Vehicle-mounted electric compressor
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Solution Overview
Problem
Existing vehicle-mounted electric compressors face high costs due to the need for thin, expensive heat-generating elements and complex manufacturing processes, which limit cooling performance and ease of production.
Innovation Solution
A vehicle-mounted electric compressor design featuring a metal substrate with electrically conductive layers, soldered metal heat-generating elements, and a resin substrate with a printed metal pattern, allowing for high-density element placement and simplified manufacturing by eliminating the need for inter-substrate terminals and complex signal line layouts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a pressing piece is used to fix the substrate onto the holding surface of the housing, then the cooling performance is improved, but the cost increases due to the need for heat-generating elements with small thickness tolerance
Solution Approach 1:
The patent combines the substrate and heat-generating elements into an integrated module where the substrate is formed as a single piece with integrated heat-generating elements. This eliminates the need for separate pressing pieces and complex assembly processes, reducing manufacturing cost while maintaining good thermal contact with the housing holding surface for effective cooling
Solution Approach 2:
The substrate is designed with self-fixing structure that allows it to be directly mounted onto the holding surface without requiring additional pressing pieces or complex fastening mechanisms. The substrate itself serves both as the mounting platform and as the component requiring cooling, eliminating the need for separate fixing components
2Reliability
If inter-substrate terminals are installed to connect metal substrate and resin substrate, then electrical connectivity is achieved, but the manufacturing complexity and time increase
Solution Approach 1:
The patent merges the electrical connection function into the heat-generating element structure itself. The metal layer of the heat-generating element serves dual purposes: as the heat-generating component and as the electrical connection terminal. This eliminates the need for separate inter-substrate terminals and complex wiring layouts, reducing manufacturing complexity while ensuring reliable electrical connectivity
Solution Approach 2:
The heat-generating element is designed to perform multiple functions simultaneously: it generates heat for cooling purposes, provides electrical connection between substrates, and serves as a structural component. This multi-functionality eliminates the need for separate dedicated connection terminals, simplifying the overall device structure and manufacturing process
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
The design achieves high cooling performance while reducing manufacturing complexity and costs, ensuring efficient heat dissipation and stable operation.
Implementation Method 1
a heat-generating element (70) that includes a metal layer (72) soldered onto the electrically conductive layer (68)
Implementation Method 2
a heat-generating element (70) that includes a metal layer (72) soldered onto the electrically conductive layer (68)
Data Source
AI summary
This vehicle-mounted electric compressor is provided with a compressor body including a motor for compressing a refrigerant, and an inverter including a power element for supplying the motor with electric current. The power element is provided with: a metal substrate having an electrically conductive layer in a partial region of the surface thereof; a heat-generating element having a metal layer solder-fixed to the electrically conductive layer; and a resin substrate which is disposed in parallel with the metal substrate in a plate thickness direction of the metal substrate, and has a metal pattern printed on the surface thereof, the metal pattern having an electronic component mounted thereon. The electronic component and a terminal of the heat-generating element are connected by means of the metal pattern.