Electric Compressor Shield Plate Resin Integration
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Solution Overview
Problem
Existing electric compressors face issues with electromagnetic noise transmission from electronic components to the bus bar, leading to potential malfunctions and increased part counts due to the need for additional components like washers and holes in the shield plate for proper molding.
Innovation Solution
An electric compressor design integrates a bus bar, shield plate, and intervening resin portion to prevent electromagnetic noise transmission, where the intervening portion and shield plate are resin-molded together, with exposed surfaces to secure the bus bar and shield plate without additional mold members, reducing part count and thermal deformation risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a shield plate is interposed between electronic components and bus bar to prevent electromagnetic noise transmission, then reliability is improved, but device complexity increases due to additional parts and assembly steps
Solution Approach 1:
The shield plate and bus bar are merged into a single integrated component through resin molding. The shield plate is positioned within the mold cavity, and resin is injected to form the bus bar while simultaneously encapsulating the shield plate, creating an integrated assembly that reduces part count while maintaining electromagnetic shielding effectiveness.
Solution Approach 2:
The invention uses a composite structure combining metal shield plate, resin material, and conductive bus bar. The resin serves as both structural matrix and electromagnetic shielding medium, while the integrated design creates a composite component that achieves both electrical connectivity and noise protection functions.
2Manufacturing precision
If the shield plate is held by mold members with surfaces in contact during resin molding, then manufacturing precision is improved, but the bus bar may not be held properly due to interference from the shield plate
Solution Approach 1:
The mold members are segmented into multiple contact points rather than continuous surfaces. Specific localized contact points are designed to touch the shield plate at predetermined positions, allowing the shield plate to be held in place without interfering with the bus bar's contact with the mold members. This segmentation resolves the spatial conflict between holding the shield plate and allowing bus bar contact.
Solution Approach 2:
The mold members have different surface properties at different locations: some areas have contact points for the shield plate while other areas remain open or have different geometries to accommodate the bus bar. This local differentiation allows each component to be properly positioned and held during molding without mutual interference.
3Ease of manufacture
If holes are formed through the shield plate to insert mold members for holding the bus bar, then ease of manufacture is improved, but electromagnetic noise transmission increases due to exposed bus bar surfaces
Solution Approach 1:
Instead of forming holes through the shield plate, the invention extracts or removes the need for such holes by using alternative holding methods. The shield plate is held by surface contact points on its outer surfaces, eliminating the need for penetrating holes and thus preventing exposed bus bar surfaces that would allow electromagnetic noise transmission.
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 prevents electromagnetic noise transmission, reduces the number of parts, and minimizes thermal deformation, ensuring reliable operation and simplified structure while maintaining effective shielding.
Implementation Method 1
The bus bar, intervening portion and the shield plate are integrated by a resin member
Implementation Method 2
a shield plate that can intercept the electromagnetic noise may be interposed between the electronic components and the bus bar
Implementation Method 3
The resin ensures insulation between the bus bar and the housing
Data Source
AI summary
An electric compressor includes a housing a compression mechanism, an electric motor and a motor driving circuit. The motor driving circuit includes a circuit board and an electronic component mounted on the circuit board. The electric compressor further includes a bus bar, a shield plate having a bolt hole and an intervening portion interposed between the bus bar and the shield plate. The bus bar, intervening portion and the shield plate are integrated by a resin member. A part of the intervening portion on a side thereof opposite from the shield plate and/or a part of the bus bar on a side thereof opposite from the shield plate is exposed without being covered with the resin member. A surface of the shield plate around the bolt hole on a side thereof opposite from the intervening portion is exposed without being covered with the resin member.