Electric Compressor Drive Circuit Filter Integration
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Solution Overview
Problem
The existing electric compressors face challenges in reducing the size of circuit boards while maintaining the electrical insulation of filter components, which are prone to vibration-induced damage due to their mounting configuration.
Innovation Solution
Integrating filter elements such as coils and capacitors with the external connector, made of insulating materials, to prevent contact with the metal housing and reduce the size of the circuit board by embedding them within the connector, thus ensuring insulation and reducing vibration impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If filter elements are mounted on the circuit board, then the circuit board size increases, but the insulation between filter elements and housing is maintained
Solution Approach 1:
The filter elements are extracted from the circuit board and relocated to the housing wall, where they are mounted independently. This separation removes the burden of accommodating large filter elements from the circuit board, thereby reducing the circuit board size while maintaining electrical insulation through the housing structure.
Solution Approach 2:
The housing wall serves as an intermediary structure between the filter elements and the internal components. By mounting filter elements on the housing wall rather than directly on the circuit board, the housing acts as a mediator that maintains electrical insulation while allowing compact circuit board design.
2Reliability
If filter elements are fixed to the housing with fixing members, then the insulation is maintained, but vibration damage occurs when coatings are worn
Solution Approach 1:
The mechanical fixing method using fixing members is replaced with an adhesive bonding system. The adhesive layer provides both mechanical fixation and electrical insulation, eliminating the need for separate fixing members that could compromise insulation when coatings wear. The adhesive bonds the filter element directly to the housing wall while maintaining electrical isolation.
3Device complexity
If filter elements are mounted on the circuit board, then electrical connection is simplified, but the circuit board requires adhesive and auxiliary fixing parts increasing its size
Solution Approach 1:
The mounting structure is segmented by separating the filter element mounting from the circuit board. Filter elements are mounted on the housing wall independently, while the circuit board focuses only on electrical connections. This segmentation eliminates the need for adhesive and auxiliary fixing parts on the circuit board, reducing its size.
Solution Approach 2:
The mounting function is extracted from the circuit board and transferred to the housing wall with adhesive application. This allows the circuit board to be minimized to only the essential electrical connection area, while the housing structure handles the mechanical support and positioning of filter elements.
Data Source
AI summary
An electric compressor includes a compression mechanism, an electric motor for driving the compression mechanism, and a drive circuit for controlling the electric motor. The drive circuit includes an external connector made of an insulating material. The external connector has a connecting terminal that is constructed to be electrically connected to an external power source. The drive circuit further includes a circuit board electrically connected to the connecting terminal and a filter element electrically connected to the circuit board. The drive circuit is accommodated in a metal housing. The filter element is integrally formed with the external connector such that contact of the filter element with the housing is prevented.