Inverter device and inverter-integrated electric compressor provided with same

Abstract

Provided is an inverter device with which it is possible to inexpensively establish an insulation distance for terminals provided in an electric component body. An inverter device (7) is provided with: an IGBT body (10a) that controls AC power supplied to an electric motor; and a plurality of terminals (10b) that are provided to the IGBT body (10a) and are arranged in parallel with a predetermined distance therebetween. An insulating coating (10b1) is provided on one terminal (10b), and no insulating coating (10b1) is provided on another terminal (10b) adjacent to said one terminal (10b).

Description

Inverter device and inverter-integrated electric compressor equipped with the same

[0001] The present disclosure relates to an inverter device and an inverter-integrated electric compressor including the inverter device.

[0002] As disclosed in Patent Document 1, an inverter-integrated electric compressor incorporating an inverter device is known as a compressor for air conditioning systems mounted on hybrid vehicles, electric vehicles, etc. This inverter-integrated electric compressor is configured such that an inverter accommodating section (inverter box) is provided in a housing that incorporates an electric motor and a compression mechanism, and an inverter device is incorporated inside the inverter box to convert DC power supplied from a power source into AC power and apply the AC power to the electric motor.

[0003] The inverter device generally includes a plurality of electrical components such as IGBTs that convert DC power into AC power.

[0004] Patent No. 5733945

[0005] In high-voltage electrical components such as IGBTs, the distance between terminals is fixed, and therefore the insulation distance is also fixed. However, if the insulation distance between terminals is fixed, it may be difficult to satisfy various specifications and performance requirements. Furthermore, even if the insulation distance is ensured by insulating the terminals, it is desirable to do so as inexpensively as possible.

[0006] The present disclosure has been made in consideration of the above circumstances, and aims to provide an inverter device that can inexpensively ensure the insulation distance of terminals provided on an electrical component body, and an inverter-integrated electric compressor equipped with the same.

[0007] An inverter device according to one aspect of the present disclosure comprises an electrical component body that controls AC power supplied to an electric motor, and a plurality of terminals that are provided on the electrical component body and arranged in parallel at a predetermined distance from each other, one of the terminals being provided with an insulating coating, and the other terminals adjacent to the one terminal not being provided with an insulating coating.

[0008] An inverter-integrated electric compressor according to one aspect of the present disclosure includes an electric motor, a compression mechanism driven by the electric motor to compress a refrigerant, a housing that accommodates the electric motor and the compression mechanism, and the above-mentioned inverter device attached to an outer wall of the housing.

[0009] The insulation distance of the terminals provided on the electrical component body can be ensured inexpensively.

[0010] 1 is a side view of an inverter-integrated electric compressor according to an embodiment of the present disclosure; FIG. 2 is a perspective view showing an IGBT; FIG. 3 is a side view showing the inverter-integrated electric compressor of FIG. 1 in a separated state; FIG. 4 is a front view showing the inside of an inverter box; FIG. 5 is a perspective view of the inverter box of FIG. 4 as seen from the back; FIG. 6 is a perspective view showing an enlarged lower part of the inverter box of FIG. 4; FIG. 7 is a rear view of the lower part of the inverter box of FIG. 4 as seen from the IGBT side, showing the board; FIG. 8 is a side view showing an IGBT with insulating coating provided on the terminals; FIG. 9 is a side view showing a state in which insulating coating is not provided on the soldered portion of the terminals; FIG. 10 is a side view showing an IGBT with no insulating coating provided on the terminals; FIG. 11 is a front view showing the insulation distance of the terminals of the IGBT; FIG. 12 is a front view of the inside of an inverter box showing a modified example of the present disclosure.

[0011] Hereinafter, an embodiment according to the present disclosure will be described with reference to the drawings. FIG. 1 shows an inverter-integrated electric compressor 1 according to one embodiment of the present disclosure. The inverter-integrated electric compressor 1 includes a housing 2 that forms an outer shell. The housing 2 is configured by integrally fastening together a motor housing 3 that houses an electric motor (not shown) and a compressor housing 4 that houses a compression mechanism (not shown) with bolts or the like. The motor housing 3 and the compressor housing 4 are pressure-resistant containers made of aluminum die-cast.

[0012] An electric motor and a compression mechanism (not shown) housed inside the housing 2 are connected via a motor shaft, and the compression mechanism is driven by rotation of the electric motor. The compression mechanism may be, for example, a scroll compression mechanism.

[0013] A refrigerant suction port (not shown) is provided at one end (e.g., the left side in FIG. 1) of the motor housing 3. Low-temperature, low-pressure refrigerant gas is drawn into the motor housing 3 from this refrigerant suction port, circulates around the electric motor along the motor axis (left-right direction in FIG. 1), and is then drawn into the compression mechanism where it is compressed. The high-temperature, high-pressure refrigerant gas compressed by the compression mechanism is discharged into the compressor housing 4 and then sent to the outside from a discharge port (not shown) provided at one end (e.g., the right side in FIG. 1) of the compressor housing 4.

[0014] The housing 2 is provided with a plurality of mounting legs (not shown) so that the inverter-integrated electric compressor 1 is fixedly installed in a motor room (or engine room) of a vehicle.

[0015] An inverter device 7 including an inverter box 9 is fixed to the rear end surface 3a (left end surface in FIG. 1 ) of the motor housing 3. The inverter box 9 can be opened and closed using a lid 9a, and is box-shaped with a peripheral wall 9b of a predetermined height and a base plate 9c. The inverter box 9 is sealed by fixing the lid 9a to the peripheral wall 9b with screws or the like.

[0016] The inverter box 9 accommodates and installs electrical components that convert DC power supplied via a power cable from a power supply unit or battery (not shown) mounted on the vehicle into three-phase AC power and apply the AC power to the electric motor accommodated inside the motor housing 3. Figure 1 shows a plurality of IGBTs (electrical components) 10, which are semiconductor switching elements.

[0017] The IGBT 10 comprises an IGBT body 10a and terminals 10b provided on the IGBT body 10a. As shown in Fig. 2, each IGBT body 10a has three terminals 10b: an emitter, a collector, and a gate. The terminals 10b extend parallel to one another. The distance between the terminals 10b is the insulation distance.

[0018] 1, the IGBT body 10a is fixed to the surface of the base plate 9c. The IGBT body 10a is cooled by the low-pressure refrigerant circulating within the motor housing 3 via the base plate 9c and the rear end surface 3a of the motor housing 3.

[0019] The tip of the terminal 10b of the IGBT 10 is electrically connected to the substrate 12 by solder or the like. The substrate 12 is fixed to the inverter box 9 in a state parallel to the surface of the base plate 9c at a predetermined distance. A switching circuit connected to the IGBT 10 is mounted on the substrate 12.

[0020] In addition to the circuit board 12, the inverter box 9 is provided with a PN terminal to which a high-voltage power supply line is connected, a UVW terminal for supplying three-phase AC power to the electric motor, an earth terminal, and the like.

[0021] 3 shows a separated state of the inverter-integrated electric compressor 1. As shown in the figure, the motor housing 3 and the inverter box 9 are separable. By assembling the inverter box 9 with the base plate 9c of the inverter box 9 in contact with the rear end surface 3a of the motor housing 3, the inverter-integrated electric compressor 1 shown in FIG. 1 is obtained.

[0022] 4 shows the inside of the inverter device 7 with the cover 9a (see FIG. 1) of the inverter box 9 removed. In this figure, the circuit board 12 (see FIG. 1) has been removed.

[0023] 4, the lower part of the inverter box 9 is a cylindrical portion 9d that is cylindrical in shape to match the outer shape of the motor housing 3. A rectangular portion 9e is connected to the upper part of the cylindrical portion 9d.

[0024] A P-N connector 14, to which DC power is supplied, is provided at an upper corner of the rectangular portion 9e. The P-N connector 14 is attached to the base plate 9c of the inverter box 9. Two wires 15 extend separately from the P-N connector 14, with, for example, the P wire 15a extending downward and the N wire 15b extending to the side (right).

[0025] An inductor coil 16 and a smoothing capacitor 17 are provided below the P-N connector 14. As shown in Figure 5, the inductor coil 16 and the smoothing capacitor 17 are housed in a recess 19 formed in the base plate 9c. The recess 19 is assembled so that its bottom 19a contacts the rear end surface 3a (see Figure 3) of the motor housing 3. This allows the inductor coil 16 and the smoothing capacitor 17 to be cooled.

[0026] 4, a UVW busbar assembly 18 is provided below the inductor coil 16 and the smoothing capacitor 17. The UVW busbar assembly 18 is provided between the rectangular portion 9e and the cylindrical portion 9d.

[0027] Six IGBTs 10 are provided in the cylindrical portion 9d of the inverter box 9. Each IGBT body 10a is fixed to a front surface 9c1(F) of an IGBT fixing plate 9c1 of the base plate 9c with a fixing screw 20. The IGBT fixing plate 9c1 has a generally rectangular shape extending upward from the lower end of the peripheral wall 9b of the inverter box 9. Three IGBTs 10 are arranged on each side of the rectangular IGBT fixing plate 9c1. The IGBTs 10 are arranged so that the terminals 10b of the IGBTs 10 facing each other on the left and right sides face each other. As shown in FIG. 5, the rear surface 9c1(R) of the IGBT fixing plate 9c1, which is the surface on which the IGBTs 10 are not fixed, is assembled so that its entire surface contacts the rear end surface 3a of the motor housing 3 (see FIG. 3).

[0028] As shown in Fig. 4, connecting portions 9c2 extending diagonally upward and to the sides are provided on both sides of the upper portion of the IGBT fixing plate 9c1. The upper portion of the IGBT fixing plate 9c1 is supported by each connecting portion 9c2. The other end of each connecting portion 9c2 is connected to the peripheral wall 9b. As shown in Fig. 5, the rear surface 9c2(R) of each connecting portion 9c2 is assembled so that its entirety contacts the rear end surface 3a of the motor housing 3 (see Fig. 3).

[0029] 6, base plate openings 22 are formed on the left and right sides and on the top of the IGBT fixing plate 9c1. The base plate 9c is not present at the position of each base plate opening 22 and has been removed. Each base plate opening 22 allows the interior of the inverter box 9 to be viewed from the back side of the base plate 9c, allowing the IGBT 10 (particularly the terminals 10b) to be inspected.

[0030] As shown in Figure 5, a seal portion 9c3 is provided around the cylindrical portion 9d so as to partially protrude from the back surface of the base plate 9c. The seal portion 9c3 is provided in a generally annular shape so as to surround and cover each base plate opening 22. When the inverter box 9 is attached to the rear end surface 3a of the motor housing 3 (see Figure 3), the seal portion 9c3 prevents moisture and the like from entering the inverter box 9 from the outside through the base plate opening 22.

[0031] 7 shows the substrate 12 viewed from the IGBT 10 side with the IGBT fixing plate 9c1 removed. The substrate 12 is fixed to the inverter box 9 using the fixing holes 12a. Three substrate fixing screws 24 for fixing the substrate 12 using the fixing holes 12a are shown in FIG.

[0032] 4, an insulating coating 10b1 is provided on the central terminal 10b of the three terminals 10b of each IGBT 10. The insulating coating 10b1 may be, for example, a tube made of an insulating material or an adhesive made of an insulating material.

[0033] 8 shows the terminal 10b provided with an insulating coating 10b1. As shown in the figure, the insulating coating 10b1 is provided continuously from the connection position with the IGBT body 10a to the substrate 12. At the connection position with the substrate 12, the insulating coating 10b1 has a fan-shaped shape that widens toward the substrate. This is because the insulating coating 10b1 is formed around the solder that connects the terminal 10b to the conductive pattern on the substrate 12.

[0034] As shown in FIG. 9, an insulating coating 10b1 may be formed in advance, avoiding the position where the solder is formed (see terminal 10b on the left side of FIG. 9), and then adhesive may be applied to cover the solder (see terminal 10b on the right side of FIG. 9).

[0035] 10, the terminals 10b on either side of the central terminal 10b are not provided with insulating coating 10b1, so that the conductive material of the terminals 10b is exposed.

[0036] 11, by providing the insulating coating 10b1 on the central terminal 10b, the distance L2 through the central terminal 10b becomes the insulation distance. This allows the insulation distance to be increased because the distance L1 between the adjacent terminals 10b becomes the insulation distance when the insulating coating 10b1 is not provided on the central terminal 10b.

[0037] If the distance L3 to the terminal of the adjacent IGBT 10 is equal to or less than the desired insulation distance, the insulating coating 10b1 is provided on one of the adjacent terminals 10b. In this way, the insulating coating 10b1 is not limited to being provided only on the center of the three terminals 10b, and the terminal 10b on which the insulating coating 10b1 is provided is determined appropriately in relation to the required insulation distance.

[0038] The effects of the present embodiment described above are as follows: One terminal 10b of the IGBT 10 is provided with an insulating coating 10b1, while the other terminal 10b adjacent to the one terminal 10b is not provided with an insulating coating. This makes it possible to ensure the insulation distance (distance L2) at lower cost than when all terminals 10b are provided with insulating coatings.

[0039] As shown in FIG. 12 , an opening 26 may be formed in the IGBT fixing plate 9c1. The opening 26 is formed in a position that can be seen from the back surface of the IGBT fixing plate 9c1. Specifically, the opening 26 is formed in a vertically elongated rectangular shape extending in the vertical direction, at the center between two rows of IGBTs 10 aligned vertically on the left and right in FIG. 12 . The number of openings 26 is not limited to one, and multiple openings 26 may be formed as long as each terminal 10b can be seen from the back surface of the IGBT fixing plate 9c1. The shape of the opening 26 is also not limited to a rectangle, and may be an oval, ellipse, or the like.

[0040] The openings 26 are formed at positions where the terminals 10b of the IGBT 10 fixed to the surface of the IGBT fixing plate 9c1 can be seen from the back surface, and therefore the insulating coating 10b1 can be provided on the terminals 10b through the openings 26. For example, even after the IGBT 10 is fixed to the surface of the IGBT fixing plate 9c1 and the terminals 10b of the IGBT 10 are connected to the substrate 12, the insulating coating 10b1 can be provided on the terminals 10b by applying an insulating adhesive through the openings 26.

[0041] The inverter device and the inverter-integrated electric compressor including the inverter device according to the above-described embodiments can be understood, for example, as follows.

[0042] The inverter device according to the first aspect of the present disclosure comprises an electrical component body (10a) that controls AC power supplied to an electric motor, and a plurality of terminals (10b) that are provided on the electrical component body and arranged in parallel at a predetermined distance from each other, with one of the terminals being provided with an insulating coating (10b1) and the other terminals adjacent to the one terminal not being provided with an insulating coating.

[0043] An electrical component such as an IGBT has, for example, three terminals extending in parallel on its body. One terminal is provided with an insulating coating, while the other terminal adjacent to the first terminal is not. This allows the insulation distance to be secured more cheaply than if all terminals were provided with insulating coatings. The insulating coating can be formed, for example, by covering the terminal with a tube made of insulating material or by applying an insulating adhesive to the terminal.

[0044] In the inverter device according to a second aspect of the present disclosure, in the first aspect, three terminals are provided for one electrical component body, and only the central terminal is provided with the insulating coating.

[0045] For example, an electrical component such as an IGBT has three terminals: an emitter, a collector, and a gate. Only the central terminal of these three terminals is provided with an insulating coating. This allows for a larger insulation distance between the terminals on either side of the central terminal.

[0046] The inverter device according to the third aspect of the present disclosure is the inverter device according to the first or second aspect, which comprises a base plate (9c) to the surface of which the electrical component body is fixed, and a substrate (12) that is spaced apart from the surface of the base plate and to which the tip ends of each of the terminals are connected, and the base plate has an opening (26) formed in a position where the terminals provided on the electrical component body fixed to the surface of the base plate can be seen from the back surface of the base plate.

[0047] The openings are formed at positions where the terminals provided on the electrical component body fixed to the surface of the base plate can be seen from the back surface, so that the terminals can be provided with insulating coatings through the openings. For example, even after the electrical component body is fixed to the surface of the base plate and the terminals provided on the electrical component body are connected to a board, the insulating coatings can be provided on the terminals through the openings.

[0048] The inverter device according to a fourth aspect of the present disclosure is the inverter device according to the third aspect, wherein the terminal provided on one of the electrical component bodies and the terminal provided on the other of the electrical component bodies are arranged opposite each other, and the opening is formed between the terminals arranged opposite each other.

[0049] Since an opening is formed between the opposing terminals, both of the opposing terminals can be seen from the rear surface of the base plate through the same opening.

[0050] The inverter-integrated electric compressor according to a first aspect of the present disclosure includes an electric motor, a compression mechanism driven by the electric motor to compress a refrigerant, a housing (2) that accommodates the electric motor and the compression mechanism, and an inverter device described above that is attached to an outer wall of the housing.

[0051] REFERENCE SIGNS LIST 1 inverter-integrated electric compressor 2 housing 3 motor housing 3a rear end surface 4 compressor housing 7 inverter device 9 inverter box 9a lid portion 9b surrounding wall 9c base plate 9c1 IGBT fixing plate 9c1 (F) front surface 9c1 (R) rear surface 9c2 connection portion 9c2 (R) rear surface 9c3 seal portion 9d cylindrical portion 9e rectangular portion 10 IGBT (electrical component) 10a IGBT body (electrical component body) 10b terminal 10b1 insulating coating 12 substrate 12a fixing hole 14 P-N connector 15 wiring 15a P wiring 15b N wiring 16 inductor coil 17 smoothing capacitor 18 UVW busbar assembly 19 recess 19a bottom portion 20 fixing screw 22 Base plate opening 24 Board fixing screw 26 Opening

Claims

1. An inverter device comprising: an electrical component body that controls AC power supplied to an electric motor; and a plurality of terminals provided on the electrical component body and arranged in parallel at a predetermined distance from each other, wherein one of the terminals is provided with an insulating coating, and the other terminals adjacent to the one terminal are not provided with an insulating coating.

2. The inverter device according to claim 1, wherein three terminals are provided for one electrical component body, and only the central terminal is provided with the insulating coating.

3. An inverter device as described in claim 1, comprising: a base plate to which the electrical component body is fixed on a surface; and a substrate provided at a distance from the surface of the base plate and to which the tip ends of each of the terminals are connected, wherein openings are formed in the base plate at positions where the terminals provided on the electrical component body fixed on the surface of the base plate can be seen from the back surface of the base plate.

4. An inverter device according to claim 3, wherein the terminal provided on one of the electrical component bodies and the terminal provided on the other of the electrical component bodies are arranged opposite each other, and the opening is formed between the terminals arranged opposite each other.

5. An inverter-integrated electric compressor comprising: an electric motor; a compression mechanism driven by the electric motor to compress a refrigerant; a housing accommodating the electric motor and the compression mechanism; and an inverter device according to any one of claims 1 to 4 attached to an outer wall of the housing.

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