JP2009062888A - Electric compressor and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an electric compressor manufacturing method which can prevent shortcircuit fault between a coil and an inner surface of a motor housing member and further can provide good assembling workability of the motor. <P>SOLUTION: The electric compressor is equipped with a motor housing member (5) formed with a motor housing chamber (32) therein and a motor (20) including a rotor (22) and a stator (23). A refrigerant-resistant and oil-resistant insulating rubber member (26) is arranged in a place which is an inner face of the motor housing chamber (32) and where an end of the coil (23b) of the stator (23) is adjacently arranged. Then, the motor (20) is installed in the motor housing chamber (32). <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to an electric compressor in which a motor is housed in a housing together with a compression mechanism, and a method for manufacturing the same.

  In the electric compressor, a motor is housed together with a compression mechanism in a housing. The motor includes a rotor that is rotatably supported by a housing and a stator that is fixed to the housing. The stator has a core and a coil wound around the core.

  By the way, in order to reduce the size and weight of the electric compressor, the compressor housing member and the motor housing member are configured to have a size capable of accommodating the compression mechanism portion and the motor with a minimum necessary volume. In particular, electric compressors mounted on vehicles are highly demanded. Therefore, the motor housing chamber of the motor housing member is slightly larger than the outer dimension of the motor. With such a configuration, the stator of the motor has a coil closer to the inner surface of the motor housing member because of its structure. Be placed. Therefore, the coil comes into contact with the inner surface of the motor housing member due to vibration of the electric compressor, and the insulating layer of the coil is peeled off due to wear. And there exists a possibility of short-circuiting between the coil from which the insulating layer was peeled off, and the motor housing member.

  As a means for preventing such a short circuit, there is a technique disclosed in Patent Document 1. As shown in FIG. 6, this short prevention means covers the end portion of the coil 102 protruding from the core 101 of the stator 100 with a resin 103.

Even if the electric compressor vibrates, the end portion of the coil 102 does not directly contact the inner surface of the motor housing member (not shown), so that the insulating layer of the coil 102 is not peeled off by rubbing. Thereby, it is possible to prevent a short circuit accident between the coil 102 from which the insulating layer has been peeled off and the motor housing member.
JP 2003-293951 A

  However, in the conventional example, since the molten resin 103 is applied to the end of the coil 102 and the motor cannot be assembled to the motor housing member until the molten resin 103 is solidified, the assembling work takes time. In addition, a troublesome process of applying the melted resin 103 to the end of the coil 102 is added as a motor assembling process. From the above, there is a problem that the workability of the motor assembly is poor.

  Therefore, an object of the present invention is to provide an electric compressor manufacturing method and an electric compressor that can prevent a short-circuit accident between the coil and the inner surface of the motor housing member and that have good motor assembly workability.

  The invention according to claim 1, which achieves the above object, comprises a motor housing member having a motor housing chamber formed therein, a motor having a rotor and a stator, an inner surface of the motor housing chamber, and a coil of the stator. An insulating rubber member having refrigerant resistance and oil resistance is disposed at a location where the end of the motor is disposed in close proximity, and then the motor is incorporated in the motor housing chamber. It is.

  A second aspect of the present invention is the method for manufacturing an electric compressor according to the first aspect, wherein the insulating rubber member is ethylene propylene rubber.

  According to a third aspect of the present invention, there is provided a motor housing member having a motor housing chamber formed therein, a rotor incorporated in the motor housing chamber of the motor housing member and rotatably supported by the motor housing member, and the motor housing member And an insulating rubber member having refrigerant resistance and oil resistance at the inner surface of the motor housing chamber and at the position where the end of the stator coil is disposed in proximity. An electric compressor characterized by being arranged.

  A fourth aspect of the present invention is the electric compressor according to the third aspect, wherein the insulating rubber member is ethylene propylene rubber.

  According to the first aspect of the present invention, since the insulating rubber member may be simply disposed on the inner surface of the motor housing chamber, the work is easier than the resin coating work as in the conventional example, and as in the conventional example. In addition, there is no time loss of waiting for solidification of the molten resin. And in the electric compressor manufactured in this way, since the insulating rubber member is interposed between the end of the coil and the inner surface of the motor housing member, the end of the coil is caused by vibration or the like. There is no direct contact with the inner surface. Therefore, according to the manufacturing method of the present invention, a short-circuit accident between the coil and the inner surface of the motor housing member can be prevented, and the motor assembly workability is good.

  According to the invention of claim 2, the same effect as that of the invention of claim 1 can be obtained.

  According to the invention of claim 3, since the insulating rubber member is interposed between the end of the coil and the inner surface of the motor housing member, the end of the coil is directly connected to the inner surface of the motor housing member by vibration of the electric compressor. There is no contact. In the manufacture of the electric compressor having such a configuration, it is sufficient to simply place the insulating rubber member on the inner surface of the motor housing member. Therefore, the operation is easier than the resin coating operation as in the conventional example. There is also no time loss of waiting for the solidification of the molten resin as in the prior art. As described above, this electric compressor can prevent a short-circuit accident between the coil and the inner surface of the motor housing member, and also has good motor assembly workability.

  According to the invention of claim 4, the same effect as that of the invention of claim 3 can be obtained.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

  1 to 5 show an embodiment of the present invention, FIG. 1 is a partially cutaway perspective view of an electric compressor, FIG. 2 is a sectional view of the electric compressor, and FIG. 3 is a sectional view taken along line AA in FIG. FIG. 4 is a cross-sectional view showing a state where an insulating rubber member is disposed on the inner surface of the motor housing chamber, and FIG.

  As shown in FIGS. 1 to 3, the electric compressor 1 has a housing 2. The housing 2 includes a compressor housing member 3, a front housing member 4 assembled on one side surface of the compressor housing member 3, and a motor housing member 5 assembled on the other side surface of the compressor housing member 3. ing. The compressor housing member 3, the front housing member 4, and the motor housing member 5 are made of an aluminum alloy. The detailed configuration of the motor housing member 5 will be described below.

  The compression mechanism unit 10 is accommodated in the compressor housing member 3. The compression mechanism unit 10 includes a cylinder block 11 having a substantially elliptical inner peripheral surface, and a front side block 12 and a rear side block 13 disposed on the side surface of the cylinder block 11. A cylinder chamber 14 is formed in these blocks 11, 12 and 13. These blocks 11, 12, 13 are made of an aluminum alloy.

  A rotor 15 is accommodated in the cylinder chamber 14. A rotation shaft 16 passes through the center of the rotor 15, and the rotor 15 and the rotation shaft 16 are fixed. The rotary shaft 16 is rotatably supported by the front side block 12 and the rear side block 13. The rear side of the rotating shaft 16 protrudes outside from the rear side block 13.

  A vane 17 is provided at an equally spaced position on the outer periphery of the rotor 15 so as to protrude and retract. Each vane 17 moves while contacting the inner wall of the cylinder chamber 14 by back pressure and its own centrifugal force when the rotor 15 rotates. A plurality of compression chambers are formed in the cylinder chamber 14 between the adjacent vanes 17. Each compression chamber expands its volume in accordance with the rotation of the rotor 15 and repeats a suction process for sucking in the refrigerant, a compression process for reducing the volume, compressing the sucked refrigerant, and discharging it.

  The front side block 12 and the front housing member 4 are formed with a refrigerant suction path 18 including a suction port (not shown) and a suction chamber 18b. The rear side block 13, the compressor housing member 3, and the motor housing member 5 are formed with a refrigerant discharge path 19 including a discharge chamber 19a and a discharge port 19b. In the compression chamber suction process, the refrigerant is sucked into the compression chamber of the cylinder chamber 14 through the refrigerant suction path 18, and in the second half of the compression stroke, the refrigerant compressed in the compression chamber of the cylinder chamber 14 is the refrigerant discharge path 19. More discharged.

  The motor 20 is accommodated in the motor housing member 5. The motor 20 includes a rotor 22 fixed to the rotating shaft 21 and a stator 23 fixed to the inner peripheral surface of the motor housing member 5. Both ends of the rotary shaft 21 are rotatably supported by the motor housing member 5 and the compressor housing member 3 via ball bearing members 24 and 25. One end side of the rotation shaft 21 is connected to the rotation shaft 16 of the compression mechanism unit 10. S and N poles are alternately magnetized in the circumferential direction on the outer periphery of the rotor 22. The stator 23 is composed of a ferromagnetic core 23a and a coil 23b wound around the core 23a. The ends of the coil 23b protrude from both side surfaces of the core 23a.

  Of the protruding end portions on both sides, the end portion disposed closer to the inner surface of the motor housing member 5 faces the motor housing member 5 with the insulating rubber member 26 interposed therebetween. The insulating resin layer 26 will be described below.

  The coil 23b is energized by a drive current from a motor control unit 27 including an inverter. The motor control unit 27 is mounted on the front housing member 4.

  Next, the configuration of the motor housing member 5 will be described. The motor housing member 5 has a cylindrical shape and has a peripheral wall portion 30 that is open at one end side, and a side wall 31 that closes the other end side of the peripheral wall portion 30. A motor housing chamber 32 is formed inside the motor housing member 5. Yes. A relief valve port 33 (shown in FIG. 3) is provided in the vicinity of the side wall 31 of the peripheral wall portion 30.

  At the center of the inner surface of the side wall 31, a substantially ring-shaped bearing support portion 31b is projected. The ball bearing member 25 is press-fitted into the bearing support portion 31b. A cylindrical protrusion 31a is provided outside the side wall 31, and the discharge port 19b is provided using the cylindrical protrusion 31a. The discharge port 19b opens to the motor storage chamber 32 (discharge chamber 19a).

  An insulating rubber member 26 is disposed on the inner surface of the motor housing chamber 32 on the side wall 31 side, that is, on the inner surface where the end portion of the coil 23b of the stator 23 is disposed in proximity. The material of the insulating rubber member 26 is an insulating rubber material having refrigerant resistance and oil resistance. In this embodiment, it is ethylene propylene rubber. In this embodiment, the refrigerant is a fluorinated hydrocarbon such as HFC-134a, and the lubricating oil is a polyalkylene glycol oil, a polyol ester oil, or a polyvinyl ether oil. .

  In the above configuration, when the motor 20 rotates, the rotation shaft 16 of the compression mechanism unit 10 rotates together with the rotation of the rotation shaft 21, thereby driving the compression mechanism unit 10. Then, the refrigerant is sucked into the cylinder chamber 14 of the compression mechanism 10 through the refrigerant suction path 18, and the refrigerant compressed in the cylinder chamber 14 of the compression mechanism 10 is discharged through the refrigerant discharge path 19.

  Even if the electric compressor 1 vibrates by its own compression operation and the coil 23b of the stator 23 vibrates with respect to the motor housing member 5, the end of the coil 23b only contacts the insulating rubber member 26, and the motor housing There is no direct contact with the inner surface of the member 5.

  Next, the assembly work of the motor 20 will be described. First, as shown in FIG. 4, the insulating rubber member 26 is inserted from the opening of the motor housing member 5, and the insulating rubber member 26 is disposed on the inner surface of the motor housing member 5 on the side wall 31 side. Next, as shown in FIG. 5, the rotor 22 and the stator 23 with the rotating shaft 21 are inserted into the motor housing chamber 32 through the opening of the motor housing member 5, and the rotor 22 and the stator 23 are assembled at predetermined positions. Complete.

  As described above, when the motor 20 is assembled, the insulating rubber member 26 has only to be disposed on the inner surface of the motor housing member 5, so that the operation is easier than the resin coating operation as in the conventional example. In addition, unlike the conventional example, there is no loss of time for waiting for the solidification of the molten resin. In the electric compressor 1 manufactured as described above, the end of the coil 23b does not directly contact the inner surface of the motor housing member 5 due to vibration or the like. Therefore, according to the electric compressor 1 and the manufacturing method thereof, a short circuit accident between the coil 23b and the inner surface of the motor housing member 5 can be prevented, and the assembly workability of the motor 20 is good.

  In this embodiment, the insulating rubber member 26 is ethylene propylene rubber, but chlorosulfonated polyethylene rubber, isobrene rubber, chlorinated polyethylene rubber, chlorobrene rubber, epichlorohydrin, urethane rubber, nitrile rubber, hydrogen A nitrile rubber, a butyl rubber, a polysulfide rubber, or the like may be used.

1 is a perspective view of an electric compressor according to an embodiment of the present invention, partly cut away. 1 is a cross-sectional view of an electric compressor according to an embodiment of the present invention. FIG. 3 shows an embodiment of the present invention and is a cross-sectional view taken along line AA in FIG. 2. FIG. 5 is a cross-sectional view showing an embodiment of the present invention and showing an insulating rubber member disposed on an inner surface of a motor housing chamber of a motor housing member. FIG. 2 is a cross-sectional view showing a state in which the motor is assembled in the motor housing chamber of the motor housing member according to the embodiment of the present invention. It is a perspective view which shows the short prevention structure of the coil of a prior art example.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Electric compressor 5 Motor housing member 20 Motor 22 Rotor 23 Stator 23b Coil 26 Insulating rubber member 32 Motor accommodation chamber

Claims (4)

A motor housing member (5) having a motor housing chamber (32) formed therein, and a motor (20) having a rotor (22) and a stator (23),
An insulating rubber member (26) having refrigerant resistance and oil resistance is provided on the inner surface of the motor housing chamber (32) and at a position where the end of the coil (23b) of the stator (23) is disposed close to the motor housing chamber (32). Place and
Next, the method for manufacturing the electric compressor (1), wherein the motor (20) is incorporated in the motor housing chamber (32). A method for producing an electric compressor (1) according to claim 1,
The method for manufacturing an electric compressor (1), wherein the insulating rubber member (26) is ethylene propylene rubber. A motor housing member (5) in which a motor housing chamber (32) is formed, and a motor housing chamber (32) of the motor housing member (5), are rotatably supported by the motor housing member (5). And a motor (20) having a stator (23) fixed to the motor housing member (5),
An insulating rubber member (26) having refrigerant resistance and oil resistance is provided on the inner surface of the motor accommodating chamber (32) and at a position where the end of the coil (23b) of the stator (23) is disposed close to the motor accommodating chamber (32). An electric compressor (1) characterized by being arranged. The electric compressor (1) according to claim 3,
The electric compressor (1), wherein the insulating rubber member (26) is ethylene propylene rubber.

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