Inverter-Integrated Electric Compressor Substrate Stress Management
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Inverter-integrated electric compressors face increased complexity, cost, and reliability issues due to the need for terminal blocks or busbars in DC power input systems, and there is a risk of damage from excessive pressing force when connecting metal terminals to circuit boards.
Innovation Solution
A direct connection system where a P-N terminal on the main substrate allows the power source cable connector to be inserted, with electrical components like smoothing capacitors placed on the opposite side to absorb stress, eliminating the need for terminal blocks or busbars and simplifying the configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a terminal block or busbar is provided in the DC power input system to connect high-voltage system components, then the reliability of connections is improved, but the device complexity and cost increase due to the increased number of components and connection portions
Solution Approach 1:
The patent merges the terminal block function directly into the substrate by providing a terminal (P-N terminal) directly on the substrate surface. This eliminates the need for separate terminal blocks or busbars, reducing the number of components while maintaining reliable electrical connections between the power source cable and high-voltage system components.
2Reliability
If metal terminals are inserted into the substrate to connect the power source cable, then the electrical connection is improved, but the substrate and mounting components may be damaged due to excessive pressing force
Solution Approach 1:
The patent places a resin layer between the metal terminal and the substrate surface. This resin layer acts as a cushioning element that absorbs excessive pressing force during terminal insertion, preventing damage to the substrate and mounting components while still ensuring reliable electrical connection through the metal terminal.
3Device complexity
If a direct connection system is used where the power source cable connector is inserted directly into the P-N terminal on the main substrate, then the configuration is simplified and cost is reduced, but stress may be caused to the substrate during connector insertion
Solution Approach 1:
The patent introduces a resin layer as an intermediary element between the P-N terminal and the substrate. This resin layer mediates the stress during connector insertion by providing a compliant interface that reduces peak stresses on the substrate while maintaining the simplified direct connection configuration.
Data Source
AI summary
The purpose of the present invention is to provide an inverter-integrated electric compressor in which a DC power input system is simplified as a configuration for directly connecting a power source cable connector to a P-N terminal on a substrate, stress caused to the substrate can be reduced even in this case, and damage to the substrate and mounting components can be prevented. In the inverter-integrated electric compressor, a P-N terminal for inputting high-voltage DC power is provided on a main substrate of an inverter device, a power source cable can be connected by inserting a connector into the P-N terminal, the connector being provided to one end the terminal, an electrical component constituting the inverter device is placed on the opposite side of the P-N terminal to sandwich the main substrate therebetween, and the stress caused to the main substrate when the connector is inserted is borne by the electrical component.