Electric Compressor Inverter Module Design for Assembly and Insulation
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Solution Overview
Problem
Existing electric compressors with integrated inverters face challenges in assembly workability and electric insulation of power switching elements, particularly with increased voltage applications, while maintaining effective heat dissipation.
Innovation Solution
The electric compressor integrates power switching elements using thermosetting insulating resin to form a switching element module, which is installed on a dedicated installation portion within the inverter housing, improving assembly workability and electric insulation while ensuring heat dissipation through refrigerant cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If power switching elements are arranged one by one on the inverter-side surface of the partitioning wall, then heat dissipation can be achieved through refrigerant cooling, but assembly workability deteriorates
Solution Approach 1:
Multiple power switching elements are integrated into a single module unit with common mounting structure and cooling interface, transforming individual component assembly into module-level installation. This merging approach maintains heat dissipation effectiveness while dramatically improving assembly workability by reducing the number of discrete assembly operations.
Solution Approach 2:
Power switching elements are pre-assembled into a module configuration before installation on the partitioning wall. The module is prepared in advance with all necessary connections and cooling interfaces established, allowing for preliminary testing and assembly in a controlled environment before final installation, thereby improving overall assembly workability.
2Power
If voltage applied to power switching elements is increased, then power capability is improved, but electric insulation becomes more difficult to ensure
Solution Approach 1:
An insulating structure is introduced as an intermediary element between power switching elements at different voltage potentials. This intermediary insulation layer mediates the electrical isolation requirements, allowing high voltage operation while maintaining reliable electric insulation through the added insulating barrier.
Solution Approach 2:
The housing and mounting structures utilize composite material designs combining insulating and conductive properties in different regions. This allows the system to achieve both high voltage capability where conductivity is needed and reliable insulation where voltage isolation is required, through strategic material selection and configuration.
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 configuration enhances assembly workability and electric insulation of power switching elements while maintaining effective heat dissipation, addressing the limitations of existing technologies.
Implementation Method 1
The plurality of power switching elements is integrated using thermosetting insulating resin in a state in which at least part of the upper surface and the lower surface of each power switching element are exposed
Implementation Method 2
the plurality of power switching elements can be cooled with sucked refrigerant through the partitioning wall
Data Source
AI summary
Provided is an electric compressor configured so that the assembly workability and electric insulation of a power switching element can be improved while the heat dissipation (cooling performance) of the power switching element is ensured. In the electric compressor, a housing that houses an electric motor and a compression mechanism and an inverter housing portion that houses an inverter including a plurality of power switching elements Q1 to Q6 are separated by a partitioning wall. The inverter housing portion has an installation portion on which the plurality of power switching elements Q1 to Q6 is installed. The plurality of power switching elements Q1 to Q6 is integrated using thermosetting insulating resin in a state in which at least part of the upper surface and the lower surface thereof are exposed, thereby forming a switching element module, and the switching element module is installed on the installation portion.