Electrical device, method for manufacturing electrical device, and electric compressor

• US 10,362,701 B2
• Filed: 09/24/2015
• Issued: 07/23/2019
• Est. Priority Date: 10/09/2014
• Status: Active Grant

• Current Assignee: DENSO Corporation
• Original Assignee: DENSO Corporation
• Inventors: Sakai, Koji
• Primary Examiner(s): Nguyen, Tran N
• Application Number:
  US15/511,682
• Publication Number:
  US 20170295662A1
• Time in Patent Office: 1,398 Days
• CPC Class Codes: F04B 35/04 the means being electric
• CPC Class Codes: F04B 39/06 Cooling; Heating; Prevention of freezing
• CPC Class Codes: F04B 39/121 Casings
• CPC Class Codes: F04B 39/14 Provisions for readily assembling or disassembling
• CPC Class Codes: F04D 13/06 the pump being electrically driven
• CPC Class Codes: F04D 29/043 Shafts
• CPC Class Codes: H02K 11/30 Structural association with control circuits or drive circuits
• CPC Class Codes: H02K 11/33 Drive circuits, e.g. power electronics H02K11/38 takes precedence
• CPC Class Codes: H02K 15/00 Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
• CPC Class Codes: H02K 15/02 of stator or rotor bodies
• CPC Class Codes: H02K 2213/09 Machines characterised by the presence of elements which are subject to variation, e.g. adjustable bearings, reconfigurable windings, variable pitch ventilators
• CPC Class Codes: H02K 5/22 Auxiliary parts of casings not covered by groups H02K5/06-H02K5/20, e.g. shaped to form connection boxes or terminal boxes
• CPC Class Codes: H02K 9/19 for machines with closed casing and closed-circuit cooling using a liquid cooling medium, e.g. oil
• CPC Class Codes: H02M 7/003 Constructional details, e.g. physical layout, assembly, wiring or busbar connections
• CPC Class Codes: H02M 7/537 using semiconductor devices only, e.g. single switched pulse inverters
• CPC Class Codes: H02M 7/53871 with automatic control of output voltage or current
• CPC Class Codes: H05K 13/0015 Orientation; Alignment; Positioning
• CPC Class Codes: H05K 7/1427 Housings
• CPC Class Codes: H05K 7/2039 characterised by the heat transfer by conduction from the heat generating element to a dissipating body arrangements for increasing/decreasing heat-transfer, e.g. fins details, F28F13/00
• CPC Class Codes: H05K 7/209 Heat transfer by conduction from internal heat source to heat radiating structure H05K7/20909 takes precedence
• CPC Class Codes: H05K 7/20927 : Liquid coolant without phase change

Abstract

An electrical device includes two or more electrical components that configure an electrical circuit, at least one or more mechanical component that supports the two or more electrical components and is fixed to the two or more electrical components, and a position-adjustment structure that adjusts positions of the two or more electrical components relative to the one or more mechanical component with the at least two or more electrical components being united together, before the one or more mechanical component is fixed to the two or more electrical components.

Claims

1. An electrical device comprising:

a drive circuit of an inverter including two or more electrical components, the two or more electrical components including at least two of a circuit board, a capacitor, a bus bar, and a coil;

an inverter case for the inverter that supports the two or more electrical components and is fixed to the two or more electrical components;

a position-adjustment structure that adjusts positions of the two or more electrical components relative to the inverter case with the two or more electrical components being united together, before the inverter case is fixed to the two or more electrical components, the position-adjustment structure including a recess in the inverter case and a deformation member, the deformation member including at least one of a potting material and grease interposed between one of the two or more electrical components and the inverter case and being capable of deforming; and

an intermediate member that is united with the two or more electrical components and electrically connected with the two or more electrical components, the intermediate member including a bus bar;

wherein;

the position-adjustment structure adjusts positions of the two or more electrical components relative to the inverter case by deformation of the deformation member, with the one of the electrical components and the inverter case being in a non-contact state by using the deformation member;

the one of the two or more electrical components is electrically connected with the intermediate member by an electrical connection terminal;

the one of the electrical components and the intermediate member are mechanically connected together with a fixing member, to minimize stress application on the electrical connection terminal from the one of the electrical components or the intermediate member; and

a distance between the intermediate member and the electrical connection terminal is made constant by the fixing member.

2. The electrical device according to claim 1, wherein

at least one of the potting material fixes one of the two or more electrical components to the mechanical component, and the grease conducts heat from the one of the electrical components to the inverter case.

3. The electrical device according to claim 1, wherein

the two or more electrical components include a first electrical component disposed inside the recess in the inverter case, and a second electrical component disposed so as to cover the first electrical component.

4. The electrical device according to claim 3, wherein

the first electrical component is the capacitor or the coil, and

the second electrical component is the circuit board.

5. A method for manufacturing the electrical device according to claim 3, the method comprising:

a first step of assembling a united electrical component that is the first electrical component and the second electrical component united together;

a second step of disposing a first deformation member as the deformation member on a bottom surface of the recess of the inverter case;

a third step of mounting the united electrical component on the inverter case such that the first electrical component is set inside the recess of the inverter case after the first step and the second step; and

a fourth step of disposing a second deformation member as the deformation member between side faces that form the recess of the inverter case and the first electrical component after the third step so as to configure the position-adjustment structure by the first and second deformation members.

6. The electrical device according to claim 4, further comprising:

a second case that configures a housing that houses the capacitor and the circuit board, together with the inverter case; and

a terminal disposed in the second case and electrically connected with the circuit board, wherein

the position-adjustment structure adjusts position of the circuit board relative to the inverter case by adjusting a position of the capacitor inside the recess of the inverter case by deformation of the deformation member.

7. A method for manufacturing the electrical device according to claim 6, the method comprising:

a first step of assembling a united electrical component that is the capacitor and the circuit board united together;

a second step of disposing a first deformation member as the deformation member on a bottom surface of the recess in the inverter case;

a third step of disposing the united electrical component in the inverter case such that the capacitor is set inside the recess of the inverter case after the first step and the second step;

a fourth step of disposing a second deformation member as the deformation member between side faces that form the recess of the inverter case and the capacitor after the third step so as to configure the position-adjustment structure by the first and second deformation members;

a fifth step of deforming the first and second deformation members to adjust the position of the capacitor after the fourth step so as to adjust the position of the circuit board relative to the inverter case;

a sixth step of fixing the circuit board to the inverter case after the fifth step, and

a seventh step of fitting the second case to the inverter case so as to configure a housing that houses the capacitor and the circuit board, and of connecting the circuit board to the terminal, after the sixth step.

8. The method according to claim 7, wherein

in the second step, the first deformation member is disposed on the bottom surface of the recess of the inverter case in a predetermined direction,

in the third step, the united electrical component is disposed on the inverter case in a direction same as the predetermined direction,

in the fourth step, the second deformation member is disposed between the side faces that form the recess and the capacitor in a direction same as the predetermined direction, and

in the seventh step, the second case is fitted to the inverter case in a direction that is the same as the predetermined direction.

9. The electrical device according to claim 1, wherein

the inverter case houses the two or more electrical components, together with a second case, and

the two or more electrical components include

a first electrical component disposed in the recess of the inverter case,

the bus bar disposed in the inverter case and including an electrical wire electrically connected with the first electrical component and a terminal electrically connected with the electrical wire, and

a second electrical component supported on the second case and electrically connected with the terminal of the bus bar.

10. The electrical device according to claim 9, wherein

the first electrical component is the capacitor or the coil, and

the second electrical component is the circuit board.

11. A method for manufacturing the electrical device according to claim 9, the method comprising:

a first step of assembling a united electrical component that is the first electrical component and the bus bar united together;

a second step of disposing a first deformation member as the deformation member on a bottom surface of a recess in the inverter case;

a third step of disposing the united electrical component in the inverter case such that the first electrical component is set inside the recess of the inverter case after the first step and the second step;

a fourth step of disposing a second deformation member as the deformation member between side faces that form the recess of the inverter case and the first electrical component after the third step so as to configure the position-adjustment structure by the first and second deformation members;

a fifth step of deforming the first and second deformation members to adjust the position of the first electrical component after the fourth step so as to adjust the position of the bus bar relative to the inverter case;

a sixth step of fixing the bus bar to the inverter case after the fifth step; and

a seventh step of fitting the second case to the inverter case so as to configure a housing that houses the first electrical component, the bus bar, and the second electrical component and connecting the terminal of the bus bar with the second electrical component after the sixth step.

12. The method according to claim 11, wherein

in the second step, the first deformation member is disposed on the bottom surface of the recess of the inverter case in a predetermined direction,

in the third step, the united electrical component is disposed on the inverter case in a direction that is the same as the predetermined direction,

in the fourth step, the second deformation member is disposed between the side faces that form the recess and the first electrical component in a direction that is the same as the predetermined direction, and

in the seventh step, the second case is fitted to the inverter case in a direction that is the same as the predetermined direction.

13. The method according to claim 5, wherein

the first deformation member includes at least one or more of the potting material that fixes the first electrical component to the inverter case, and the grease that conducts heat from the first electrical component to the inverter case, and

the second deformation member includes the potting material that fixes the first electrical component to the inverter case.

14. An electric compressor comprising:

the electrical device according to claim 1.