Electric compressor

Abstract

Provided is an electric compressor capable of suppressing enlargement of a projection area of an inverter storage unit even when a filter component for measures against electromagnetic noise is enlarged or the number of filter components is increased.　In an electric compressor (1), a filter circuit unit (30) includes a first filter circuit board (31) on which a plurality of electrolytic capacitors (51) are mounted, and a second filter circuit board (33) on which a normal mode choke coil (53), a common mode choke coil (55), and the like are mounted. The first filter circuit board (31) and the second filter circuit board (33) are electrically connected to each other, and are stored in an inverter storage unit (7) in a state of overlapping each other with a plate-like resin member (35) interposed therebetween.

Description

Electric compressor

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

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

[0003] Japanese Patent Application Laid-Open No. 2020-143594

[0004] In recent years, the advancement of electronic control units in response to the electrification of automobiles has led to the demand for further electromagnetic noise countermeasures in electric compressors used in automotive air conditioners. One such electromagnetic noise countermeasure is the use of coils with higher inductance values ​​than conventional coils. However, coils with higher inductance values ​​are large in component size. Therefore, simply using a coil with a higher inductance value increases the projected area of ​​the filter circuit board and, in turn, the projected area of ​​the inverter housing section that houses the filter circuit board. Increasing the projected area of ​​the inverter housing section is undesirable because it limits the installation location of the electric compressor and may make the cover that closes the inverter housing section more susceptible to vibration, increasing noise caused by cover vibration.

[0005] Therefore, an object of the present invention is to provide an electric compressor that can suppress an increase in the projected area of ​​the inverter accommodating section even when the filter components for electromagnetic noise countermeasures become larger or the number of filter components increases.

[0006] According to one aspect of the present invention, there is provided an electric compressor. The electric compressor includes: a housing that accommodates a motor that rotates a rotating shaft and a compression mechanism driven by the rotation of the rotating shaft; an inverter accommodating section that is integral with the housing and has an opening and accommodates an inverter that drives the motor; and a cover member that closes the opening of the inverter accommodating section. The inverter includes an inverter circuit section that supplies power to the motor and a filter circuit section that reduces electromagnetic noise. The filter circuit section includes a first filter circuit board that has at least one first filter component mounted thereon and a second filter circuit board that has at least one second filter component mounted thereon. The first filter circuit board and the second filter circuit board are electrically connected to each other and are accommodated in the inverter accommodating section in a stacked state with a plate-shaped resin member sandwiched therebetween.

[0007] According to the present invention, it is possible to provide an electric compressor that can suppress an increase in the projected area of ​​the inverter accommodating section even when the filter components for electromagnetic noise countermeasures become larger or the number of filter components increases.

[0008] Fig. 1 is a schematic longitudinal sectional view of an electric compressor according to an embodiment; Fig. 2 is a schematic perspective view showing an inverter and an inverter accommodating section; Fig. 3 is a sectional view of a filter circuit section; Fig. 4 is an exploded perspective view of the filter circuit section; Fig. 5 is a perspective view of a resin member; Fig. 6 is a partially enlarged sectional view of the resin member; Fig. 7 is a perspective view showing a modified example of the filter circuit section; Fig. 8 is a perspective view showing a modified example of the filter circuit section;

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

[0010] FIG. 1 is a schematic longitudinal cross-sectional view of an electric compressor 1 according to an embodiment of the present invention. The electric compressor 1 according to the embodiment is an inverter-integrated electric compressor having an inverter integrated therein. The electric compressor 1 is used in a vehicle air conditioner. That is, the electric compressor 1 is mounted on a vehicle and forms part of the refrigerant circuit of the vehicle air conditioner, and is configured to compress and discharge refrigerant.

[0011] The electric compressor 1 includes a rotating shaft 2 , a motor 3 , a compression mechanism 4 , a housing 5 , an inverter 6 , an inverter accommodating portion 7 , and a cover member 8 .

[0012] The rotating shaft 2 is rotatably supported in the housing 5 by bearings (not shown). The motor 3 is a three-phase synchronous motor (brushless DC motor) that is driven by power supply to rotate the rotating shaft 2. The compression mechanism 4 is, for example, a scroll compression mechanism that is driven by the rotation of the rotating shaft 2. The housing 5 has a cylindrical cross section and accommodates the rotating shaft 2, the motor 3, and the compression mechanism 4. Within the housing 5, the motor 3 and the compression mechanism 4 are arranged in series in the axial direction of the rotating shaft 2.

[0013] The inverter 6 supplies power to the motor 3 to drive the motor 3. The inverter 6 includes an inverter circuit unit 20 that supplies power to the motor 3 and a filter circuit unit 30 that reduces electromagnetic noise. The inverter accommodating section 7 is integral with the housing 5 and accommodates the inverter 6. Specifically, the inverter accommodating section 7 is provided at the end of the housing 5 on the motor 3 side. In this embodiment, the inverter accommodating section 7 has a larger projected area than the housing 5. The inverter accommodating section 7 is formed by a bottom wall 71 and a peripheral wall 73 that rises from the periphery of the bottom wall 71, and has an opening 75 facing the bottom wall 71. The inverter circuit unit 20 and the filter circuit unit 30 that constitute the inverter 6 are accommodated in the inverter accommodating section 7, and the opening 75 of the inverter accommodating section 7 is closed by a cover member 8. The cover member 8 is fixed to the peripheral wall of the inverter accommodating section 7 (which is also part of the housing 5) with bolts (not shown).

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

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

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

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

[0018] The inverter circuit unit 20 is configured to convert DC power supplied from the vehicle battery via the HV connector 9 into three-phase AC power and supply it to the motor 3 (the stator coil 3 a) via a power supply line 10 extending through the partition wall 77. Therefore, the inverter circuit unit 20 includes six power switching elements 21 and an inverter control board 25 on which a control circuit 23 for controlling the six power switching elements 21 is mounted.

[0019] In this embodiment, the six power switching elements 21 are placed on a sheet-like first heat dissipation member 11 that is installed on the surface of the partition wall 77 that faces the inverter accommodating section 7. Each of the six power switching elements 21 is fixed in a state in which it is pressed against the first heat dissipation member 11 by an arm member 12 (see FIG. 1 ). The arm member 12 is attached with a bolt 13 to an arm attachment portion 14 that is provided inside the inverter accommodating section 7.

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

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

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

[0023] At least one filter component (hereinafter referred to as the “first filter component”) for electromagnetic noise reduction is mounted on one surface of the first filter circuit board 31. The at least one first filter component mounted on the one surface of the first filter circuit board 31 is a relatively large filter component. The at least one first filter component may include multiple filter components of the same or different types. Although not particularly limited, in this embodiment, multiple (here, nine) electrolytic capacitors 51 are mounted on the one surface of the first filter circuit board as the at least one first filter component. Note that the one surface of the first filter circuit board 31 is the top surface in FIGS. 1 , 3 , and 4 , and is the surface that faces the cover member 8 when the first filter circuit board 31 is housed in the inverter housing 7.

[0024] Although not shown in the drawings, a plurality of electronic components that are smaller than the at least one first filter component (here, electrolytic capacitor 51) are also mounted on first filter circuit board 31. At least some of these small electronic components are mounted on the other surface (the lower surface in FIGS. 1, 3, and 4, which faces the bottom of inverter accommodating section 7 when accommodated in inverter accommodating section 7) of first filter circuit board 31, or more specifically, at positions on the other surface of first filter circuit board 31 that avoid the area below the plurality of electrolytic capacitors 51.

[0025] At least one filter component (hereinafter referred to as the “second filter component”) for electromagnetic noise reduction is mounted on one surface of the second filter circuit board 33. Like the at least one first filter component, the at least one second filter component mounted on the one surface of the second filter circuit board 33 is a relatively large filter component and may include multiple filter components of the same or different types. Although not particularly limited, in this embodiment, a normal mode choke coil 53, a common mode choke coil 55, an X capacitor, and a Y capacitor are mounted on the one surface of the second filter circuit board 33 as the at least one second filter component. However, the X capacitor and the Y capacitor are not shown in the figures. The one surface of the second filter circuit board 33 is the bottom surface in FIGS. 1 , 3 , and 4 , and is the surface facing the bottom of the inverter accommodating section 7 when the second filter circuit board 33 is accommodated in the inverter accommodating section 7.

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

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

[0028] In this embodiment, the first filter circuit board 31 and the second filter circuit board 33 are electrically connected to each other and are housed in the inverter accommodating section 7 in a state where the first filter circuit board 31 and the second filter circuit board 33 are stacked with the plate-shaped resin member 35 sandwiched between them. Specifically, the first filter circuit board 31 and the second filter circuit board 33 are electrically connected to each other and housed in the inverter accommodating section 7 in a state where the other surface of the first filter circuit board 31 (the surface on which the electrolytic capacitor 51 is not mounted) and the other surface of the second filter circuit board 33 (the surface on which the normal mode choke coil 53, the common mode choke coil 55, etc. are not mounted) are disposed opposite each other with the plate-shaped resin member 35 sandwiched between them. This will be described in detail below.

[0029] First, the resin member 35 will be described. FIG. 5 is a perspective view of the resin member 35. In this embodiment, the resin member 35 includes a pair of metal bus bars 351 for electrically connecting the first filter circuit board 31 and the second filter circuit board 33, a resin main body 352 that holds the pair of bus bars 351, and a metal shielding plate 41 that is disposed inside the main body 352 and blocks electromagnetic noise. In other words, the resin member 35 includes the pair of bus bars 351 and also incorporates the shielding plate 41. Specifically, in this embodiment, the resin member 35 is formed as a plate-shaped resin molded body into which the pair of bus bars 351 and the shielding plate 41 are inserted. Furthermore, in this embodiment, the resin member 35 is formed to have an outer shape that corresponds to (substantially matches) the outer shape of the first filter circuit board 31.

[0030] The main body 352 of the resin member 35 is formed in a plate shape with a generally H-shaped cross section, in which a peripheral edge 352a having a predetermined width is protruded on both sides in the thickness direction relative to an inner portion 352b other than the peripheral edge 352a. In other words, both surfaces of the main body 352, i.e., both surfaces of the resin member 35, are formed such that the inner portions 352b are recessed relative to the peripheral edge 352a.

[0031] The pair of bus bars 351, 351 are arranged at a predetermined interval on the peripheral edge 352a of the main body 352. Each of the pair of bus bars 351, 351 penetrates the peripheral edge 352a of the main body 352 in the thickness direction, and has a first protruding portion 351a protruding from the peripheral edge 352a to one side in the thickness direction (upper side in FIGS. 1 and 3 to 5) and a second protruding portion 351b protruding from the peripheral edge 352a of the main body 352 to the other side in the thickness direction (lower side in FIGS. 1 and 3 to 5).

[0032] FIG. 6 is a partially enlarged cross-sectional view of the resin member 35, showing the bus bar 351 and its surrounding area. As shown in FIG. 6 , in this embodiment, the bus bar 351 is formed as a cross-shaped terminal. The bus bar 351 has a conductive portion 3511 for electrically connecting the first filter circuit board 31 and the second filter circuit board 33. The conductive portion 3511 extends through the peripheral edge portion 352 a of the main body portion 352 in the thickness direction, and a held portion 3513 extends intersecting the conductive portion 3511 and is held by the main body portion 352. One end of the conductive portion 3511 forms a first protrusion 351 a, and the other end of the conductive portion 3511 forms a second protrusion 351 b.

[0033] More specifically, in this embodiment, a through hole 353 penetrating the thickness direction is formed in the peripheral edge portion 352a of the main body portion 352, and the bus bar 351 is disposed in this through hole 353. The conductive portion 3511 of the bus bar 351 extends axially within the through hole 353, with one end protruding from one side of the through hole 353 (upper side in FIG. 6 ) as a first protrusion 351a and the other end protruding from the other side of the through hole 353 (lower side in FIG. 6 ) as a second protrusion 351b. The held portion 3513 extends in a direction perpendicular to the axial direction of the through hole 353, with both ends embedded in the peripheral wall of the through hole 353, i.e., in the main body portion 352, thereby holding the held portion 3513 and, therefore, the bus bar 351, by the main body portion 352.

[0034] That is, in this embodiment, only both ends of the held portion 3513 of the bus bar 351 are embedded in the main body portion 352 (i.e., the resin portion), and the other portion is exposed from the main body portion 352. Furthermore, in this embodiment, the conductive portion 3511 of the bus bar 351 does not contact the peripheral wall of the through hole 353, i.e., the main body portion 352.

[0035] Furthermore, although not particularly limited, in this embodiment, the shielding plate 41 is formed to have an outer shape that roughly corresponds to the inner portion 352b of the main body portion 352, as shown by the dashed lines in Figures 4 and 5.

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

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

[0038] The first filter circuit board 31 is also formed with a pair of first bus bar insertion holes 313 corresponding to the pair of bus bars 351 of the resin member 35. When the first filter circuit board 31 is attached to the resin member 35, the first protrusions 351 a of the pair of bus bars 351 of the resin member 35 are inserted into the pair of first bus bar insertion holes 313 of the first filter circuit board 31, and the first protrusions 351 a of the pair of bus bars 351 of the resin member 35 are soldered to the first filter circuit board 31. This electrically connects the pair of bus bars 351 of the resin member 35 and the first filter circuit board 31.

[0039] As described above, the first protrusion 351a of the bus bar 351 is part of the conductive portion 3511 of the bus bar 351, and most of the conductive portion 3511 of the bus bar 351 is located within the through hole 353 and is not in contact with the main body portion 352 (resin portion). Furthermore, in the bus bar 351, only both ends of the held portion 3513, which are located away from the first protrusion 351a, are embedded in the main body portion 352. This suppresses the diffusion of heat generated when the first protrusion 351a is soldered to the first filter circuit board 31, thereby stabilizing the soldering quality. Furthermore, the main body portion 352 is prevented from melting, deforming, or the like, due to the heat generated when the first protrusion 351a is soldered to the first filter circuit board 31.

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

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

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

[0043] The second filter circuit board 33 is also formed with a pair of second busbar insertion holes 333 corresponding to the pair of busbars 351 of the resin member 35. When the second filter circuit board 33 is attached to the resin member 35, the second protrusions 351 b of the pair of busbars 351 of the resin member 35 are inserted into the pair of second busbar insertion holes 333 of the second filter circuit board 33, and the second protrusions 351 b of the pair of busbars 351 are soldered to the second filter circuit board 33. This electrically connects the pair of busbars 351 of the resin member 35 to the second filter circuit board 33. Furthermore, the first filter circuit board 31 and the second filter circuit board 33 are electrically connected via the resin member 35 (the pair of busbars 351 of the resin member 35).

[0044] As described above, the second protrusion 351b of the bus bar 351 is part of the conductive portion 3511 of the bus bar 351, and most of the conductive portion 3511 of the bus bar 351 is located within the through-hole 353 and is not in contact with the main body portion 352 (resin portion). Furthermore, in the bus bar 351, only both ends of the held portion 3513, which are located away from the second protrusion 351b, are embedded in the main body portion 352. This suppresses the diffusion of heat generated when the second protrusion 351b is soldered to the second filter circuit board 33, thereby stabilizing the soldering quality. Furthermore, the main body portion 352 is prevented from melting, deforming, or the like, due to the heat generated when the second protrusion 351b is soldered to the second filter circuit board 33.

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

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

[0047] In this embodiment, the filter circuit section 30 further includes a first case member 37 and a second case member 39 .

[0048] The first case member 37 is made of, for example, a hard resin and is attached to the one surface of the first filter circuit board 31 to accommodate the plurality of electrolytic capacitors 51 mounted on the one surface of the first filter circuit board 31.

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

[0050] First, a predetermined amount of resin R in a softened or molten state is filled into the first case member 37. Next, the first filter circuit board 31 and the first case member 37 are aligned, and the first case member 37 is attached to the one surface of the first filter circuit board 31. The first filter circuit board 31 and the first case member 37 are aligned by inserting two third pins (not shown) provided on the first case member 37 into the third pin insertion holes 315a and the first pin insertion elongated holes 315b formed in the first filter circuit board 31. The resin R filled into the first case member 37 is then hardened. This fixes the first case member 37 to the one surface of the first filter circuit board 31. Furthermore, gaps within the first case member 37, i.e., gaps between the electrolytic capacitors 51 and gaps between the electrolytic capacitors 51 and the first case member 37, are filled with the resin R. The resin R is preferably a heat-resistant thermoplastic resin or a thermosetting resin.

[0051] The second case member 39 is formed of, for example, hard resin, similar to the first case member 37. The second case member 39 is attached to the one surface of the second filter circuit board 33 and is configured to house the normal mode choke coil 53 and the like mounted on the one surface of the second filter circuit board 33.

[0052] In this embodiment, the second case member 39, like the first case member 37, is attached to the one surface of the second filter circuit board 33 in the following manner.

[0053] First, a predetermined amount of resin R in a softened or molten state is filled into the second case member 39. Next, the second filter circuit board 33 and the second case member 39 are aligned, and the second case member 39 is attached to the one surface of the second filter circuit board 33. The second filter circuit board 33 and the second case member 39 are aligned by inserting the two fourth pin portions 391 provided on the second case member 39 into the fourth pin insertion holes 335a and the second pin insertion elongated holes 335b formed in the second filter circuit board 33. The filled resin R is then hardened. This fixes the second case member 39 to the one surface of the second filter circuit board 33. Furthermore, gaps within the second case member 39, i.e., gaps between components such as the normal mode choke coil 53 and gaps between the normal mode choke coil 53 and the second case member 39, are filled with the resin R.

[0054] In this way, the first filter circuit board 31 and the second filter circuit board 33 are integrated via the resin member 35, and the first case member 37 and the second case member 39 are also integrated. That is, in this embodiment, the filter circuit unit 30 includes the first filter circuit board 31, the second filter circuit board 33, the resin member 35, the first case member 37, and the second case member 39, which are integrated together to form the filter circuit unit 30.

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

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

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

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

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

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

[0061] In the electric compressor 1 according to this embodiment, the filter circuit section 30 includes a first filter circuit board 31 on which a plurality of electrolytic capacitors 51 serving as the at least one first filter component are mounted, and a second filter circuit board 33 on which a normal mode choke coil 53, a common mode choke coil 55, and the like are mounted as the at least one second filter component. The first filter circuit board 31 and the second filter circuit board 33 are electrically connected to each other and are housed in the inverter housing section 7 in a stacked state with a plate-shaped resin member 35 sandwiched therebetween.

[0062] That is, in this embodiment, multiple filter components for combating electromagnetic noise (such as the electrolytic capacitor 51, the normal mode choke coil 53, and the common mode choke coil 55) are mounted in a distributed manner on two circuit boards (the first filter circuit board 31 and the second filter circuit board 33). These two circuit boards (the first filter circuit board 31 and the second filter circuit board 33) can be arranged, for example, one above the other within the inverter accommodating section 7, with the resin member 35 sandwiched between them. Therefore, even if the filter components are increased in size or in number, an increase in the projected area of ​​the filter circuit boards constituting the filter circuit section 30 and therefore an increase in the projected area of ​​the inverter accommodating section 7 are suppressed. This also suppresses restrictions on the installation location of the electric compressor 1 and an increase in noise due to vibration of the cover member 8. Furthermore, because the electrolytic capacitor 51, the normal mode choke coil 53, and the common mode choke coil 55 are mounted on separate circuit boards, thermal interference therebetween is suppressed.

[0063] In particular, in this embodiment, the plurality of electrolytic capacitors 51 are mounted on the one surface of the first filter circuit board 31, and the normal mode choke coil 53, the common mode choke coil 55, etc. are mounted on the one surface of the second filter circuit board 33. The first filter circuit board 31 and the second filter circuit board 33 are accommodated in the inverter accommodating section 7 with the other surface of the first filter circuit board 31 and the other surface of the second filter circuit board 33 arranged to face each other with the resin member 35 in between. Therefore, the first filter circuit board 31 and the second filter circuit board 33 are each reinforced by the plate-shaped resin member 35, improving the vibration resistance of the filter circuit boards, and ultimately the filter circuit section 30.

[0064] Furthermore, the resin member 35 has a pair of metal bus bars 351, 351 that electrically connect the first filter circuit board 31 and the second filter circuit board 33, and also incorporates a shielding plate 41 that blocks electromagnetic noise. Therefore, there is no need to separately prepare components or the like for electrically connecting the first filter circuit board 31 and the second filter circuit board 33, and a compact and stable connection structure between the first filter circuit board 31 and the second filter circuit board 33 can be achieved, and malfunctions and the like due to interference from radiated noise between the first filter circuit board 31 and the second filter circuit board 33 can be prevented.

[0065] Furthermore, the resin member 35 has an outer shape that corresponds to the outer shape of the first filter circuit board 31. Therefore, the resin member 35 functions as an insulating wall between the first filter circuit board 31 and the second filter circuit board 33, and an insulating distance between the first filter circuit board 31 and the second filter circuit board 33 can be ensured.

[0066] Furthermore, the first filter circuit board 31 is fixed to the one surface of the resin member 35 by thermal caulking, and the second filter circuit board 33 is fixed to the other surface of the resin member 35 by thermal caulking. Therefore, the first filter circuit board 31 and the second filter circuit board 33 can be integrated (modularized), and a decrease in ease of assembly of the filter circuit unit 30 into the inverter accommodating unit 7 caused by distributing and mounting the filter components on two circuit boards is suppressed.

[0067] Furthermore, small electronic components mounted on the other surface of the first filter circuit board 31 are accommodated in the recessed inner portion 352b on the one surface of the main body 352 of the resin member 35, and small electronic components mounted on the other surface of the second filter circuit board 33 are accommodated in the recessed inner portion 352b on the other surface of the main body 352 of the resin member 35. In other words, recesses for accommodating small electronic components are formed on each of the one surface and the other surface of the resin member 35. This more effectively prevents an increase in the projected area of ​​the filter circuit board constituting the filter circuit unit 30, and therefore an increase in the projected area of ​​the inverter accommodating portion 7. This also effectively prevents interference with small electronic components such as the plurality of electrolytic capacitors 51, the normal mode choke coil 53, and the common mode choke coil 55.

[0068] The filter circuit section 30 also includes a first case member 37 that is disposed on the one surface of the first filter circuit board 31 and that houses the plurality of electrolytic capacitors 51, and a second case member 39 that is disposed on the one surface of the second filter circuit board 33 and that houses the normal mode choke coil 53, the common mode choke coil 55, and the like. In other words, the plurality of electrolytic capacitors 51 can be protected from vibration by the first case member 37, and the normal mode choke coil 53, the common mode choke coil 55, and the like can be protected from vibration by the second case member 39. This improves the vibration resistance of the filter circuit section 30.

[0069] Furthermore, gaps within the first case member 37 and gaps within the second case member 39 are filled with resin. This further improves the vibration resistance of the filter circuit unit 30, and also makes it possible to integrate (module) the first case member 37 and the second case member 39 in addition to the first filter circuit board 31 and the second filter circuit board 33, thereby improving the ease of assembling the filter circuit unit 30 to the inverter accommodating unit 7.

[0070] The filter circuit unit 30 is fixed with bolts 16, and is sandwiched between the bottom of the inverter accommodating unit 7 and the cover member 8, with a first vibration-isolating member 18 interposed between the second case member 39 and the bottom of the inverter accommodating unit 7 and a second vibration-isolating member 19 interposed between the first case member 37 and the cover member 8. Therefore, the filter circuit unit 30 is firmly fixed within the inverter accommodating unit 7, and high vibration resistance is achieved.

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

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

[0073] Furthermore, in the above-described embodiment, the resin member 35 has a pair of metal bus bars 351 that electrically connect the first filter circuit board 31 and the second filter circuit board 33, and also has a built-in metal shielding plate 41 that blocks electromagnetic noise. However, this is not limited to this. The pair of bus bars 351 and / or the shielding plate 41 may be omitted. This is because the first filter circuit board 31 and the second filter circuit board 33 can be electrically connected by a component other than the pair of bus bars 351, and there may be cases where the shielding plate 41 is not necessary, such as when the level of electromagnetic noise is relatively low. In other words, in addition to the aspects described in the above-described embodiment, the resin member 35 can also be implemented in any of the following aspects: (1) a first aspect having a pair of bus bars 351, 351 but not incorporating a shielding plate 41; (2) a second aspect having an incorporated shielding plate 41 but not incorporating a pair of bus bars 351, 351; and (3) a third aspect not having a pair of bus bars 351, 351 and not incorporating a shielding plate 41.

[0074] Furthermore, in the above-described embodiment, the resin member 35 is formed to have an outer shape that corresponds to the outer shape of the first filter circuit board 31. However, this is not limited to this. The resin member 35 may be formed to have an outer shape that corresponds to (substantially matches) the outer shape of at least one of the first filter circuit board 31 and the second filter circuit board 33. Preferably, the first filter circuit board 31, the second filter circuit board 33, and the resin member 35 are formed so that their outer shapes are substantially the same.

[0075] Furthermore, in the above-described embodiment, the filter circuit unit 30 is sandwiched between the bottom of the inverter accommodating unit 7 and the cover member 8, with vibration-isolating members interposed between the second case member 39 and the bottom of the inverter accommodating unit 7 and between the first case member 37 and the cover member 8. However, this is not limiting. The filter circuit unit 30 may be sandwiched between the bottom of the inverter accommodating unit 7 and the cover member 8, with vibration-isolating members interposed between at least one of the second case member 39 and the bottom of the inverter accommodating unit 7 and the first case member 37 and the cover member 8.

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

[0077] The above describes the embodiments of the present invention and their modifications. However, the present invention is not limited to the above-described embodiments and modifications, and it goes without saying that further modifications are possible based on the technical concept of the present invention.

[0078] DESCRIPTION OF SYMBOLS 1...electric compressor, 2...rotating shaft, 3...motor, 4...compression mechanism, 5...housing, 6...inverter, 7...inverter accommodating section, 8...cover member, 11...first heat dissipation member, 18...first vibration-isolating member, 19...second vibration-isolating member, 20...inverter circuit section, 21...power switching element, 23...control circuit, 25...inverter control board, 30...filter circuit section, 31...first filter circuit board, 33...second filter circuit board, 35...resin section material, 37...first case member, 39...second case member, 41...shielding plate, 43...second heat dissipation member, 45...third heat dissipation member, 51...electrolytic capacitor, 53...normal mode choke coil, 55...common mode choke coil, 317...first mounting hole, 337...second mounting hole, 351...bus bar, 352...main body portion, 352a...periphery portion, 352b...inner portion, 357...third mounting hole, 371...fourth mounting hole, 393...fifth mounting hole, R...resin

Claims

1. An electric compressor having: a housing that accommodates a motor that rotates a rotating shaft and a compression mechanism driven by the rotation of the rotating shaft; an inverter accommodating section that is formed integrally with the housing, has an opening, and accommodates an inverter that drives the motor; and a cover member that closes the opening of the inverter accommodating section, wherein the inverter has an inverter circuit section that supplies power to the motor and a filter circuit section for reducing electromagnetic noise, and the filter circuit section includes a first filter circuit board having at least one first filter component mounted thereon, and a second filter circuit board having at least one second filter component mounted thereon, the first filter circuit board and the second filter circuit board are electrically connected to each other and are accommodated in the inverter accommodating section in a stacked state with a plate-shaped resin member sandwiched between them.

2. The electric compressor according to claim 1, wherein the at least one first filter component is mounted on one surface of the first filter circuit board, the at least one second filter component is mounted on one surface of the second filter circuit board, and the first filter circuit board and the second filter circuit board are housed in the inverter accommodating section with the other surface of the first filter circuit board and the other surface of the second filter circuit board disposed opposite each other with the resin member in between.

3. The electric compressor according to claim 1, wherein the resin member has a bus bar that electrically connects the first filter circuit board and the second filter circuit board.

4. The electric compressor according to claim 1, wherein the resin member has a bus bar that electrically connects the first filter circuit board and the second filter circuit board, and incorporates a shielding plate that blocks electromagnetic noise.

5. The electric compressor according to claim 1, wherein said resin member has an outer shape corresponding to at least one of an outer shape of said first filter circuit board and an outer shape of said second filter circuit board.

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

7. The electric compressor according to claim 2, wherein an electronic component smaller than the at least one first filter component is mounted on the other surface of the first filter circuit board, and an electronic component smaller than the at least one second filter component is mounted on the other surface of the second filter circuit board, a first recess for accommodating an electronic component smaller than the at least one first filter component is formed on one surface of the resin member, and a second recess for accommodating an electronic component smaller than the at least one second filter component is formed on the other surface of the resin member.

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

9. The electric compressor according to claim 2, wherein the filter circuit section further includes: a first case member arranged on the one surface of the first filter circuit board and housing the at least one first filter component; and a second case member arranged on the one surface of the second filter circuit board and housing the at least one second filter component.

10. The electric compressor according to claim 9, wherein gaps within said first case member and gaps within said second case member are filled with resin.

11. The electric compressor as described in claim 9, wherein the filter circuit section is fixed within the inverter accommodating section by bolts and is sandwiched between the bottom of the inverter accommodating section and the cover member with a vibration-isolating member interposed between at least one of the second case member and the bottom of the inverter accommodating section and the first case member and the cover member.

12. The electric compressor according to any one of claims 1 to 11, wherein one of the at least one first filter component and the at least one second filter component includes a plurality of electrolytic capacitors, and the other of the at least one first filter component and the at least one second filter component includes a normal mode choke coil and a common mode choke coil.

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