Integrated Inverter Compressor Layout for Compact Cooling
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Solution Overview
Problem
Integrated electric compressors face challenges in achieving a compact design due to increased size from extra overhangs for capacitors, reduced capacitor effectiveness from long busbars, limited flexibility in wiring layout, and inadequate heat dissipation for electrical components.
Innovation Solution
The solution involves forming a heat-dissipating flat portion on the housing's outer wall parallel to the control circuit board, allowing electrical components to be positioned between this flat portion and the board, enhancing cooling efficiency and reducing the inverter box's height and volume, while using multilayer film capacitors for further compactness and improved anti-vibration properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the capacitor is disposed vertically at a position not overlapping the control circuit board, then the capacitor can be electrically connected to the control circuit board, but the inverter box needs an extra overhang which increases the size of the integrated electric compressor
Solution Approach 1:
The patent changes the spatial arrangement by disposing the capacitor horizontally at the bottom of the inverter box rather than vertically, and positions it to overlap with the control circuit board in the plan view. This dimensional repositioning allows the capacitor to be connected via a short busbar without requiring extra overhang of the inverter box, thus reducing the overall volume while maintaining electrical connection reliability.
Solution Approach 2:
The patent merges the capacitor position with the control circuit board area by allowing the capacitor to be disposed at a position overlapping the control circuit board. This merging of spatial zones eliminates the need for separate non-overlapping positioning, thereby removing the requirement for extra inverter box overhang and reducing the total volume.
2Adaptability or versatility
If the capacitor is remote from the switching element, then the capacitor can be disposed at a separate position, but a long busbar is required for interconnection which reduces the effect of the capacitor due to resistive and inductive components
Solution Approach 1:
The patent repositions the capacitor in the horizontal plane at the bottom of the inverter box to overlap with the control circuit board, changing from a vertical separation arrangement to a horizontal co-location arrangement. This dimensional change enables short busbar connection while maintaining positioning flexibility, thus preserving capacitor effectiveness by minimizing resistive and inductive components.
3Volume of moving object
If the inverter box is compact without extra overhang, then the size of the integrated electric compressor is reduced, but it becomes difficult to accommodate relatively large electrical components such as capacitors
Solution Approach 1:
The patent utilizes the vertical depth dimension of the inverter box by disposing the capacitor at the bottom, and allows horizontal overlap with the control circuit board. This three-dimensional spatial optimization enables compact inverter box design without sacrificing the ability to accommodate large electrical components, as the capacitor fits within the existing footprint by efficient vertical and horizontal positioning.
4Productivity
If the lead-out direction of the power cable is restricted to directions perpendicular to the main shaft, then the cable connection can be made via shortest distance, but the flexibility of wiring layout is reduced
Solution Approach 1:
The patent positions the capacitor at the bottom of the inverter box with horizontal overlap with the control circuit board, creating multiple possible connection paths. This spatial arrangement allows power cables to be routed in various directions (not just perpendicular to the main shaft) while still achieving short connection distances, thereby enhancing wiring layout flexibility without sacrificing connection efficiency.
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 results in a more compact design with improved cooling and anti-vibration properties, increased flexibility in wiring layout, and reduced internal volume and capacitance, effectively addressing the limitations of previous integrated electric compressors.
Implementation Method 1
a heat-dissipating flat portion that constitutes an outer wall of the housing and that is parallel to the control circuit board of the inverter is formed in the inverter box, and the electrical component is disposed in a space between the heat-dissipating flat portion and the control circuit board
Data Source
AI summary
An object is to achieve a compact design by using a dead space in an inverter box effectively, to improve cooling properties of heat-generating electrical components disposed on a control circuit board of an inverter, and to increase flexibility of wiring layout. In an inverter box provided at a periphery of a housing, a heat-dissipating flat portion that is parallel to a control circuit board of an inverter is formed, and electrical components are disposed in a space between the heat-dissipating flat portion and the control circuit board. Preferably, the electrical components are installed so that the back faces thereof abut against the heat-dissipating flat portion either directly or via a heat-conducting member. More preferably, faces of the electrical components on the board side abut against the control circuit board.