Electric Compressor Inverter Cover With Metal-Resin EMI Shielding
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Solution Overview
Problem
Conventional electric compressors have heavy covers made of metallic materials to protect the inverter and shield electromagnetic waves, which increases processing costs and weight.
Innovation Solution
The electric compressor incorporates a cover made of a metal plate with integrally injection-molded first and second resin portions, reducing weight and processing costs while maintaining protection and electromagnetic shielding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the cover is made of metallic material to shield electromagnetic waves, then electromagnetic shielding is improved, but weight increases
Solution Approach 1:
The cover is constructed as a composite structure combining a metal plate with resin portions. The metal plate provides electromagnetic shielding while the resin portions reduce overall weight and provide additional protective functions. This composite approach resolves the contradiction by integrating materials with complementary properties rather than using a single material for all functions.
Solution Approach 2:
The cover is divided into multiple functional segments: a metal plate for electromagnetic shielding and separate resin portions for weight reduction and protection. The resin portions are disposed on both inside and outside of the metal plate, creating a segmented structure where each segment performs its specific function optimally.
2Reliability
If the cover is made seamless by diecasting to prevent foreign substances, then protection reliability is improved, but manufacturing cost increases
Solution Approach 1:
Instead of using a single diecast metal cover, the invention uses a composite assembly of metal plate and resin portions. This approach achieves equivalent or superior protection reliability while significantly reducing manufacturing complexity and cost, as each component can be manufactured separately using appropriate processes and then assembled.
Solution Approach 2:
The metal plate and resin portions are combined to form an integrated cover assembly that achieves the protective function. The resin portions are molded to fit over the metal plate, creating a unified protective structure that prevents foreign substance ingress while being manufacturable at lower cost.
Data Source
AI summary
An electric compressor including: a motor unit configured to generate power; a compression unit configured to receive the power from the motor unit and to compress a refrigerant; an inverter configured to control the motor unit; and a cover configured to be coupled to one side of the inverter. The cover includes: a metal plate formed in a shape corresponding to the inverter; a first resin portion configured to be disposed on an inside of the metal plate; and a second resin portion configured to be disposed on an outside of the metal plate in such a way as to correspond to some areas of the first resin portion.