ELECTRIC COMPRESSOR

Abstract

In an electric compressor, an inverter includes a circuit board on which an electronic component is mounted, and an inverter housing portion that houses the inverter includes a housing body, a board fixing portion to which the circuit board is to be fixed, and a cover member. A predetermined electronic component included in the electronic component, such as a smoothing capacitor and a filter capacitor, is fixed to and disposed on the cover member-side surface of the circuit board in a state of being molded and sealed with thermosetting second insulating resin, and a vibration insulating member that reduces vibration of the cover member is disposed between the molded and sealed predetermined electronic component and the cover member.

Description

TECHNICAL FIELD

The present invention relates to an electric compressor integrally including an inverter.

BACKGROUND ART

Many electric compressors used for compressing refrigerant in vehicle air conditioners integrally have inverters, and control power supply to electric motors that drive compression mechanisms while converting DC power from, e.g., in-vehicle batteries into AC power. In this manner, the electric compressors drive the electric motors. The electric compressor of this type includes a housing that houses an electric motor and a compression mechanism, and an inverter housing portion provided integrally with the housing to house an inverter. In addition, the inverter housing portion includes a housing body having an opening, and a cover member that closes the opening of the housing body. The cover member is configured such that a peripheral edge portion thereof is fastened and fixed to the housing body with, e.g., a bolt.

Here, vibration generated by, e.g., the compression mechanism may be transmitted to the cover member through the housing and the housing body, and the cover member may vibrate and generate noise. In this regard, Patent Literature 1 describes that vibration of a cover member is reduced and noise due to vibration of the cover member is reduced by disposing a vibration insulating member between a head portion of a bolt for fixing a circuit board forming an inverter and the cover member.

CITATION LIST

Patent Literature

Patent Literature 1: JP-A-2020-56376

SUMMARY OF INVENTION

Problems to be Solved by Invention

With recent electrification of automobiles, measures for weight reduction, noise reduction, and electromagnetic compatibility (EMC) have been required more than ever for electric compressors used in the automobiles. In particular, a noise filter of an inverter has been increased in size due to the measure for EMC, and the volume of an inverter housing portion has also been increased. For this reason, the rigidity of a cover member is relatively reduced, or a fastening location (fixing location) of the cover member to a housing body is separated. Thus, the cover member is easily affected by vibration, and there is a possibility that noise due to vibration of the cover member cannot be sufficiently reduced in the related art.

On the other hand, it is also conceivable to increase the rigidity of the cover member by increasing the number of fastening locations (fixing locations) on the center side of the cover member. However, the inverter includes a circuit board on which various electronic components such as a noise filter are mounted. Thus, if the number of fastening locations (fixing locations) is increased on the center side of the cover member, the electronic component mounting area of the circuit board is reduced, which is not preferable because of a limitation when the electronic components are mounted on the circuit board.

In addition, some of the electronic components mounted on the circuit board of the inverter may need to be strengthened (vibration strengthening) in order to ensure the vibration resistance of the circuit board.

Thus, an object of the present invention is to provide an electric compressor configured so that the vibration resistance of a circuit board of an inverter can be ensured and noise due to vibration of a cover member of an inverter housing portion can be reduced while a decrease in the electronic component mounting area of the circuit board of the inverter is suppressed.

Solution to Problems

According to one aspect of the present invention, an electric compressor is provided. This electric compressor includes a housing that houses an electric motor and a compression mechanism driven by the electric motor, an inverter that drives the electric motor, the inverter including a circuit board on which an electronic component is mounted, an inverter housing portion that houses the inverter, the inverter housing portion including a housing body having an opening, a board fixing portion which is provided so as to protrude from the inner bottom surface of the housing body facing the opening and to which the circuit board is fixed, and a cover member that closes the opening of the housing body, and a vibration insulating member that reduces vibration of the cover member. A predetermined electronic component included in the electronic component is fixed to and disposed on the cover member-side surface of the circuit board in a state of being molded and sealed with thermosetting insulating resin, and the vibration insulating member is disposed between the molded and sealed predetermined electronic component and the cover member.

Effects of Invention

According to the present invention, the electric compressor can be provided, which is configured so that the vibration resistance of the circuit board of the inverter can be ensured and noise due to vibration of the cover member of the inverter housing portion can be reduced while a decrease in the electronic component mounting area of the circuit board of the inverter is suppressed.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a schematic longitudinal sectional view of an electric compressor according to a first embodiment.

FIG. 2 is a view of the electric compressor according to the first embodiment in a state of a cover member of an inverter housing portion being detached as viewed from the inverter housing portion side.

FIG. 3 is a diagram illustrating a circuit configuration example of an inverter of the electric compressor according to the first embodiment.

FIG. 4 is a view illustrating the inside of the inverter housing portion.

FIG. 5 is a view illustrating a power switching element.

FIG. 6 is a view illustrating a switching element module.

FIG. 7 is a view illustrating the state of installation of the switching element module (power switching element) in the inverter housing portion.

FIG. 8 is a view illustrating a circuit board of the inverter.

FIG. 9 is a view illustrating the circuit board of the inverter.

FIG. 10 is a view illustrating the circuit board of the inverter.

FIG. 11 is a view illustrating a state in which the circuit board of the inverter is mounted on a board fixing portion.

FIG. 12 is a view illustrating the inverter housing portion (housing body, cover member), a vibration insulating member, and the circuit board of the inverter.

FIG. 13 is a schematic longitudinal sectional view of an electric compressor according to a second embodiment.

FIG. 14 is a schematic longitudinal sectional view of an electric compressor according to a third embodiment.

DESCRIPTION OF EMBODIMENTS

An embodiment of the present invention is described hereinafter with reference to the accompanying drawings.

First Embodiment

FIG. 1 is a schematic longitudinal sectional view of an electric compressor 1 according to a first embodiment. The electric compressor 1 according to the embodiment is a so-called inverter-integrated electric compressor integrally having an inverter. For example, the electric compressor 1 may be mounted on a vehicle to form part of a refrigerant circuit of a vehicle air conditioner, and may be configured to compress and discharge refrigerant.

Referring to FIG. 1, the electric compressor 1 includes an electric motor 2, a compression mechanism 3 driven by the electric motor to compress refrigerant, a housing 4 that houses the electric motor 2 and the compression mechanism 3, an inverter 5 that drives the electric motor 2, and an inverter housing portion 6 that houses the inverter 5.

The electric motor 2 is, for example, a three-phase synchronous motor (brushless DC motor). The compression mechanism 3 is, for example, a scroll compression mechanism. The electric motor 2 and the compression mechanism 3 are arranged in series in the axial direction of an output shaft 2a of the electric motor 2 in the housing 4. The output shaft 2a of the electric motor 2 is coupled to the compression mechanism 3 (orbiting scroll in the case of the scroll compression mechanism).

The inverter 5 includes various electronic components (described later) and a circuit board 7 on which these various electronic components are mounted. In other words, in the present embodiment, various electronic components are mounted on the circuit board 7 to form the inverter 5.

The inverter housing portion 6 is provided integrally with the housing 4. The inverter housing portion 6 is disposed on one end side of the housing 4 in the axial direction, specifically, on the opposite side of the electric motor 2 from the compression mechanism 3. In the present embodiment, the inverter housing portion 6 includes a housing body 61 formed integrally with the housing 4 and a cover member 62 detachable from the housing body 61.

The housing body 61 has a bottom wall 611 and a peripheral wall 612 standing from the peripheral edge of the bottom wall 611 and defining an opening facing the bottom wall 611. The cover member 62 is attached to the housing body 61 to close the opening. Part of the bottom wall 611 (which is also the bottom wall of the inverter housing portion 6) of the housing body 61 forms a partitioning wall 8 that separates the inside of the housing 4 and the inside of the inverter housing portion 6 from each other. Note that a power supply line 9 from the inverter 5 to the electric motor 2 extends through the partitioning wall 8 (the bottom wall 611 of the housing body 61) in an airtight and liquid-tight state.

FIG. 2 is a view of the electric compressor 1 in a state of the cover member 62 of the inverter housing portion 6 being detached as viewed from the inverter housing portion 6 side. As illustrated in FIG. 2, the circuit board 7 forming the inverter 5 is attached in the inverter housing portion 6 (housing body 61) with a plurality of first fixing bolts 11 (fixing members).

Returning to FIG. 1, a refrigerant inlet 4a through which refrigerant from the outside flows into the housing 4 is formed in a portion of the housing 4 on the partition wall 8 side. The refrigerant having flowed into the housing 4 flows through the housing 4 (gap in the electric motor 2) and reaches the compression mechanism 3. The compression mechanism 3 is driven by the electric motor 2 to compress and discharge the refrigerant.

The refrigerant having flowed into the housing 4 is, for example, refrigerant having passed through, e.g., an expansion valve and an evaporator in the refrigerant circuit of the vehicle air conditioner, and is low-temperature low-pressure refrigerant. Thus, the partitioning wall 8 and the electric motor 2 can be cooled with the refrigerant having flowed into the housing 4 through the refrigerant inlet 4a. The refrigerant having flowed in the housing 4 is compressed into high-temperature high-pressure refrigerant by the compression mechanism 3, and is discharged from the compression mechanism 3. The (high-temperature high-pressure) refrigerant discharged from the compression mechanism 3 flows out through a refrigerant outlet 4b formed in the housing 4.

Here, the inverter 5 will be briefly described. FIG. 3 is a diagram illustrating a circuit configuration example of the inverter 5. In the present embodiment, the inverter 5 is configured to convert DC power from an external power source (for example, in-vehicle battery) VB into three-phase AC power and supply the three-phase AC power to the electric motor 2.

As illustrated in FIG. 3, the inverter 5 includes a smoothing capacitor 51, a switching unit 52, a control circuit 53, and a noise filter 54. As described above, these components are mounted on the circuit board 7 to form the inverter 5.

The smoothing capacitor 51 is connected between a power line and a ground line of the external power source VB, and smooths DC voltage from the external power source VB.

The switching unit 52 includes six power switching elements Q1 to Q6 and six diodes D1 to D6. Although not particularly limited, the power switching elements Q1 to Q6 may be insulated gate bipolar transistors (IGBTs). The switching unit 52 is configured to convert the DC voltage smoothed by the smoothing capacitor 51 after having been supplied from the external power source VB into three-phase AC voltage and supply the three-phase AC voltage to the electric motor 2 by control (PMW control) of the power switching elements Q1 to Q6.

The switching unit 52 will be further described. The switching unit 52 has a U-phase arm, a V-phase arm, and a W-phase arm provided in parallel with each other between the power line and the ground line of the external power source VB.

Two power switching elements Q1, Q2 are connected in series to the U-phase arm, and the diodes D1, D2 are each connected in inverse parallel to the power switching elements Q1, Q2. Two power switching elements Q3, Q4 are connected in series to the V-phase arm, and the diodes D3, D4 are each connected in inverse parallel to the power switching elements Q3, Q4. Two power switching elements Q5, Q6 are connected in series to the W-phase arm, and the diodes D5, D6 are each connected in inverse parallel to the power switching elements Q5, Q6.

The midpoint of each of the U-, V-, and W-phase arms is connected to the other end of each of U-, V-, and W-phase coils of the electric motor 2 star-connected at one ends thereof. That is, the midpoint between the power switching elements Q1, Q2 of the U-phase arm is connected to the U-phase coil, the midpoint between the power switching elements Q3, Q4 of the V-phase arm is connected to the V-phase coil, and the midpoint between the power switching elements Q5, Q6 of the W-phase arm is connected to the W-phase coil.

By controlling a ratio between the ON period of the power line-side power switching element of each phase arm and the ON period of the ground line-side power switching element, i.e., by performing the PWM control on the plurality of power switching elements Q1 to Q6, the switching unit 52 can convert the DC power smoothed by the smoothing capacitor 51 after having been supplied from the external power source VB into the three-phase AC power and supply the three-phase AC power to the electric motor 2, thereby driving the electric motor 2.

The control circuit 53 controls (PWM control) the power switching elements Q1 to Q6 to drive the electric motor 2 and thus the compression mechanism 3 based on a control signal from the outside (for example, a control device for the vehicle air conditioner described above).

The noise filter 54 includes, e.g., a capacitor and a coil (inductor). Although not particularly limited, in the present embodiment, the noise filter 54 is provided between the smoothing capacitor 51 and the switching unit 52, and mainly reduces, e.g., ripple noise and EMI/EMC noise due to operation of the power switching elements Q1 to Q6.

Next, a housing structure for the inverter 5 in the present embodiment will be described. As described above, in the present embodiment, the inverter 5 is housed in the inverter housing portion 6.

Inverter Housing Portion 6

FIG. 4 is a view illustrating the inside of the inverter housing portion 6 (in a state in which the inverter 5 is not housed). As described above, the inverter housing portion 6 includes the housing body 61 and the cover member 62. Moreover, in the present embodiment, the inverter housing portion 6 includes an installation portion 63 on which the power switching elements Q1 to Q6 are installed, and a board fixing portion 64 to which the circuit board 7 forming the inverter 5 is fixed.

The installation portion 63 is provided on the inner bottom surface 61a of the housing body 61, i.e., the surface of the partitioning wall 8 on the inverter housing portion 6 side. The inner bottom surface 61a of the housing body 61 faces the opening of the housing body 61.

Although only one bolt hole is illustrated in FIG. 4, the installation portion 63 is formed with the same number of bolt holes 631 as the number of power switching elements Q1 to Q6 (i.e., six bolt holes 631), into which second fixing bolts 12 (see FIG. 5) as fixing members for fixing the power switching elements Q1 to Q6 are screwed.

The board fixing portion 64 is provided so as to protrude from the inner bottom surface 61a of the housing body 61 (toward the opening of the housing body 61), and is configured to support the circuit board 7 at a position farther from the inner bottom surface 61a of the housing body 61 than the installation portion 63. That is, in the inverter housing portion 6, the circuit board 7 is disposed at a position closer to the cover member 62 than the power switching elements Q1 to Q6. In the present embodiment, the board fixing portion 64 includes a plurality of protruding portions 641 protruding from the inner bottom surface of the housing body 61, and bolt holes into which the first fixing bolts 11 (see FIGS. 1 and 2) as the fixing members are screwed are each formed in the top surfaces of the plurality of protruding portions 641.

Power Switching Elements Q1 to Q6 and Switching Element Module

FIG. 5 is a view illustrating the power switching element. In the present embodiment, each of the power switching elements Q1 to Q6 has an insertion hole (hereinafter referred to as a “first insertion hole”) 21 into which the second fixing bolt 12 for fixing the power switching element itself is to be inserted. The first insertion hole 21 penetrates the power switching element from an upper surface to a lower surface.

Each of the power switching elements Q1 to Q6 has three terminals 22. In the present embodiment, the three terminals 22 extend laterally from one side surface of the power switching element, are bent in the middle, and face upward at tip ends thereof.

In the present embodiment, as illustrated in FIG. 6, the power switching elements Q1 to Q6 are fixed with thermosetting first insulating resin IR1 such as epoxy resin, i.e., are integrated to form a switching element module 30.

Then, in the present embodiment, as illustrated in FIG. 7, the switching element module 30 is fixed to the installation portion 63 with the same number of second fixing bolts 12 as the number of power switching elements Q1 to Q6.

Circuit Board 7

The circuit board 7 will be described with reference to FIGS. 1 and 8 to 11. In the present embodiment, the circuit board 7 is attached and fixed to the board fixing portion 64 after the switching element module 30 has been installed (fixed) on the installation portion 63.

In the present embodiment, among the electronic components forming the inverter 5, the electronic components other than the power switching elements Q1 to Q6 are mounted on the circuit board 7 in advance. Specifically, in the present embodiment, in the inverter housing portion 6, the smoothing capacitor 51, the diodes D1 to D6, the control circuit 53, a filter capacitor 54a forming the noise filter 54, and a filter coil 54b forming the noise filter 54 are mounted in advance on the surface (hereinafter referred to as a “cover member-side surface”) 7a of the circuit board 7 facing the cover member 62. Note that in FIGS. 8 to 11, the diodes D1 to D6 are omitted.

The circuit board 7 is formed with terminal holes 71 to which the terminals 22 of the power switching elements Q1 to Q6 are connected (inserted). Further, the circuit board 7 is formed with a plurality of insertion holes (hereinafter referred to as “second insertion holes”) 72 into which the first fixing bolts 11 can be each inserted. The plurality of second insertion holes 72 is arranged corresponding to the plurality of protruding portions 641 forming the board fixing portion 64.

Here, in the present embodiment, among the other electronic components mounted on the circuit board 7, a predetermined electronic component having a relatively-high height, in other words, an electronic component easily affected by vibration, is subjected to vibration strengthening. Although not particularly limited, in the present embodiment, the predetermined electronic component having the relatively-high height (susceptible to vibration) includes the smoothing capacitor 51, the filter capacitor 54a, and the filter coil 54b.

Specifically, referring to FIGS. 1, 8, and 9, the predetermined electronic component (smoothing capacitor 51, filter capacitor 54a, and filter coil 54b) is molded and sealed with thermosetting second insulating resin IR2 in the filter case 55 and is integrated with the filter case 55, and in this state (i.e., together with the filter case 55), is fixed and disposed on the cover member-side surface 7a of the circuit board 7. The second insulating resin IR2 may be the same type of resin as the first insulating resin IR1 or may be a different type.

The vibration strengthening for the predetermined electronic component will be further described. The predetermined electronic component (smoothing capacitor 51, filter capacitor 54a, and filter coil 54b) is attached to the cover member-side surface 7a of the circuit board 7 by soldering.

The filter case 55 is made of, for example, a metal material. As illustrated in FIG. 10, the filter case 55 is formed in a box shape with one surface opened, and has a size which can house the predetermined electronic component attached to the cover member-side surface 7a of the circuit board 7. At least part of the outer bottom surface 55a of the filter case 55 is formed as a flat surface. The filter case 55 has, around the opening, a plurality of insertion holes (hereinafter referred to as “third insertion holes”) 551 into which the first fixing bolts 11 can be inserted. The plurality of third insertion holes 551 is arranged corresponding to some of the second insertion holes 72 of the circuit board 7.

The circuit board 7 to which the predetermined electronic component is attached is combined with the filter case 55 filled with an appropriate amount of the thermosetting second insulating resin IR2. Specifically, as illustrated in FIG. 10, the circuit board 7 and the filter case 55 are combined such that the predetermined electronic component is inserted into the filter case 55 through the opening of the filter case 55 with the circuit board 7 on the upper side and the filter case 55 (filled with the second insulating resin IR2) on the lower side. At this time, each third insertion hole 551 of the filter case 55 is aligned with the corresponding second insertion hole 72 of the circuit board 7. In this manner, the predetermined electronic component soldered to the cover member-side surface 7a of the circuit board 7 is molded and sealed with the second insulating resin IR2 in the filter case 55 and integrated with the filter case 55.

Thereafter, as illustrated in FIG. 11, the circuit board 7 is mounted on the board fixing portion 64 (i.e., the top surfaces of the plurality of protruding portions 641) of the inverter housing portion 6 with the cover member-side surface 7a on the upper side. At this time, the plurality of second insertion holes 72 of the circuit board 7 is arranged on the bolt holes formed on the top surfaces of the plurality of protruding portions 641. Moreover, each terminal 22 of the power switching elements Q1 to Q6 in the switching element module 30 installed on the installation portion 63 is inserted into a terminal hole 71 of the circuit board 7, and a tip end portion of the terminal 22 protrudes from the cover member-side surface 7a of the circuit board 7.

Thereafter, the circuit board 7 mounted on the board fixing portion 64 (the top surfaces of the plurality of protruding portions 641) is fixed to the board fixing portion 64 with the plurality of first fixing bolts 11. Specifically, the plurality of first fixing bolts 11 inserted into the plurality of second insertion holes 72 is screwed into the bolt holes formed in the top surfaces of the plurality of protruding portions 641, and in this manner, the circuit board 7 is fixed to the board fixing portion 64. At this time, the filter case 55 is fastened and fixed to the board fixing portion 64 together with the circuit board 7 with some of the first fixing bolts 11 (see FIG. 2). In this manner, the filter case 55 is arranged in a state of being firmly fixed onto the cover member-side surface 7a of the circuit board 7. Note that the outer bottom surface 55a of the filter case 55 forms the tip end surface of the filter case 55 fixed to and disposed on the cover member-side surface 7a of the circuit board 7.

In addition, the power switching elements Q1 to Q6 are electrically connected to the circuit board 7 in such a manner that the tip end portions of the terminals 22 of the power switching elements Q1 to Q6 are soldered to the circuit board 7. That is, the power switching elements Q1 to Q6 are mounted on the surface (surface of the housing body 61 on the inner bottom surface 61a side) of the circuit board 7 opposite to the cover member-side surface 7a.

Note that although detailed description is omitted, the power supply line 9 (or a terminal portion thereof) is also inserted into an insertion hole formed in the circuit board 7, and a tip end portion thereof protrudes from the cover member-side surface 7a of the circuit board 7, and is electrically connected to the circuit board 7 by, e.g., a not-illustrated connection member. In addition, the circuit board 7 is electrically connected to the external power source VB through a connector 13 when mounted on the board fixing portion 64.

Cover Member 62

FIG. 12 is a view illustrating the inverter housing portion 6 (housing body 61, cover member 62), a vibration insulating member 70, and the circuit board 7. In the present embodiment, after the circuit board 7 has been fixed to the board fixing portion 64 and the above-described electrical connection has been made, the cover member 62 is attached to the housing body 61 through, e.g., a not-illustrated fastening bolt. In this manner, the inverter 5 is housed in the inverter housing portion 6.

In the present embodiment, the cover member 62 has a bulging portion 62a bulging in a direction away from the housing body 61 than other portions of the cover member 62, in other words, in a direction away from the circuit board 7 fixed to the board fixing portion 64. The bulging portion 62a is provided at a position corresponding to the filter case 55 on the cover member-side surface 7a of the circuit board 7, and is configured to house a tip end portion of the filter case 55 therein. Note that the inner surface of the bulging portion 62a is a flat surface.

When the cover member 62 is attached to the housing body 61, the vibration insulating member 70 is disposed between the tip end surface (outer bottom surface 55a) of the filter case 55 on the circuit board 7 and the inner surface of the bulging portion 62a of the cover member 62. The vibration insulating member 70 is provided mainly for reducing (including absorbing) vibration of the cover member 62. The vibration insulating member 70 may be made of a material having flexibility, preferably a material having flexibility and heat dissipation. Although not particularly limited, for example, a sheet-like heat dissipation/vibration insulating material containing silicone resin as a main component can be used as the vibration insulating member 70.

When the cover member 62 is attached to the housing body 61, the vibration insulating member 70 is sandwiched between the tip end surface (outer bottom surface 55a) of the filter case 55 and the inner surface of the bulging portion 62a of the cover member 62, and is compressed by an appropriate amount.

The electric compressor 1 according to the present embodiment has the following effects.

The predetermined electronic component (smoothing capacitor 51, filter capacitor 54a, and filter coil 54b) among the electronic components mounted on the circuit board 7 of the inverter 5 is fixed to and disposed on the cover member-side surface 7a of the circuit board 7 in a state of being molded and sealed with the thermosetting second insulating resin IR2. More specifically, the predetermined electronic component is molded and sealed with the thermosetting second insulating resin IR2 in the filter case 55 and is integrated with the filter case 55. Then, the filter case 55 is fastened and fixed to the board fixing portion 64 together with the circuit board 7, whereby the predetermined electronic component is fixed to and disposed on the cover member-side surface 7a of the circuit board 7 together with the filter case 55. Thus, the predetermined electronic component is firmly fixed in the integrated state, and the vibration resistance of the predetermined electronic component and thus the circuit board 7 can be ensured.

The vibration insulating member 70 that reduces vibration of the cover member 62 is disposed between the molded and sealed predetermined electronic component and the cover member 62. More specifically, the vibration insulating member 70 is sandwiched between the tip end surface of the filter case 55 and the inner surface of the bulging portion 62a of the cover member 62 housing the tip end portion of the filter case 55. That is, in the present embodiment, the vibration insulating member 70 is disposed using a space above the region of the circuit board 7 where the predetermined electronic component is mounted. Thus, vibration of the cover member 62 can be reduced by the vibration insulating member 70 while a decrease in the electronic component mounting area of the circuit board 7 is suppressed. Consequently, noise due to vibration of the cover member 62 can also be reduced.

In particular, since the cover member 62 has the bulging portion 62a, the rigidity of the cover member 62 is enhanced, and a thicker (more compressible) vibration insulating member 70 can be used. Thus, vibration of the cover member 62 and noise caused by such vibration can be further reduced.

Note that in the above-described embodiment, the filter case 55 is fastened and fixed to the board fixing portion 64 together with the circuit board 7. However, the present invention is not limited thereto. The filter case 55 is only required to be fixed to and disposed on the cover member-side surface 7a of the circuit board 7, and may be fixed to and disposed on the cover member-side surface 7a of the circuit board 7 by being fixed to a portion of the housing body 61 other than the board fixing portion 64, or may be directly fixed to the circuit board 7.

In the above-described embodiment, the cover member 62 includes the bulging portion 62a. However, the cover member 62 does not necessarily have the bulging portion 62a. In this case, the vibration insulating member 70 may be sandwiched between the (flat) tip end surface of the filter case 55 and the (flat) inner surface (flat surface) of the cover member 62 and be compressed by an appropriate amount.

Second Embodiment

FIG. 13 is a schematic longitudinal sectional view of an electric compressor 10 according to a second embodiment. Hereinafter, the configuration of the electric compressor 10 according to the second embodiment, which is different from that of the electric compressor 1 according to the first embodiment, will be mainly described, and description of a configuration common to that of the electric compressor 1 according to the first embodiment will be omitted. Moreover, components common to those of the electric compressor 1 (FIG. 1) according to the first embodiment will be denoted by the same reference numerals, and description thereof will be omitted.

A main difference between the electric compressor 1 (FIG. 1) according to the first embodiment and the electric compressor 10 (FIG. 13) according to the second embodiment is that the filter case 55 is not used in the electric compressor 10 according to the second embodiment.

In the electric compressor 10 according to the second embodiment, the predetermined electronic component (smoothing capacitor 51, filter capacitor 54a, and filter coil 54b) is also fixed to and disposed on the cover member-side surface 7a of the circuit board 7 in a state of being molded and sealed with the second insulating resin IR2. Note that in the electric compressor 10 according to the second embodiment, the filter case 55 is not used, and the predetermined electronic component is attached to the cover member-side surface 7a of the circuit board 7 by soldering, and then, is molded and sealed with the thermosetting second insulating resin IR2 on the cover member-side surface 7a of the circuit board 7 and is integrated with the circuit board 7.

Preferably, in this case, the entire predetermined electronic component is covered with the thermosetting second insulating resin IR2 on the cover member-side surface 7a of the circuit board 7, and at least part of a tip end portion of the thermosetting second insulating resin IR2, in other words, a tip end portion of the predetermined electronic component molded and sealed with the thermosetting second insulating resin IR2, is formed as a flat surface.

Further, the vibration insulating member 70 is sandwiched between the molded and sealed predetermined electronic component and the cover member 62 and is compressed by an appropriate amount. More specifically, the cover member 62 has a bulging portion 62a bulging in a direction away from the circuit board 7 fixed to the board fixing portion 64 than other portions of the cover member 62. The bulging portion 62a is configured to house the tip end portion of the molded and sealed predetermined electronic component therein. The inner surface of the bulging portion 62a is a flat surface. The vibration insulating member 70 is sandwiched between the tip end portion of the molded and sealed predetermined electronic component and the bulging portion 62a of the cover member 62 and is compressed by an appropriate amount.

The electric compressor 10 according to the second embodiment also provides effects similar to those of the electric compressor 1 according to the first embodiment. That is, the vibration resistance of the circuit board 7 can be ensured, and noise due to vibration of the cover member 62 can be reduced while a decrease in the electronic component mounting area of the circuit board 7 is suppressed. Note that also in the electric compressor 10 according to the second embodiment, the cover member 62 does not necessarily have the bulging portion 62a.

Third Embodiment

FIG. 14 is a schematic longitudinal sectional view of an electric compressor 100 according to a third embodiment. Hereinafter, the configuration of the electric compressor 100 according to the third embodiment, which is different from that of the electric compressor 10 according to the second embodiment, will be mainly described, and description of a configuration common to that of the electric compressor 1 (FIG. 1) according to the first embodiment and that of the electric compressor 10 according to the second embodiment will be omitted. Moreover, components common to those of the electric compressor 1 (FIG. 1) according to the first embodiment and the electric compressor 10 according to the second embodiment will be denoted by the same reference numerals, and description thereof will be omitted.

A main difference between the electric compressor 10 (FIG. 13) according to the second embodiment and the electric compressor 100 (FIG. 14) according to the third embodiment is that in the electric compressor 100 according to the third embodiment, among the predetermined electronic components (smoothing capacitor 51, filter capacitor 54a, and filter coil 54b), the smoothing capacitor 51 and the filter capacitor 54a having higher heights are not molded and sealed.

In the electric compressor 100 according to the third embodiment, molding and sealing of the smoothing capacitor 51 and the filter capacitor 54a among the predetermined electronic components are omitted. The vibration insulating member 70 is configured to reduce not only vibration of the cover member 62, but also vibration of the smoothing capacitor 51 and the filter capacitor 54a among the predetermined electronic components. That is, in the electric compressor 100 according to the third embodiment, the vibration insulating member 70 is sandwiched between the smoothing capacitor 51 and the cover member 62 and is compressed by an appropriate amount, and is sandwiched between the filter capacitor 54a and the cover member 62 and is compressed by an appropriate amount.

More specifically, the cover member 62 has a bulging portion 62a bulging in a direction away from the circuit board 7 fixed to the board fixing portion 64 than other portions of the cover member 62. The bulging portion 62a is configured to house a tip end portion of the smoothing capacitor 51 and a tip end portion of the filter capacitor 54a therein. The vibration insulating member 70 is sandwiched between the tip end portion of the smoothing capacitor 51 and the inner surface of the bulging portion 62a of the cover member 62 and is compressed by an appropriate amount, and is sandwiched between the tip end portion of the filter capacitor 54a and the inner surface of the bulging portion 62a of the cover member 62 and is compressed by an appropriate amount. Here, the shape of the vibration insulating member 70 is determined in consideration of, for example, the shape of the tip end portion of the smoothing capacitor 51, the distance between the tip end portion of the smoothing capacitor 51 and the inner surface of the bulging portion 62a of the cover member 62, the shape of the tip end portion of the filter capacitor 54a, and the distance between the tip end portion of the filter capacitor 54a and the inner surface of the bulging portion 62a of the cover member 62.

Also in the electric compressor 100 according to the third embodiment, the vibration resistance of the predetermined electronic component and thus the circuit board 7 can be ensured, and noise due to vibration of the cover member 62 can be reduced while a decrease in the electronic component mounting area of the circuit board 7 is suppressed.

Up to this point the embodiment of the present invention and the modification thereof have been described above. However, the present invention is not limited to the above-mentioned embodiment and modification, and as a matter of course, can be further modified on the basis of the technical idea of the present invention.

LIST OF REFERENCE SIGNS

• • 1,10,100 Electric Compressor
  • 2 Electric Motor
  • 3 Compression Mechanism
  • 4 Housing
  • 5 Inverter
  • 6 Inverter Housing Portion
  • 7 Circuit Board
  • 7 a Cover Member-Side Surface
  • 30 Switching Element Module
  • 51 Smoothing Capacitor
  • 54 Noise Filter
  • 54 a Filter Capacitor
  • 55 Filter Case (Case Member)
  • 61 Housing Body
  • 62 Cover Member
  • 62 a Bulging Portion
  • 64 Board Fixing Portion
  • 70 Vibration Insulating Member
  • IR1 Thermosetting First Insulating Resin
  • IR2 Thermosetting Second Insulating Resin (Thermosetting Resin)
  • Q1 to Q6 Power Switching Element

Claims

1. An electric compressor comprising: a housing that houses an electric motor and a compression mechanism driven by the electric motor;an inverter that drives the electric motor, the inverter including a circuit board on which an electronic component is mounted;an inverter housing portion that houses the inverter, the inverter housing portion including a housing body having an opening, a board fixing portion which is provided so as to protrude from an inner bottom surface of the housing body facing the opening and to which the circuit board is fixed, and a cover member that closes the opening of the housing body; anda vibration insulating member that reduces vibration of the cover member,wherein a predetermined electronic component included in the electronic component is fixed to and disposed on a cover member-side surface of the circuit board in a state of being molded and sealed with thermosetting resin, andthe vibration insulating member is disposed between the molded and sealed predetermined electronic component and the cover member.

2. The electric compressor according to claim 1, wherein the predetermined electronic component is molded and sealed with the thermosetting resin in a case member and is integrated with the case member, and is fixed to and disposed on the cover member-side surface of the circuit board together with the case member, andthe vibration insulating member is sandwiched between the case member and the cover member.

3. The electric compressor according to claim 2, wherein the case member is fastened and fixed to the board fixing portion together with the circuit board.

4. The electric compressor according to claim 2, wherein the cover member has a bulging portion that bulges in a direction away from the circuit board than other portions of the cover member and houses a tip end side of the case member therein, andthe vibration insulating member is sandwiched between a tip end surface of the case member and an inner surface of the bulging portion of the cover member.

5. The electric compressor according to claim 1, wherein the predetermined electronic component is integrated with the circuit board by the thermosetting resin, andthe vibration insulating member is sandwiched between the molded and sealed predetermined electronic component and the cover member.

6. The electric compressor according to claim 5, wherein the cover member has a bulging portion that bulges in a direction away from the circuit board than other portions of the cover member and houses a tip end side of the molded and sealed predetermined electronic component therein, andthe vibration insulating member is sandwiched between a tip end portion of the molded and sealed predetermined electronic component and an inner surface of the bulging portion of the cover member.

7. An electric compressor comprising: a housing that houses an electric motor and a compression mechanism driven by the electric motor;an inverter that drives the electric motor, the inverter including a circuit board on which an electronic component is mounted;an inverter housing portion that houses the inverter, the inverter housing portion including a housing body having an opening, a board fixing portion which is provided so as to protrude from an inner bottom surface of the housing body facing the opening and to which the circuit board is fixed, and a cover member that closes the opening of the housing body; anda vibration insulating member that reduces vibration of the cover member,wherein a predetermined electronic component included in the electronic component is disposed on a cover member-side surface of the circuit board, andthe vibration insulating member is sandwiched between the predetermined electronic component and the cover member.

8. The electric compressor according to claim 7, wherein the cover member has a bulging portion that bulges in a direction away from the circuit board than other portions of the cover member and houses a tip end side of the predetermined electronic component therein, andthe vibration insulating member is sandwiched between a tip end portion of the predetermined electronic component and an inner surface of the bulging portion of the cover member.

9. The electric compressor according to claim 1, wherein the predetermined electronic component includes at least one of a smoothing capacitor that smooths DC voltage from a DC power supply, a filter capacitor that forms a noise filter, or a filter coil that forms the noise filter.

10. The electric compressor according to claim 7, wherein the predetermined electronic component includes at least one of a smoothing capacitor that smooths DC voltage from a DC power supply, a filter capacitor that forms a noise filter, or a filter coil that forms the noise filter.