Air compressor

Abstract

The present invention relates to an air compressor that is compacted by improving the arrangement structure between the filter section and the discharge resistor, thereby reducing interference between the filter section and the discharge resistor and increasing the space utilization of the filter section. The air compressor comprises a housing, a rotating shaft disposed inside the housing, a compression section connected to the rotating shaft to compress and discharge incoming air, a motor section driving the rotating shaft, a control board controlling the motor section, and a filter section that filters noise from external power and supplies it to the control board. The filter section comprises a capacitor assembly connected to an external power source, a transistor connected to the control board, a current sensor assembly connected to the transistor, and a discharge resistor connected to the capacitor assembly to discharge the charge remaining in the capacitor assembly.

Description

Technology Field

[0001] The present invention relates to an air compressor, and more specifically, to an air compressor having a control unit integrated therein. Background Technology

[0002] Generally, a fuel cell vehicle refers to a vehicle that supplies electrical energy generated through an electrochemical reaction, which is the reverse reaction of water electrolysis, by supplying hydrogen and oxygen to a humidifier, and a general fuel cell vehicle is disclosed in Korean Patent Registration No. 0962903.

[0003] Typically, passenger fuel cell vehicles are equipped with an 80 kW fuel cell stack. When operating the fuel cell stack under pressurized conditions, the air supplied to the fuel cell stack is supplied at a high pressure of 1.2 to 3.0 bar; therefore, an air compressor with a rotational speed of 5,000 to 100,000 rpm must be used for this purpose.

[0004] A fuel cell vehicle typically consists of a fuel cell stack that generates electricity, a humidifier that humidifies and supplies fuel and air to the fuel cell stack, a fuel supply unit that supplies hydrogen to the humidifier, an air supply unit that supplies air containing oxygen to the humidifier, and a cooling module for cooling the fuel cell stack.

[0005] The air supply unit consists of an air cleaner that filters foreign substances contained in the air, an air compressor that compresses and supplies the air filtered by the air cleaner, and a control box that controls the air compressor.

[0006] The aforementioned air compressor compresses air drawn in from the outside using an impeller and then sends it to the fuel cell stack through the exhaust port. At this time, the impeller and shaft constituting the compression section are driven by the rotational force of a motor.

[0007] The motor of such an air compressor is powered and its operation is controlled through an inverter. The inverter includes a printed circuit board (PCB) on which electrical components such as transistors, capacitors, inductors, fixed resistors, diodes, and drivers are mounted.

[0008] However, conventional air compressors have poor space utilization between parts, which leads to poor assembly and limits the miniaturization of the air compressor.

[0009] In addition, as a high-voltage current is applied, the internal structure overheats due to the heat generated by the constant flow of current. Prior art literature

[0010] Republic of Korea Registered Patent No. 0962903 (Registered on June 1, 2010) The problem to be solved

[0011] The present invention is designed to solve the problems described above and aims to provide an air compressor that improves space utilization between parts and facilitates internal heat dissipation.

[0012] The problems that the present invention aims to solve are not limited to those mentioned above, and other problems not mentioned herein will be clearly understood by those skilled in the art from the description below. means of solving the problem

[0013] An air compressor according to one aspect of the present invention comprises: a housing; a rotating shaft disposed inside the housing; a compression unit connected to the rotating shaft to compress and discharge incoming air; a motor unit driving the rotating shaft; a control board controlling the motor unit; and a filter unit that filters noise from external power and supplies it to the control board; wherein the filter unit comprises: a capacitor assembly connected to an external power source; a transistor connected to the control board; a current sensor assembly connected to the transistor; and a discharge resistor connected to the capacitor assembly to discharge the charge remaining in the capacitor assembly.

[0014] It further includes a transfer module that transmits power from the control board to the motor part; wherein the discharge resistor is disposed adjacent to the transfer module, and the transfer module may include a transfer unit that extends radially outward from the motor part.

[0015] The capacitor assembly comprises: a capacitor; a case supporting the capacitor; and a resistor connection terminal connected to the discharge resistor; wherein the resistor connection terminal may be disposed on the capacitor.

[0016] It may include a first cover disposed to cover at least one side of the filter portion; and a heat exchange means disposed between the first cover and the transistor.

[0017] The current sensor assembly and the capacitor assembly may be arranged in a first direction perpendicular to the axial direction, and the transistor may be arranged in a second direction perpendicular to the first direction with respect to the current sensor assembly and the capacitor assembly.

[0018] It includes at least one cooling channel disposed between the motor part and the filter part, and the discharge resistor may be disposed adjacent to the cooling channel.

[0019] The first cover is positioned on the upper side of the transistor, and the discharge resistor may be positioned on the upper surface of the first cover.

[0020] It may include a fixing member that is coupled with the discharge resistor and disposed on the upper surface of the first cover to fix the discharge resistor to the first cover.

[0021] The discharge resistor may be placed adjacent to the current sensor assembly.

[0022] The first cover is positioned so that the width in the first direction is longer than the width in the second direction, and the discharge resistor can be positioned so that the width in the first direction is longer than the width in the second direction.

[0023] One side of the first cover, on which the discharge resistor is fixed, may be positioned lower than the resistor connection terminal.

[0024] The internal space of the above housing is divided into a first space in which the capacitor assembly is placed and a second space in which the current sensor assembly is placed, based on a virtual line extended in the axial direction, and the discharge resistor may be placed in the first space.

[0025] The above discharge resistor can be placed on the lower side of the case.

[0026] It includes a second cover disposed inside the housing; wherein the second cover may include a first support member supporting the current sensor assembly and a second support member supporting the transmission unit.

[0027] The second support member includes a protrusion surrounding a part of the transmission unit, and the housing may further include a through hole that accommodates the protrusion.

[0028] The above housing further includes a groove spaced apart from the through hole and a sealing disposed inside the groove, and when the second cover is disposed inside the housing, the upper side of the groove and the sealing can be covered by the second cover.

[0029] The first cover above may be made of at least one of aluminum, synthetic resin, and steel.

[0030] The first cover and the heat exchange means can be provided as a single unit. Effects of the invention

[0031] According to an embodiment, by improving the arrangement structure between the filter section and the discharge resistor, interference between the filter section and the discharge resistor is reduced, and the space utilization of the filter section is increased, thereby making the air compressor more compact.

[0032] In addition, by placing the discharge resistor on the upper surface of the cover or in a location where heat dissipation is easy, overheating of the discharge resistor can be prevented, and the problem of the temperature around the filter section rising can be solved. Brief explanation of the drawing

[0033] FIG. 1 is a cross-sectional view schematically illustrating an air compressor according to one embodiment of the present invention. FIG. 2 is a plan view of a housing and a filter part according to one embodiment of the present invention. FIG. 3 is a partial cross-sectional view of an air compressor according to one embodiment of the present invention. FIG. 4 is a plan view of a capacitor assembly according to one embodiment of the present invention. FIG. 5 is a plan view of an air compressor according to one embodiment of the present invention. FIG. 6 is a perspective view of a connector portion according to one embodiment of the present invention. FIG. 7 is a perspective view of a cover according to one embodiment of the present invention. FIG. 8 is a perspective view of a capacitor assembly and a discharge resistor according to one embodiment of the present invention. FIG. 9 is a circuit diagram of a capacitor assembly and a discharge resistor according to one embodiment of the present invention. FIG. 10 is a diagram comparing the third-directional height difference between a capacitor assembly and a discharge resistor according to one embodiment of the present invention. FIG. 11 is a diagram comparing the third-directional height difference of a capacitor assembly, a discharge resistor, and a cover according to one embodiment of the present invention. FIG. 12 is a drawing showing a part of a filter unit according to one embodiment of the present invention. FIG. 13 is a schematic plan view illustrating an air compressor according to another embodiment of the present invention. FIG. 14 is a plan view of an air compressor according to another embodiment of the present invention. FIG. 15 is a perspective view of a cover according to another embodiment of the present invention. FIG. 16 is a partial cross-sectional view of an air compressor according to another embodiment of the present invention. FIG. 17 is a perspective view of a second housing according to another embodiment of the present invention. FIG. 18 is a cross-sectional view illustrating a portion in which a cover according to another embodiment of the present invention is coupled to a second housing. FIG. 19 is a perspective view illustrating a discharge resistor coupled to a capacitor assembly according to another embodiment of the present invention. FIG. 20 is a front view illustrating a discharge resistor coupled to a capacitor assembly according to another embodiment of the present invention. Specific details for implementing the invention

[0034] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the attached drawings.

[0035] However, the technical concept of the present invention is not limited to some of the described embodiments but can be implemented in various different forms, and within the scope of the technical concept of the present invention, one or more of the components among the embodiments may be selectively combined or substituted.

[0036] In addition, terms used in the embodiments of the present invention (including technical and scientific terms) may be interpreted in a sense that is generally understood by those skilled in the art to which the present invention belongs, unless explicitly and specifically defined otherwise. Terms that are commonly used, such as terms defined in advance, may be interpreted in consideration of their meaning in the context of the relevant technology.

[0037] Furthermore, the terms used in the embodiments of the present invention are for the purpose of describing the embodiments and are not intended to limit the present invention.

[0038] In this specification, the singular form may include the plural form unless specifically stated otherwise in the text, and when described as "at least one of A and B and C (or more than one)," it may include one or more of all combinations that can be formed from A, B, and C.

[0039] In addition, terms such as first, second, A, B, (a), (b), etc. may be used when describing the components of the embodiments of the present invention.

[0040] These terms are intended merely to distinguish a component from other components and are not limited by the nature, order, sequence, etc., of the said component.

[0041] And, where it is stated that a component is 'connected', 'combined', or 'joined' to another component, this may include not only cases where the component is directly connected, combined, or joined to the other component, but also cases where it is 'connected', 'combined', or 'joined' due to another component located between the component and the other component.

[0042] Furthermore, when described as being formed or placed "above or below" each component, "above" or "below" includes not only cases where two components are in direct contact with each other, but also cases where one or more other components are formed or placed between the two components. Additionally, when expressed as "above or below," it may include the meaning of a downward direction as well as an upward direction relative to a single component.

[0043] FIG. 1 is a cross-sectional view schematically illustrating an air compressor according to one embodiment of the present invention.

[0044] Referring to FIG. 1, the air compressor may include a housing (100), a compression unit (200), a motor unit (300), a control board (400), a filter unit (500), and a transmission module (600).

[0045] The above housing (100) may form an exterior. The above housing (100) may include a first housing (110) and a second housing (120). The first housing (110) may have a rotating shaft (101), a compression unit (200), and a motor unit (300) arranged inside. The second housing (120) may be provided with a receiving portion in which a filter unit (500) is arranged. The first housing (110) and the second housing (120) may be formed integrally, but are not limited thereto.

[0046] The compression unit (200) is positioned at the front inside the housing (100). Here, the front is the direction toward the compression unit (200) relative to the motor unit (300), and the rear means the opposite direction of the front.

[0047] The motor unit (300) serves to provide driving force to the compression unit (200) by rotating the rotation shaft (101). At this time, the motor unit (300) includes a rotor (310) and a stator (320). The stator (320) includes a driving coil, and the driving coil generates electromagnetic force when power is supplied from the outside. Accordingly, the rotor (310) can rotate due to the electromagnetic interaction between the rotor (310) and the stator (320). Meanwhile, one side of the rotor (310) is connected to the compression unit (200) to drive the compression unit (200). Here, it is preferable that the driving coil operates by receiving three-phase AC power.

[0048] The above-mentioned control board (400) is equipped with circuits and components for controlling the motor unit (300). At this time, the above-mentioned control board (400) may be a PCB (Printed Circuit Board) substrate. The above-mentioned control board (400) may be positioned at the rear side of the rotation axis (101) and the motor unit (300), and may be spaced apart from the rear end of the rotation axis (101). At this time, the above-mentioned control board (400) may be formed in the shape of a substrate and positioned so that its thickness direction faces the axial direction of the rotation axis (101).

[0049] The filter unit (500) receives external power and supplies it to the control board (400), but supplies it in a state where noise from the power has been removed. At this time, the filter unit (500) may be positioned radially outside the motor unit (300).

[0050] The above transmission module (600) transmits power from the control board (400) to the motor unit (300). At this time, the power can be transmitted to the motor unit (300) through the transmission module (600) via the filter unit (500). The above transmission module (600) can transmit the three-phase AC voltage converted by the filter unit (500) to the motor unit (300). The transmission module (600) may include a busbar or a wire, and may include any means capable of transmitting power to the motor unit (300).

[0051] FIG. 2 is a plan view of a housing and filter section according to one embodiment of the present invention, and FIG. 3 is a partial cross-sectional view of an air compressor according to one embodiment of the present invention.

[0052] Referring to FIGS. 2 and FIGS. 3, the filter unit (500) may include a transistor (510), a capacitor assembly (520), and a current sensor assembly (530).

[0053] The transistor (510) converts a DC voltage into a driving voltage of the motor unit (300) through switching drive. The transistor (510) is positioned at the rear of the second housing (120) and connected to the control board (400). At this time, the transistor (510) may be an Insulated Gate Bipolar Transistor (IGBT).

[0054] The above transistor (510) includes six IGBTs and may consist of a first phase (Phase U) high switching element, a first phase (Phase U) low switching element, a second phase (Phase V) high switching element, a second phase (Phase V) low switching element, a third phase (Phase W) high switching element, and a third phase (Phase W) low switching element. The above transistor (510) is connected to a capacitor assembly (520) and a current sensor assembly (530).

[0055] The capacitor assembly (520) is electrically connected to an external power source to receive and store high-voltage DC current. Additionally, the capacitor assembly (520) is electrically connected to the transistor (510) and the transfer module (600).

[0056] The current sensor assembly (530) detects the current transmitted to the motor unit (300). The current sensor assembly (530) is electrically connected to the transistor (510) and the transmission module (600).

[0057] The above transistor (510), the capacitor assembly (520), and the current sensor assembly (530) can be mounted in a second housing (120). At this time, the capacitor assembly (520) and the current sensor assembly (530) can be arranged in a first direction (X-axis direction). Also, the transistor (510) can be arranged in a second direction (Y-axis direction) with respect to the capacitor assembly (520) and the current sensor assembly (530). At this time, the first direction (X-axis direction) and the second direction (Y-axis direction) are perpendicular, and the second direction (Y-axis direction) can be parallel to the axial direction.

[0058] The transfer module (600) connects the motor unit (300) and the filter unit (500). The transfer module (600) transfers power from the control board (400) to the motor unit (300). At this time, the transfer module (600) may be electrically connected to the capacitor assembly (520) and the current sensor assembly (530). The transfer module (600) includes a transfer unit, at least one of the transfer units may be connected to the capacitor assembly (520), and at least one of the other transfer units may be connected to the current sensor assembly (530).

[0059] The transfer module (600) can be spaced apart from the transistor (510) in a second direction (Y-axis direction) with the capacitor assembly (520) and the current sensor assembly (530) in between. At this time, the transfer module (600) can be connected to the motor unit (300) by passing through the second housing (120).

[0060] A through hole (120H) in which the transmission module (600) is disposed may be formed in the second housing (120). One end of the transmission module (600) may be connected to the motor unit (300) and the other end may be connected to the filter unit (500) based on the through hole (120H).

[0061] An air compressor of this structure can reduce the size of the air compressor by minimizing the housing thickness between the motor part (300) and the filter part (500) and compactly arranging the parts of the filter part (500) within the second housing (120).

[0062] The transmission module (600) may include a transmission unit (610) and a fixing means (620).

[0063] The above transmission unit (610) is electrically connected to the motor unit (300). At this time, the transmission unit (610) supplies the AC voltage converted by the transistor (510) to the motor unit (300). There may be multiple transmission units (610). The transmission unit (610) of this embodiment may be composed of a busbar. Accordingly, the transmission unit (610) may include a U-phase busbar (611) that transmits AC power of the first phase (Phase U), a V-phase busbar (612) that transmits AC power of the second phase (Phase V), and a W-phase busbar (613) that transmits AC power of the third phase (Phase W).

[0064] The above transmission unit (610) may be extended radially outward from the motor unit (300). Additionally, the above transmission unit (610) may be bent toward the filter unit (500) by passing through the through hole (120H). At this time, the U-phase busbar (611) may be bent toward the capacitor assembly (520), and the V-phase and W-phase busbars (612, 613) may be bent toward the current sensor assembly (530).

[0065] The ends of the U-phase, V-phase, and W-phase busbars (611, 612, 613) may be exposed from the fixing means (620) in a spaced-apart manner. At this time, at least one end of the transmission unit (610) may be connected to the capacitor assembly (520), and the remainder of the transmission unit (610) may be connected to the current sensor assembly (530).

[0066] According to the embodiment, by arranging the ends of the transmission unit (610) in both directions, assembly space can be secured between the transmission unit (610), the capacitor assembly (520), and the current sensor assembly (530), and assembly convenience can be improved.

[0067] The above fixing means (620) fixes the above transmission unit (610) to the housing (100) in an insulated state. To this end, the fixing means (620) may include a grommet (621) and a guide member (622).

[0068] The grommet (621) is positioned in the through hole (120H) to secure the transmission unit (610) passing through the through hole (120H). At this time, the grommet (621) may have elasticity and may be an insulating material. Preferably, the grommet (621) may be a rubber material.

[0069] The guide member (622) can guide each end of the transmission unit (610) to the capacitor assembly (520) or the current sensor assembly (530). The guide member (622) may be made of an insulating material. Preferably, the guide member (622) may be made of a plastic material.

[0070] According to an embodiment, the air compressor according to the present invention includes a plurality of cooling channels (700) for cooling the motor unit (300). The plurality of cooling channels (700) may extend parallel to the axial direction of the rotation shaft (101 in FIG. 1). The plurality of cooling channels (700) may be embedded in the housing (100) and positioned between the motor unit (300) and the filter unit (500).

[0071] A plurality of cooling channels (700) are spaced apart in the circumferential direction of the motor unit (300) to surround at least one side of the motor unit (300), so as to absorb heat generated from the motor unit (300). At this time, the plurality of cooling channels (700) may be positioned between the filter unit (500) and the motor unit (300) to absorb heat generated from the filter unit (500).

[0072] The above-mentioned transfer module (600) may be arranged to pass through the spaced-apart spaces of the plurality of cooling channels (700). At this time, the plurality of cooling channels (700) may also absorb heat generated in the transfer unit (610) to prevent overheating of the transfer unit (610).

[0073] FIG. 4 is a plan view of a capacitor assembly according to one embodiment of the present invention.

[0074] Referring to FIG. 4, the capacitor assembly (520) may include a capacitor (521), a case (522), a terminal part (523), and a resistor connection terminal (524).

[0075] The capacitor (521) may be a multilayer ceramic capacitor or a film capacitor.

[0076] The above case (522) can support the capacitor (521). The above case (522) can be fixed to the receiving portion of the second housing (120 in FIG. 2).

[0077] The terminal portion (523) may be placed on the case (522). At this time, the terminal portion (523) may be integrally formed with the case (522) by insert injection molding.

[0078] The terminal portion (523) may include a power output busbar (523C). The power output busbar (523C) is electrically connected to the transmission module (600). The power output busbar (523C) can be formed integrally with the case (522) to ensure insulation, reduce the number of parts, and improve assembly.

[0079] Additionally, the terminal portion (523) may include an input terminal (523P1, 523N1) connected to the connector portion (800) described later, an output terminal (523P2, 523N2) connected to the transistor (510), and a ground terminal (523G) connected to ground in the housing (100).

[0080] The resistance connection terminal (524) can be electrically connected to the discharge resistor (1000). The resistance connection terminal (524) can be connected to the terminal of the connecting member (1200) to be described later. Also, the resistance connection terminal (524) can be placed on the capacitor (521).

[0081] Although not shown in the drawing, the resistor connection terminal (524) may be placed in the case (522). Alternatively, it is possible to connect the capacitor assembly (520) and the discharge resistor (1000) by connecting the terminal portion (523) and the terminal of the connecting member (1200), and to omit the resistor connection terminal (524).

[0082] FIG. 5 is a plan view of an air compressor according to one embodiment of the present invention, FIG. 6 is a perspective view of a connector part according to one embodiment of the present invention, and FIG. 7 is a perspective view of a cover according to one embodiment of the present invention.

[0083] Referring to FIGS. 5 and 6, an air compressor according to the present invention may include a connector part (800), a first cover (900), a discharge resistor (1000), a first fixing member (1100), and a connecting member (1200).

[0084] The connector section (800) can apply external power to the filter section (500) and transmit a signal detected by the filter section (500) to the control board (400). The connector section (800) may include a first connector (810) and a second connector (820).

[0085] The first connector (810) electrically connects the control board (400) and the current sensor assembly (530). Additionally, a portion of the first connector (810) is connected to the second connector (820) to check whether the second connector (820) and the capacitor assembly (520) are connected. To this end, the first connector (810) may include a first terminal (811), a second terminal (812), a first wire (813), and an interlock wire (814).

[0086] The first terminal (811) is connected to the current sensor assembly (530), and the second terminal (812) is spaced apart from the first terminal (811) and connected to the control board (400). At this time, the first wire (813) is provided in six parts so that it can be electrically connected to the first terminal (811) and the second terminal (812).

[0087] At this time, a plurality of first wires (813) can be bundled by a band (B). And, the plurality of first wires (813) can be arranged to pass over the upper side of the transistor (510). At this time, a fixing clip (830) is installed on the upper side of the transistor (510) to fix the movement of the plurality of first wires (813).

[0088] The interlock wire (814) can be electrically connected to the second terminal (812) and the second connector (820). At this time, the interlock wire (814) can be connected to an interlock pin (not shown) to be described later. The interlock wire (814) detects whether the second connector (820) is connected to an external power source.

[0089] The second connector (820) electrically connects an external power source to the capacitor assembly (520) to apply a high-voltage DC current to the capacitor assembly (520). To this end, the second connector (820) may include a shield member (821), a second cable (822), high-voltage electrodes (823N1, 823P1) and an interlock pin (not shown).

[0090] The shield member (821) can be mounted on one side of the housing (100). At this time, the shield member (821) may be made of an insulating material. The shield member (821) may be combined with the second cable (822) to secure the second cable (822) to the housing (100).

[0091] The second cable (822) may extend from the shield member (821) toward the capacitor assembly (520). At this time, the second cable (822) may be provided in two.

[0092] High-voltage electrodes (823N1, 823P1) may be provided at the ends of each of the two second cables (822). At this time, the high-voltage electrodes (823N1, 823P1) may be connected to the input terminals (523P1, 523N1) of the capacitor assembly (520).

[0093] The above interlock pin (not shown) may be embedded in the shield member (821). At this time, the interlock pin (not shown) may be connected to the interlock cable.

[0094] The first cover (900) may be a cover for cooling the filter unit (500). The first cover (900) may cover one side of the filter unit (500) to absorb heat generated from the filter unit (500). Accordingly, the first cover (900) may be made of a material with excellent thermal conductivity. According to an embodiment, the first cover (900) may be made of at least one of aluminum, synthetic resin, and steel.

[0095] The first cover (900) may be positioned on the upper side of the filter unit (500). Additionally, the first cover (900) may cover at least one side of the filter unit (500) to absorb heat generated from the filter unit (500). According to an embodiment, the first cover (900) may be fixedly installed in the second housing while covering at least the upper side of the transistor (510). However, it is not limited thereto, and the position of the first cover (900) may be placed anywhere on the filter unit (500).

[0096] The discharge resistor (1000) can be connected to the capacitor assembly (520). The discharge resistor (1000) can discharge the charge remaining in the capacitor assembly (520) when the capacitor assembly (520) is separated from the connector part (800). That is, when the power supply from an external power source is interrupted, the discharge resistor (1000) can discharge the charge remaining in the capacitor assembly (520) to prevent electric shock accidents.

[0097] The discharge resistor (1000) may be a separate component separated from the capacitor assembly (520). Additionally, the discharge resistor (1000) may be spaced apart from the capacitor assembly (520) in a second direction (Y-axis direction).

[0098] The discharge resistor (1000) may be placed on the first cover (900). At this time, the discharge resistor (1000) may overheat during long-term operation because a high-voltage current flows through it constantly. The first cover (900) can prevent overheating by absorbing the heat from the discharge resistor (1000).

[0099] The first fixing member (1100) can fix the discharge resistor (1000) to the first cover (900). The first fixing member (1100) is coupled with the discharge resistor (1000) and can be placed on the upper surface of the first cover (900).

[0100] The first fixing member (1100) may include a first fastening part (1110) and a first fixing part (1120). The first fastening part (1110) may be in contact with the first cover (900) and may be fastened to a resistance fixing part (940) extending from the upper surface of the first cover (900). Additionally, the first fixing part (1120) may extend from the first fastening part (1110) to clamp the discharge resistor (1000). The first fastening part (1110) and the first fixing part (1120) may be integrally formed and may be elastic members.

[0101] Referring to FIG. 7, the first cover (900) may include a body (910), a fixing part (920), a connector part fixing part (930), and a resistor fixing part (940).

[0102] The body (910) is positioned above the transistor (510) and can cover at least a portion of the upper surface and side surface of the transistor (510). At this time, the body (910) can absorb heat generated from the transistor (510) to prevent overheating of the transistor (510).

[0103] The above fixing part (920) is a plurality of times, and each of the above fixing part (920) may extend from the edge of the body (910). The plurality of fixing parts (920) may be formed integrally with the body (910) and may be made of the same material as the body (910). At this time, the plurality of fixing parts (920) may be connected to the first housing (120 in FIG. 2) by means of fastening bolts.

[0104] The connector fixing part (930) may be positioned on the upper surface (911) of the body (910). The connector fixing part (930) may fix the connector part (800) passing over the upper side of the first cover (900). The connector fixing part (930) may protrude upward from the upper surface of the body (910) to form a fixing hole (931) into which the fixing clip (830) is inserted. At this time, the end of the fixing clip (830) may be inserted into the fixing hole (931) to fix its movement.

[0105] The resistance fixing part (940) can be connected to the discharge resistor (1000). More specifically, the resistance fixing part (940) can be connected to the first fixing member (1100) for fixing the discharge resistor (1000).

[0106] The above resistance fixing part (940) is a plurality of units, and the plurality of resistance fixing parts (420) may be spaced apart in a first direction (X-axis direction). At this time, the discharge resistor (1000) may be placed between the spaced-apart units of the plurality of resistance fixing parts (940). At this time, the first direction (X-axis direction) spacing distance (D) between the plurality of resistance fixing parts (940) may be greater than the width of the discharge resistor (1000).

[0107] The first cover (900) may be a rectangular member. The first cover (900) may have a width (WC1) in the first direction (X-axis direction) that is larger than the width (WC2) in the second direction (Y-axis direction).

[0108] FIG. 8 is a perspective view of a capacitor assembly and a discharge resistor according to an embodiment of the present invention, FIG. 9 is a circuit diagram of a capacitor assembly and a discharge resistor according to an embodiment of the present invention, FIG. 10 is a diagram comparing the third-directional height difference of a capacitor assembly and a discharge resistor according to an embodiment of the present invention, and FIG. 11 is a diagram comparing the third-directional height difference of a capacitor assembly, a discharge resistor, and a cover according to an embodiment of the present invention.

[0109] Referring to FIGS. 8 to 11, the air compressor according to the present invention may further include a connecting member (1200) for electrically connecting the discharge resistor (1000) and the capacitor assembly (520). Additionally, the discharge resistor (1000) may be spaced apart from the capacitor assembly (520). In this case, by separating the discharge resistor (1000) and the capacitor assembly (520), the degree of design freedom can be increased and space can be utilized more compactly.

[0110] Referring to FIGS. 8 and 9, the height in the third direction (Z-axis direction) at the location where the discharge resistor (1000) is placed may be lower than the height in the third direction (Z-axis direction) of the upper surface of the capacitor assembly (520). Here, the height refers to a distance in the third direction (Z-axis direction) relative to the lower surface of the capacitor assembly (520).

[0111] The height (H1) of the lower surface of the discharge resistor (1000) may be positioned lower than the height (H2) of the resistor connection terminal (524). Additionally, the height (H1) of the lower surface of the discharge resistor (1000) may be lower than the height of the upper surface of the capacitor assembly (520) and higher than the height (H3) of the lower surface of the capacitor assembly (520).

[0112] Likewise, the height (H4) at the bottom of the first cover (900) may be positioned lower than the height (H2) of the resistor connection terminal (524). Also, the height (H4) at the bottom of the first cover (900) may be lower than the height of the upper surface of the capacitor assembly (520) and higher than the height (H3) of the lower surface of the capacitor assembly (520). A transistor (510) may be positioned on the lower side of the first cover (900).

[0113] The air compressor according to the present invention can eliminate protruding parts by positioning the discharge resistor lower than the capacitor assembly, reduce interference between parts, and increase space utilization around the filter section.

[0114] FIG. 12 is a drawing showing a part of a filter unit according to one embodiment of the present invention.

[0115] Referring to FIG. 12, the air compressor may further include a heat exchange means (1300) disposed between the first cover (900) and the transistor (510) to increase cooling efficiency.

[0116] The heat exchange means (1300) is connected to the transistor (510) so as to be heat-exchangeable, and can be heated by the heat generated by the transistor (510) or cooled together with the transistor (510).

[0117] The above heat exchange means (1300) may be in direct contact and heat exchanged through conduction, but is not limited thereto. Additionally, the first cover (900) may be disposed on the upper side of the heat exchange means (1300). Furthermore, the discharge resistor (1000) may be disposed on the upper side of the first cover (900).

[0118] In this way, by further providing a heat exchange means (1300) between the first cover (900) and the transistor (510), the transistor (510) can be cooled more effectively, and the cooling efficiency of the discharge resistor (1000) placed on the upper side of the first cover (900) can also be increased.

[0119] Referring again to FIG. 12, the heat exchange means (1300) can be provided integrally with the first cover (900).

[0120] Since the first cover (900) is positioned above the heat exchange means (1300), the shaking phenomenon of the first cover (900) due to vibration caused by external force can be reduced while the first cover (900) and the heat exchange means (1300) are provided as a single unit. The first cover (900) and the heat exchange means (1300) can be formed as a single unit through an adhesive member such as an adhesive, or can also be formed as a single unit through injection molding.

[0121] Hereinafter, an air compressor according to another embodiment will be described with reference to FIG. 13.

[0122] FIG. 13 is a schematic plan view illustrating an air compressor according to another embodiment of the present invention.

[0123] This embodiment is substantially identical to the air compressor shown in FIG. 5, except for the location of the discharge resistor. Therefore, components identical to those in FIG. 5 are given the same reference numerals, and repetitive descriptions are omitted.

[0124] Referring to FIG. 13, the air compressor according to the present invention may include a discharge resistor (2000) electrically connected to a capacitor assembly (520).

[0125] The discharge resistor (2000) is a rectangular member and can be arranged in a first direction (X-axis direction). That is, the width (WR1) of the discharge resistor (2000) in the first direction (X-axis direction) can be smaller than the width (WR2) in the second direction (Y-axis direction). The discharge resistor (2000) arranged in this way can reduce interference with the filter section and can be arranged parallel to the flow direction of the cooling channel (700 in FIG. 3) to facilitate heat dissipation.

[0126] The internal space of the second housing (120) can be divided into a first space (120A) and a second space (120B) based on an arbitrary virtual line (C) extended in the second direction. At this time, the virtual line (C) may pass through the transmission module (600). A capacitor assembly (520) may be placed in the first space (120A), and a current sensor assembly (530) may be placed in the second space (120B). At this time, a discharge resistor (2000) may be placed in the first space (120A).

[0127] In one embodiment, although not shown in the drawings, the discharge resistor (1000) may be disposed adjacent to the current sensor assembly (530). The discharge resistor (1000) may be coupled to the current sensor assembly (530).

[0128] In one embodiment, although not shown in the drawing, the discharge resistor (1000) may be positioned adjacent to the transfer module (600). The discharge resistor (1000) may be coupled to the fixing means (620 in FIG. 3).

[0129] In one embodiment, although not illustrated in the drawings, the discharge resistor (1000) may be coupled to the second housing (120). In this case, the second housing (120) has a receiving portion in which the filter portion (500) is disposed, and the discharge resistor (1000) may be mounted in the receiving portion. In this case, the air compressor may further include a second fixing member for fixing the discharge resistor (1000) to the upper surface of the second housing (120).

[0130] The air compressor according to the present invention can be made compact by improving the arrangement structure between the filter section (500) and the discharge resistor (1000), thereby reducing interference between the filter section (500) and the discharge resistor (1000) and increasing the space utilization of the filter section (500).

[0131] In addition, by placing the discharge resistor (1000) on the upper surface of the first cover (900) or in a location where heat can be easily dissipated, the discharge resistor (1000) can be prevented from overheating, and the problem of the temperature around the filter part (500) rising can be solved.

[0132] Hereinafter, an air compressor according to another embodiment will be described with reference to FIGS. 14 to 20.

[0133] FIG. 14 is a plan view of an air compressor according to another embodiment of the present invention, FIG. 15 is a perspective view of a cover according to another embodiment of the present invention, FIG. 16 is a partial cross-sectional view of an air compressor according to another embodiment of the present invention, FIG. 17 is a perspective view of a second housing according to another embodiment of the present invention, FIG. 18 is a cross-sectional view showing a part of the cover coupled to the second housing according to another embodiment of the present invention, FIG. 19 is a perspective view showing a discharge resistor coupled to a capacitor assembly according to another embodiment of the present invention, and FIG. 20 is a front view showing a discharge resistor coupled to a capacitor assembly according to another embodiment of the present invention.

[0134] The air compressor of the present embodiment illustrated in FIGS. 14 to 20 is substantially the same as the air compressor illustrated in FIG. 5. Therefore, components identical to those in FIG. 5 are given the same reference numerals, and repetitive descriptions are omitted.

[0135] Referring to FIGS. 14 to 18, an air compressor according to another embodiment of the present invention may include a second cover (3000).

[0136] The second cover (3000) may be placed inside the second housing (120). The second cover (3000) may be placed on one side of the capacitor assembly (520) along the first direction (X-axis direction) inside the second housing (120). Additionally, the second cover (3000) may be placed on one side of the first cover (900) along the second direction (Y-axis direction) inside the second housing (120). That is, the second cover (3000) may cover the interior of the second housing (120) that is not covered by the capacitor assembly (520) and the first cover (900).

[0137] The second cover (3000) may include a first support member (3100) and a second support member (3200).

[0138] The first support member (3100) may be disposed on one side of the second cover (3000) along the first direction (X-axis direction). The first support member (3100) may support the current sensor assembly (530). The first support member (3100) may have a shape corresponding to the shape of the current sensor assembly (530) to support the current sensor assembly (530), but is not limited thereto.

[0139] The second support member (3200) can support the transmission unit (610). More specifically, the second support member (3200) can support the U-phase bus bar (611) that transmits the AC power of the first phase (Phase U), the V-phase bus bar (612) that transmits the AC power of the second phase (Phase V), and the W-phase bus bar (613) that transmits the AC power of the third phase (Phase W), respectively. At this time, each bus bar (611, 612, 613) may have a shape that is bent toward the current sensor assembly (530), as shown in FIG. 15. Since each bus bar (611, 612, 613) is bent in the same direction, the convenience of assembly is improved and the assembly time can be shortened.

[0140] The second support member (3200) may include a protrusion (3210) that protrudes in a third direction (Z-axis direction) along the shape of the transmission unit (610). While the transmission unit (610) is supported by the second cover (3000), a portion of it may protrude outward from the second cover (3000) along the third direction (Z-axis direction). The protrusion (3210) may surround the portion of the transmission unit (610) that protrudes outward from the second cover (3000).

[0141] The protrusion (3210) can be received in the through hole (120H) of the second housing (120) shown in FIGS. 17 and 18. The protrusion (3210) may have a thickness corresponding to the distance between the two surfaces of the second housing (120) that form the through hole (120H). By doing so, the gap between the outer surface of the protrusion (3210) and the one surface of the second housing (120) that forms the through hole (120H) is suppressed, so that the state in which the transmission unit (610) is supported by the protrusion (3210) can be stably maintained.

[0142] In addition, since the second cover (3000) of the air compressor according to the present invention supports the U-phase, V-phase, and W-phase busbars (611, 612, 613), the amount of fastening members, such as bolts used to support the U-phase, V-phase, and W-phase busbars (611, 612, 613), is reduced, thereby saving costs and assembly time consumed to manufacture the air compressor.

[0143] In addition, the air compressor according to the present invention covers an area in the second housing (120) that is not covered by the capacitor assembly (520) and the first cover (900) by means of the second cover (3000), so that fastening members, etc., may be prevented from entering the interior of the second housing (120) due to an operator's mistake.

[0144] In addition, since the second cover (3000) of the air compressor according to the present invention simultaneously supports the current sensor assembly (530) and the transmission unit (610), the process of double injection molding the cover to support each component can be omitted. As a result, cost reduction and savings in assembly costs and assembly time can be achieved.

[0145] Referring again to FIGS. 16 to 18, an air compressor according to another embodiment of the present invention may include a groove (4000) disposed inside a second housing (120) and a seal ring (5000) disposed in the groove (4000).

[0146] The groove (4000) may be positioned near the through hole (120H) located inside the second housing (120). The groove (4000) may be positioned spaced apart from the through hole (120H). The groove (4000) may be formed in a square ring shape along the surfaces of the second housing (120) that form the through hole (120H), but is not limited thereto. The groove (4000) may be formed along a third direction (Z-axis direction) on one surface of the second housing (120). When the second cover (3000) is positioned inside the second housing (120), the open upper side of the groove (4000) may be covered by the second cover (3000).

[0147] The sealing (5000) can be placed in the groove (4000). The sealing (5000) can be formed to have a circular cross-section. A portion of the sealing (5000) can be pressed by the second cover (3000). When the second cover (3000) is placed in the second housing (120) and covers the upper side of the groove (4000), the sealing (5000) can maintain airtightness between the bonding surface of the second cover (3000) and the bonding surface of the groove (4000). By doing so, the entry of foreign substances, etc. into the interior of the second housing (120) can be prevented.

[0148] Additionally, the sealing (5000) can prevent hot air generated from the air compressor from entering the inverter (not shown) that supplies power to the motor unit (300). By doing so, the performance of the inverter (not shown) can be maintained, and power can be stably supplied to the motor unit (300) through the inverter (not shown).

[0149] In this embodiment, the shape of the sealing (5000) is exemplified as a circle, but it is not limited thereto, and the shape of the sealing (5000) can also be provided in a polygonal shape such as a square or a pentagon.

[0150] Referring to FIGS. 14, 19 to 20, a discharge resistor (1000) and a first fixing member (1100) according to another embodiment of the present invention may be placed on the lower side of the case (522) of a capacitor assembly (520).

[0151] More specifically, the discharge resistor (1000) is coupled to the first fixing member (1100) and can be fixed to the lower side of the case (522) by the first fixing member (1100). At this time, the discharge resistor (1000) can be positioned along the second direction (Y-axis direction) on the lower side of the case (522). The discharge resistor (1000), through which a high-voltage current flows, can be cooled by cooling water flowing inside the second housing (120).

[0152] The discharge resistor (1000) and the first fixing member (1100) according to the present embodiment may be integrally provided in the case (522) of the capacitor assembly (520).

[0153] As the discharge resistor (1000) is positioned on the lower side of the case (522), a connecting member (1200) for electrically connecting the discharge resistor (1000) and the capacitor assembly (520) can be wound along the outer surface of the case (520).

[0154] Although the present invention has been described above with reference to preferred embodiments, those skilled in the art will understand that various modifications and changes can be made to the invention without departing from the spirit and scope of the invention as described in the following claims. Explanation of the symbols

[0155] 100: Housing 200: Compression section 300: Motor section 400: Control board 500: Filter section 600: Transfer module 620: Fixing means 700: Cooling channel 800: Connector section 900: First Cover 1000,2000: Discharge resistor 1100: First fixing member 1200: Connecting member

Claims

Claim 1 An air compressor comprising: a housing; a rotating shaft disposed inside the housing; a compression unit connected to the rotating shaft to compress and discharge incoming air; a motor unit driving the rotating shaft; a control board controlling the motor unit; a filter unit filtering noise from external power and supplying it to the control board; and a first cover disposed to cover at least one side of the filter unit; wherein the filter unit comprises: a capacitor assembly connected to an external power source; a transistor connected to the control board; a current sensor assembly connected to the transistor; and a discharge resistor connected to the capacitor assembly to discharge the charge remaining in the capacitor assembly; and wherein a heat exchange means disposed between the first cover and the transistor. Claim 2 An air compressor according to claim 1, further comprising: a transmission module that transmits power from the control board to the motor part; wherein the discharge resistor is disposed adjacent to the transmission module, and the transmission module comprises a transmission unit extending radially outward from the motor part. Claim 3 In paragraph 2, the capacitor assembly comprises a capacitor; a case supporting the capacitor; and a resistor connection terminal connected to the discharge resistor; wherein the resistor connection terminal is an air compressor disposed on the capacitor. Claim 4 delete Claim 5 An air compressor according to paragraph 3, wherein the current sensor assembly and the capacitor assembly are arranged in a first direction perpendicular to the axial direction, and the transistor is arranged in a second direction perpendicular to the first direction with respect to the current sensor assembly and the capacitor assembly. Claim 6 In claim 5, the air compressor comprises at least one cooling channel disposed between the motor section and the filter section, and the discharge resistor is disposed adjacent to the cooling channel. Claim 7 An air compressor according to claim 1, wherein the first cover is positioned above the transistor and the discharge resistor is positioned on the upper surface of the first cover. Claim 8 An air compressor comprising, in claim 7, a fixing member coupled to the discharge resistor and disposed on the upper surface of the first cover to fix the discharge resistor to the first cover. Claim 9 In claim 7, the discharge resistor is an air compressor disposed adjacent to the current sensor assembly. Claim 10 An air compressor according to claim 1, wherein the first cover is positioned such that the width in the first direction is longer than the width in the second direction, and the discharge resistor is positioned such that the width in the first direction is longer than the width in the second direction. Claim 11 In paragraph 3, an air compressor in which one side of the first cover, on which the discharge resistor is fixed, is positioned lower than the resistor connection terminal. Claim 12 In paragraph 5, the internal space of the housing is divided into a first space in which the capacitor assembly is placed and a second space in which the current sensor assembly is placed, based on a virtual line extending in the axial direction, and the discharge resistor is an air compressor placed in the first space. Claim 13 In Clause 12, the discharge resistor is an air compressor positioned on the lower side of the case. Claim 14 An air compressor comprising: a housing; a rotating shaft disposed inside the housing; a compression unit connected to the rotating shaft to compress and discharge incoming air; a motor unit driving the rotating shaft; a control board controlling the motor unit; a filter unit that filters noise from external power and supplies it to the control board; a transmission module that transmits power from the control board to the motor unit; and a second cover disposed inside the housing; wherein the filter unit comprises: a capacitor assembly connected to an external power source; a transistor connected to the control board; a current sensor assembly connected to the transistor; and a discharge resistor connected to the capacitor assembly to discharge a charge remaining in the capacitor assembly; wherein the discharge resistor is disposed adjacent to the transmission module, and the transmission module comprises a transmission unit extending radially outward from the motor unit; and wherein the second cover comprises a first support member supporting the current sensor assembly and a second support member supporting the transmission unit. Claim 15 An air compressor according to claim 14, wherein the second support member includes a protrusion surrounding a part of the transmission unit, and the housing further includes a through hole for receiving the protrusion. Claim 16 An air compressor according to claim 15, wherein the housing further comprises a groove spaced apart from the through hole and a seal disposed inside the groove, and when the second cover is disposed inside the housing, the upper side of the groove and the seal are covered by the second cover. Claim 17 In claim 1, the first cover is an air compressor made of at least one of aluminum, synthetic resin, and steel. Claim 18 An air compressor according to claim 1, wherein the first cover and the heat exchange means are integrally formed.

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