Inverter-Integrated Electric Compressor Thermal Management
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Solution Overview
Problem
Inverter-integrated electric compressors face issues with heat dissipation and lead terminal breakage due to vibrations, and have complex assembly processes that hinder workability.
Innovation Solution
The integration of a spacer member between the control circuit board and electrical components, along with a heat-dissipating flat section, prevents relative displacement and enhances heat dissipation, while a bonding member or pressing member improves assembly efficiency by eliminating the need for screws.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If electrical components are fastened to the bottom surface of the inverter box using fastening members or adhesive sheets to maximize heat dissipation, then heat dissipation efficiency is improved, but the assembly process becomes complex and workability deteriorates
Solution Approach 1:
The inverter box bottom surface is segmented into a recessed portion and a flat surface portion. The recessed portion accommodates the electrical components, while the flat surface portion provides the heat dissipation area. This segmentation allows the components to be naturally positioned and thermally connected without requiring additional fastening members or adhesive sheets, thus simplifying the assembly process while maintaining effective heat dissipation.
2Reliability
If electrical components are mounted on the control circuit board with gaps between them to allow vibration absorption, then reliability under vibration is improved, but heat dissipation efficiency deteriorates
Solution Approach 1:
A cushioning member is introduced as an intermediary between the electrical component and the recessed portion of the inverter box. This cushioning member serves dual functions: it absorbs vibrations to prevent lead terminal breakage (improving reliability) while still allowing thermal contact between the electrical component and the heat-dissipating flat surface portion (maintaining heat dissipation efficiency).
3Device complexity
If the control circuit board is directly attached to the inverter box without additional spacing components, then device complexity is reduced, but relative displacement between components during vibration occurs causing lead terminal breakage
Solution Approach 1:
The recessed portion of the inverter box is designed to serve multiple functions: it positions the electrical components, provides cushioning through the cushioning member to absorb vibrations, and facilitates heat dissipation. This multi-functional design prevents relative displacement between the control circuit board and electrical components during vibration (protecting lead terminals) without adding significant complexity to the overall structure.
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
Effective heat dissipation and prevention of lead terminal breakage, along with simplified assembly processes, are achieved by using a spacer member and bonding or pressing mechanisms to stabilize components and enhance heat transfer.
Implementation Method 1
The electrical component is disposed in abutment with the heat-dissipating flat section directly or via a heat conducting member so as to dissipate heat of the electrical component toward the housing
Implementation Method 2
A spacer member is interposed between the control circuit board and the electrical component so as to fill a space between the control circuit board and the electrical component. The spacer member is rigid enough that the control circuit board and the electrical component are prevented from being displaced toward and away from each other
Data Source
AI summary
An IGBT serving as a heat-generating electrical component mounted on the lower surface of a lower board serving as a control circuit board of an inverter is disposed in abutment with a heat-dissipating flat section provided on an inner wall of an inverter box provided on the outer periphery of a housing so that the heat of the IGBT is dissipated toward the housing. Moreover, a spacer member is interposed between the lower board and the IGBT so as to fill a space between the lower board and the IGBT, and the spacer member is rigid enough that the lower board and the IGBT are prevented from being displaced toward and away from each other.