Inverter-integrated motor for an automotive vehicle

• US 7,207,187 B2
• Filed: 04/25/2003
• Issued: 04/24/2007
• Est. Priority Date: 04/26/2002
• Status: Expired due to Fees

• Current Assignee: DENSO Corporation
• Original Assignee: DENSO Corporation
• Inventors: Ohkouchi, Yasuyuki, Kawata, Hiroyuki, Hamada, Ken, Funahashi, Kenji
• Primary Examiner(s): Norman; Marc
• Assistant Examiner(s): BANKHEAD, GENE LOUIS
• Application Number:
  US10/422,958
• Publication Number:
  US 20030200761A1
• Time in Patent Office: 1,460 Days
• Field of Search: 622/284, 625/05, 625/13, 621/13, 622/592, 417/410.1, 417/366, 417/367, 417/368
• US Class Current: 62/228.4
• CPC Class Codes: F01C 21/10 Outer members for co-operation with rotary pistons; Casings casings for rotary engines or machines in general F16M
• CPC Class Codes: F04B 2203/0204 Frequency of the electric current
• CPC Class Codes: F04B 35/04 the means being electric
• CPC Class Codes: F04B 39/121 Casings
• CPC Class Codes: F04C 2240/808 Electronic circuits (e.g. inverters) installed inside the machine
• CPC Class Codes: F04C 29/0085 Prime movers
• CPC Class Codes: F25B 2400/077 Compressor control units, e.g. terminal boxes, mounted on the compressor casing wall containing for example starter, protection switches or connector contacts
• CPC Class Codes: H02K 11/33 Drive circuits, e.g. power electronics H02K11/38 takes precedence
• CPC Class Codes: H02K 5/225 Terminal boxes or connection arrangements specially adapted for submersible motors H02K5/132

Abstract

A bus-bar integrated plate and outer frame section, arranged into a double-deck structure and having numerous bus bars molded with a resin molding plate portion, is provided as a wiring for connecting power switching elements and a smoothing capacitor, fixed on an outer surface of a cylindrical wall of a motor housing, to a printed circuit board serving as a control circuit.

Claims

1. An inverter-integrated motor-driven compressor for an automotive vehicle, comprising:

a compressor section constituting part of a refrigerating cycle apparatus;

a motor section integrally connected to said compressor section for driving said compressor section;

a housing for accommodating said compressor section and said motor section; and

an inverter circuit section including a predetermined number of power switching elements for converting direct-current power into three-phase alternating-current power and supplying the converted alternating-current power to said motor section,

wherein said motor section is cooled by a low-pressure coolant gas,

said power switching elements are constituted by discrete transistors corresponding to each of phases, each discrete transistor having a side surface from which electrode terminals of the discrete transitor protrude and a flat bottom surface directly placed on an outer surface of a wall of said housing at a portion surrounding said motor section,

the wall of the housing has both a mounting base portion having a flat mounting base surface and a stepped flat portion protruded along a radial direction of the motor section so as to be raised from the flat mounting base surface toward an outer side of the motor section, the flat bottom surfaces of the discrete transistors being fixedly placed on the flat mounting base surface of the mounting base portion,

each of groups of discrete transistors have mutually different phases and are disposed in a line along an axial direction of the motor section,

two discrete transistors corresponding to each of the phases are disposed adjacent to each other along a circumferential direction of the motor section through a wiring region in which the electrode terminals of one discrete transistor face the electrode terminals of the other discrete transistor, and

the wiring region is placed on the stepped flat portion of the wall of the housing.

2. The inverter-integrated motor-driven compressor for an automotive vehicle in accordance with claim 1, wherein

said discrete transistors are anchored into screw holes formed on said wall of said housing, said screw holes extending perpendicularly to said mounting base surface and being offset in the circumferential direction toward a thicker wall region of said housing within said mounting base surface.

3. The inverter-integrated motor-driven compressor for an automotive vehicle in accordance with claim 2, wherein said electrode terminals of said discrete transistors protrude in the circumferential direction toward a thinner wall region of said housing within said mounting base surface.

4. The inverter-integrated motor-driven compressor for an automotive vehicle in accordance with claim 3, wherein said discrete transistors are placed on the same plane constituted by said mounting base surface.

5. The inverter-integrated motor-driven compressor for an automotive vehicle in accordance with claim 4, wherein said discrete transistors are accommodated in a space defined by an outer frame portion brought into contact with said outer surface of said wall of said housing, and said space for accommodating said discrete transistors is filled with a resin member.

6. The inverter-integrated motor-driven compressor for an automotive vehicle in accordance with claim 4, wherein a resin insulation sheet is disposed on said outer surface of the wall of said housing at a region facing to said wiring region.

7. The inverter-integrated motor-driven compressor for an automotive vehicle in accordance with claim 4, wherein a smoothing capacitor is provided at a circumferential end of said power switching elements with said wiring region disposed at an opposite side.

8. The inverter-integrated motor-driven compressor for an automotive vehicle in accordance with claim 7, wherein an alternating-current output terminal section is provided at another circumferential end of said power switching elements far from said smoothing capacitor.

14. The inverter-integrated motor-driven compressor for an automotive vehicle in accordance with claim 1, wherein the outer surface of the wall of the housing has a first area and a second area facing the first area, the first area is nearer to a center of the motor section than the second area, the wall of the housing is configured to position the second area between the center of the motor section and a first line which passes through a point of the first area and is perpendicular to a second line passing through the point of the first area and the center of the motor section, and the discrete transistors are separately placed only on the second area.

15. The inverter-integrated motor-driven compressor for an automotive vehicle in accordance with claim 14, wherein the motor section is configured in a cylindrical shape, the first area extends along a center axis of the motor section, and the second area has two divided areas facing each other through the first area.

16. The inverter-integrated motor-driven compressor for an automotive vehicle in accordance with claim 14, wherein a thickness of the wall in the first area is set at a predetermined value, and a thickness of the wall at the second area is equal to or larger than that in the first area.

9. An inverter-integrated motor-driven compressor for an automotive vehicle, comprising:

a compressor section constituting part of a refrigerating cycle apparatus;

a motor section integrally connected to said compressor section for driving said compressor section;

a housing for accommodating said compressor section and said motor section;

an inverter circuit section including a predetermined number of power switching elements for converting direct-current power into multi-phase alternating-current power and supplying the converted alternating-current power to said motor section;

an inverter casing fixed on an upper end portion of an outer cylindrical wall of said housing for accommodating said inverter circuit section;

a motor power connector being detachably connected to a cable power connector of a power cable supplying electric power to said inverter circuit section; and

a motor communication connector being detachably connected to a cable communication connector of a communication cable constituting a communication path between said inverter circuit section and an external electronic device,

wherein said motor power connector and said motor communication connector protrude upward from a top surface of said inverter casing fixed on the upper end portion of the outer cylindrical wall of said housing.

10. The inverter-integrated motor-driven compressor for an automotive vehicle in accordance with claim 9, wherein

said inverter circuit section comprises said power switching elements fixed on the outer cylindrical wall of said housing, a control circuit section disposed above said power switching elements and including a printed circuit board mounting electronic circuit elements for controlling said power switching elements, and bus bars connecting said motor power connector and said motor communication connector to said power switching elements or to said control circuit section,

said inverter casing comprises a metallic base frame portion integrally formed with said outer cylindrical wall of said housing and opening upward so as to surround said power switching elements, a resin frame portion fixed to said base frame portion and opening upward so as to surround said printed circuit board of said control circuit section, and a cover plate closing the upper opening of said resin frame portion, and

said motor power connector and said motor communication connector comprises connecting terminals constituted by distal ends of said bus bars and extending vertically and a resin body portion integrally formed with said resin frame portion so as to be coupled with said cable power connector and said cable communication connector inserted or removed in a vertical direction.

11. The inverter-integrated motor-driven compressor for an automotive vehicle in accordance with claim 10, wherein

said housing or said base frame portion comprises at least one protruding portion protruding laterally from said resin frame portion in a direction perpendicular to an axis of said motor-driven compressor.

17. The inverter-integrated motor-driven compressor for an automotive vehicle in accordance with claim 9, wherein a wall of the housing comprises a mounting base portion having a flat mounting base surface and a stepped flat portion protruded along a radial direction of the motor section so as to be raised from the flat mounting base surface toward an outer side of the motor section;

each of the power switching elements has both a side surface from which an electrode terminal of the power switching element protrudes and a flat bottom surface directly placed on the flat mounting base surface of the mounting base portion,

the power switching elements are divided in two groups, each group of power switching elements being disposed in a line along an axial direction of the motor section such that the groups face each other along a circumferential direction of the motor section through a wiring region in which the electrode terminals of the power switching elements are placed, and

the wiring region is placed on the stepped flat portion of the wall of the housing.

12. An inverter-integrated motor-driven compressor for an automotive vehicle, comprising a housing, a motor-driven compressor accommodated in said housing, and an inverter circuit section fixed to said housing for converting direct-current power into multi-phase alternating-current power and supplying the converted alternating-current power to said motor-driven compressor,

wherein said inverter circuit section comprises power switching elements constituting respective arms of a multi-phase inverter circuit, a smoothing capacitor connected between a pair of direct-current input terminals of said multi-phase inverter circuit, a control circuit for controlling said power switching elements, and a wiring section for connecting said power switching elements, said smoothing capacitor, and said control circuit,

an inverter casing for accommodating said inverter circuit section is constituted by a metallic frame portion surrounding said inverter circuit section and protruding from an outer cylindrical surface of said housing, a cover plate closing an upper opening of said frame portion, and a cylindrical wall of said housing,

said power switching elements and said smoothing capacitor are placed on a mounting surface formed on the outer cylindrical surface of said housing and surrounded by said frame portion,

said wiring section comprises a bus-bar assembly and a printed circuit board,

said bus-bar assembly includes numerous bus bars integrally molded into a resin molding plate portion so as to assure mutual electrical insulation, and said bus-bar assembly is fixed to the outer cylindrical surface of said housing or to said frame portion via said resin molding plate portion and disposed at a radial outer side of said power switching elements so as to extend in a tangential direction of said motor-drive compressor, and

said printed circuit board is interposed between said bus-bar assembly and said cover plate so as to extend in parallel with said bus-bar assembly for mounting said control circuit.

13. The inverter-integrated motor-driven compressor for an automotive vehicle in accordance with claim 12, wherein

said bus-bar assembly comprises a connector protruding out of said frame portion or said cover plate for communications or power supply,

said connector comprises a connector base portion integrally formed with said resin molding plate portion of said bus-bar assembly and penetrating and protruding outward via an opening of said cover plate, and

connector terminals integrally formed with said bus bars and supported by said connector base portion.

18. The inverter-integrated motor-driven compressor for an automotive vehicle in accordance with claim 12, wherein a wall of the housing comprises a mounting base portion having a flat mounting base surface and a stepped flat portion protruded along a radial direction of the motor-driven compressor so as to be raised from the flat mounting base surface toward an outer side of the motor-driven compressor;

each of the power switching elements has both a side surface from which an electrode terminal of the power switching element protrudes and a flat bottom surface directly placed on the flat mounting base surface of the mounting base portion,

the power switching elements are divided in two groups, each group of power switching elements being disposed in a line along an axial direction of the motor-driven compressor such that the groups face each other along a circumferential direction of the motor-driven compressor through a wiring region in which the electrode terminals of the power switching elements are placed, and

the wiring region is placed on the stepped flat portion of the wall of the housing.