U.S. patent application number 14/312855 was filed with the patent office on 2014-12-25 for motor-driven compressor.
This patent application is currently assigned to KABUSHIKI KAISHA TOYOTA JIDOSHOKKI. The applicant listed for this patent is KABUSHIKI KAISHA TOYOTA JIDOSHOKKI. Invention is credited to Akio FUJII, Junichi TAKAHATA, Junya YANO.
Application Number | 20140377095 14/312855 |
Document ID | / |
Family ID | 50979614 |
Filed Date | 2014-12-25 |
United States Patent
Application |
20140377095 |
Kind Code |
A1 |
YANO; Junya ; et
al. |
December 25, 2014 |
MOTOR-DRIVEN COMPRESSOR
Abstract
A motor-driven compressor includes a motor driving circuit
including a capacitor electrically connected through a lead to a
circuit board, and a capacitor holder that is made of a plastic and
holds the capacitor. The capacitor holder includes a side wall,
which covers a side surface of the capacitor. The lead protrudes
from the side surface. The side wall includes a through-hole, which
opens through each of a first end surface of the side wall facing
the circuit board and a second end surface of the side wall
opposite to the circuit board and guides the lead to a portion of
the circuit board to which the lead is to be connected. The side
wall includes a wall surface facing the capacitor. The wall surface
includes a slit, which is continuous with the through-hole and
opens opposite to the circuit board.
Inventors: |
YANO; Junya; (Kariya-shi,
JP) ; FUJII; Akio; (Kariya-shi, JP) ;
TAKAHATA; Junichi; (Kariya-shi, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
KABUSHIKI KAISHA TOYOTA JIDOSHOKKI |
Kariya-shi |
|
JP |
|
|
Assignee: |
KABUSHIKI KAISHA TOYOTA
JIDOSHOKKI
Kariya-shi
JP
|
Family ID: |
50979614 |
Appl. No.: |
14/312855 |
Filed: |
June 24, 2014 |
Current U.S.
Class: |
417/411 |
Current CPC
Class: |
F04C 18/0215 20130101;
F04C 23/008 20130101; F04D 25/0693 20130101; F04B 35/04 20130101;
F04C 2240/808 20130101; F04B 27/0873 20130101; F04B 39/121
20130101; H02K 11/33 20160101 |
Class at
Publication: |
417/411 |
International
Class: |
F04D 25/06 20060101
F04D025/06 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 25, 2013 |
JP |
2013-132614 |
Claims
1. A motor-driven compressor, comprising: a compression unit
adapted to compress refrigerant; an electric motor adapted to drive
the compression unit; a housing that accommodates the compression
unit and the electric motor; a motor driving circuit that is
adapted to drive the electric motor and includes a circuit board
and a capacitor, wherein the capacitor is electrically connected
through a lead to the circuit board; and a capacitor holder that is
made of a plastic and holds the capacitor, wherein the capacitor
holder includes a side wall, which covers a side surface of the
capacitor, wherein the lead protrudes from the side surface, the
side wall includes a through-hole, which opens through each of a
first end surface of the side wall facing the circuit board and a
second end surface of the side wall opposite to the first end
surface, wherein the through-hole guides the lead toward a portion
of the circuit board to which the lead is to be connected, and the
side wall includes a wall surface facing the capacitor, and the
side wall includes a slit in the wall surface, which is continuous
with the through-hole and opens opposite to the circuit board.
2. The motor-driven compressor according to claim 1, wherein the
capacitor has a substantially box shape, and the capacitor holder
has a hollowed polygonal shape having the side wall as one side
such that the capacitor holder surrounds four sides of the
capacitor.
3. The motor-driven compressor according to claim 2, wherein the
capacitor of the motor driving circuit is one of a plurality of
capacitors, and the capacitor holder holds the capacitors.
4. The motor-driven compressor according to claim 3, wherein the
through-hole is one of a plurality of through-holes, and the
through-holes each correspond to an adjacent pair of the
capacitors.
5. The motor-driven compressor according to claim 4, wherein the
first end surface of the side wall includes openings of the
through-holes each corresponding to an adjacent pair of the
capacitors, wherein the openings of the through-holes are arranged
on the same straight line, and the capacitors in each adjacent pair
are arranged shifted from each other in a direction in which the
openings of the through-holes are arranged.
6. The motor-driven compressor according to claim 1, wherein the
capacitor is a film capacitor.
7. The motor-driven compressor according to claim 1, further
comprising a rotation shaft that is accommodated in the housing and
rotated integrally with a rotor of the electric motor, wherein the
compression unit, the electric motor, and the motor driving circuit
are arranged in this order along an axis of the rotation shaft.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a motor-driven compressor
that includes a compression unit, which compresses refrigerant, an
electric motor, which drives the compression unit, and a motor
driving circuit, which drives the electric motor.
[0002] Japanese Laid-Open Patent Publication No. 2007-263061
describes an example of such a motor-driven compressor. The
motor-driven compressor includes a motor driving circuit, which
includes a planar circuit board and a plurality of electric
components of various types. The electric components, which are
electrically connected to the circuit board, include a switching
element and a plurality of capacitors, for example. The capacitors
are provided on the circuit board. Each capacitor includes
protruding leads and is electrically connected to the circuit board
through the leads. The capacitors are held by a capacitor
holder.
[0003] If the capacitors are arranged such that the protruding
direction of the leads is perpendicular to the mounting surface of
the circuit board, on which various types of the electric
components are mounted, the size of the motor-driven compressor is
increased in the direction perpendicular to the mounting surface of
the circuit board. Accordingly, the capacitors may be arranged such
that the protruding direction of the leads is in parallel with the
mounting surface of the circuit board, and the leads are bent
toward the mounting surface of the circuit board. This reduces the
size of the motor-driven compressor in the direction perpendicular
to the mounting surface of the circuit board in comparison to the
case where the leads are not bent and the capacitors are arranged
such that the protruding direction of the leads is perpendicular to
the mounting surface of the circuit board.
[0004] However, the positions of the leads at which the bent
portions are formed vary between the capacitors during the bending
process of the leads. Accordingly, when the leads of each capacitor
and the circuit board are connected to each other in the state
where the capacitor is held by the capacitor holder, the positions
of the leads, which extend toward the mounting surface of the
circuit board, may be shifted with respect to portions of the
circuit board to which the leads are to be connected. This makes a
connection operation between the leads of each capacitor and the
circuit board difficult.
SUMMARY OF THE INVENTION
[0005] Accordingly, it is an objective of the present invention to
provide a motor-driven compressor that facilitates the connection
operation between the leads of each capacitor and the circuit
board.
[0006] To achieve the foregoing object, a motor-driven compressor
including: a compression unit, an electric motor, a housing, a
motor driving circuit, and a capacitor holder is provided. The
compression unit is adapted to compress refrigerant. The electric
motor is adapted to drive the compression unit. The housing
accommodates the compression unit and the electric motor. The motor
driving circuit is adapted to drive the electric motor and includes
a circuit board and a capacitor. The capacitor is electrically
connected through a lead to the circuit board. The capacitor holder
is made of a plastic and holds the capacitor. The capacitor holder
includes a side wall, which covers a side surface of the capacitor.
The lead protrudes from the side surface. The side wall includes a
through-hole, which opens through each of a first end surface of
the side wall facing the circuit board and a second end surface of
the side wall opposite to the first end surface. The through-hole
guides the lead toward a portion of the circuit board to which the
lead is to be connected. The side wall includes a wall surface
facing the capacitor, and the side wall includes a slit in the wall
surface, which is continuous with the through-hole and opens
opposite to the circuit board.
[0007] Other aspects and advantages of the present invention will
become apparent from the following description, taken in
conjunction with the accompanying drawings, illustrating by way of
example the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The invention, together with objects and advantages thereof,
may best be understood by reference to the following description of
the presently preferred embodiments together with the accompanying
drawings in which:
[0009] FIG. 1 is a partial cross-sectional view showing a
motor-driven compressor of one embodiment;
[0010] FIG. 2 is an exploded perspective view showing film
capacitors and a capacitor holder;
[0011] FIG. 3 is a perspective view showing the capacitor holder,
which holds the film capacitors, and a circuit board; and
[0012] FIG. 4 is a longitudinal cross-sectional view showing a part
of the film capacitor and a part of the capacitor holder.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] Referring to FIGS. 1 to 4, one embodiment will now be
described. As shown in FIG. 1, a motor-driven compressor 10
includes a housing H. The housing H includes a discharge housing
member 11, a suction housing member 12, and a cover 13, which are
made of a metal, preferably aluminum. The discharge housing member
11, the suction housing member 12, and the cover 13 are cylindrical
and each include a closed end. The suction housing member 12 is
coupled to the discharge housing member 11. The suction housing
member 12 has a circumferential wall including a suction port (not
shown) connected to an external refrigerant circuit (not shown).
The discharge housing member 11 includes a discharge port 14
connected to the external refrigerant circuit. The suction housing
member 12 accommodates a compression unit 15 (indicated by the
broken lines in FIG. 1), which compresses refrigerant, and an
electric motor 16, which drives the compression unit 15. Although
not shown in the drawings, the compression unit 15 of the present
embodiment includes a fixed scroll, which is fixed in the suction
housing member 12, and a movable scroll, which is engaged with the
fixed scroll.
[0014] A stator 17 is fixed to the inner surface of the suction
housing member 12. The stator 17 includes a stator core 17a, which
is fixed to the inner surface of the suction housing member 12, and
coils 17b, which are wound around teeth (not shown) of the stator
core 17a. A rotatable rotation shaft 19 extends through the stator
17 in the suction housing member 12. A rotor 18 is fixed to the
rotation shaft 19.
[0015] The suction housing member 12 has an end wall 12a to which
the cover 13 is coupled. A planar coupling base 31 is arranged
between the suction housing member 12 and the cover 13. The
coupling base 31 is made of a metal, preferably aluminum. The
coupling base 31 is coupled to the end wall 12a of the suction
housing member 12. The coupling base 31 is thermally coupled to the
suction housing member 12.
[0016] The cover 13 and the coupling base 31 define an
accommodation chamber 13a in the housing H. The accommodation
chamber 13a accommodates a motor driving circuit 20 that drives the
electric motor 16. In the present embodiment, the compression unit
15, the electric motor 16, and the motor driving circuit 20 are
arranged in this order along the axis L of the rotation shaft 19
(in the axial direction).
[0017] The electric motor 16 is supplied with power that is
controlled by the motor driving circuit 20. This rotates the rotor
18 and the rotation shaft 19 at a controlled rotation speed and
drives the compression unit 15. The driving of the compression unit
15 draws refrigerant from the external refrigerant circuit into the
suction housing member 12 through the suction port, compresses the
refrigerant in the suction housing member 12 with the compression
unit 15, and discharges the compressed refrigerant to the external
refrigerant circuit through the discharge port 14.
[0018] The motor driving circuit 20 includes a flat circuit board
21 and a plurality of electric components of various types, which
are electrically connected to the circuit board 21. The circuit
board 21 is arranged in the accommodation chamber 13a such that a
mounting surface 21a of the circuit board 21 on which the electric
components are arranged is perpendicular to the axis of the
rotation shaft 19. The electric components include film capacitors
22, for example. The motor driving circuit 20 includes a plurality
of film capacitors 22. Each film capacitor 22 includes a flat,
rectangular casing. Each film capacitor 22 includes a side surface
22e, from which leads 22a protrude. The leads 22a electrically
connect the film capacitor 22 to the circuit board 21.
[0019] A plastic capacitor holder 23 holds the film capacitors 22.
The capacitor holder 23, which holds the film capacitors 22, is
coupled to the side of the coupling base 31 that is opposite to the
end wall 12a of the suction housing member 12.
[0020] A plurality of bosses 31f (only one shown in FIG. 1)
projects from the surface of the coupling base 31 that is opposite
to the end wall 12a of the suction housing member 12. Bolts B1 are
inserted through the cover 13 and engaged with the corresponding
bosses 31f to fasten the coupling base 31 to the cover 13.
Accordingly, the cover 13, the coupling base 31, and the motor
driving circuit 20 are combined to form a module. A bolt B2 fastens
the cover 13, which is combined with the coupling base 31 and the
motor driving circuit 20, to the suction housing member 12.
[0021] As shown in FIGS. 2 and 3, each film capacitor 22 is
arranged such that the projection direction (the direction of arrow
X1) of the leads 22a from the side surface 22e and the mounting
surface 21a of the circuit board 21 are parallel with each other.
Each lead 22a is bent toward the mounting surface 21a of circuit
board 21.
[0022] The capacitor holder 23 includes a plurality of
accommodation portions 23a, each of which accommodates the
corresponding film capacitor 22. Each accommodation portion 23a
includes a hollowed polygonal shape having a side wall 23e as one
side, which covers the corresponding side surface 22e of the film
capacitor 22 such that the accommodation portion 23a surrounds four
sides of the corresponding film capacitor 22.
[0023] As shown in FIG. 4, the side wall 23e of the capacitor
holder 23 includes a plurality of through-holes 23h, which open
through each of the first end surface 231 of the side wall 23e
facing the circuit board 21 and the second end surface 232 of the
side wall 23e opposite to the first end surface 231 and guide the
corresponding leads 22a toward the portions of the circuit board 21
to which the leads 22a are to be connected.
[0024] As shown in FIGS. 2 and 3, each accommodation portion 23a of
the capacitor holder 23 includes a plurality of first retaining
pieces 25. The first retaining pieces 25 extend at positions facing
the circuit boards 21, and engage with the end surface of the
corresponding film capacitor 22 opposite to the coupling base 31.
The accommodation portion 23a of the capacitor holder 23 also
includes a plurality of second retaining pieces 26. The second
retaining pieces 26 extend at positions opposite to the circuit
board 21, and engage with the other end surface of the
corresponding film capacitor 22 facing the coupling base 31.
[0025] Two of the film capacitors 22 that are adjacent to each
other are held by the capacitor holder 23 such that the side
surfaces 22e, from which the leads 22a protrude, face each other.
The side wall 23e positioned between the side surfaces 22e that are
arranged facing each other includes the through-holes 23h
corresponding to each of the film capacitors 22 that are adjacent
to each other. The first end surface 231 of each side wall 23e
includes the openings of the through-holes 23h corresponding to one
of the film capacitors 22 that are adjacent to each other. The
openings are arranged on the same straight line. The film
capacitors 22 that are adjacent to each other are arranged shifted
from each other in the direction in which the openings of the
through-holes 23h are arranged (direction of arrow Z1).
[0026] As shown in FIG. 4, the side wall 23e includes a wall
surface 233 facing the film capacitor 22. The wall surface 233
includes a slit 23b, which is continuous with the through-holes 23h
and extend toward the circuit board 21 from a portion of the side
wall 23e opposite to the circuit board 21. The slit opens opposite
to the circuit board. The basal portion of each lead 22a with
respect to the bent portion can extend through the slit 23b. Each
film capacitor 22 is inserted into the corresponding accommodation
portion 23a in the extended direction, in which the leads 22a
extend toward the mounting surface 21a of the circuit board 21
(direction of arrow Y1). The leads 22a, which extend toward the
mounting surface 21a of the circuit board 21, then extend through
the corresponding through-holes 23h and are guided to the
corresponding portions of the circuit board 21 to which the leads
22a are to be connected. Further, the basal portion of each lead
22a with respect to the bent portion extends through the slit 23b
and is covered by the capacitor holder 23. Each film capacitor 22
is held between the first retaining pieces 25 and the second
retaining pieces 26. This maintains the state where the
accommodation portions 23a accommodate the corresponding film
capacitors 22.
[0027] The operation of the present embodiment will now be
described.
[0028] Each lead 22a extends from the side surface 22e of the
corresponding film capacitor 22, and its basal portion with respect
to the bent portion extends through the slit 23b. Each lead 22a,
which extends toward the mounting surface 21a of the circuit board
21, extends through the corresponding through-hole 23h. This
maintains the film capacitors 22 in the capacitor holder 23 in the
state where the leads 22a, which extend toward the mounting surface
21a of the circuit board 21, are positioned at the corresponding
portions of the circuit board 21 to which the leads 22a are to be
connected. This facilitates the operation of coupling the leads 22a
of each film capacitor 22 to the circuit board 21 in the state
where the film capacitors 22 are held by the capacitor holder
23.
[0029] Further, the leads 22a, which extend toward the mounting
surface 21a of the circuit board 21, extend through the
corresponding through-holes 23h. This limits the bending of the
leads 22a, which extend toward the mounting surface 21a of the
circuit board 21, when coupling the leads 22a of each film
capacitor 22 to the circuit board 21. This reduces the stress
acting on the leads 22a.
[0030] The advantages of the present embodiment will now be
described.
[0031] (1) Each side wall 23e of the capacitor holder 23 includes
the through-holes 23h, which open through each of the first end
surface 231 facing the circuit board 21 and the second end surface
232 opposite to the first end surface 231, and guide the
corresponding leads 22a toward the portions of the circuit board 21
to which the leads 22a are to be connected. Further, the side wall
23e includes the wall surface 233 facing the corresponding film
capacitor 22. The wall surface 233 includes the slit 23b, which is
continuous with the through-holes 23h and opens opposite to the
circuit board 21. The leads 22a, which extend from the side surface
22e of the corresponding film capacitor 22, extend through the slit
23b. The leads 22a, which extend toward the mounting surface 21a of
the circuit board 21, extend through the corresponding
through-holes 23h. This maintains the film capacitors 22 in the
capacitor holder 23 in the state where the leads 22a, which extend
toward the circuit board 21, are positioned at the corresponding
portions of the circuit board 21 to which the leads 22a are to be
connected. This facilitates the operation of coupling the leads 22a
of each film capacitor 22 to the circuit board 21 in the state
where the film capacitors 22 are held by the capacitor holder
23.
[0032] (2) Each film capacitor 22 has a substantially box shape,
and the capacitor holder 23 has a polygonal shape having the side
wall 23e and hollow, rectangular sections such that the capacitor
holder 23 surrounds four sides of each film capacitor 22. According
to this, the four sides of each film capacitor 22 are surrounded by
the capacitor holder 23 formed in the hollowed polygonal shapes
each having the side wall 23e as one side. This ensures that the
film capacitors 22 are held by the capacitor holder 23.
[0033] (3) The motor driving circuit 20 includes a plurality of the
film capacitors 22, and the capacitor holder 23 holds the film
capacitors 22. Accordingly, the single capacitor holder 23
positions the leads 22a of the film capacitors 22, which extend
toward the circuit board 21, at the corresponding portions of the
circuit board 21 to which the leads 22a are to be connected. This
facilitates the operation of coupling the leads 22a of the film
capacitors 22 to the circuit board 21.
[0034] (4) The side wall 23e of the capacitor holder 23 includes
the through-holes 23h corresponding to an adjacent pair of the film
capacitors 22. Accordingly, the through-holes 23h corresponding to
the adjacent pair of the film capacitors 22 are formed in the
single side wall 23e. This reduces the size of the capacitor holder
23 and simplifies the configuration in comparison to the case where
the through-holes 23h corresponding to the adjacent pair are formed
in separate side walls.
[0035] (5) The first end surface 231 of each side wall 23e of the
capacitor holder 23 includes the openings of the through-holes 23h
corresponding to one of the film capacitors 22 that are adjacent to
each other. The openings are arranged on the same straight line.
The film capacitors 22 that are adjacent to each other are shifted
with respect to each other in the direction in which the openings
of the through-holes 23h are arranged. This limits the interference
between the leads 22a of the film capacitors 22 that are adjacent
to each other and brings the film capacitors 22 that are adjacent
to each other as close as possible. This reduces the size of the
capacitor holder 23, contributing the reduction of the size of the
motor-driven compressor 10.
[0036] (6) According to the present embodiment, the capacitor
holder 23 covers the basal portion of each lead 22a with respect to
the bent portion. This facilitates the achievement of the
insulation of the lead 22a in comparison to the case where the
basal portion of each lead 22a with respect to the bent portion is
exposed from the capacitor holder 23.
[0037] (7) The capacitor holder 23 covers the basal portion of each
lead 22a with respect to the bent portion by inserting the basal
portion into the slit 23b. This facilitates the achievement of the
insulation between the leads 22a even when the leads 22a that
protrude from each film capacitor 22 and are adjacent to each other
are brought close to each other. This brings the leads 22a that
protrude from each film capacitor 22 and are adjacent to each other
as close as possible so that the size of the capacitor holder 23 is
reduced.
[0038] The above described embodiment may be modified as
follows.
[0039] In the embodiment, the basal portion of each lead 22a with
respect to the bent portion may be exposed from the capacitor
holder 23.
[0040] In the embodiment, the through-holes 23h may be formed in
the side wall 23e such that the openings of the through-holes 23h
each corresponding to one of the film capacitors 22 that are
adjacent to each other are arranged in the protruding direction
(direction of arrow X1) of the leads 22a from the side surface 22e
of each film capacitor 22.
[0041] In the embodiment, the through-holes 23h each corresponding
to one of the film capacitors 22 that are adjacent to each other
may be formed in separate side walls.
[0042] In the embodiment, the capacitor holder 23 may be configured
to hold a single film capacitor 22.
[0043] In the embodiment, the number of the film capacitor 22 is
not particularly limited. That is, the number may be appropriately
changed.
[0044] In the embodiment, the capacitors may include an
electrolytic capacitor, for example.
[0045] In the embodiment, the motor driving circuit 20 may be
located radially outward of the rotation shaft 19.
[0046] In the embodiment, the compression unit 15 may be of a
piston type or a vane type, for example.
[0047] Therefore, the present examples and embodiments are to be
considered as illustrative and not restrictive and the invention is
not to be limited to the details given herein, but may be modified
within the scope and equivalence of the appended claims.
* * * * *