Electric Compressor Busbar Support Structure for Board Stiffness
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Solution Overview
Problem
Electric compressors require additional components, such as dummy busbars, to ensure necessary stiffness for stacked members, which increases the number of components and complexity.
Innovation Solution
Incorporating a busbar with an embedded portion in a resin supporting plate, where the embedded portion extends perpendicular to the supporting plate's thickness direction, functions as part of the wiring and enhances stiffness without adding extra components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If dummy busbars are added to ensure stiffness for stacked members, then structural stability is improved, but device complexity increases due to additional components
Solution Approach 1:
The busbar is merged with the supporting plate by embedding the busbar into the supporting plate, creating an integrated structure. This combination eliminates the need for separate dummy busbars while providing both electrical connectivity and structural reinforcement, thereby improving stiffness without increasing component count
Solution Approach 2:
The busbar serves multiple functions: it provides electrical connectivity as part of the wiring and simultaneously acts as a reinforcement member to maintain the gap and ensure stiffness of the stacked members. This multi-functionality eliminates the need for dedicated dummy busbars, reducing device complexity while maintaining structural stability
2Device complexity
If the number of components is reduced by eliminating dummy busbars, then device complexity decreases, but manufacturing precision requirements increase for the embedded busbar structure
Solution Approach 1:
The busbar is pre-formed with an embedded portion having a thickness direction perpendicular to the supporting plate's thickness direction before assembly. This preliminary preparation of the busbar geometry enables precise embedding into the supporting plate, ensuring proper gap maintenance and structural stiffness while simplifying the overall component structure
Data Source
AI summary
Provided is an electric compressor that can ensure necessary stiffness for stacked members including a supporting plate and a control board, without increasing the number of components. An inverter circuit portion of an inverter-equipped electric compressor includes busbars 6a (61, 62, and 63) that are each formed by a thin plate member made of metal and that each constitutes part of the wiring of the inverter circuit portion, and includes a plate-like supporting plate 6b that is formed by a resin member molded integrally with the busbars 6a. Each of the busbars 6a (61, 62, and 63) has an embedded portion (a U-phase embedded portion 611, a V-phase embedded portion 621, or a W-phase embedded portion 631) that is embedded in the supporting plate 6b. Each of the embedded portions (the U-phase embedded portion 611, the V-phase embedded portion 621, and the W-phase embedded portion 631) extends in a direction perpendicular to the thickness direction of the supporting plate 6b, and the thickness direction of the thin plate member of each embedded portion (the U-phase embedded portion 611, the V-phase embedded portion 621, and the W-phase embedded portion 631) is perpendicular to the thickness direction of the supporting plate 6b.