U.S. patent application number 13/128618 was filed with the patent office on 2011-09-08 for inverter-integrated electric compressor.
Invention is credited to Eisuke Fujimra, Jun Mizuno, Atsushi Saito, Makoto Shibuya.
Application Number | 20110217191 13/128618 |
Document ID | / |
Family ID | 42152749 |
Filed Date | 2011-09-08 |
United States Patent
Application |
20110217191 |
Kind Code |
A1 |
Fujimra; Eisuke ; et
al. |
September 8, 2011 |
Inverter-Integrated Electric Compressor
Abstract
Provided is an inverter-integrated electric compressor whose
inverter section is molded using a urethane resin and which is
excellent in joining reliability of electrically connected section.
An inverter-integrated electric compressor, wherein the compressor
incorporates a motor and wherein a motor drive circuit including
the inverter is provided in a containing space surrounded by a
compressor housing. A crimping section of a terminal of a
conducting wire connected to the inverter is molded, together with
the inverter, in a resin charged into the containing space. A gap
at the crimping section, the gap being open to the outside, is
previously covered and sealed by a gap sealant.
Inventors: |
Fujimra; Eisuke; ( Gunma,
JP) ; Mizuno; Jun; ( Gunma, JP) ; Shibuya;
Makoto; ( Gunma, JP) ; Saito; Atsushi; (
Gunma, JP) |
Family ID: |
42152749 |
Appl. No.: |
13/128618 |
Filed: |
November 10, 2009 |
PCT Filed: |
November 10, 2009 |
PCT NO: |
PCT/JP2009/005980 |
371 Date: |
May 10, 2011 |
Current U.S.
Class: |
417/410.1 |
Current CPC
Class: |
F04B 39/121 20130101;
F04C 2240/808 20130101; F04C 2240/803 20130101; F04C 18/0215
20130101; F04C 23/008 20130101 |
Class at
Publication: |
417/410.1 |
International
Class: |
F04B 35/04 20060101
F04B035/04 |
Foreign Application Data
Date |
Code |
Application Number |
Nov 10, 2008 |
JP |
2008287719 |
Claims
1. An inverter-integrated electric compressor having a built-in
motor and provided with a motor drive circuit including an inverter
which is installed in a containing space surrounded by a compressor
housing, wherein a crimping section of a terminal of a conducting
wire connected to said inverter is molded, together with said
inverter, in a resin charged into said containing space, and a gap
open to the outside at said crimping section is previously covered
and sealed by a gap sealant.
2. The inverter-integrated electric compressor according to claim
1, wherein a cross-sectional portion of a tip of said conducting
wire is covered by said gap sealant.
3. The inverter-integrated electric compressor according to claim
1, wherein said gap sealant consists of a solder.
4. The inverter-integrated electric compressor according to claim
1, wherein said inverter-integrated electric compressor is a
compressor mounted on a vehicle.
Description
TECHNICAL FIELD OF THE INVENTION
[0001] The present invention relates to an inverter-integrated
electric compressor in which a motor drive circuit including an
inverter is assembled, and specifically, relates to an
inverter-integrated electric compressor in which the inverter
portion is molded by urethane resin, etc.
BACKGROUND ART OF THE INVENTION
[0002] As a structure of an inverter-integrated electric compressor
in which a motor drive circuit including an inverter is assembled,
a structure is known wherein a motor drive circuit is coated by a
resin mold material for insulation so as to be buried in the resin
mold material (e.g. Patent document 1). A lead wire for inputting
high voltage to the inverter portion in such a compressor, for
example, is connected to the inverter portion by being connected by
a screw to a circuit board for the inverter portion through a
connector for high voltage (an HV connector) comprising a
solderless terminal.
PRIOR ART DOCUMENTS
Patent Documents
[0003] Patent document 1: JP-A-2002-70743
SUMMARY OF THE INVENTION
Problems to be Solved by the Invention
[0004] In an inverter-integrated electric compressor shown in
Patent document 1, a space for housing a motor drive circuit is
filled with a mold material such as urethane resin, etc. in order
to protect parts constituting the inverter portion, etc. from heat
and vibration. However, if the mold material flows in a gap around
a conducting wire at a crimping section of the HV connector during
the filling operation, because the mold material repeats expansion
and contraction caused by a temperature variation of the HV
connector accompanied with fluctuation of the operation condition
of the compressor, there is a fear that a connection reliability of
the crimping section of the HV connector may reduce.
[0005] Accordingly, an object of the present invention is to
provide an inverter-integrated electric compressor in which an
inverter portion is molded by urethane resin, etc. and which is
excellent in joining reliability of electrically connected
section.
Means for Solving the Problems
[0006] To achieve the above-described object, an
inverter-integrated electric compressor according to the present
invention has a built-in motor and is provided with a motor drive
circuit including an inverter which is installed in a containing
space surrounded by a compressor housing, and is characterized in
that a crimping section of a terminal of a conducting wire
connected to the inverter is molded, together with the inverter, in
a resin charged into the containing space, and a gap open to the
outside at the crimping section is previously covered and sealed by
a gap sealant.
[0007] In the inverter-integrated electric compressor according to
the present invention, because the crimping section is molded
together with the inverter at a condition where a gap open to the
outside at the crimping section of the terminal of the lead wire
connected to the inverter is covered and sealed by a gap sealant,
the mold material is prevented from flowing in an inner gap of the
crimping section and therefore the joining reliability of the
crimping section is secured. As the above-described gap sealant, it
is preferred to use a material whose degree of an expansion or
contraction caused by a temperature variation of an HV connector is
small. By using such a material, it becomes possible to secure a
sufficient connection reliability of the above-described crimping
section.
[0008] Further, in order to cover and seal the inside of the
above-described open gap efficiently by using the above-described
gap sealant, as for the gap sealant, it is preferred to use a
material which can exhibit a fluidized state temporarily by
heating, etc. and can be solidified by cooling, etc. Concretely, a
gap sealant consisting of solder can be preferably used. For
example, by making a condition where a solder is fluidized
temporarily by a heated soldering iron, and at that condition, by
charging the solder into the open gap, and by solidifying the
solder by natural or forcible cooling, the covering and sealing of
the gap open to the outside at the crimping section can be
performed efficiently.
[0009] Further, in the present invention, even though the inside of
the open gap is covered and sealed, if a cross-sectional portion of
a tip of the conducting wire is exposed, there is a fear that a
mold material adhering to an irregularity part of the
cross-sectional portion of the tip repeats expansion and
contraction, whereby a stress may be applied to the tip of the
conducting wire and the joining reliability of the crimping section
may reduce. Therefore, it is preferred that the cross-sectional
portion of the tip of the conducting wire is covered by the gap
sealant so that the irregularity part of the cross-sectional
portion of the tip of the conducting wire is smothered thereby.
[0010] The inverter-integrated electric compressor according to the
present invention can be applied to substantially any types of
compressors, and in particular, it can be suitably used as a
compressor mounted on a vehicle, which is often installed in a
narrow space and its motor drive circuit of which is liable to be
affected by heat and vibration.
Effect According to the Invention
[0011] In the inverter-integrated electric compressor according to
the present invention, because the containing space surrounded by
the compressor housing is molded, together with the inverter, under
a condition where the gap open to the outside at the crimping
section of the terminal of the conducting wire connected to the
inverter is previously covered and sealed by the gap sealant, the
mold material is prevented from flowing into the crimping section
of the terminal of the conducting wire connected to the inverter,
and therefore it is possible to secure the connection stability and
connection reliability of the crimping section.
BRIEF EXPLANATION OF THE DRAWINGS
[0012] FIG. 1 is a schematic vertical cross-sectional view showing
a basic configuration of an inverter-integrated electric compressor
according to an embodiment of the present invention.
[0013] FIG. 2 is a diagram of a configuration showing a control
mechanism of air conditioning system including the compressor
depicted in FIG. 1 from the viewpoint of electric circuit.
[0014] FIG. 3 is a perspective view showing a state where a motor
drive circuit is installed in a containing space surrounded by a
front housing depicted in FIG. 1.
[0015] FIG. 4 depicts a crimping section connecting an HV connector
and a lead wire depicted in FIG. 3, where (A) is a perspective view
showing an uncovered state of the section and (B) is a perspective
view showing a covered state of the section.
EMBODIMENTS FOR CARRYING OUT THE INVENTION
[0016] Hereinafter, desirable embodiments of the present invention
will be explained referring to figures.
[0017] FIG. 1 shows an example of a scroll type inverter-integrated
electric compressor for automotive air conditioning system as a
basic configuration of an inverter-integrated electric compressor 1
according to an embodiment of the present invention. In FIG. 1,
symbol 2 shows a compression mechanism comprising a fixed scroll 3
and a movable scroll 4. Movable scroll 4 is moved orbitally
relative to fixed scroll 3 at a condition where the rotation is
prevented via ball coupling 5. Motor 7 is incorporated into
compressor housing 6 (center housing), and main shaft 8 (rotation
axis) is driven to be rotated by the built-in motor 7. Rotational
movement of main shaft 8 is transformed to an orbital movement of
movable scroll 4, through eccentric pin 9 provided at one end of
main shaft 8 and eccentric bush 10 which is engaged rotatably with
it. In this embodiment, suction port 11 sucking a refrigerant as a
fluid to be compressed is provided in compressor housing 12 (front
housing), and the sucked refrigerant is led to compression
mechanism 2 through a section placed with motor 7, and the
refrigerant which has been compressed by compression mechanism 2 is
delivered to an external circuit through discharge hole 13,
discharge chamber 14, and discharge port 16 which is provided in
compressor housing 15 (rear housing).
[0018] Motor drive circuit 21 for motor 7 is provided in compressor
housing 12 (front housing), and in more detail, motor drive circuit
21 is provided at the outer surface side of partition wall 22 which
is formed in compressor housing 12 for separating from the side of
the refrigerant suction route. Motor drive circuit 21 supplies
electric power to motor 7 via sealed terminal 23 (output terminal
of motor drive circuit 21) attached through partition wall 22, and
lead wire 24, and the side of refrigerant suction route and the
side of a section placing motor drive circuit 21 are sealed from
each other at a section placing sealed terminal 23. By providing
motor drive circuit 21 at the outer surface side of partition wall
22, at least a part of electric parts including motor drive circuit
21 can exchange heat through partition wall 22 with sucked
refrigerant, so as to be cooled by the sucked refrigerant.
[0019] Motor drive circuit 21 includes IPM 25 (intelligent Power
Module) having an inverter function and control circuit 26, and is
provided with electric parts such as capacitor 27, etc. separately
therefrom or integrally therewith. This motor drive circuit 21 is
connected to an external power supply (not shown) through connector
28 as an input terminal. The side open to the outside of compressor
housing 12, in which electric parts including motor drive circuit
21 are mounted, is covered by lid member 29 at a sealed condition,
and these electric parts are protected by the lid member 29.
[0020] From the viewpoint of electric circuit, the above-described
configuration can be depicted as shown in FIG. 2, for example. In
FIG. 2, electric compressor 1 is provided with motor drive circuit
21, and by supplying an output of motor drive circuit 21 to
respective motor coils 47 of built-in motor 7 through sealed
terminal 23 and lead wire 24, motor 7 is rotationally driven, and
compression by compression mechanism 2 is performed. Motor drive
circuit 21 has high voltage circuit for driving motor 30, and low
voltage circuit for control 45 which is provided with motor control
circuit 44 for controlling respective power elements 43 (switching
elements) of inverter 42 in high voltage circuit for driving motor
30, and this low voltage circuit for control 45 is configured in
control circuit 26 shown in FIG. 1. Power from external power
source 46 (for example, a battery) is supplied to high voltage
circuit for driving motor 30 through high voltage connector 47 and
is supplied to inverter 42 through noise filter 37 and capacitor
for smoothing 27, and after the DC from power source 46 is
converted to pseudo three-phase AC by inverter 42, the power is
supplied to motor 7. Motor control circuit 44 is supplied with low
voltage power, for example, from air conditioning control unit for
vehicles 48 through connector for control signal 49. Although this
connector for control signal 49 and connector for high voltage 47
are depicted in FIG. 2 at positions separate from each other, both
of the connectors are actually installed inside the same connector
28 shown in FIG. 1. Shield plate 31 is fixed to control circuit 26
and, as shown in FIG. 2, this shield plate 31 is interposed between
high voltage circuit for driving motors 30 and control circuit 26
provided with low voltage circuit for control 45, covering high
voltage circuit for driving motor 30 over an area as broad as
possible so as to suppress an influence of noise from the side of
high voltage circuit for driving motor 30 to the side of low
voltage circuit for control 45.
[0021] FIG. 3 is a perspective view showing motor drive circuit 21
being located in containing space 60 surrounded by compressor
housing 12 (front housing). Case member 58 and IPM 25 are stored in
containing space 60. Further, connector for high voltage 47
consisting of a solderless terminal is connected to the tip of lead
wire 24 by being crimped. Connector for high voltage 47 is fixed by
a screw to case member 58 and is connected electrically between
capacitor 27 and noise filter 37 which are mounted on the back
surface of case member 58.
[0022] FIG. 4 depicts a crimping section joining connector for high
voltage 47 to lead wire 24 shown in FIG. 3, where (A) is a
perspective view depicting a state where the crimping section is
not covered, and (B) is a perspective view depicting a state where
the crimping section is covered with solder. In FIG. 4 (A),
connector for high voltage 47 is connected to lead wire 24 by being
crimped. In crimping section 61, a plurality of conducting wires
bundled by a cover of lead wire 24 forms a gap open to the outside
63, and if a mold material consisting of urethane resin, etc.
enters into this open gap 63, the connection reliability of
crimping section 61 will reduce. Therefore, as shown in FIG. 4 (B),
by molding containing space 60 together with inverter 42 by flowing
solder 64 as a gap sealant into open gap 63, and charging the mold
material into containing space 60 shown in FIG. 3, the mold
material can be prevented from flowing into crimping section 61. In
particular, as shown in FIG. 4 (B), by covering the cross-sectional
portion of the tip of conducting wire 62 with solder 64 completely,
it is possible to secure the connection reliability of crimping
section 61 sufficiently even when the mold material adheres to this
portion.
INDUSTRIAL APPLICATIONS OF THE INVENTION
[0023] The inverter-integrated electric compressor according to the
present invention can be applied substantially to all types of
compressors, and is specifically suitable for a compressor mounted
on a vehicle, which is often installed in a narrow space and is
provided with a motor drive circuit that is liable to be affected
by heat and vibration.
EXPLANATION OF SYMBOLS
[0024] 1: inverter-integrated electric compressor [0025] 2:
compression mechanism [0026] 3: fixed scroll [0027] 4: movable
scroll [0028] 5: ball coupling [0029] 6: compressor housing (center
housing) [0030] 7: motor [0031] 8: main shaft [0032] 9: eccentric
pin [0033] 10: eccentric bush [0034] 11: suction port [0035] 12:
compressor housing (front housing) [0036] 13: discharge hole [0037]
14: discharge chamber [0038] 15: compressor housing (rear housing)
[0039] 16: discharge port [0040] 21: motor drive circuit [0041] 22:
partition wall [0042] 23: sealed terminal [0043] 24: lead wire
[0044] 25: IPM [0045] 26: control circuit [0046] 27: capacitor
[0047] 28: connector [0048] 29: lid member [0049] 30: high voltage
circuit for driving motor [0050] 31: shield plate [0051] 37: noise
filter [0052] 41: motor coil [0053] 42: inverter [0054] 43: power
element [0055] 44: motor control circuit [0056] 45: low voltage
circuit for control [0057] 46: external power supply [0058] 47:
connector for high voltage (HV connector) [0059] 48: air
conditioning control unit [0060] 49: connector for control signal
[0061] 58: case member [0062] 60: containing space [0063] 61:
crimping section [0064] 62: conducting wire [0065] 63: open gap
[0066] 64: solder as a gap sealant
* * * * *