Electric Compressor Protector Structure for Impact Load Absorption

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Solution Overview

Problem

Existing electric compressors are vulnerable to damage and deformation due to high impact loads during collisions, particularly in vehicles, as the cover members and support structures fail to effectively absorb and dissipate the energy, leading to housing deformation and potential damage.

Innovation Solution

The electric compressor structure incorporates a protector with deformation-inducing parts, such as step parts, cutouts, and reduced-rigidity sections, positioned to face the electrically operated units, allowing the protector to deform and absorb impact energy, thereby reducing the load transmitted to the housing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a cover member is provided on the outer side of the housing to protect the electric compressor from external forces, then the protection capability is improved, but the load transmitted to the fixing parts and support boss increases, causing housing deformation

Engineering Contradiction:

Improveprotection capabilityVSAvoidhousing deformation

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The protector is divided into multiple functional zones: a load-receiving outer surface, deformation inducing parts (ridges and grooves) that segment the structure, and a load-transmitting inner surface. This segmentation allows the protector to absorb and distribute impact loads through controlled deformation, reducing the transmitted load to the housing fixing parts and support boss.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The deformation inducing parts (ridges and grooves) change the structural parameters of the protector by creating regions of varying rigidity. These geometric features enable the protector to undergo controlled deformation under impact, transforming the rigid protection structure into a energy-absorbing system that reduces peak load transmission to the housing.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If the vehicle body structure is made more robust to protect the electric compressor from impact loads, then the protection capability is improved, but the vehicle body weight increases

Engineering Contradiction:

Improveprotection capabilityVSAvoidvehicle body weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The protector acts as an intermediary component between the external impact environment and the electric compressor housing. Instead of strengthening the entire vehicle body structure, the protector serves as a dedicated energy-absorbing interface that protects the compressor while maintaining the original vehicle body weight and layout.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The protector converts harmful impact energy into beneficial controlled deformation. The deformation inducing parts are designed to absorb impact energy through plastic deformation, transforming the harmful collision force into a protective mechanism that reduces the load transmitted to the housing and support structures.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If the vehicle body structure is enhanced in rigidity to protect the electric compressor, then the protection capability is improved, but the layout flexibility is restricted

Engineering Contradiction:

Improveprotection capabilityVSAvoidlayout flexibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The protector serves as a standalone intermediary protection layer that can be independently designed and installed on the electric compressor housing. This approach maintains layout flexibility because it does not require modifications to the overall vehicle body structure, allowing the compressor to be positioned according to standard packaging arrangements.

Inventive Principle:

Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This design effectively reduces damage and deformation of the housing by absorbing impact energy through the protector's deformation, enhancing the compressor's resilience to external forces without increasing the vehicle's weight or restricting layout.

Implementation Method 1

a deformation inducing part that induces deformation when a load acts on the protector from the outside is provided in the protector, at a position facing the electrically operated unit

Methodology Applied

Scientific EffectDeformation: Deformation

Data Source

PatentEP4321357B1Electric compressor structure and protector for electric compressor

Publication Date: 2025.12.03 SUZUKI MOTOR CORP

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AI summary

The present invention makes it possible to reduce, by means of a protector of an electric compressor, damage and deformation of a housing of the electric compressor due to an external force transmitted to the housing. An electric compressor (1) includes: a compression mechanism (2); electrically operated units (3, 4); a housing (10) that houses the compression mechanism (2) and the electrically operated units (3, 4); and a protector (40) that has fixing surface parts (41, 42) to be fixed to the housing (10) and is disposed on the outer side of the housing (10), at a position facing the electrically operated units (3, 4). A deformation inducing part (49, 51-54, 56, 61, 62) that induces deformation when a load acts on the protector (40) from the outside is provided in the protector (40), at a position facing the electrically operated units (3, 4).