corresponding to FIG. 8 of the electric compressor of yet another embodiment. [Figure 14] It is a cross-sectional view corresponding to FIG. 7 of the electric compressor of still another embodiment (Embodiment 4). [Figure 15] It is a cross-sectional view corresponding to FIG. 8 of the electric compressor of still another embodiment. [Figure 16] It is an enlarged view of the winding connection portion of the electric compressor for explaining still another embodiment (Embodiment 5). [Figure 17] It is a diagram for explaining the bus bar unit in the case of the embodiment in FIG. 16. [Figure 18] It is a plan view of the seal member in the case of FIG. 17. [Figure 19] It is a plan view of the inverter chamber of the through-hole portion in the case of FIG. 17. [Figure 20] It is a diagram for explaining the attachment procedure of the bus bar unit in the case of FIG. 17. [Figure 21] It is a diagram for explaining another embodiment of the bus bar unit corresponding to FIG. 17 (Embodiment 6). [Figure 22] It is a plan view of the seal member in the case of FIG. 21. [Figure 23]This is a plan view of the inverter room in the case of the through-hole portion shown in Figure 21. [Modes for carrying out the invention]

[0018] Embodiments of the present invention will be described in detail below with reference to the drawings. [Examples]

[0019] Figure 1 is a schematic longitudinal side view of the electric compressor 1 equipped with the motor 4 of the embodiment, Figure 2 is a side view of the stator 21 and busbar unit 26 of the motor 4, Figure 3 is a perspective view of the busbar unit 26, and Figure 4 is a cross-sectional view of the main part of the motor 4.

[0020] (1) Electric compressor 1 In Figure 1, the electric compressor 1 of the embodiment is an inverter-integrated scroll-type electric compressor in which a scroll compression element 3, as an example of a compression element, and the motor 4 of the embodiment are housed in a metal casing 2 made of aluminum or the like. The inside of the casing 2 is divided into a motor room 15 and an inverter room 17 by a partition wall 10, and the motor 4 is housed in the motor room 15 and fixed to the casing 2 by shrink-fitting.

[0021] Furthermore, a scroll compression element 3 is also housed within the motor chamber 15. The scroll compression element 3 in this embodiment consists of a fixed scroll 6 fixed to the casing 2 and a movable scroll 7 that revolves around the fixed scroll 6 without rotating relative to it, due to the rotation axis 8 of the motor 4. The spiral wrap 11 formed on the fixed scroll 6 and the spiral wrap 12 formed on the movable scroll 7 are arranged to interlock.

[0022] Refrigerant is introduced into the casing 2 from a refrigerant introduction passage (not shown) and is drawn in from the outside into a compression chamber formed between the two wraps 11 and 12. As this compression chamber narrows towards the center due to the orbital motion of the movable scroll 7, the drawn-in refrigerant is compressed and discharged from the center through the discharge chamber 14 and a refrigerant discharge passage (not shown). Also, because the inside of the casing 2 is at low pressure, refrigerant passes around the motor 4, and the motor 4 is cooled by this refrigerant.

[0023] At the end of the casing 2, located on the opposite side of the scroll compression element 3, the inverter chamber 17 described above is formed, as shown in Figure 1, to house the inverter 16 for driving the motor 4. The three-phase terminal 33 of the busbar unit 26, which will be described in detail later, penetrates the partition wall 10 described above, which forms the bottom wall of the inverter chamber 17, and its tip faces into the inverter chamber 17 and connects to the connection terminal 18 provided on the inverter 16. Since the connection terminal 18 and the three-phase terminal 33 are connected by press-fitting, the motor 4 and the inverter 16 are electrically connected, and power is supplied from the inverter 16 to the motor 4.

[0024] (2) Motor 4 Next, the motor 4 of the embodiment will be described. The motor 4 of the embodiment is a permanent magnet synchronous motor and consists of a stator 21 made of a core 22 made of multiple laminated electromagnetic steel sheets, magnet wires 23 (windings; Figure 4) and insulators 25 and 27, and a magnet-embedded rotor 24 (also made of multiple laminated electromagnetic steel sheets) which is fixed to the rotating shaft 8 and rotates inside the stator 21.

[0025] The core 22 of the stator 21 has multiple teeth 28 corresponding to the magnetic poles, and the slots 29 between each tooth 28 are shaped to be open toward the center (Figure 4). An insulator 25 is attached to the end of the core 22 on the scroll compression element 3 side, and an insulator 27 is attached to the end of the core 22 on the inverter chamber 17 side, and the magnet wire 23 is wound around these insulators 25 and 27.

[0026] As a result, the insulators 25 and 27 are fixed to the core 22, and are positioned between the core 22 and the magnet wire 23, providing insulation. In this embodiment, the insulators 25 and 27 are formed in an annular shape by injection molding of an insulating synthetic resin such as LCP, PPS, or PBT.

[0027] Furthermore, multiple keyways 31 (three in this embodiment) are formed on the outer circumferential surface of the insulator 27 in the embodiment, extending in the axial direction of the stator 21 (Figures 2 and 4). Note that the keyways 31 may be formed on the core 22 instead of the insulator 27. However, forming them on the insulator 27 as in this embodiment reduces the adverse effect on the characteristics of the motor 4 compared to forming them on the core 22.

[0028] (3) Busbar unit 26 Next, the aforementioned busbar unit 26, which is fixed to the inverter chamber 17 side of the stator 21, will be described. The busbar unit 26 is a connecting member for electrically connecting the magnet wires 23 coming out of each slot 29 of the core 22 of the stator 21 and the aforementioned three-phase terminals 33. It consists of a metal (conductive material) busbar 36 molded with a resin part 37 (insulating hard resin) in the shape shown in Figure 3.

[0029] In this embodiment, the busbar 36 has an annular shape and is integrally provided with a plurality of winding connection parts 41 that protrude outward from the circle. Each winding connection part 41 is formed to correspond to the number of magnet wires 23 coming out of each slot 29. In addition, the aforementioned three-phase terminals 33 are arranged along the arc of the busbar 36 and their bases are electrically connected to the busbar 36.

[0030] The busbar 36 and the three-phase terminal 33 are then molded by the resin part 37 (inserter molding), forming a busbar unit 26 in which the busbar 36, the three-phase terminal 33, and the resin part 37 are integrated. In this case, the busbar 36 is embedded within the annular part 42 of the busbar unit 26, and each winding connection part 41 protrudes in the radial direction of the annular part 42, protruding from and exposed from the resin part 37.

[0031] Furthermore, only the bases of the three three-phase terminals 33 are embedded in the resin part 37, and they protrude in the axial direction of the ring part 42, with their tips exposed from the resin part 37 (Figures 2 and 3). In this case, the resin part 37 in the portion where each three-phase terminal 33 protrudes has a large-diameter part 37A and a small-diameter part 37B at its tip, and each three-phase terminal 33 protrudes and is exposed from this small-diameter part 37B (Figure 3).

[0032] Furthermore, the annular portion 42 of the busbar unit 26 has multiple legs 43 (three in this embodiment) that extend radially outward (radially) from the outside of the circle of the annular portion 42 by integral molding of resin. In this case, one leg 43 is formed extending outward from a position opposite the circle of the annular portion 42 from the three-phase terminal 33, and the remaining two legs 43 are formed extending outward from the annular portion 42 where the three-phase terminals on both sides of the three-phase terminal 33 are located.

[0033] Each leg portion 43 is bent at a right angle in the opposite direction to the three-phase terminal 33, and their tips are designated as claw portions 47. On the other hand, the aforementioned keyway 31 of the insulator 27 is formed at positions corresponding to the claw portions 47 of each leg portion 43 of the busbar unit 26. Furthermore, the width of the claw portion 47 of the leg portion 43 is smaller than the width of the keyway 31 formed in the insulator 27 (Figure 5).

[0034] With the above configuration, when attaching the busbar unit 26 to the stator 21, the claw portions 47 of each leg portion 43 of the busbar unit 26 are inserted axially into the keyway 31 of the insulator 27. At this time, the width of the claw portion 47 is smaller than the width of the keyway 31 of the insulator 27 (Figure 5), so the claw portion 47 is positioned to a certain extent so that it can move circumferentially (circumferentially in the direction of the motor 4) and axially (axially in the direction of the motor 4) within the keyway 31. After inserting the claw portions 47 of the legs 43 of the busbar unit 26 into the keyway 31 of the insulator 27 and positioning them to a certain extent, the lead portions 23A of the magnet wires 23 coming out of each slot 29 are welded to the winding connection portion 41 of the busbar 36.

[0035] (4) Partition wall 10 of casing 2 The inverter chamber 17, as described above, is located at the end of the casing 2 opposite to the scroll compression element 3 when viewed from the motor 4, and is separated from the motor chamber 15 by a partition wall 10. The inverter 16 (circuit board) that drives the motor 4 is mounted inside this inverter chamber 17. The inverter 16 passes through three through holes 51 formed in the partition wall 10 of the casing 2, and is electrically connected to the motor 4 via the aforementioned three-phase terminal 33, one end of which faces from the motor chamber 15 to the inverter chamber 17, and the aforementioned connection terminal 18 on the inverter 16 side.

[0036] Figure 6 is a plan view of the electric compressor 1 as seen from the inverter room 17 side, Figure 7 is a cross-sectional view along line AA in Figure 6, and Figure 8 is a cross-sectional view along line BB in Figure 6. The inverter room 17 has an opening on the opposite side of the partition wall 10, and this opening is closed by a cover 52 (Figure 6 shows the state with the cover 52 removed). This cover 52 is attached to the casing 2 after the inverter 16 is installed in the inverter room 17, but it does not create an airtight seal, so the inverter room 17 is at atmospheric pressure.

[0037] (5) O-ring 53 In Figures 1, 7, and 8, 53 is an O-ring made of an elastic material used as a sealing material. The O-ring 53 is inserted into each through-hole 51 from the inverter chamber 17 side, with the three-phase terminals 33 inserted into each through-hole 51 and its tip facing the inverter chamber 17. At this time, a chamfered portion 54 is formed on the partition wall 10 at the opening edge of each through-hole 51 on the inverter chamber side, making it easier to insert the O-ring into the through-hole 51. The motor chamber 15 side of the O-ring 53 is then held by the large-diameter portion 37A (the stepped portion between the large-diameter portion 37A and the small-diameter portion 38B) of the resin portion 37 of the busbar unit 26. In this state, the O-ring 53 seals the gap between the small-diameter portion 37B of the resin portion 37 and the through-hole 51.

[0038] Then, an O-ring 53 retention member 56 is attached to the inverter chamber 17 side of the partition wall 10 in the area corresponding to the three through holes 51. In this embodiment, the retention member 56 consists of a metal plate member 57 attached to the inverter chamber 17 side of the partition wall 10 by bolts 59, and a resin anti-loosening ring 58 positioned between the plate member 57 and the O-ring 53 and fitted into the through holes 51. The anti-loosening ring 58 has a shape that matches the inclination of the chamfered portion 54 of the through hole 51. The plate member 57 also has three holes 61 through which each small diameter portion 37B passes.

[0039] (6) Assembly procedure for motor 4 Next, the assembly procedure for the motor 4 and inverter 16 of the electric compressor 1 configured as described above will be explained. The motor 4, to which the busbar unit 26 is attached as described above, is housed in the motor chamber 15 of the casing 2 as shown by the arrow in Figure 9, with the busbar unit 26 facing the partition wall 10. The three-phase terminal 33 is inserted into the through-hole 51 of the partition wall 10, and the tip of the three-phase terminal 33 is brought into the inverter chamber 17 by passing through the through-hole 51.

[0040] Next, the core 22 of the motor 4 is shrink-fitted and fixed to the inner surface of the casing 2. Here, the through hole 51 is sized to allow the large-diameter portion 37A of the resin portion 37 of the busbar unit 26 to enter, and the stepped portion between the large-diameter portion 37A and the small-diameter portion 38B is located inside the through hole 51. Furthermore, even if there is some error in the positional relationship between the busbar unit 26, the core 22, and the casing 2 at this time, as mentioned above, the busbar unit 26 is movable in the circumferential direction, so if the tip of the three-phase terminal 33 can enter the through hole 51, then the small-diameter portion 37B and then the large-diameter portion 37A will enter the through hole 51 in that order, and the three-phase terminal 33 will be able to pass through the through hole 51. Accordingly, the dimensional tolerances required for the busbar unit 26 and the casing 2, and the positional tolerances required when assembling the electric compressor 1 are relaxed.

[0041] Subsequently, the O-rings 53 are inserted into each through-hole 51 from the inverter chamber 17 side, and the motor chamber 15 side of the O-rings 53 is held in place by the stepped portion between the large-diameter portion 37A and the small-diameter portion 38B of the resin part 37 of the busbar unit 26. In this state, the O-rings 53 are positioned in the gap between the small-diameter portion 37B of the resin part 37 and the through-hole 51, and seal it.

[0042] Next, the anti-loosening ring 58 of the retaining member 56 is inserted into each through hole 51 and fitted, aligning with the inclination of the chamfered portion 54. Then, the plate member 57 is positioned on the inverter chamber 17 side of the partition wall 10 by inserting the small diameter portion 37B of each three-phase terminal 33 into the hole 61 of the plate member 57, and attached to the partition wall 10 with bolts 59. In this state, the busbar unit 26 is held in place by the partition wall 10. In addition, the anti-loosening member 56 is provided on the inverter chamber 17 side of the O-ring 53, preventing refrigerant and oil from leaking from the motor chamber 10 side into the inverter chamber 17.

[0043] Next, the inverter 16 is housed and installed in the inverter room 17, and at the same time, the connection terminal 18 is connected to one end of the three-phase terminal 33. Finally, the cover 52 is attached to the casing 2 to close it.

[0044] As described above, a keyway 31 is formed on the outer circumference of the insulator 27 (or core 22), and the busbar unit 26 is provided with a claw portion 47 of a leg portion 43 that enters the keyway 31. The width of the claw portion 47 of this leg portion 43 is made smaller than the width of the keyway 31, so that the busbar unit 26 can rotate in the circumferential direction of the motor 4.

[0045] In other words, because the position of the busbar unit 26 is flexible, even in the case of an electric compressor 1 in which the three-phase terminals 33 of the busbar unit 26 are inserted into the through-hole 51 of the partition wall 10 from the motor room 15 side, and the tips of the three-phase terminals 33 are brought out towards the inverter room 17 after passing through the through-hole 51, the dimensional tolerances required for the busbar unit 26 and the casing 2 of the electric compressor 1, as well as the positional tolerances required when assembling the electric compressor 1, are relaxed. This makes it possible to improve the productivity of parts and improve assembly workability.

[0046] In this embodiment, since the keyway 31 is formed on the outer circumference of the insulator 27, the problem of adverse effects on the characteristics of the motor 4, as would occur if it were formed on the core 22, can be resolved.

[0047] Furthermore, in this embodiment, an O-ring 53 is provided to seal the gap between the small-diameter portion 37B of the resin portion 37 of the busbar unit 26 where the three-phase terminal 33 protrudes and the through-hole 51 of the partition wall 10. This O-ring 53 is inserted into the through-hole 51 from the inverter chamber 17 side and held on the motor chamber 15 side by the stepped portion between the large-diameter portion 37A and the small-diameter portion 37B of the resin portion 37. As a result, it is no longer necessary to create a stepped shape in the through-hole 51 to hold the O-ring 53, improving the processability of the casing 2 of the electric compressor 1, and also improving quality as the insertion state of the O-ring 53 can be confirmed from the inverter chamber 17 side.

[0048] Furthermore, since the partition wall 10 is configured to have an O-ring retaining member 56 attached to the inverter chamber 17 side, the O-ring 53 may be pushed out of the through hole 51 into the inverter chamber 17 by the pressure from the motor chamber 15 side, preventing the inconvenience of refrigerant or oil entering the inverter chamber 17 from the motor chamber 15.

[0049] Furthermore, in this embodiment, the busbar unit 26 is held by the partition wall 10 with the three-phase terminal 33 inserted into the through hole 51 of the partition wall 10 and the plate member 57 of the retaining member 56 attached to the partition wall 10. As a result, the position of the busbar unit 26 is fixed, and it can be stably attached to the partition wall 10.

[0050] In this embodiment, the retaining member 56 is configured to have a plate member 57 fixed to the inverter chamber 17 side of the partition wall 10, and a retaining ring 58 positioned between the plate member 57 and the O-ring 53 and fitted into the through hole 51. This makes it possible to prevent the O-ring 53 from coming off with a relatively simple configuration.

[0051] Furthermore, in this embodiment, a chamfered portion 54 is formed on the partition wall 10 at the opening edge of the through hole 51 on the inverter chamber 17 side, making it easier to insert the O-ring 53 into the through hole 51. In addition, since the anti-slip ring 58 is shaped to match the inclination of the chamfered portion 54, the O-ring 53 can be more reliably prevented from coming loose. [Examples]

[0052] Next, Figures 10 and 11 show cross-sectional views of electric compressor 1 of other embodiments, corresponding to Figures 7 and 8 described above. Components indicated by the same reference numerals in each figure as those in Figures 7 and 8 perform the same or similar functions.

[0053] In this embodiment, the anti-dislodgement ring 58 of the aforementioned retaining member 56 is shaped to match the gap between the end of the chamfered portion 54 of the partition wall 10 on the motor chamber 15 side and the small diameter portion 37B of the resin portion 37. This anti-dislodgement ring 58 also ensures that the O-ring 53 is reliably prevented from coming off. [Examples]

[0054] Next, Figures 12 and 13 show cross-sectional views of another embodiment of the electric compressor 1, corresponding to Figures 7 and 8 described above. Components indicated by the same reference numerals in each figure as those in Figures 7 and 8 are assumed to perform the same or similar functions.

[0055] In this embodiment, the aforementioned retaining member 56 does not have a retaining ring 58. Instead, a projection 62 is provided around the hole 61 of the plate member 57 that enters into the through hole 51, and this projection 62 is shaped to match the gap dimension between the end of the chamfered portion 54 on the motor chamber 15 side and the small diameter portion 37B of the resin portion 37.

[0056] This configuration makes it possible to more reliably prevent the O-ring 53 from coming off using the protrusion 62 of the plate member 57, without using a separate component such as the aforementioned anti-slip ring. [Examples]

[0057] Next, Figures 14 and 15 show cross-sectional views of another embodiment of the electric compressor 1, corresponding to Figures 7 and 8 mentioned above. In each figure, components indicated by the same reference numerals as those in Figures 12 and 13 are assumed to perform the same or similar functions.

[0058] In this embodiment as well, the aforementioned retaining member 56 does not have a retaining ring 58. Instead, a projection 62 is provided around the hole 61 of the plate member 57 that enters into the through hole 51, and this projection 62 is shaped to match the inclination of the chamfered portion 54.

[0059] Even with this configuration, it is possible to reliably prevent the O-ring 53 from coming off using the protrusion 62 of the plate member 57 without using separate components such as the aforementioned anti-slip ring. [Examples]

[0060] Next, we will describe yet another embodiment of the electric compressor 1 with reference to Figures 16 to 20. Figure 16 is an enlarged view of the winding connection part 41 of the electric compressor 1 in this embodiment, and Figures 17 to 19 illustrate the busbar unit 26, through hole 51, and sealing member 63 of this embodiment. In each figure, parts indicated by the same reference numerals as in Figures 1 to 15 are considered to have the same or similar functions.

[0061] In this embodiment, as in the previously described embodiment, a keyway 31 is formed in the insulator 27 of the motor 4, and the claw portion 47 of the leg portion 43 of the busbar unit 26 enters the keyway 31, allowing it to move in the axial direction. However, the sealing structure of the through hole 51 portion is different.

[0062] In this embodiment, the lead portion 23A of the magnet wire 23 is connected to the winding connection portion 41 of the busbar unit 26 with a predetermined allowance in its length. This allowance is set to a length greater than the distance the busbar unit 26 is pulled towards the bulkhead 10, as will be described later, and is assumed to be guided to bend in a certain direction before being pulled (left side of Figure 16).

[0063] Furthermore, in this embodiment, three terminal holding portions 37C are formed upright on the resin portion 37 of the busbar unit 26, and the three-phase terminals 33 protrude from each terminal holding portion 37C. Two bolt holes 64 are formed on the surface of the busbar unit 26 on the terminal holding portion 37C side, and bolt holes 66 and 67 are also formed in the sealing member (gasket) 63 and partition wall 10 at positions corresponding to each bolt hole 64. In addition, holes 68 are formed in the sealing member 63 at positions corresponding to each terminal holding portion 37C.

[0064] Next, the installation procedure for the busbar unit 26 in this embodiment will be described with reference to Figure 20. After the busbar unit 26 is installed on the insulator 27 as described above, the sealing member 63 is placed on the side of the busbar unit 26 facing the terminal holding portion 37C. At this time, each terminal holding portion 37C passes through the hole 68 of the sealing member 63. Also, at this time, the lead portion 23A of the magnet wire 23 is in the state shown on the left side of Figure 16.

[0065] In this state, the motor 4 is shrink-fitted into the casing 2. At this time, each three-phase terminal 33 corresponds to each through-hole 51, and the bolt holes 64 correspond to each bolt holes 66 and 67 (left side of Figure 20). In this state, two bolts 71 are inserted into the bolt holes 67 and 66 from the inverter room 17 side (center of Figure 20), and their ends are screwed into the bolt holes 64 of the busbar unit 26. By screwing in these bolts 71, the busbar unit 26 is pulled towards the bulkhead 10 side, and finally fixed to the motor room 15 side of the bulkhead 10 via the sealing member 63, as shown on the right side of Figure 20.

[0066] During this installation process, the lead portion 23A extends as shown on the right side of Figure 16 (the excess length extends), so the lead portion 23A will not come off the winding connection portion 41. Then, with the busbar unit 26 attached to the bulkhead 10 as described above, each three-phase terminal 33 passes through each through-hole 51, and its tip faces the inverter room 17.

[0067] In this manner, the lead portion 23A of the magnet wire 23 is connected to the winding connection portion 41 of the busbar unit 26 with a predetermined allowance in its length, and a bolt 71 that penetrates the bulkhead from the inverter room 17 side is screwed into the busbar unit 26, pulling the busbar unit 26 towards the bulkhead 10 side and fixing it to the motor room 15 side of the bulkhead 10. As a result, the three-phase terminal 33 is inserted into the through hole 51, passes through the through hole 51, and its tip faces the inverter room 17, so that the busbar unit 26 and the motor 4 can be attached to the casing 2 independently. Furthermore, the allowance in the lead portion 23A can absorb any misalignment between the busbar unit 26 and the motor 4, thereby improving the ease of installation of the busbar unit 26.

[0068] In this case, as in the embodiment, a keyway 31 is formed in the insulator 27 of the motor 4, and a claw portion 47 of the leg portion 43 that enters the keyway 31 is formed on the busbar unit 26, and by making this claw portion 47 movable in the axial direction within the keyway 31, the busbar unit 26 can be held by the motor 4 and pulled towards the partition wall 10 by screwing in the bolt 71.

[0069] Furthermore, by interposing a sealing member 63 between the partition wall 10 and the busbar unit 26, as in the embodiment, it becomes possible to ensure a seal between the motor room 15 and the inverter room 17.

[0070] Furthermore, in this embodiment, the slack provided in the lead portion 23A is set to a dimension greater than the distance by which the busbar unit 26 is pulled towards the bulkhead 10 by the screwing in of the bolt 71, so that the busbar unit 26 can be fixed to the bulkhead 10 without any problems. [Examples]

[0071] Next, we will describe another embodiment of the electric compressor 1 shown in Figures 16 to 20, referring to Figures 21 to 23. In this case, the busbar unit 26 has one terminal holding portion 37D, and three three-phase terminals 33 protrude from this terminal holding portion 37D. Therefore, there is only one hole 68 in the sealing member 63, and only one through-hole 51 in the partition wall 10. The rest is the same as in Figures 16 to 20. This configuration also produces the same effects as described above. [Explanation of Symbols]

[0072] 1. Electric compressor 2 Casing 3. Scroll compression element 4 motors 8 rotation axes 10 Bulkhead 15 Motor Room 16 Inverters 17 Inverter Room 21 stata 22 cores 23 Magnet wire 23A Lead section 24 rotors 26 Busbar Units 25, 27 Insulators 29 slots 31 keyways 33 Three-phase terminal 36 Bus Bar 37 Resin part 41 Winding connection section 43 Legs 47. Nail area 51 Through hole 53 O-rings 54 Chamfer 56 Retaining member 57 Plate members 58 Anti-slip ring 62 Protrusion 63 Sealing member 71 volts

Claims

1. In an electric compressor comprising a motor room containing a motor, an inverter room equipped with an inverter that supplies power to the motor, and a casing having a partition wall separating the motor room and the inverter room, the motor and the inverter are electrically connected by three-phase terminals that penetrate the partition wall, The busbar unit is located on the motor chamber side and comprises a busbar that electrically connects the magnet wires coming out of the motor to the three-phase terminals, and the three-phase terminals are molded with a resin part. The busbar has a winding connection portion to which the lead portion of the magnet wire is connected, and the winding connection portion and the three-phase terminal protrude from the resin portion. The lead portion is connected to the winding connection portion with a predetermined allowance in its length, An electric compressor characterized in that a through hole is formed in the partition wall, the busbar unit is fixed to the partition wall from the inverter room side by bolts screwed into the busbar unit, and in this state the three-phase terminals pass through the through hole and their tips face the inverter room.

2. The electric compressor according to claim 1, characterized in that the busbar unit is movable in the axial direction.

3. The electric compressor according to claim 1 or 2, further comprising a sealing member interposed between the partition wall and the busbar unit.

4. A method for manufacturing an electric compressor comprising a motor room containing a motor, an inverter room equipped with an inverter that supplies power to the motor, and a casing having a partition wall separating the motor room and the inverter room, wherein the motor and the inverter are electrically connected by three-phase terminals that penetrate the partition wall, The busbar unit is arranged on the motor chamber side and comprises a busbar that electrically connects the magnet wires coming out of the motor to the three-phase terminals, and the three-phase terminals are molded with a resin part, and a through hole formed in the partition wall. The busbar has a winding connection portion to which the lead portion of the magnet wire is connected, and the winding connection portion and the three-phase terminal protrude from the resin portion. The lead portion is connected to the winding connection portion with a predetermined allowance in its length, A method for manufacturing an electric compressor, characterized in that a bolt passing through the partition wall from the inverter room side is screwed into the busbar unit, the busbar unit is pulled towards the partition wall side and fixed to the motor room side of the partition wall, so that the three-phase terminal is inserted into the through hole, passes through the through hole and its tip faces the inverter room.

5. The method for manufacturing an electric compressor according to claim 4, characterized in that the slack portion to be held in the lead portion is set to a dimension greater than or equal to the distance by which the busbar unit is pulled towards the bulkhead by the screwing of the bolt.

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